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

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

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 TRANSFORMER SCR BRIGE LC FILTER LOAD

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

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.

Page 4 of 9

LOGIC SHEET OF FLOAT CUM BOOST CHARGER

System Conditon

Charger Mode

FCBC

Battery

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

AC Mains Available & Battery is healthy AC Mains Available & Battery is in Discharged Condition

AUTO

ON

On Float

AUTO

ON

On Boost

AC Mains Available

FLOAT

ON

On Float irrespective of its condition

AC Mains Available

BOOST

ON

On Boost irrespective of its condition

AC Mains Fail / FCBC Fail

ANY MODE

OFF

On Discharge

Battery will supply to Load

Page 5 of 9

TECHNICAL SPECIFICATION OF THE BATTERY CHARGER

Scheme Type Type of battery INPUT a) Three phase Input b) Frequency OUTPUT a) Nominal Voltages b) Output Currents c) Ripple d) Efficiency : : : Float cum Boost Charger Full Wave Full Controlled Suitable for VRLA / NI-CD / PLANTE / TUBULAR

: : : : : :

415V AC 10% (Three Phase, Four Wire) 50Hz 5% 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
Voltages Float Voltage Boost Voltage Equalize Voltage Load Voltage
24V 27.0V 27.6V --27.6V

VRLA
48V 54.0V 55.2V --55.2V 110V 220V 24V 28V 34V --34V

NI-CD
48V 56V 68V --68V 110V 220V

PLANTE / TUBULAR
24V 27.0V 31.8V 33.0V 33.0V 48V 54.0V 63.6V 66.0V 66.0V 110V 220V

123.75V 247.5V 126.5V --126.5V 253.0V --253.0V

121.8V 243.6V 147.9V 295.8V -----

123.75V 247.5V 145.75V 291.5V 151.25V 302.5V 151.25V 302.5V

147.9V 295.8V

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 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

: : : :

10 - 100% 10% 5% 0 - 50 C

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 : 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 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

Page 7 of 9

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 C to +50 C 25 C + 70 C 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 IP 42 Exterior: Mat Black RAL-9005 Interior : Glossy Orange RAL-2000 Natural Air Cooling As per the Dimensional Drawings

Protection Paint Shade Nature of Cooling Dimensions in mm

: : : :

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

Page 8 of 9

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

TB D
R

TB
LA ST CELL

AC INPUT
B N

CIRCU IT BRE AKER

FCBC

CIRCU IT BREAKE R

BATTERY INPUT FUSE S

TO BATT ERY BANK

1st Cell

TB

+
TO LOAD/DCDB

FUNCTIONAL BLOCK DIAGRAM OF FLOAT CUM BOOST CHARGER

10

11

A
-H1

A1

A6

.E6 2.E6 A5 .E6 2.D6 A4 .E6 2.D6 D2

A2 A99

-H2
A3

-H3
A99

-SCR R
B27 B28

A7 2.E6 2.E6

-SCR R
B33 B34

D1 2.E6 2.E6

-X1
A1

-Q1
A4

-T1 -CT1
A4
+ M G

A7 H1 X1 D2 H2 H3 X3 X2 A8 A8

R 415V AC +/- 10%

CN.[CT1]

-SCR Y
B29 B30

A10 2.E5 2.E5

-SCR Y
B35 B36

B
D1 2.E6 2.E6

-CT2
A2 A5
+ M G

A5

-F2
A10

AC INPUT

A10

CN.[CT2]

-CT3
A3 A6
+ - M G

A6 .F2 .F2

D2

-SCR B
B31 B32

A11 2.E5 2.E5

-SCR B
B37 B38

D1 2.E5 2.E5 D1 2.C2

B
A99 A99

A9

-F3
A9 A11

A11

CN.[CT3]
A1

.F2

.F2

D2

D2

2.B2

-F1 -S1 -SC1

B2
L G N

D
B99
B16 B15 B17 B10 B12 B11 B13 B7 B9 B18 B14 B8

ITEM CODE:

VARIANT

\ls ia te D C B C F \n io s r e V ta e B iftw S \p to k s e \D b jr \s g tin e S d n a ts n e m u c o D \: C

-S2
B1

B3

-B1

B4

-E1
A99

-T2
B19 B20 B21 B22
CN.A 4 X1 3 X2 2 X3 1 X0 CN.A 8 Y1 7 Y2 6 Y3 5 Y0

-DS1
B5

-DL1

H1

A4

.A4

H2

A5

.A4 .A4
1 2

CN.[PC2(4)]

CN.[PC2(3)]

CN.[PC2(2)]

FLAT CABLE

.G9 2.G6 B26

F1

CN.[PC2(1)]

B23 B24 B25

H3

A6

CN.[PC2(10)]

(AT-5174)

CN.[T2]
2.F3 2.G3 2.F3

CN.[PC2(20)]
.C8 .C8 .C7 .C8 2.B9 2.B9 2.B9 2.B9
A11 A9
1 1 2

-PC3 MICRO BOARD

CN.2 16 Pin CN.4 34 Pin CN.6

CN.5

4 5 6 7

34 PIN
CN.10

A8 A10 U29 U30 U31 U32

2 3 4 5 6 7 8

CN.20

1 2 3 4 CN.4

1 2 3 4 CN.3

1 2 3 4 CN.2

1 2 3 4 CN.1

1 2 3 4
+ - M G CN.19 CN.6

1 2 1 2 3 4 B+

8 9

CN.5

-PC2 SENSING BOARD

CN.17
C NC NO

PATH

CN.9

CN.18
C NC NO

CN.16
C NC NO

CN.15
C NC NO

CN.14
C NC NO

CN.13
C NC NO

CN.12
C NC NO

CN.11
C NC NO

CN.7 - M G

E L-

CN.8 L+

B-

CN.[PC3(2)] CN.[PC3(4)] CN.[PC2(8)]

2.G5 F2
FLAT CABLE

1 2 3 4

1 2 3 4 5 6 7 8

CN.[PC3(6)]
B26 2.G6

.E3

F1
FLAT CABLE

CN.[PC2(18)]

CN.[PC2(17)]

CN.[PC2(16)]

CN.[PC2(15)]

CN.[PC2(14)]

CN.[PC2(13)]

CN.[PC2(12)]

U1

U4

U7

CN.[PC2(5)]

CN.[PC2(11)]

CN.[PC2(7)]

J1 J2 J3 J4 B99

2.E4 2.E4 2.E9 2.E9

U10

U13

U16

U19

U11

U14

U17

U20

U26 U27

U2

U5

U8

U12

U15

U18

U21

U28

U3

U9

U25 U24 U23

-X2
H
GROUP CHARGER BATTERY SCR FUSE ALARM FAIL EF FAIL DC UV FLOAT ON BOOST ON DC OV

U6

U22

2.B8 2.B8 2.B8 2.B8

FCBC
H
PROJECT : CUST : CONSULTANCY : P.O.NO. :

POTENTIAL FREE CONTACTS

DATE DRAWN CHKD. REV ECO REMARKS DATE APPD. APPD.

01/02/13 JRB 4

SIGN

AM
6 7

A R A R A J
SYSTEMS

A
LTD

POWER

Registered Office & Works. Karakambadi-517520,Tirupati (AP) Ph.(0877) 2265000

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

DRG. NO

: SCH

- XX-XXXX
REV : THIS NEXT

SALE ORDER NO : - - - - -

10

11

LOC. :

10

11

A
1.G2

.F7

.F7

1.F2

U31

-L1
1.D11 D2 D2 D3 D4 D3

-Q2
J4

-CT4
J4
+ M G

-F4 AUX
J2

1.F2

U22

1.G5

1.G5

1.G5

1.C11

D1

D1 D1 D4

D1

-V1

1.G5

U29

U30

D1 D5 J3

U24

U23

U25

-R2

-C2

1.F2

-C1

-R1

D3

-SH1
CN.[CT4]

-F4
B

U32

-X3

C1

C2

TO BATTERY

-F5 AUX

J1

+
C

-F5

.G7

.F7

-X4
J4

-T3
D
CN.B

H1

A4

1.A4

CN.[T3]
\ls ia te D C B C F \n io s r e V ta e B iftw S \p to k s e \D b jr \s g tin e S d n a ts n e m u c o D \: C
1 X1 2 X2 3 X3 4 X0

TO LOAD

H2

A5

1.A4

H3

A6

1.A4

J3

B39

B40 B41

1.G6

1.G6

J4 1.C9 1.C9 1.C10 1.C10 1.C9 1.B9 1.C10 1.B10 1.B9 1.B9 1.B10 1.B10

1.G6

B32

B38

B30

B36

B28

B34

J3

CN.[PC1(7)]

CN.[PC1(1)]

CN.[PC1(6)]

CN.6

CN.1

CN.5

CN.7

ITEM CODE:

L1 1 L2 2 L3 3

G1

K1

G1

K1

VARIANT

G2

K2

G2

K2

FIRING BOARD

BATT+VE

BATT-VE

G2

K2

G1

K1

CN.[PC1(5)]

1.G6

B31

B37

B27

B29

B35

B33

J1

J2

C2 C1
5 6

.B5 .B5 .C5

PATH

2 3 CN.2

1.F5 1.F5

B24 B23

CN.3

1.F5

B25

-PC1

D1

D4
1 CN.9

CN.[PC1(2)]
CN.4 16 PIN 1 2

.C5

CN.[PC1(3)]

CN.[PC1(4)] CN.[PC4(9)]
F2
FLAT CABLE

G
1.G8 B26 B26 1.E2 1.G10

H
DATE DRAWN CHKD. REV ECO REMARKS DATE APPD. APPD.

FCBC
H
01/02/13 JRB 4
SIGN

PROJECT : CUST : CONSULTANCY : P.O.NO. :

AM
6 7

A R A R A J
SYSTEMS

A
LTD

POWER

Registered Office & Works. Karakambadi-517520,Tirupati (AP) Ph.(0877) 2265000

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

DRG. NO

: SCH

- XX-XXXX
REV : THIS NEXT

SALE ORDER NO : - - - - -

10

11

LOC. :