Ope

rational & M

aintenance

Manual for 2

20V 550A D

FCBC

d

ubas

1

du

ba

s

MX SERIES BATTERY CHARGER

80010

200010

80010

80010

80010

100 190010

FCBC - 1FCBC - 1

FCBC - 2FCBC - 2

80010

SWC

DU

AL

FL

OA

T C

UM

BO

OS

T C

HA

RG

ER

+ S

WIT

CH

ING

CU

BIC

LE

Ope

rational & M

aintenance

Manual for 2

20V 550A D

FCBC

d

ubas

2

CO

NG

RA

TU

LA

TIO

N

Congratulation

s for choosing dubas Product. Y

ou now belon

g to dubas family of

over many satisfied custom

er across the world. d

ubas is a 100%

dedicated company to

Power Electron

ics Industry

. With

absolute knowledge

of techn

ologies and

understan

ding the

importan

ce of Battery

Charger

in a critical

automated

environ

ment, we have built our products to provide reliability

to the industry

and

commerce. d

ubas is been

in pow

er electronics in

dustry over a decade an

d has done

various pioneerin

g works in

power electron

ics. dubas is an

ISO 9001 certified

company. dubas delivers un

comprom

ised quality products an

d services to accomplish

highest customer satisfaction

.

Ope

rational & M

aintenance

Manual for 2

20V 550A D

FCBC

d

ubas

3

Op

era

tion

& In

stru

ctio

n M

an

ual

Fo

r

MX

-SE

RIE

S B

AT

TE

RY

CH

AR

GE

R

DE

SC

RIP

TIO

N

: D

UA

L F

LO

AT

CU

M B

OO

ST

CH

AR

GE

R

+ S

WIT

CH

ING

CU

BIC

LE

RA

TIN

G

: 1

36

KW

INP

UT

: 3-4W, 415V, +

10% -1

0%, 5

0 Hz,

OU

TP

UT

: 220V

DC

Co

nfig

ura

tion

: T

he System consists of fo

llowing sub-systems.

a) C

harger 1

& 2

: 3, 415V AC input, O

/P 136KW, 220V DC

b) S

witching Cubicle

: 220VDC, 5

50A

This m

anual is a

ccompanying the above-referred

product, w

hich has been manufactured in accordance w

ith the

customer p

urchase o

rder, co

nforming to dubas quality system

s for manufacturing quality. T

he operating procedure,

maintenance, in

stallation, tro

uble sh

ooting in the even

t of fault occurren

ce has been given

in this m

anual. Electrica

l

hazards given

in this m

anual must be understo

od and strictly fo

llowed otherwise it co

uld prove fa

tal. P

lease refer

to warranty certifica

te for warranty co

ver details.

PLEASE READ THE M

ANUAL THOROUGHLY, B

EFORE OPERATING THE SYSTEM.

DU

BA

S E

NG

INE

ER

ING

PV

T. L

TD

.,

# 43 (P

), Electro

nics City Phase II,

Hosur M

ain Road, B

angalore, 5

60 100.

Phone: +

91-80-40336000 (3

0Lines) F

ax: 0

80-40336222,

E-m

ail d

ubas@vsnl.com, service@dubaspower.c

om visit u

s @

www.dubaspower.c

om

Ope

rational & M

aintenance

Manual for 2

20V 550A D

FCBC

d

ubas

4

Ta

ble

of C

on

ten

ts

1

.0

Syste

m D

es

crip

tion

----------

5

2.0

T

ec

hn

ica

l Sp

ec

ifica

tion

----------

6

3.0

In

sta

llatio

n &

Co

mm

iss

ion

ing

Im

po

rtan

t Sa

fety

Ins

truc

tion

s ----------

9

Ins

talla

tion

----------

10

Co

mm

issio

nin

g

----------

16

4.0

S

yste

m C

on

stru

ctio

n

----------

17

5.0

O

pe

ratin

g M

od

es

----------

22

6.0

In

dic

atio

ns

, Co

ntro

ls a

nd

Dis

pla

y ----------

2

5

7.0

Us

er In

terfa

ce

Dis

pla

y

----------

28

8.0

B

atte

ry C

ha

rgin

g M

eth

od

s

----------

30

9.0

R

ou

tine

Main

ten

an

ce

----------

3

2

10

.0

Re

pla

ce

me

nts

---------

33

11

.0

Tro

ub

le S

ho

otin

g F

or

Ba

ttery

Ch

arg

er

----------

37

12

.0 F

ailu

re R

ep

ort

----------

3

9

13

.0 Q

ua

lity P

olic

y

----------

4

1

14

.0 P

rod

uct V

arie

ties

----------

42

15

.0 M

ajo

r Bill o

f Qu

an

tity

---------

43

16

.0 A

S B

UIL

T D

RA

WIN

GS

---------

5

3-5

9

FU

NC

TIO

NA

L C

HA

RT

Ope

rational & M

aintenance

Manual for 2

20V 550A D

FCBC

d

ubas

5

1.0

SY

ST

EM

DE

SC

RIP

TIO

N

The availability

factor o

f a DC UPS SYSTEM is

paramount. W

hich is determ

ined by th

e quality

and perio

dicity of

preventive m

aintenance, o

perating conditio

ns (e

nviro

nmental, lo

ad determ

ined and operator d

eterm

ined), a

s well a

s

the dovetail o

f the actual application re

quire

ments and system design crite

ria.

The document is

intended to

facilita

te th

e operator to

optionally utiliz

e th

e 220V BC as DC UPS SYSTEM and we

sincerely believe th

at it a

chieves th

is goal effe

ctively.

Du

ba

s Batte

ry Chargers, ty

pe M

X: B

atte

ry Charger is

a ra

nge of IG

BT contro

lled re

ctifie

r units, fo

r charging `L

ead

Acid' or `N

ickel C

admium' B

atte

ries. T

his can also be used as a general power s

upply without a

batte

ry connected

in parallel. In

case batte

ry is always connected in parallel w

ith th

e charger a

nd lo

ad, th

is system constitu

tes a DC

UPS system.

The Charger is

of C

onstant V

oltage Curre

nt lim

ited type, w

ith th

ree levels of voltage fo

r charging th

e batte

ry. T

hese

levels are `A

uto Float C

harge', M

anual flo

at C

harge and `M

anual B

oost C

harge' le

vels; w

hich essentially designate

band voltage le

vels th

at c

an be set a

s per c

harging re

quire

ment o

f the batte

ry (w

hich is determ

ined by th

e ty

pe of

batte

ry). "M

anual B

oost C

harge" v

oltage is re

quire

d to

recharge a discharged batte

ry, a

nd "A

uto Float C

harge" is

require

d fo

r keeping th

e alre

ady charged batte

ry in

fully charged conditio

n. U

nder b

oth Float a

s w

ell a

s B

oost

charging conditio

n th

e Charger o

utput c

urre

nt c

an be lim

ited to

values ra

nging fro

m 10% to

100% of th

e charger

output capacity.

Output v

oltage re

gulation is

achieved by IG

BT contro

l. IGBT bridges w

hich are switched using PWM te

chnique

ensures bette

r input power factor under all working conditio

ns which is a plus point compared to a thyristor

contro

lled re

ctifie

r circuits. T

his w

ill also ensure a very lo

w percentage of in

put h

arm

onics curre

nt is

fed to

the

source and also th

e in

put P

ower fa

ctor is

maintained to

unity fro

m 10% to

100% of ra

ted lo

ad. T

he C

onverte

r

contro

l logic is fu

lly softw

are based & is perfo

rmed by W

orlds leading D

igita

l Sig

na

l Pro

ce

ss

or.

This batte

ry charger h

ere onwards re

ferre

d as equipment consists The DC system shall c

omprise of 2

no.s Float

cum Boost C

hargers (e

ach ra

ted fo

r 100% capacity) o

perating in parallel m

ode and equally sharin

g to

tal lo

ad

simultaneously a

nd 1 sets of B

atte

ries (ra

ted fo

r 100% Capacity). T

he details of th

e scheme are explained in th

e

furth

er c

hapter.

WARNING

1.

The Batte

ry Charger P

anel has to

be operated only by skille

d operators, w

ith necessary authorization.

2.

The Batte

ry Charger s

hall n

ot b

e accessible to

unauthorized personnel.

3.

The Batte

ry Charger p

anel shall b

e opened only in Power O

ff conditio

n.

4.

Only qualifie

d service te

chnicians shall h

ave th

e access to

open th

e door. In

side of B

atte

ry C

harger

panel has Very dangerous electric

al components, which can potentially electro

cute the careless

operator.

Ope

rational & M

aintenance

Manual for 2

20V 550A D

FCBC

d

ubas

6

2.0

TE

CH

NIC

AL

SP

EC

IFIC

AT

ION

(GU

AR

AN

TE

ED

TE

CH

NIC

AL

PA

RT

ICU

LA

RS

)

A) B

atte

ry C

ha

rge

r

1. Ite

m No. a

s per P

.O

----

2. T

ag No.

----

3.M

anufacturers Name

d

ub

as E

ng

ine

erin

g P

vt L

td.

4. T

ype

D

FC

BC

5. N

o. o

f Dual F

CQ Chargers

1

SE

T (2

NO

s)

6. In

put A

C Voltage

4

15

V +

/-1

0%

, 3

, 4 w

ire

7. Frequency

50

Hz +

/-3

%

8.In

put P

ower fa

ctor a

t rated voltage & load

>

0.9

5

8.1 Fault le

vel

50

KA

Fo

r 1S

ec

9. In

put A

C curre

nt : a

. Float m

ode

b. Q

uick m

ode

24

4A

10

4A

10.Rating in Float m

ode

a.) C

harger R

ating

13

6K

W

b.) O

utput V

oltage & %

varia

tion

2

47

V, +

/-1

%

c.) Output C

urre

nt &

% variation

5

50

A, +

/-1

%

11

. Rating in quick m

ode

a.) C

harger R

ating

58

KW

b.) O

utput V

oltage & %

varia

tion

2

64

V, +

/-1

%

c.) Output C

urre

nt &

% variation

2

20

A, +

/-1

%

12

. Nominal V

oltage

a.) F

loat C

harging

2

47

V

b.) Q

uick Charging

2

64

V

13.M

anual F

loat C

harging voltage ra

nge

2

20

2

47

V (S

etta

ble

)

14. M

anual B

oost C

harging voltage ra

nge

2

20

2

96

V (S

etta

ble

)

15.M

inimum effic

iency o

f the charger

a.) A

t 25% load

>8

0%

b.) A

t 40% load

>8

0%

c.) A

t 50% load

>8

0%

d.) A

t 75% load

>8

5%

e.) A

t 100% load

>8

5%

16

. Ma

x. e

fficien

cy a

t No

min

al in

pu

t & co

rresp

on

din

g o

utp

ut

>8

5%

@ R

ate

d lo

ad

17

. Ma

x. R

MS

ripp

le v

olta

ge

con

ten

t at ra

ted

loa

d

a). W

ith b

atte

ry co

nn

ecte

d

+/

-1%

b). W

itho

ut b

atte

ry co

nn

ecte

d

+/

-1%

Ope

rational & M

aintenance

Manual for 2

20V 550A D

FCBC

d

ubas

7

18

. Me

tho

d o

f vo

ltag

e co

ntro

l

a). In

floa

t mo

de

C

V

b). In

qu

ick m

od

e

VL

19

. Me

tho

d o

f curre

nt co

ntro

l

a). In

floa

t mo

de

C

L

b). In

qu

ick m

od

e

CC

20

. Sa

fety

Fa

ctor u

sed

for se

lectin

g co

mp

on

en

ts 1

.5 fo

r Ele

ctron

ic po

we

r de

vice

s & 1

.25

for

Ele

ctrical co

mp

on

en

t

21

. Ch

arg

er D

ime

nsio

ns

a). W

idth

(mm

)

80

0 m

m

b). D

ep

th (m

m)

70

0 m

m

c). He

igh

t (mm

) 2

00

0m

m

22

. Ma

x. H

ea

t loss in

wa

tts 4

77

96

Wa

tts

23

. De

gre

e o

f pro

tectio

n (IP

) IP

31

24

. Re

fere

nce

Sta

nd

ard

s IE

C-6

01

46

25

. Pa

int S

ha

de

a).In

side

R

AL

70

32

b).O

utsid

e

RA

L 7

03

2

26

. Dim

en

sion

s of sw

itchin

g cu

bicle

a).W

idth

(mm

) 8

00

mm

b). D

ep

th (m

m)

70

0 m

m

c). He

igh

t (mm

) 2

00

0m

m

27

.No

ise le

ve

l AQ CO Set)

OFF/FLT AF AF AF CW OFF OFF OFF ON ON 2

AQ changeover don't occur when Alternate FCBC is

OFF/Fault

6

FCBC 2 is MF Charging the BATT & FCBC1 is Feeding the load

AF AF MF MF CW ON OFF OFF OFF ON 2

7

FCBC 2 is MB Charging the BATT & FCBC1 is Feeding the load

AF AF MB MB CW ON OFF OFF OFF ON 2

8

FCBC 2 was MB charging the BATT & FCBC1 is Feeding the load

later boost charge timer is completed at FCBC2

AF AF AF MB CW ON OFF OFF OFF ON 2

To repeat the Manual Boost charge of BATT , position

MSS to AF and reposition MSS to MB by this timer will

reset to zero and manual boost charge shall commence

at FCBC2.

9

FCBC 2 was MF/MB charging the BATT & FCBC1 is Feeding the

load later FCBC2 fails

AF AF OFF/Fault MB CW ON ON OFF OFF OFF 2

DC2A / DC2B switches OFF when Alternate FCBC is

healthy & Alternate FCBC MSS is selected to MF/MB OR

Alternate FCBC is on AQ mode.

10

FCBC 2 was MB charging the BATT & FCBC1 is Feeding the load

later boost charge timer is completed at FCBC2 , BATT Amps >

AQ CO Set).

AF AF AF MB CW ON OFF OFF OFF ON 2

FCBC2 working in AF mode will not go AQ CO(Even if

BATT Amp > AQ CO set) unless MSS is positioned to

AF

11

FCBC 2 was MF/MB charging the BATT & FCBC1 is Feeding the

load later MSS at FCBC1 selected to MF/MB

AF MF/MB MF/MB MF/MB CW ON OFF OFF OFF ON 2

FCBC1 with not work in MF/MB/AQ when PSSw is

selected to FCBC2

12

FCBC 2 was MF/MB charging the BATT & FCBC1 is Fault/OFF

Load is Fed Through TCD

OFF/Fault AF MF/MB MF/MB CW OFF OFF OFF OFF ON 2

13

FCBC 2 was MF/MB charging the BATT & FCBC1 is Fault/OFF

Load is Fed Through TCD later FCBC 2 is OFF/Fault

OFF/Fault AF OFF/Fault MF/MB CW OFF OFF ON OFF OFF 2

14

FCBC 1 is AQ charging the BATT, FCBC2 is Feeding the load

(BATT Amps > AQ CO Set) AQ AF AF AF CW OFF ON OFF ON OFF 1

FCBC1 goes to AQ CO only if PSSw is selected to

FCBC1 & BATT1 Amps > AQ CO Set

15

FCBC 1 is MF/MB Charging the BATT & FCBC2 is Feeding the

load

MF/MB MF/MB AF AF CW OFF ON OFF ON OFF 1

LF

Ref

FCBC1 FCBC2

FCBC which is operating in AQ/MF/MB mode BATT

contactor is switched OFF i.e., DC1A /DC1B

Notes:-

--> Column PSSw if mentioned 2 it is to be understood that AQ/MF/MB Pre-Select switch is selected to FCBC2

---> In status column if AF is mentioned, it say the FCBC is ON in AF mode similarly for MF & MB

--> If any one node (controller ) i.e. Main Controller / Auxiliary Controller of FCBC1 / 2 is disconnected from the CAN BUS it will be displayed as CF (CAN Fail)

--> With PSSw selected to FCBC 1 above mentioned Logics (LC1-13) can be performed, (Replace FCBC1 to FCBC2 & FCBC 2 to FCBC1)

--> When FCBC1 & FCBC2 are working in parallel mode, If the Load current is less than 120A , entire load current shall be fed by the FCBC which is working as MASTER

--> When FCBC1 & FCBC2 are working in parallel mode, If the Load current is greater than 120A , entire load current shared between FCBC1 & 2

--> FCBC working as master is indicated with M at STATUS & OUTPUTPARAMETER at GT100 diplay

--> When FCBC operating as slave (Indicated as S at Status & Output Parameter) FCBC does not share any of the load current.

--> When FCBC operating as slave parallel (Indicated as S PAR at Status & Output Parameter) Both the FCBC's shares the total load current.

Abbreviations

MF : Manual Float MSS : Mode Select Switch

MB: Manual Boost PSSw : Pre-Select Switch

AQ : Auto Quick AQ CO : AutoQuick Change Over

BATT : Battery CF/CW : CAN bus Fail / Working