OPERATION & MAINTENANCE MANUAL

AUTOMATIC FLOAT AND BOOST BATTERY

CHARGING EQUIPMENT SUITABLE FOR
220 VOLTS 187 AH PLANTE BATTERY

OWNER

OWNERS
CONSULTANT :

ANDHRA PADESH POWER DEVELOPMENT

COMPANY LIMITED, HYDERABAD

DESEIN PVT. LTD CONSULTING ENGINEERS,

NEW DELHI

P. O. NO.

3191400105

DATED

07/09/11

PANEL SL. NO. :

2740/1, 2
BIP/75/1, 2

CHLORIDE POWER SYSTEMS & SOLUTIONS LIMITED

(A wholly owned subsidiary of EXIDE Industries Limited)
AN ISO 9001:2008 COMPANY
REGISTERED OFFICE: EXIDE HOUSE
59 E, CHOWRINGHEE ROAD,
KOLKATA 700020
ADDRESS FOR CORRESPONDENCE: PLOT NO. Y-21, BLOCK EP, SECTOR-V
SALT LAKE ELECTRONICS COMPLEX
BIDHAN NAGAR, KOLKATA 700 091
PHONE NOS: 2357-5851 / 2357-5852 / 2357-5853 / 2357-5854
E-mail: info@caldyneautomatics.com
URL: http://www.caldyneautomatics.com

UIN 1007018

CPSSL.

Page 1 of 16

CONTENTS
ANNEXURE - I

TECHNICAL SPECIFICATION

ANNEXURE - II

SYSTEM DESCRIPTION

ANNEXURE - III -

SYSTEM DESCRIPTION OF THE AVR UNIT

ANNEXURE IIIA -

SYSTEM DESCRIPTION OF THE ACR UNIT

ANNEXURE IV

PROTECTION & ANNUNCIATION CIRCUIT

ANNEXURE V

PRE-COMMISSIONING CHECKS & COMMISSIONING

PROCEDURE

ANNEXURE VI

TROUBLE SHOOTING PROCEDURES

ANNEXURE VII -

WITNESSED TEST REPORT

ANNEXURE VIII -

DRAWINGS & BILL OF MATERIALS

DRAWING & BOM NOS.

BATTERY
CHARGER

UIN 1007018

POWER CIRCUIT
GENERAL ARRANGEMENT
RELAY MODULE WIRING DETAILS
BILL OF MATERIALS

CPSSL.

BC-11-288
BC-11-289
RL -11-289
BOM-BC-11-288-289

Page 2 of 16

ANNEXURE - I
TECHNICAL SPECIFICATION OF AUTOMATIC FLOAT & BOOST
BATTERY CHARGING EQUIPMENT
SUITABLE FOR 220 VOLTS 187AH PLANTE BATTERY

FLOAT CHARGER - SCR CONTROL:

1.00

Input Power Supply

415 Volts + or - 10%, 3-Phase, 3Wire,

50 Hz. 5%.

2.00
2.01
2.02
3.00

Output Voltage
Auto
Manual
Output Current

243 Volts (2.23V/cell)

218V 243 Volts
40 Amps DC continuous including 70mA trickle
charging current.
Around 1% r.m.s. at full load and 243V DC.

4.00

Output Ripple

5.00

Output Regulation

6.00

Mode of Operation

7.00

Control Configuration

3-Phase full wave fully controlled thyristorised

bridge fed thru' 3-phase transformer and
controlled by constant potential controller
unit with load limiting feature (AVR).

8.00

DC Voltage setting adjustment

10% of nominal voltage

Around + or -1% for + or -10% supply

voltage fluctuation and 10% to 100% load
variation.
Automatic / Manual

BOOST CHARGER - SCR CONTROL:

1.00

Input Power Supply

2.00
3.00
3.01

Output Voltage
Output Current
Boost Charging
a) Normal charging
b) Initial charging

:
-

415 Volts + or - 10%, 3-Phase, 3 Wire,

50 Hz. 5%
Up to 2.4V/cell
40 Amps (max.)

18.2 Amps (max.) up to 2.4 V/cell

18.2 Amps (max.) up to 2.65 V/cell

4.00
5.00

Mode of Operation
Termination of Charging

Automatic / Manual
Automatic / Manual

6.00

Control Configuration

3-Phase full wave fully controlled thyristorised

bridge fed thru' 3-phase transformer and
controlled by constant current controller
unit (ACR).

7.00

Matching Battery Bank

109 Nos. lead acid cells of 187 AH capacity

(PLANTE)

8.00

DC Voltage setting adjustment

for Boost charging

70% - 100% of maximum Boost charging voltage.

UIN 1007018

CPSSL.

Page 3 of 16

9.00

DC current adjustment for Boost

Charging

10.00

Power factor at a)100% Load

b) 50% Load

11.00

30% - 100% of Boost charging current.

0.8 (displacement p.f.) (Displacement power factor

as per IS-4540)
0.78 (displacement p.f.) (Displacement power factor
as per IS-4540)

Current stabilisation for constant

current regulator for boost charger and time.

2%

12.00

Efficiency () at a) 100% load

b) 50% load

85%
80%

13.00

Boost Charging time

Within 10Hrs.

UIN 1007018

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ANNEXURE II
SYSTEM DESCRIPTION
FLOAT CHARGER (SCR CONTROL)
The float charger is meant for supplying the continuous DC load and at the same time trickle
charging the battery to keep it in fully charged condition.
The float charger may either be operated in Auto or Manual mode. In the Automatic mode, the
output voltage is held constant at a preset value whereas in manual position the output voltage
may be varied within the specified limit by an external potentiometer. The incoming AC supply to
the charger will be fed to a 3-phase double wound step down transformer thru' suitably rated
switch & fuse unit. The secondary of transformer will be fed to a 3-phase full wave full control
thyristorised bridge thru' line surge suppressor and high-speed semi conductor protection fuses.
The bridge circuit consists of 6 nos. of thyristors which are adequately protected by snubber
circuit against voltage transients. The triggering of the thyristors are controlled by the A.V.R unit
which senses feedback from the output voltage and current. These feedback signals are suitably
processed and compared with the reference generated in the A.V.R circuits, then the error is
amplified and phase compensated by high gain operational amplifier. The incorporation of
feedback ensures automatic correction of any deviation of the set voltage, which may arise due
to line or load fluctuations. The output of the final amplifier will be fed to triggering circuits,
which control the output voltage of the charger by adjusting the firing angle of the thyristors.
With the help of the A.V.R unit the regulation of the output voltage of the float charger may be
kept constant around 1% of the rated voltage against line or load fluctuations. Due to
incorporation of inner current loop, by which the output voltage drops as the rated load is
increased thereby automatically transferring the load to the battery in order to avoid the
overloading of the charger. Suitably designed L-C filter circuit is provided in this system to bring
down the ripple within the specified limit.

BOOST CHARGER (SCR CONTROL)

The Boost Charger is basically meant for quick charging the battery after a heavy discharge, so
as to restore the capacity of the battery within minimum time.
In this system the boost charger is an automatic constant current charger, consisting of a
suitably rated 3-phase double wound step down transformer fed thru' a suitably rated switch &
fuse unit. The secondary of the transformer is fed to a 3-phase full wave full control thyristorised
bridge thru' line surge suppressors and high-speed semi conductor protection fuses.
The bridge circuit consists of 6 nos. of thyristors, which are adequately protected by snubber
network as protection against voltage transients. The triggering of the thyristors are controlled
by an ACR Unit, which senses feedback from both the battery voltage and charging current.
These feedback signals are suitably processed and compared with the reference generated in the
ACR circuit, then the error will be amplified and phase compensated by high gain operational
amplifier. The incorporation of feedback ensures automatic correction of any deviation of the set
current, which may arise due to line fluctuations.
When battery voltage drops below a set value, the battery charging starts automatically at a
starting rate. Once the battery voltage reaches around 2.35 v/cell, the charging current will
automatically be reduced to the finishing rate by a current control circuit, which adjusts the
current limit reference to the charger with increase in battery voltage and will be maintained
constant up to the end point i.e. 2.75 v/cell. Once the battery voltage reaches around2.75 v/cell,
the battery will automatically be transferred to float mode and float charging continues as usual
manner.
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FUNCTIONAL DESCRIPTION OF CHARGER:

This system consists of a Float charger and a Boost charger. In this system the battery will
normally float across the float charger so that in case of power failure the battery can maintain
the load without interruption.
However, after heavy discharge of battery, the battery is placed on boost mode operation. At
that time load is taken care by float charger and boost charging is done by Boost charger.
Now if supply fails, the battery will be connected to the load bus through the DC contactor and
share the load.
When supply is present and battery is in boost charging condition and Float charger fails then
boost charging of Battery will be continued and the load is taken care by the battery through tap
cell diode & when Boost charging will be completed then DC contactor will be closed & Battery
will take care the load thru DC contactor.
However, if power supply fails, while boost-charging operation is in progress, the battery should
be connected to the load immediately to avoid any interruption.
During normal operation the tap cell diode will be reverse biased. In the event of power failure
during boost charging with battery isolated, the output voltage will start dropping. As soon as it
drops slightly lower than the cell voltage the diode will conduct thereby maintaining the voltage
at the load bus, though lower in magnitude, to avoid complete interruption of load supply.
However, after this brief interval, the DC contactor will energize thereby connecting the battery
to the load bus and restricting the original load voltage. Thus, this arrangement provides an
uninterrupted DC supply to the load.
In this system as described above a suitably AC voltmeter or Ammeter with Selector Switch is
provided for monitoring input supply voltage or current. DC Voltmeters are provided for
monitoring the output voltage of float chargers and boost charger. DC Ammeters are provided
for monitoring the output current of float chargers and boost charger. DC Ammeter is provided
for monitoring the battery path current. Necessary indications are provided for different status
and fault monitoring.

TABLE SHOWING THE SEQUENCE OF THE CHARGERS :

SL.
NO.
1

FLOAT
CHARGER
Float mode

BOOST
CHARGER
standby

Float mode

Boost mode

Fails to operate

Boost charger

UIN 1007018

BATTERY

CPSSL.

Trickle charging by float

charger
Boost charging by boost
charger
discharging

LOAD
Fed by the float
charger
Fed
by
float
charger
Battery feeds the
load

Page 6 of 16

ANNEXURE III
SYSTEM DESCRIPTION OF AVR UNIT
FOR 3-PHASE FULL CONTROLLED SCR BRIDGE
The electronic controller (A.V.R) is the heart of the system, which maintains stable output D.C
voltage
of the charger in spite of supply voltage fluctuations and load variations. The electronic controller
basically consists of the following sections: -

1.0

POWER SUPPLY:

The power supply consists of a transformer which gives a dual step down voltage of 20 Volts A.C
from the line voltage which is rectified by two bridge rectifiers and further filtered by suitably
rated capacitors. The filtered output is then fed to 2 Nos. 3 terminal regulators which gives a
stable output of + or - 15 Volts D.C. Red and green LEDs are provided for visual indication of a
healthy supply voltage. From -15 V another voltage of 6.8 V is derived with the help of a
precision zener, which gives the reference signal for setting the output voltage. An unregulated
supply of + 24 Volts is also tapped to drive circuit.

2.0

REGULATOR CARD:

The regulator consists of the following sections:

a)

RAMP GENERATOR:

The ramp generator is provided to give a soft start feature which ensures gradual rise of output
voltage even if the reference is set at full value. It consists of an integrator, which determines
the slope i.e. the time for gradual rise of voltage.

b)

VOLTAGE REGULATOR WITH CURRENT LIMIT FEATURE:

The output of the ramp generator is fed to the voltage regulator, which consists of a suitably
compensated OPAMP. The reference signal is compared with the voltage feedback signal
obtained from the output. Then the error is phase compensated and amplified. The output is
then fed to the current regulator thru a potentiometer for giving current limiting action. The
voltage at the potentiometer is compared with the current feedback signal and is further
amplified and phase compensated by a precision OPAMP by properly setting the current limiting
potentiometer, the output current from the charger can be fixed at a required value.
The feedback signal is suitably processed and compared with the reference signal, then the error
will be amplified and phase compensated by high gain operational amplifier. The incorporation of
feedback ensures automatic correction of any deviation of the set voltage, which may arise due
to line or load fluctuations. Due to incorporation of inner current loop by which the output
voltage drops as the rated load is increased, thereby automatically transferring the load to the
battery in order to avoid the overloading of the charger. This part only functions when the
system is in constant voltage mode.
UIN 1007018

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c)

CURRENT REGULATOR:

The current regulator controls the load current/ charging current by comparing the current
feedback signal with an internal reference signal and subsequent amplifications and phase
compensation thru the amplifier. The reference signal is proportional to the 10% extra of load
current / charging the battery up to 2.30 v/cell of battery. Whenever an error is encountered at
the input of the amplifier, the error will immediately be amplified and phase compensated by a
high gain operational amplifier. The incorporation of feedback ensures automatic correction of
any deviation of the set current, which may arise due to line or load fluctuation. The output of
the final amplifier is fed to the triggering circuit, which controls the output current by adjusting
the firing angle of the thyristor.

d)

FIRING CIRCUIT:

The output of the current regulator is fed to the firing circuit for modulating the position of the
pulse, fed to the thyristor for achieving the closed loop control action. The firing circuit consists
of 3 nos. identical "UJT" controlled osicillator circuits for triggering thyristors. Each section is
properly synchronised with the line voltage so as to trigger the thyristors in right sequence. The
frequency of the oscillator circuit is varied by the control signal from current regulator, thereby
achieving pulse position modulation. The output pulse obtained from the base terminals of UJT's
are utilised for triggering thyristors. Potentiometers are provided on each firing channel for
balancing the conduction angle of individual phases at operating conditions to ensure balance
loading on input supply lines.

3.0

AUXILIARY CARD:

The auxiliary card consists of 3 nos. additional pulse generator circuits, synchronized with the
negative half cycle of the input line voltage. The main card and auxiliary thus generate 6
independent triggering pulses necessary for sequential firing of 6 nos. thyristors of the 3-phase
full control Thyristorised Bridge.

4.0

GATE FIRING LOGIC CARD:

The pulse logic module is used for feeding the trigger pulses to the gate-cathode of the
thyristors, after necessary cross coupling between primary pulses thru' double secondary pulse
transformer.

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ANNEXURE IIIA
SYSTEM DESCRIPTION OF ACR UNIT
FOR 3-PHASE FULL CONTROLLED SCR BRIDGE
The electronic controller (A.C.R) is the heart of the system, which maintains stable output D.C.
voltage of the charger in spite of supply voltage fluctuations and load variations. The electronic
controller basically consists of the following sections: 1.0

POWER SUPPLY :

The power supply consists of a transformer, which gives a dual step down voltage of 20 Volts
A.C from the line voltage, which is rectified by two bridge rectifiers and further filtered by
suitably rated capacitors. The filtered output is then fed to 2 Nos. 3 terminal regulators which
gives a stable output of + or - 12 Volts D.C within a regulation of + or - 1%. Red and green
LEDs are provided for visual indication of a healthy supply volatage. From -12 V another voltage
of 5.6 V is derived with the help of a precision zener, which gives the reference signal for setting
the output voltage. An unregulated supply of + 24 Volts is also tapped for drive circuit.
2.0

REGULATOR CARD :

The regulator consists of the following sections:

a)

RAMP GENERATOR:

The ramp generator is provided to give a soft start feature from which ensures gradual rise of
output voltage /current even if the reference is set at full value. It consists of an integrator,
which determines the slope i.e. the time for gradual rise of voltage/current.
b)

CURRENT REGULATOR:

During constant current mode, Shunt amplifier is incorporated to amplify the current feedback
signal obtained from the output shunt. The amplifier has provisions for variable gain under
different operating conditions of the battery charger.
The current regulator controls the charging current by comparing the current feedback signal
with an internal reference signal and subsequent amplifications and phase compensation thru
the amplifier. The reference signal is proportional to the starting rate of charging, after which the
reference is automatically reduced to the finishing value of current.
Whenever an error is encountered at the input of the amplifier, the error will immediately be
amplified and phase compensated by a high gain operational amplifier. The incorporation of
feedback ensures automatic correction of any deviation of the set current, which may arise due
to line or load fluctuation. The output of the final amplifier is fed to the triggering circuit, which
controls the output current by adjusting the firing angle of the thyristor.

UIN 1007018

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Page 9 of 16

c)

FIRING CIRCUIT:

The output of the current regulator is fed to the firing circuit for modulating the position of the
pulse, fed to the thyristor for achieving the closed loop control action. The firing circuit consists
of 3 nos. identical pulse generator oscillator circuits for triggring thyristors. Each section is
properly synchronised with the line voltage so as to trigger the thyristors in right sequence. The
output pulse obtained from the base terminals of UJT are that is utilised for triggering thyristors.
The frequency of the oscillator circuit is varied by the control signal from current regulator,
thereby achieving pulse position modulation. Potentiometers are provided on each firing channel
for balancing the conduction angle of individual phases at operating conditions to ensure balance
loading on input supply lines.

3.0

AUXILIARY CARD:

The auxiliary card consists of 3 nos. additional pulse generator circuits, synchronized with the
negative half cycle of the input line voltage. The main card and auxiliary thus generate 6
independent triggering pulses necessary for sequential firing of 6 nos. thyristors of the 3-phase
full control Thyristorised Bridge.

4.0

GATE FIRING LOGIC CARD:

The pulse logic module is used for feeding the trigger pulses to the gate-cathode of the
thyristors, after necessary cross coupling between primary pulses thru' double secondary pulse
transformer.

UIN 1007018

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Page 10 of 16

ANNEXURE IV
ANNUNCIATION AND PROTECTION SCHEME
ALARM AND PROTECTION SCHEME
The basic controls circuits are protected with suitably rated SWITCHE/MCB/MCCB & fuses to
protect the controller section, relay module power supplies, aux. AC supply and annunciation.
The fault sensing circuits are AC supplies trouble, charger over current, DC output under &
over voltage etc.
The Alarm Module is an electronic circuitry with LED lamps and alarms, with separate TEST,
ACCEPT & RESET push buttons. On occurrence of a fault that particular lamp will glow with
huge sound of HOOTER and when ACCEPT button is pressed, it only stop the sound of
HOOTER but the respective lamp still will be in glow mode. The lamp remains glowing until
RESET push button is pressed. If the fault is already cleared, the lamp goes off but glows
again if the fault persists.
A set of potential free NO contact common to all faults of Relay is provided for remote
annunciation of BATTERY CHARGER TROUBLE for customers use.

AC SUPPLY TROUBLE (ACSTR)

These consist of sensing circuits, which sense the input, supply voltage and OPAMP
comparator circuits at the input of which the input supply voltage, after being suitably scaled
down or up, are compared with a preset stable reference voltage. When the AC input supply
voltage becomes lower or higher than the preset minimum or maximum level the comparator
output switches thus energizing the relay or when phase failure occurs the comparator
output switches thus de-energising the relay. The relay activates the audio/visual
annunciation circuit for fault monitoring.

Unbalance voltage
between any two
phases
Cut off at
Trip
delay

time

Auto reset gap

UIN 1007018

Under Voltage

Over Voltage

40V 6V

Site selectable between Site selectable

80%-95%
of
Aux. 105% - 120%
supply
supply

3.5 Sec 1.5 sec

Less than 2 sec.

between
of Aux.

Less than 2 sec.

Less
than
74V
Set value plus 3% + Set value plus 3% + 1% of
unbalance between all
1% of Aux. supply
Aux. supply
three phases

CPSSL.

Page 11 of 16

CHARGER OVER CURRENT RELAY

The charger is provided with DC over current relay driver circuit which trips charger AC
contactor when the load current exceeds the preset value. In this control circuit high gain opamp comparator circuits are provided for over load protection of the chargers. The load
current is compared with the input of the comparator and a stable preset maximum level of
current. The output of the comparator drives the over current relays thru timer circuits to
introduce time delay for relay actuation to prevent tripping due to momentary over load.
Separate push buttons are provided for re-setting the relay once the fault is acknowledged.
Relay contacts are also interlocked with the audio/visual annunciation circuit for fault
monitoring. This circuit will only operate if the current limiting circuit in the main controller
fails to operate.

CHARGER UNDER CURRENT RELAY

The charger is provided with DC under current relay driver circuit which trips charger AC
contactor when the load current goes below the preset value. In this control circuit high gain
op-amp comparator circuits are provided for under load protection of the chargers. The load
current is compared with the input of the comparator and a stable preset minimum level of
current. The output of the comparator drives the under current relays thru timer circuits to
introduce time delay for relay actuation to prevent tripping due to momentary under load.
Separate push buttons are provided for re-setting the relay once the fault is acknowledged.
Relay contacts are also interlocked with the audio/visual annunciation circuit for fault
monitoring. This circuit will only operate if the current limiting circuit in the main controller
fails to operate.

INTEGRATED DC SENSING RELAY MODULE

DC UNDER/OVER VOLTAGE RELAY
These consist of sensing circuit which sense the output DC voltage at the load terminal, after
being suitably scaled down and is compared with the stable preset reference. When this
voltage goes lower or higher than the stable preset level, the under or over voltage relay
actuates. Relay contacts are interlocked with the audio-visual annunciation circuit for fault
monitoring.
DC under voltage can occur in case of power failure and charger failure below set voltage.
DC over voltage will occur only if the controller circuit becomes faulty or if the filter capacitor
fuse fails imposing a high ripple voltage above set voltage at the output.

CHARGER FAIL:
This consists of high gain op-amp comparator circuit at the input of which the charger output
voltage, after being suitably scaled down, is compared with a stable preset reference. When
the charger output voltage does not appear or becomes lower than the preset minimum level
the comparator output switches after a fixed time delay to avoid false tripping, thereby
energising the charger fail relay. Relay contact is interlocked with the audio/visual
annunciation circuit for fault monitoring & to give some back-up power to load.

UIN 1007018

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Page 12 of 16

BATTERY ON LOAD RELAY

This electronic circuit ensures the battery discharge condition. This incorporates a time delay
feature to prevent wronged signal of the relays during short current discharge as often
happens during float charging operations due to the closing or tripping operation of circuit
breakers. The relay circuits drive its DC supply from the battery bank and the battery signal
is compared with a suitable reference at the input of the high gain comparator. When the
battery signal reaches in stable condition during discharge, the relay actuate with a time
delay thru' switching of the comparator. The relay contacts are also interlocked with the
annunciation circuit for fault monitoring.

AUTO EQUALISING RELAY:

Auto equalizing charging facilities are provided in this system. The purpose of equalizing
charge is to bring the cells in a battery bank in step, since they tend to fall out of step during
prolonged float charging operation.

Auto equalizing relay card is meant for automatic equalizing charging of the battery
bank (recommended half rate of charging current), when the battery draws a current
more than a specified value continuously during floating operation. The electronic
control card basically consists of a shunt amplifier, which constantly monitors the
battery trickle charging current by amplifying the signal derived from the ammeter
shunt in series with the battery. The amplified signal is compared with a stable
reference at the input of a high gain comparator and when it exceeds the preset
reference for more than 30 Sec. the output switches, thereby actuating the auto
equalizing relay which is suitably interlocked to switch the float cum boost charger in
equalizing mode of Charging, as per selection of the switch. The battery voltage is
also compared with a stable reference at the input of another comparator. When the
battery voltage on charge reaches around set value, it switches off the relay after a
pre-adjusted time delay and the battery is again transferred to the float-charging
mode and trickle charging continues in the usual manner.

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ANNEXURE V
COMMISSIONING INSTRUCTIONS
VISUAL CHECK:
After unpacking the panel, inspect the panel externally for any damage of components during
transits (lamps, switches, meters, etc). If anything is found damaged, replace it at the earliest.
Open the panel and check all connections and the mounting conditions of relays and printed
circuit boards.

Check the insulation of the input lines (marked R, Y, B) the bottom of the back of the panel
with a 500 Volts megger. If megger is not available, the same should be checked using a
good avometer in the higher resistance scale. The insulation resistance should be more than
5 M-ohms.

Check the input supply voltage. This should be within 415 Volts 10%. If found O. K. then
connect the line at the input terminals (R, Y, B) after checking the phase sequence. The
panel should be properly earthed thru the earthing terminals provided at the back of the
panel. Connect a resistive load at the output terminal (F+ & F-) after making sure that there
is no shorting in the load circuit.

FLOAT CHARGER CHECK:

Keep the Auto / Manual selector switch, provided inside the panel to "manual" position.
Switch on float input and output MCCB. Indicating lamps should glow and output voltage
and load current should be shown in the voltmeter and ammeter. If any adjustment in the
output voltage is required, the setting of the potentiometer, provided on the front door of
the panel, should be adjusted to set the voltage at the required value. Do not tamper the
setting of any other potentiometer, which may otherwise lead to serious malfunctioning of
the float charger. If the above tests are O.K switch off the input isolator.

BOOST CHARGER CHECK:

Connect a dummy load same as in the float charger to the terminals marked B+ and B-.
Keep the Auto / Manual selector switch, provided inside panel, to manual position Change
the voltmeter selector switch to boost position. Switch on boost charger input and output
MCCB. DC voltmeter will show some voltage and ammeter will show some current. The
input and output indicating lamps should glow.

If any adjustment in the charging current is required the setting of the potentiometer,
provided on the front door of the panel, should be adjusted to set the current at the
required value. Do not tamper the setting of any other potentiometer, which may otherwise
lead to serious malfunctioning of the boost charger. If above tests are O.K switch off the
input isolator.

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LOAD TEST
FLOAT CHARGER:

After performing the above tests connect the actual load across the float charger output
terminals after making sure that there is no shorting in the load circuit.

Now, keeping the auto / manual selector switch to auto position. Switch on float input
isolator. The output voltage and load current will be shown in the voltmeter and ammeter.
If the load/current exceeds the rated value, the output voltage will start dropping due to
load limiting action. If the above tests are O.K. switch off input isolator.

BOOST CHARGER:

Connect the battery +ve and -ve terminals carefully to the boost charger output terminals
marked B+ and B- and also connect the battery tap cell point to the terminals marked TC.
Keep the auto/ manual selector switch to auto position. Switch on boost charger input
isolator. Now check the boost charging current in the Ammeter. Once the battery voltage
reaches up to 2.75 v/cell, the battery will automatically be transferred to float charging thru'
the float/boost changeover relay circuit and float charging continues as usual manner.

SPECIAL NOTE:

From the tap cell of the battery, a diode bank is connected to the output of the float
charger for supplying uninterrupted load during the change over interval due to the finite
time constant of the DC contactor coil. However, during commissioning special care
should be taken regarding its connection to avoid damage to the tap cell diode and
associated circuit if by mistake the float charger is switched on during the initial charging
operation with the load connected to the system, in that case a continuous current will
flow thru the tap cell circuit and it may get damaged due to overheating and also results
in uneven charging of the battery cells. It is preferable to disconnect the tap cell diode
from the circuit during commissioning and connection should only be restored with
battery fully charged and kept in floating condition with float charger energised to keep
the tap cell diode in reverse biased condition.

NOTES : FOR INITIAL CHARGING OF THE BATTERY, STRICTLY FOLLOW

THE PROCEDURE MENTIONED IN THE BATTERY MANUAL.

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A N N E X U R E VI
TROUBLE SHOOTING PROCEDURE
POWER CIRCUITS
OBSERVATION: No Voltage is obtained at the output of Charger
Disconnect the output load circuits and Switch ON input isolator
Input Indicating Lamps are glowing?

No
|
Is AC Supply voltage available?
|
No

Yes
|
Is AC voltage available at the input of the rectifier bridge ?
|
Yes

a) Check for input supply failure

No

a) Check the lamp ballast resistance

and lamps, rectify the fault.

b) Check the input fuses. Replace

it after rectifying any possible
fault which could be an earth
fault or short circuit in the
Charger

a) Check AC Contactors

b) If even after energising the

Contactor no output results
then check the transformer
secondary voltage.

Yes
a) Check Thyristors by measuring
the Anond Cathode resistance

b) Check the electronic control

circuit provided for automatic
operations.

c) If secondary voltage is O.K. then

Check the High-speed fuse/MCB.
NOTE :

UIN 1007018

It is very much desirable to have a ready stock of critical spares such as Thyristors, Diodes, HRC Fuses, Filter Capacitors,
Electronic Control Card etc. so as to replace the damaged components with minimum delay.
CPSSL.

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