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Technical Service Bulletin 12-2012

Date :30th Jun 12 Reference

Recommendations from
Subject : Charger Installation & fault diagnostics of Rege make
Charger manufactures on their
Applicable Model: 1. Rege make 3ph & 1ph chargers. obersvations during complaint
handling

Purpose: Facitliate Service Technician to understand & address charger issues.

A. Compulsory and immediate B. Modification to be done as C. For information

modifaction and when required

No. Parts Names New part no. Qty Current part no. Interchangeability

Caution !

Before performing any work be sure to refer to and follow all recommended safety precaution set out in the applicable Godrej service manual. Godrej recommends that all mechanics wear appropriates protective
items, Such as safety glasses, work gloves and steel toed shoes, wherever performing maintenance work on Godrej equipment. In addition, all national safety regulations should be followed.

Go Green ! Conserve the Environment by proper disposal of waste e.g. used oil, used battery, used tyres & ensure optimal use of natrural resources such as water, fuel, oil & lubricants.

Distinction of current and new parts

Digital Ammeter

LED INDICATION

I/P Supply Indicators

ON/OFF position
switch
Full/Equa. Mode
switch

Charger Name plate

Rege make 3 phase 24, 36, 48,72, 80V chargers Rege make Single phase chargers

3 Phase Charger with Analog Amps display & Charging timer for Boost
Current

Fault Diagnostics procedure .

1. Pls ref the attached annexure.
Note : For any queries, clarifications or more details if required, contact Technical Cell ( doc@godrej.com,
jsp@godrej.com, sandipb@godrej.com, mnpatil@godrej.com )
Godrej & Boyce Mfg. Co. Ltd.
Material Handling, Plant - 16
Pirojshanagar, Vikhroli
Mumbai 400079, India
www.godrejmhe.in
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Annexure of TSB 12-2012

General Description:
The Battery Charger is for charging lead acid traction batteries only. The Charger is electronically protected against over current, short circuit and
reverse battery connection. The charging profile is constant current followed by a forced taper, while sensing voltage to evaluate 100% charge
condition.

Installation and safety instructions

1. Inspect charger phisically for damages, missing parts & manuals. Incase any descripancy, note & inform to concerned.

2. Check & ensure specs (input/output voltages, output current and single rate or double rate) of supplied charger are as per order.
3. Fix the battery charger to a stable surface.
4. Do not put the battery charger near heat sources. Make sure that free space around the battery charger is sufficient to
provide adequate ventilation and an easy access to cables, sockets.
5. Protect the battery charger from ingress of water.

6. Check electric input board where charger is to be installed. The input socket must be with on/off facility which may be Switch or MCB.
7. Verify that the available supply voltage corresponds to the voltage that is stated on the battery charger name plate.
In case of any doubt, consult customer's maint personnel. Verify that the nominal voltage of the battery to be re-charged
corresponds to the voltage stated on the battery charger name plate.
8. The AC supply voltage must be close to +/- 10V to that input volatge indicated on Charger and without fluctuations in it.
There are 4 voltage tappings provided inside the charger facilitates to match the supply volatge, those are 380, 400,
420 & 440. Tapping 420 is factory set and can be chaged if needed to match the supply voltage, refer Annexture I
9. The current rating of input wires/fuse/Circuit breaker/switch should be sufficient to take charger load, Charger input current
given on the nameplate.
10. Check Earthing for connectivity and for voltage leakage. Voltage more than 5 V when measured between earthing and -ve
is not acceptable.
11. Insist on and use appropriate socket/pin on charger side input cable or connect all 3 wire to MCB/switch output terminal with screws. Cut cable
tie on MCB inside the charger. Ref : TSB 22-2011 Dt 30 Dec 2011
12. Demonstrate Battery charging, maintenance & safety to operator in presense of customer's competant/responsible personnel and record the
same on job card.

Charger with analog timer:- Time set on the timer is time to shut off the unit after battery getting 80% charged. i.e. if you set the timer for 2 hours
it will shut off 2 hrs after battery achives 80% charge.

CHARGER FLOW CHART

The Charger can be divided into 3 sections viz.. AC part , rectifiers & controller. AC part consist of MCB (eliminated input fuses), Aux transformer
(eliminates need of neutral in AC input for multphase charger), choke ( one for single phase & 3 for 3 Phase) step down transformer, two switches
one to start the charger and other for change over from high to low current & viseverca charging & contactors.
The controller which monitor the voltage and thus the status of battery is macro processor unit (PCB) this controls the
charging and eventually display the status of battery.

INPUT  TERMINALS 
THREE PHASE SINGLE PHASE
R Y  B     L N        ER

SWITCH  CHARGER  ON ‐ OFF
MCB, PILOT LAMPS & AUX TRANS 
MODE SWITCH  EQUALIZING ‐ FULL MODE

CONTACTOR
MICROPROCESSOR 
CONTROLLER/ANALOG TIMER

BALLAST CHOKE

RECTIFIER DIODE BRIDGE MAIN TRANSFORMER

SHUNT WITH AMMETER DC FUSE
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Annexure of TSB 12-2012

OUTPUT TERMINALS
POSITIVE                                   NEGATIVE                                                    

Fault Finding Rege make 3ph & 1ph chargers.

Charger does not start at all in either mode (Most probably the issue will be at AC INPUT SIDE)
1. Check Input Supply.
2. Check the I/p fuses of charger.
3. Check Aux Transformer, it should give output around 230V

Aux transformer

4. Check Power on Switch, MCB & Mode switch in charger.

5. If above all ok then defect may be connectivity of chokes, transformars, Check end connections. If all ok then call vendor
for tech support.

Works in Equalizing but not in Full mode

1. Check Mode switch
2. Check C1 coil and contacts

C1 contactor
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Annexure of TSB 12-2012

3. Check PCB connections

4. Replace PCB

Macro processor unit (PCB)

DC Fault LED on
1. Check battery, ensure it is not deep discharged.
2. Check DC fuse & connections. DC fuse may blow off incase of short ckt in out put cables, connectors, battery.
3. Check the battery & charger connector connections. Check visually that battery & charger connector tips are not pitted
4. Check the polarity of o/p cables. Correct polarity of battery & charger cables.
5. Wrong battery (voltage) connected.

AC Fuse Blowing off / MCB tripping after switching ON the Charger

Check diodes, procedure given under.
* Disconnect diodes.
* Digital multimeters have a special setting for testing a diode, usually labelled with the diode symbol.
* Connect the red (+) lead to the anode and the black (-) to the cathode. The diode should conduct and the meter will display a value (usually the
voltage across the diode in mV, 1000mV = 1V).

* Reverse the connections. The diode should NOT conduct this way so the meter will display "off the scale" (usually blank except for a 1 on the left).
* Replace the defective diode.

cathode

anode

Charger not charging effectively/poor battery back up.

Handle this issue very carefully, most of the reasons are related to applications/usage at customer's place and not in Charger
or Battery manufacturar's scope. Check & ensure customer's charging procedure for 1 cycle i.e. discharge battery up to lift
cut off (80%),charge fully and discharge up to lift cut off (80%).
In this way you can ensure SG level after 80% discharge (should be around 1.160) and full charge (should be around around
1.27) are correct and also BDI functions properly. Measure and note the per cell voltage of all cells after discharge and

charge. Charge battery. overnight (refer battery charging procedure) if charger cuts off after charging, then issue may not be
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Annexure of TSB 12-2012

with charger.If charger does not cut off or it takes too long to cut off -
1. Check AC input voltage, if it is not matching the voltage tapping in the charger or fluctuating then charger
shall not give full out put.Operational voltage range is 380 - 440V for 3 phase or 200 - 250V for Single phase.
In that case change the tapping to match the input voltage. Ref Annex I.
2. Check DC out put* - If it is not around 25% more than battery voltage then - check diodes in rectifier bridge
or connections. If all Ok then check main transformer secondary connections to bridge circuit, any
loose/open connection can cause low DC output.
* Battery V Charger output V
24 30-32
36 45-47
48 60-63
72 90-93
Transformar connections (Tapping no 2 & 3 are connected with jumper)
Tapping points 3 Phase
R phase Transformar Choke
1
6 5 4 3 2 1 2
380V
3 380V
4 400V 400V
18 5 420V 420V
Y Phase 6 440V 440V

6 5 4 3 2 1 Tapping points 1 phase

Transformar Choke
36/48 model 24V model

Not
22 1

r
eqd
B Phase 2 210V
3 220V

, no
6 5 4 3 2 1 4 210V 230V

tap
5 230V 240V

pin
6 250V 250V

g
26

MainTransformer
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Annexure of TSB 12-2012

Choke connections
R phase 18 14 9

6 5 4 3 2 1

Y phase 22 15 11

6 5 4 3 2 1

B phase 26 16 13

6 5 4 3 2 1

18, 22 & 26 are ferrule nos on the wires.

Choke