3 SW12 pole, 2 way ‘NO OFF’ cam type Auto/Manual mode selector switch for controller.
10A
4 SW2A/B2 pole Isolator for isolation of load (4 Pole isolator - 2Pole connected in parallel)
250A
5 SW3, 4 1 pole ON/OFF toggle switch for cubical lamp & heater. 10A
6 SW5, 6 1 pole ON/OFF switch for FAN 1-2 10A
REV.27 SW71pole, 2 way ‘NO OFF’ cam type Auto/Manual mode selector switch for CH.A/B
10A
REV.28 SW81pole, 2 way ‘NO OFF’ cam type Auto/Manual mode selector switch for Buscoupler
10A
1 VM1DC moving coil Voltmeter to read the charger output voltage
0-50V DC
2 AM1DC moving coil ammeter to suitable shunt to read the charger o/p current.
0-400A
3 AM2DC moving coil Ammeter with suitable shunt to read the discharge /charge of the battery.
400A-0-400A
4 SH1-3Shunt for the Charger output current, Load current & Batt. Voltage
0 - 400A / 75mV
PRINTED CKT.BOARD, ELECTRONIC RELAY, FFDS & CONTROL CARDS.
1 FFD1,2Fuse Fail Detector Circuit of solid state sensing type for FS4-9
24V
2 FFD3Fuse Fail Detector Circuit of solid state sensing type for FS10
24V
3 FFD4Fuse Fail Detector Circuit of solid state sensing type for FS11-12
24V
4HV & PF PSR CKT.
High Voltage & Phase fail/phase sequence reversal ckt. 25VA/415V
5 CPC13-phase SCR controller for constant voltage/current mode of operation.
24V
6
DISPLAY UNIT WITH ANNUNCIATOR
Charger Monitoring & Annunciation circuit for displaying voltage/current parameters on LCD as well as Window type Annunciation with RS485 communication.
24V
7 mV AmpMillivolt amplifier circuit for battery current limit in float mode
4A
REV.28 ACORAutomatic change-over relay for auto float/boost mode change-over.
24V
CONTACTOR'S & AUXILARY RELAY
1 CA1, CA2Auxiliary contactor for AC mains fails annunciation & interlocking purpose.
4A/415V AC Coil
2 CA3 Auxiliary contactors for Float / Boost selection. 4A/24V DC Coil
3 CA4 Auxiliary contactor for charger DC O/P failure annunciation. 4A/24V DC Coil
OPERATION WRITEUP The System comprises of 2x100% Float Cum Boost Chargers (Charger-A & Charger-B), 1x100% DC Distribution Board & 2x100% Battery.The float-cum-Boost Chargers A&B, DC Distribution Board and Battery are connected in parallel. The battery charger-A&B will float charge respective battery &Charger-A supply the load connected through DCDB.
When Both the AC source fails then buscoupler C2 will close automatically depending on the position of SW-8 ( Auto/ Maual Closing selection of Bus coupler )& both batterie will get discharge to certain extent depending upon the duration of power failuer & Load current.
When charger operateds in float mode DC contactor C1A/B remains closed. When the power resumes, the battery has to be recharged. Regharging of batteries is automatic as well as manual.Automatic boost charging selection will be through ACOR & Manual Boost charging operation will be through push buttons. During boost charging of batteries the load will be supplied through the dropping diodes.. Interlock is provided such that when both the chargers are healthy then only ( Charger -A& Charger-B) will operate in Boost Mode.
For detail operation of charger refer LOGICAL SIMULATION TABLE attached.
DISPLAY UNIT :
The Display unit consist of
a) 4 Line LCD display : The Upper 2 lines are utilised for Metering purpose & Lower 2 lines are utilised for Battery Cell Status display.The Metering Parameters will be displayed are as follows,i) Charger A DC Vii) Charger A DC Aiii) Charger B DC Viv) Charger B DC Av) Load DC Vvi) Load DC AThe Battery Cell status parameters will be dispalyed as follows,i) Cell No.ii) Cell Voltageiii) Cell status (High / Low / Normal)
PROTECTIONS PROVIDED:1 AC MCCB2 DC SWITCH+FUSES3 DC CURRENT LIMIT 4 BLOCKER DIODE FOR REVERSE VOLTAGE BLOCKING5 FUSES FOR RECTIFIER, CAPACITOR, CONTROL SUPPLY
When battery gets full charger the ACOR gets rest & Charger will revert back in float mode.If the ACOR fails to revert back the charger in float mode then the suporting Timer T1 will revert back the charger in float mode when the set time on the timer laps.Thus the batterise are prvented from geting over charge.
Each Float cum Boost charger has i) Constant Current & ii) Constant Voltage mode.
Normally, in float mode the charger will float the batteries at 1.4V per cell within a stabilization of ±1% of the floating voltage. The float charger-A will supply the trickle charging current required for the batteries and will also feed the DC continuous load as required. During this time, the float charger-A and the battery are across the DC load terminals.When Charger-A fails the bus coupler will close automaticaly( depend on position of Switch SW 8) & load will be supplied by battery charger -B as well as both batteries will be trickle charge by charger-B Or When Charger-B fails the bus coupler will close automaticaly( depend on position of Switch SW 8 , by selection of this switch one can close the bus coupler manualy also) & load will be supplied by battery charger -A as well as both batteries will be trickle charge by charger-A.
After resumption of AC power both chargers will operate inetially in float mode. The battery draws higher current, this Higher current will be senced by the ACOR ( Automatic Change Over Relay) which will operate the charger in boost mode automatically , when Switch SW-7A/B is at Auto Float -Boost position.One can operate the charger in boost mode Manualy by selecting the switch SW 7 at Manual float -boost mode through the push buttons. During boost charging of batteries DC Contactor C1 A/B gets open & the load will be supplied through the dropping diode by maintaing the load voltage within the range of 20V-31Volts
b) Inputs / Outputsi) Analog Input - 7Nos. [ i) Charger A DC V, ii) Charger A DC A, iii) Charger B DC V, iv) Charger B DC A, v) Load DC V, vi) Load DC A, vii) Cell Voltage ]ii) Digital Inputs - 18Nos. [Annunciation Faults - 14Nos. + ATRH]iii) Digital Outputs - 15Nos.[Annunciation Faults - 14Nos. + Bz]iv) RS485 Modbus serial communication port
The Digital ouputs for Annunciation will be as followsa) CH.A AC MAINS FAILb) CH.A RECTIFIER FUSE BLOWNc) CH.A FILT. FUSE BLOWNd) CH.A DC FAILe) CH.A FLOAT MODE ONf) CH.A BOOST MODE ONg) CH.A DC FUSE BLOWNh) CH.B AC MAINS FAILi) CH.B RECTIFIER FUSE BLOWNj) CH.B FILT. FUSE BLOWNk) CH.B DC FAILl) CH.B FLOAT MODE ONm) CH.B BOOST MODE ONn) CH.B DC FUSE BLOWNo) LOAD DC UNDER VOLTAGEp) LOAD DC OVER VOLTAGE
c) Power Supply : 24V DC
The Digital inputs for Annunciation will be as followsa) CH.A AC MAINS FAILb) CH.A RECTIFIER FUSE BLOWNc) CH.A FILT. FUSE BLOWNd) CH.A DC FAILe) CH.A FLOAT MODE ONf) CH.A BOOST MODE ONg) CH.A DC FUSE BLOWNh) CH.B AC MAINS FAILi) CH.B RECTIFIER FUSE BLOWNj) CH.B FILT. FUSE BLOWNk) CH.B DC FAILl) CH.B FLOAT MODE ONm) CH.B BOOST MODE ONn) CH.B DC FUSE BLOWN
BHMS
The Battery Health Monitoring System comprises of the Battery data collector & transmits the same to the dispaly unit.The data collector will select the data of individual cell which will be transmitted to the LCD dispaly & the LCD dispaly will dispaly the same as above.
2 - 2
CHARGER-A CHARGER-B CONTACTOR C1A
CONTACTOR C1B
BUS COUPLER C2
LOAD BATTERY-A BATTERY-B REMARK
AC Mains/DC Fail AC Mains /DC Fail
CLOSE CLOSE CLOSE By Battery __ __ Load will be supplied by both the Battery Banks.
Float Mode AC Mains/DC Fail
CLOSE CLOSE CLOSE By Charger-A Trickled charged by Charger-A
Trickled charged by Charger-A
Charger-A will operate in float mode & will supply load as well as trickle charge both the Battery set.
AC Mains/DC Fail Float Mode CLOSE CLOSE CLOSE By Charger-B Trickled charged by Charger-B
Trickled charged by Charger-B
Charger-B will operate in float mode & will supply load as well as trickle charge both the Battery set.
Float Mode Float Mode CLOSE CLOSE OPEN By Charger-A Trickled charged by Charger-A
Trickled charged by Charger-B
Charger-A will operate in float mode & will supply load as well as trickle charge battery-A & Charger–B will trickle charger Battery B.
Boost Mode (Manually by
PB1A /Automatically through ACOR-
A)
Float Mode OPEN CLOSE OPEN By Charger-A Battery will be Boost charged by Charger-A
Trickled charged by Charger-B
Charger-A will boost charge the battery-A as well as supply load through the dropping diodes. Bus coupler will remains open. Charger-B will trickle charger battery-B. During this condition if the charger-B fails, Charger-A will revert back in float mode & will supply the total load & also trickle charge both the battery banks by closing C1A & Bus coupler and load will be supplied by Charger-A.
Float Mode Boost Mode (Manually by
PB1B /Automatically through ACOR-
B)
CLOSE OPEN OPEN By Charger-A Trickled charged by Charger-A
Battery will be Boost charged by Charger-B
Charger-B will boost charge the battery-B. Bus coupler will remains open. Charger-A will trickle charger battery-A. During this condition if the charger-A fails, Charger-B will revert back in float mode & will supply the total load & also trickle charge both the battery banks by closing C1B & Bus coupler and load will be supplied by Charger-B.
