FCBC Technical Package

β

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

Page 2 of 9

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 (3 PHASE)

Y B

LC FILTER TRANSFORMER

LOAD

SCR BRIGE

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

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.

Page 4 of 9

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

AC Mains Available

FLOAT

ON

On Float irrespective of it’s condition

AC Mains Available

BOOST

ON

On Boost irrespective of it’s condition

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

ANY MODE

OFF

On Discharge

Battery will supply to Load

AC Mains Fail / FCBC Fail

Page 5 of 9

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 b) Frequency

: :

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

OUTPUT a) Nominal Voltages b) Output Currents c) Ripple d) Efficiency

: : : :

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

VRLA

Voltages

24V

48V

Float Voltage

27.0V

54.0V

Boost Voltage

27.6V

Equalize Voltage Load Voltage

110V

NI-CD 220V

24V

48V

123.75V 247.5V

28V

56V

55.2V

126.5V

253.0V

34V

68V

---

---

---

---

---

---

27.6V

55.2V

126.5V

253.0V

34V

68V

110V

PLANTE / TUBULAR 24V

48V

121.8V 243.6V

27.0V

54.0V

123.75V 247.5V

147.9V 295.8V

31.8V

63.6V

145.75V 291.5V

33.0V

66.0V

151.25V 302.5V

33.0V

66.0V

151.25V 302.5V

---

220V

---

147.9V 295.8V

110V

220V

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

: : : :

10 - 100% ± 10% ± 5% 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 Page 6 of 9

β

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 :

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

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

Page 7 of 9

β

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 ºC to +50 ºC 25 ºC + 70 ºC 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

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

Page 8 of 9

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

Page 9 of 9

β

TB

TB

D R

Y

AC INPUT B

CIRCUIT BREAKER

+

FCBC

CIRCUIT BREAKER

LAST CELL

TO BATTERY BANK

BATTERY INPUT FUSES

-

N

1st Cell

TB

+ TO LOAD/DCDB

FUNCTIONAL BLOCK DIAGRAM OF FLOAT CUM BOOST CHARGER

1

2

A

3

5

4

A1

A6

6

7

8

9

11

10

.E6 2.E6

-H1 A99

A2

A5

A

.E6 2.D6

-H2 A3

A4

.E6 2.D6

-H3 D2

A99

-X1

-Q1

-CT1 A4 -

X1

H1

D2

A5

A5 +

-

H2

H3

X3

X2

-SCR Y

A8

-CT3

-F3

A9 A99

A99

-SCR B

-SCR B

A11 B31 B32

D1 B37 B38

2.E5

2.E5 2.E5

2.E5

A11

C

D1

CN.[CT3]

A9

2.C2

A11

.F2

A1

N

D2

D2

.F2

B

D2

- M G

2.E6 2.E6

A10

A6 +

D1 B35 B36

2.E5 2.E5

A10

.F2

A6

A3

B

-SCR Y

A10 B29 B30

-F2

A8

M G

CN.[CT2]

.F2

C

415V AC +/- 10%

AC INPUT

CN.[CT1] A2

2.E6 2.E6

M G

-CT2 Y

D1 B33 B34

2.E6 2.E6

A7

A4 +

R

-SCR R

A7 B27 B28

-T1

A1

B

-SCR R

2.B2

-F1 -SC1 N

D

G

B18

B16 B17

B14 B15

B8 B9

B7

-E1

-T2

-DL1

CN.[PC2(1)]

B25

A4

H1

A5

H2

A6

H3

.A4

.A4

E 1

.A4

2 3

(AT-5174)

-PC3 MICRO BOARD

CN.[T2] 2.F3

CN.[PC2(2)]

B24

2.F3

A11

CN.A 8 Y1 7 Y2 6 Y3 5 Y0

B23

2.G3

CN.[PC2(20)]

CN.[PC2(3)]

CN.[PC2(10)]

FLAT CABLE

.G9

.C8

CN.[PC2(4)]

F1

B26

2.G6

CN.A 4 X1 3 X2 2 X3 1 X0

B19 B20 B21 B22

CN.5

A99

B4

B1

-B1

B5

7

A8

.C7

1

CN.20

34 PIN

2

1 2 3 4 CN.4

CN.10

5

CN.5

6

U30

2.B9

7 8

U31

2.B9

CN.18 C

1 2 3 4

1 2 3 4

1 2 3 4

CN.3

CN.2

CN.1

1 2 3 4 +

- M G CN.19

-PC2 SENSING BOARD

4

U29

2.B9

1 2 3

A10

.C8

NC

CN.16

CN.17

NO

C

NC

C

NO

NC

CN.15

NO

C

NC

CN.13

CN.14

NO

C

NC

NO

C

NC

CN.12 C

NO

NC

CN.11

NO

C

NC

+

CN.7 - M G

E L-

CN.8 L+

B-

2 1 2 3 4

U28

CN.[PC2(7)]

CN.[PC2(11)]

U26 U27

CN.[PC2(12)]

U19 U20 U21

U18

CN.[PC2(13)]

U16 U17

U14 U15

CN.[PC2(14)]

U13

CN.[PC2(15)]

U10 U11

CN.[PC2(16)]

U12

U7 U9

U8

CN.[PC2(17)]

U4 U5

U2

U1

CN.[PC2(18)] U3

J2 J3 J4 B99

U24 U23

U6

U22

-X2 DC UV

16 Pin

34 Pin

8

CN.6

F

9

CN.[PC3(4)]

J1

U25

GROUP CHARGER BATTERY SCR FUSE ALARM FAIL EF FAIL

CN.4

CN.[PC3(2)]

B+

2.G5

G

CN.2

1 2 3 4 5 6 7 8

1 2 3 4

NO

1

CN.[PC2(8)] CN.[PC2(5)]

H

CN.6

CN.9

U32

2.B9

4 5 6

A9

.C8 :

:

B3

-DS1

VARIANT

PATH

F

-S2

ITEM CODE:

E

\ls ia te D BC C F\ no is re V tae Bt ifw S\ po kts eD \b jr\ gsn ti eS dn a tsn e m cuo D \: C

B12

B99 B13

L

B11

B2

B10

-S1

D

F2 FLAT CABLE

.E3

CN.[PC3(6)]

F1

B26

FLAT CABLE

2.G6

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

G

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

FCBC

FLOAT ON BOOST ON DC OV

H

POTENTIAL FREE CONTACTS

01/02/13 JRB

DATE DRAWN CHKD. REV

1

REMARKS

ECO

2

DATE

3

APPD.

APPD.

4

SIGN

AM

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

5

A R A R A J

POWER

SYSTEMS

A LTD

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

6

7

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

: SCH

DRG. NO

- XX-XXXX

SALE ORDER NO : - - - - -

10

11

REV :

THIS

1

LOC. :

NEXT

2

1

2

3

5

4

6

7

8

9

11

10

D1 D1

D5

U32

-F4 1.F2

B

TO BATTERY

U24

U25

1.G5

-V1

D1

C

1.G5

D1 D1

1.G5

+

U22

-C2

J2

M G

1.F2

-

CN.[CT4]

-R2

1.C11

J4 +

U23

-R1

J4

1.G5

-C1

D3

B

D4

-SH1

D3

-F5 AUX

U30

D3

-X3

-F4 AUX

U29

D2 D2

1.D11

-CT4

A

1.G2

1.F2

-Q2

-L1

U31

.F7 C2

C1

.F7

A

J3

+

J1

-F5

D4

.F7

.G7

C

-X4 J4

-T3 D

CN.B

A4

H1

1.A4

1.A4

+

3 X3 X0

A6

H3

J3

1.A4

K1

B33 4

G1

C2

1.G6

F

.B5

5

.C5

3

4

D1

2

CN.3

-PC1

D4

.C5

1

G

E

1.G6

.B5

C1 6

3

K2

CN.[PC1(5)]

B34

B28 1

2

G2

B27

CN.[PC1(6)]

B35 4

CN.5

K1

1.B9 1.B9 1.B10 1.B10

1.C9 1.B9 1.C10 1.B10 B36 3 G1

CN.[PC1(7)]

B30

2 K2

B29 1 G2

4 K1

CN.6

B38 3 G1

B31 1

2 K2

CN.7

G2

FIRING BOARD

B37

B32

1.C9 1.C9 1.C10 1.C10

1.G6

CN.[PC1(1)]

1.G6

J2 BATT-VE

B23

J3

CN.[PC1(2)] CN.4

1.F5

J4

8

J1 6

4

5

BATT+VE

4

B24

L1 1 L2 2 L3 3

CN.1

B25

1

1.F5

2 3 CN.2

1.F5

7

B39

B40 B41

4

:

:

A5

H2

2 X2

VARIANT

PATH

F

1 X1

ITEM CODE:

E

\ls ia te D BC C F\ no is re V tae Bt ifw S\ po kts eD \b jr\ gsn ti eS dn a tsn e m cuo D \: C

D

TO LOAD

CN.[T3]

CN.[PC1(3)]

CN.9 16 PIN

1

2

G

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

1.G8

FLAT CABLE

B26 B26

1.E2 1.G10

FCBC

H

H 01/02/13 JRB

DATE DRAWN CHKD. REV

1

REMARKS

ECO

2

DATE

3

APPD.

APPD.

4

SIGN

AM

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

5

A R A R A J

POWER

SYSTEMS

A LTD

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

6

7

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

: SCH

DRG. NO

- XX-XXXX

SALE ORDER NO : - - - - -

10

11

REV :

THIS

LOC. :

NEXT

2