DOCUMENT No PCPL-0532-4-407-04-12 1.

0 SCOPE

BATTERY CHARGER

SECTION - 4 PAGE: 1 of 6

This specification covers requirements of Battery Charger & DC Distribution Board (DCDB) equipment comprising of rectifier rectifier transformer and au!i"iary equipment. #.0 #.1 CODES STANDARDS The design manufacture and performance of equipment sha"" comp"y $ith a"" current"y app"icab"e statutes regu"ations and safety codes in the "oca"ity $here the equipment $i"" be insta""ed. %othing in this specification sha"" be construed to re"ieve &'%D() of this responsibi"ity. *n"ess other$ise specified equipment sha"" conform to the "atest app"icab"e standards as mentioned in Data +heet,-#. TYPE The battery charger sha"" be static type preferab"y composed of si"icon contro""ed rectifiers (+C)s) connected in three,phase fu"" $ave bridge circuit. Transducer contro" may be offered as an a"ternative for "arge sets if +C)s are not feasib"e. The rectifier transformer sha"" be indoor dry type doub"e $ound $ith adequate number of primary and secondary taps. RATING The f"oat charger sha"" be designed for supp"ying0 a.) The DC "oads specified in Data +heet,-. b) The f"oat charging current of the battery. /.# /.. /./ The boost charger sha"" be designed for supp"ying the boost charging current of the battery. 1hen a composite (f"oat2Boost) charger is specified it sha"" be designed to meet the requirements specified in C"auses /.1 and /.#. 3t sha"" be the responsibi"ity of &'%D() to co,ordinate $ith the battery 4-%*5-CT*)') and ascertain the f"oat and boost charging currents and vo"tages required by the battery. CHARGER DCDB CUBICLE !IRING Cubic"e accessories and $iring sha"" conform to the requirements as stated in the fo""o$ing c"auses and in the companion specification for Contro" Cabinets. 7.0 7.1 7.# ACCESSORIES 'ach battery charger sha"" inc"ude the fo""o$ing0 (ne (1) set , si"icon contro""ed rectifiers connected in three phase fu"" $ave bridge circuit $ith ripp"e fi"tering device. (ne (1) set , doub"e $ound dry type main transformer of suitab"e rating $ith adequate primary and secondary taps for the charger output vo"tage contro".

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DATE:22-06-2006 ISSUE No: P0

DOCUMENT No PCPL-0532-4-407-04-12 7.. 7./ 7.6 7.7 7.9 7.: 7.; 7.10 7.11 7.1# 7.1. 7.1/ 7.16 7.17 7.19 9.0

BATTERY CHARGER

SECTION - 4 PAGE: 2 of 6

(ne (1) set , booster transformers as required. (ne (1) set , automatic vo"tage regu"ator unit (for f"oat chargers) $ith manua"2auto contro" s$itch. (ne (1) set , coarse and fine contro" 8nobs for manua" contro". (ne (1) , se"ector s$itch for modes of charging i.e. f"oat charging2boost charging. This sha"" be as indicated in the diagram referred to in Data +heet,-. (ne (1) , off "oad tap changing s$itch for changing the primary taps of the transformer. (ne (1) , D.C. vo"tmeter $ith 4CB and se"ector s$itch for measuring the output vo"tage. (ne (1) , D.C. ammeter $ith shunt (ne (1) T<% incoming 4CCB unit on -.C. side of each charger a"ong $ith +C (= & '5 re"eases and a"arm contacts. (ne (1) D< 4CCB on D.C. output side of each charger $ith +C (= '5 and a"arm contacts. (ne (1) , centre >ero ammeter $ith shunt for battery circuit. T$o (#) sets , si"icon diodes arranged in series for connection bet$een the end ce"" tap on the battery and the positive bus of charger output. (ne (1) , cubic"e space heater $ith contro" s$itch and 4CB suitab"e for #/0& -C 60 ?>. sing"e phase supp"y. (ne (1) , #/0 & -C "amp for cubic"e interna" "ighting. T$o (#) , (n , (ff s$itch $ith 4CB for items 7.1/ and 7.16. T$o (#) , si"icon diodes in series in the f"oat charger circuit. INDICATION PROTECTION 'ach battery charger sha"" be provided $ith the fo""o$ing indication and protective devices0

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Three (.) c"uster ='D type indicating "amps on the -C supp"y of the charger. (ne (1) c"uster ='D type indicating "amp on the DC output side. T$o (#) -C under vo"tage re"ays connected across phases on the -C supp"y side $ith a"arm contacts for annunciator. Therma" over"oad e"ements on each phase of the -C contactor on the supp"y side $ith a"arm contacts for remote annunciator. PER"ORMANCE The automatic constant vo"tage regu"ator sha"" regu"ate the DC vo"tage $ithin 1@ of the set va"ue from no "oad to fu"" "oad under the supp"y vo"tage and frequency f"uctuations of A2, 10@ and A2, 6@ respective"y.

DATE:22-06-2006 ISSUE No: P0

DOCUMENT No PCPL-0532-4-407-04-12 :.# :.. ;.0 ;.1

BATTERY CHARGER

SECTION - 4 PAGE: 3 of 6

The f"oat charger sha"" have bui"t,in current "imiting feature to drop the output vo"tage on currents more than 110@ of the rated current. +uitab"e ripp"e fi"tering circuits sha"" be provided to give a smooth DC output. The ripp"e content sha"" be "imited to "ess than A2, 6@ on resistive "oad. DCDB: Battery charger sha"" inc"ude a DCDB for distribution of DC supp"y to various essentia" "oads. DCDB sha"" be provided $ith 4CCB for incomer & outgoing contro". The detai"ed feeder ratings sha"" be as detai"ed at Data +heet DCDB CONSTRUCTION DETAILS: +$itchgear sha"" be designed in such a $ay that a"" component equipment operate satisfactori"y $ithout e!ceeding their respective ma!imum permissib"e temperature rises under temperature conditions prevai"ing $ithin the s$itchgear cubic"es. )eference ambient temperature outside the s$itchgear cubic"es is specified in Data +heet B-. &enti"ating "ouvers are genera""y not preferred. 3f venti"ating "ouvers are considered essentia" by the &endor these may be provided. ?o$ever a"" venti"ating "ouvers sha"" be of C.3 or non,ferrous meta" and sha"" be provided $ith fine,screened meshes to prevent entry of &ermin. +$itchgear sha"" be provided $ith t$o bus bars. Bus bars sha"" be uniform cross section throughout the "ength of the s$itchgear and up to the incoming termina"s of feeder circuit brea8er2s$itch. '!cept $hen other$ise noted in Data +heet,- a"" bus bars sha"" be made of high conductivity a"uminium. -"" bus bars bus taps and Doints sha"" be using se"f adhesive <&C tape. <ositive and negative bus bars sha"" be comp"ete"y segregated from each other by sheet stee" partition. Bus bars sha"" be adequate"y supported and braced to $ithstand the stresses due to the specified short circuit currents of the associated s$itchgear. Bus bar supports sha"" be made of ?y"am sheets mou"ded p"astic materia" or perma"i $ood. +eparate supports sha"" be provided for bus bar of each po"arity. 3f a common support is provided for both the bus bars anti,trac8ing barriers sha"" be provided. Bus bar Doints sha"" be of the bo"ted type comp"ete $ith Be""evi""e $asher. Bus bars sha"" be thorough"y c"eaned at the Doint "ocations and suitab"e contact grease sha"" be app"ied Dust before ma8ing a Doint. MOULDED CASE CIRCUIT BREA%ER 3ncomer and outgoing feeder contro" sha"" be $ith 4CCBEs of suitab"e rating as specified in Data +heet,-. 4ou"ded case circuit brea8ers sha"" comp"y $ith the requirements of the specification. MINIATURE CIRCUIT BREA%ERS

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DATE:22-06-2006 ISSUE No: P0

DOCUMENT No PCPL-0532-4-407-04-12 11.1

BATTERY CHARGER

SECTION - 4 PAGE: 4 of 6

4iniature circuit brea8ers sha"" be provided in a"" contro" circuits in p"ace of ?)C fuses. 4CBEs sha"" be suitab"e for DC app"ication and sha"" comp"y $ith the requirements of the specification. CONTROL AND SELECTOR S!ITCHES Contro" and se"ector s$itches sha"" be0 i) ii) iii) (f the rotary type $ith enc"osed contacts -dequate"y rated for the purpose intended (minimum acceptab"e rating is 10-) <rovided $ith escutcheon p"ates c"ear"y mar8ed to sho$ the positions.

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INDICATING INSTRUMENTS AND METERS '"ectrica" indicating instruments sha"" be of the taut band type $ith 110,mm square dia" and #/0( sca"e. 3ndicating instruments sha"" have provision for >ero adDustment from outside the cover. 3nstrument dia"s sha"" be para""a! free $ith b"ac8 numera"s on $hite bac8ground dia". INDICATING LAMPS 3ndicating "amps sha"" be0 i) ii) (f the c"uster type ='D type and of "o$ $att consumption. <rovided $ith trans"ucent "amp covers of co"ours F)edG FCreenG and F-mberG as specified in Data +heet,- Contro" $iring diagrams

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PUSH BUTTONS <ush buttons sha"" be0 i) ii) iii) i) ii) iii) iv) (f the momentary contact push to actuator type rated to carry 7- at ##0& D.C. 5itted $ith se"f reset %2( and %2C contacts <rovided $ith integra" escutcheon p"ates mar8ed $ith its function. F+tartG push button sha"" be green in co"our. F+topG push button sha"" be red in co"our. -"" other push button sha"" be b"ac8 in co"our. F'mergency stopG push button sha"" be of the "oc8ab"e type in the pushed position and sha"" be shrouded to prevent accidenta" contact by operating personna".

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SPACE HEATERS +pace heaters sha"" be0 i) ii) +uitab"e for operation on #/0 & sing"e phase 60 ?> supp"y. <rovided $ith rotary type F(%,(55G s$itches ?)C fuses on "ine "eads and "in8s on the neutra" "eads or doub"e po"e 4CBGs $ith over"oad and short circuit re"eases on the main side.

DATE:22-06-2006 ISSUE No: P0

DOCUMENT No PCPL-0532-4-407-04-12 iii) 19.0 19.1

BATTERY CHARGER

SECTION - 4 PAGE: 5 of 6

<rovided $ith humidistat to contro" the space heater in order to maintain s$itchgear interior at a temperature 6(c above the ambient.

CABLE TERMINATIONS +uitab"e compression type of brass cab"e g"ands mounted on a removab"e g"and p"ate sha"" be provided to support a"" po$er and contro" cab"es entering the s$itchgear. Cab"e g"ands sha"" incorporate bui"t,in faci"ities for earthing the $ire armour of cab"es. -"" cab"e cores sha"" be adequate"y supported at regu"ar interva"s inside the cab"e a""eys by means of suitab"e rubber or <&C "ined c"amps up to the respective termina" b"oc8s. %ecessary crimping type of cab"e "ugs for connecting the individua" cores to the respective termina"s sha"" be provided. INTERNAL !IRING -"" $iring inside the s$itchgear sha"" be carried out $ith 76021100& grade 5)=+ <&C insu"ated stranded Copper conductor $ires. 4inimum si>e of conductor for po$er circuits is 7 sq. mm a"uminium. Contro" circuits sha"" be $ired $ith copper conductor $ires of at "east #.6 sq. mm si>e. 'ngraved identification ferru"es mar8ed to correspond $ith the enc"osed $iring diagrams sha"" be fitted to each $ire. 5erru"es sha"" be of ye""o$ co"our $ith b"ac8 "ettering. -"" $ires forming part of a tripping circuit sha"" be provided $ith an additiona" red ferru"e mar8ed FTG. +pare au!i"iary contacts of a"" equipment forming part of the s$itchgear sha"" be $ired up to the termina" b"oc8s. -"" $iring for equipment supp"ied by the <urchaser for $hich &endor has to provide cutouts ($here indicated in the Data +heets) sha"" be provided up to the termina" b"oc8s. +pare and unassigned modu"es sha"" be comp"ete $ith interna" $iring. -"" $iring sha"" be terminated on to termina" b"oc8s using crimping type of "ugs. TERMINAL BLOC%S -"" termina" b"oc8s (both for po$er and contro" circuits) sha"" be of the 760& grade stud type comprising fine"y threaded pairs of brass studs of at "east 7 mm diameter "in8s bet$een each pair of studs $ashers nuts and "oc8 nuts. The studs sha"" be secure"y "oc8ed $ithin the mounting base to prevent its turning. 3nsu"ated barriers sha"" be provided bet$een adDacent termina"s. -"" termina"s for circuits $ith vo"tage e!ceeding 1#6& sha"" be shrouded. Termina" b"oc8s sha"" be grouped and suitab"y segregated depending on circuit vo"tage. Different vo"tage groups of termina" b"oc8s sha"" be segregated. Termina" b"oc8s sha"" be adequate"y rated to carry the current of the associated circuit. 4inimum rating of the termina" b"oc8 sha"" be 10<rovision sha"" be made to insert termina" "abe"s bet$een t$o successive insu"ating barriers. DATE:22-06-2006 ISSUE No: P0

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DOCUMENT No PCPL-0532-4-407-04-12 1;.6

BATTERY CHARGER

SECTION - 4 PAGE: 6 of 6

Termina"s sha"" be numbered for identification and grouped according to function. 'ngraved $hite,on,b"oc8 "abe"s sha"" be provided on the termina" b"oc8s describing the function of the circuit. 1here dup"ication of a termina" b"oc8 is necessary it sha"" be achieved by so"id bonding "in8s. Termina" b"oc8s for CT secondary "ead $ires sha"" be provided $ith short,circuiting "in8s and earthing faci"ities. Termina" b"oc8s sha"" be arranged $ith at "east 100,mm c"earance bet$een t$o ro$s of termina" b"oc8s. LABELS -"" "abe"s sha"" comprise $hite "etters on a b"ac8 bac8ground. =abe"s sha"" be made of non,rusting meta" or .,p"y "amicoid sheet. =abe"s sha"" be proper"y fi!ed $ith provision to prevent distortion due to e!pansion. +i>es of "abe"s and "ettering are subDect to <urchaserGs approva". EARTHING The s$itchgear sha"" be provided $ith an earth bus bar running a"ong the entire "ength of the board provided $ith stud ho"e at either ends to connect purchaserGs earth bus. 4ateria" and si>e of the earth bus bar sha"" be as specified in Data +heet,-. 'arth bus bars sha"" be supported at suitab"e interva"s. <ositive connection bet$een a"" the frames of equipment mounted in the s$itchboard and earth bus bar sha"" be provided by using insu"ated copper $ires2bare bus bars of cross section equa" to that of the bus bar or equa" to ha"f the si>e of circuit "oad current carrying conductor. -"" instrument and re"ay meta""ic cases sha"" be connected to the earth bus bar using 76021100& grade <&C insu"ated #.6 sq. mm stranded tinned copper earthing conductor. TESTS "ACTORY TESTS -"" type and routine tests as "isted in app"icab"e standards sha"" be carried out at 4-%*5-CT*)')Gs $or8s.

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ACCEPTANCE TEST )outine tests as per app"icab"e standards $i"" a"so be carried out on the assemb"ed unit at site.

DATE:22-06-2006 ISSUE No: P0