DOC.NO.

: S-MAN-126-12

OPERATION AND MAINTENANCE MANUAL

FOR
220V/450A FLOAT & 450A FLOAT-CUM-BOOST CHARGER

INPUT VOLTS : 415 VAC ± 10%, PHASE-3, FREQ. : 50 Hz. ± 5%

OUTPUT VOLTS : FLOAT: 247.5V BOOST: 302.5V

OUTPUT AMPS : FLOAT: 450.0 A BOOST: 450.0 A

UNIT SERIAL NOS. : 13B08215- 13B08217

CLIENT : BHARAT HEAVY ELECTRICALS LIMITED

OWNER : WEST BENGAL POWER DEVELOPMENT CORPN. LTD.
CONSULTANT : DEVELOPMENT CONSULTANTS PVT. LTD., KOLKATA
PROJECT : SAGARDIGHI THERMAL POWER PROJECT UNIT-3 & 4
(2X500MW)

MANUFACTURED BY
Statcon Power controls Ltd.
A-34, SECTOR-59, NOIDA,G. B. NAGAR - 201301 (U.P.)
TELE: 0120-3851760, FAX: 0120- 3851796
Email: info@stat-con.com, Web site : www.stat-con.com

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 DOC.NO.: S-MAN-126-12

CONTENTS

Sl. No. PARTICULARS PAGE NO.

1. INTRODUCTION 3

2. SAFETY PRECAUTIONS, HEALTH & SAFETY 4

3. INSPECTION AND INSTALLATION 5

4. GUARANTEED TECHNICAL PARTICULARS- BATTERY CHARGER 6

5. FRONT PANEL DOOR CONTROLS, INDICATIONS AND DISPLAY FLOAT CHARGER 10

6. CONTROLS & POTENTIOMETER PROVIDED INSIDE AT THE FRONT –FLOAT CH. 12

7. FRONT PANEL DOOR CONTROLS, INDICATIONS AND DISPLAY FCBC 13

8. CONTROLS & POTENTIOMETER PROVIDED INSIDE AT THE FRONT FCBC 15

9. TERMINALS PROVIDED IN BATTERY CHARGER 16

10. COMMON CONTRLS, INDICATION & METERS 16

11. INITIAL INSTALLATION AND OPERATING INSTRUCTIONS 17

12. OPERATING PROCEDURE 18

13. GENERAL DESCRIPTION & OPERATION OF 220V FLOAT AND BOOST CHARGER 26

14. DESCRIPTION OF MAIN CONTROL CARD CC1 (SPCL-312V3) 29

15. DESCRIPTION OF AUTO FIRING CARD CC2 (SPCL-333V1) 31

16. DETAILS OF PRESET OF AUTO FIRING CARD (SPCL-333V1) 32

17. DESCRIPTION OF MANUAL FIRING CARD CC7 (SPCL-404V1) 33

18. DESCRIPTION OF MAINS SENSING CARD CC3 (SPCL-326V1) 34

19. TROUBLE SHOOTINGS 35

20. CUSTOMER FEED BACK FORM 37

21. ENCLOSURES

a. MECHANICAL DRAWING

b. ELECTRICAL DRAWING

c. BILL OF MATERIAL

d. CONTROL CARDS

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 DOC.NO.: S-MAN-126-12

INTRODUCTION

All protection circuits work on a D.C. Source. This is generally stationary lead acid battery.
Once the battery is charged it requires to be kept on float to meet internal losses of the
battery. Also it needs recharging in case of battery is drained. This is accomplished with the
help of battery charger. To meet the load demand, the D.C source of power should be a
highly stable and reliable. In addition batteries need a high voltage for its charge completion
(called boost charging). At the same time battery bank can’t be and should not be
disconnected from load while being boost charged. Since in case of mains power interruption
it might take limited time, battery should be available at load bus.

Therefore, the D.C power equipment should meet following requirements:-

i. It should operate on AC commercial mains available.

ii. It should supply a highly stable D.C power at very low ripple.

iii. It should meet full load demand.

iv. It should be capable of supplying battery boost charge current while still
supplying the protection circuits load demands.

v. Voltage at the load terminals should not exceed the defined limits & protection
should be produced against over voltage appearing at load terminals.

STATCON’S BATTERY CHARGER is designed to meet all these requirements.

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 DOC.NO.: S-MAN-126-12

SAFETY PRECAUTIONS

HEALTH & SAFETY

Installation, testing, fault location and repair should only be attempted by authorized,
qualified and skilled electrical technician. This equipment carries dangerous voltages and
stores electrical energy. Statcon shall not be held responsible for electrocution of the
personnel, in any way, carrying out any type of work in the equipment.

Before touching, remove metal objects, e.g., metal bracelets, rings or necklaces which
comes into contact with electricity carrying items. Carry out the following instructions.

1. Isolate the AC main supply external to the equipment.

2. Isolate the Battery and the load external to the equipment.

3. Discharge all electrolytic filter capacitors (Refer to circuit diagram if necessary) by

connecting a 5 Kilo Ohm, 10 Watt Resistor across the terminals of each capacitor for a
minimum period of 10 seconds.

Care must be take not to short-circuit the capacitor terminals.

4. Isolate any live Alarm signal lead external to the equipment.

5. Check with a suitable scaled voltmeter fitted with insulated test prods that the
equipment does not carry any voltage at either the input or the output before
commissioning work.

The above instructions (1) to (5) must always be followed before making any adjustment, and
also before making any electrical connections to the part of the equipment for the purpose of
servicing. Such connections should always be checked for safety before re-applying power.

The above instructions (1) to (5) must also be carried out before any connection is modified
or removed.

Note:

Adjustment should only be carried out with a non-conducting tool taking care not
to touch any item carrying electricity while doing so.

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INSPECTION AND INSTALLATION

Initial inspection and preliminary check out procedure are recommended for safe operation.
Please follow step-by-step procedure described in the chapter.

INITIAL INSPECTION:

Inspect the package for external evidence of damage and inform company handling in transit.
Notify the damage and inform company immediately if any. Do not destroy or remove any of
packing materials used in damaged shipment.

After unpacking unit inspect through visual check to detect any transit damage to any
component on the front panel or inside the cubicle. If any loose or broken connections are
noticed set them right.

MECHANICAL INSTALLATION:

The panels are free standing steel structure and should be installed in dust free well
ventilated place.

Clean the equipment properly to remove dust particles settled on the components and the
equipment.

ELECTRICAL INSTALLATION:

1. Connect AC input supply on terminal/strip provided in this equipment.

2. Connect the firm earth to the panel.

3. Push all the fuses, they might have become loose in transit.

4. Check that all the PCB connections are properly connected in their correct position.

Important Note: - Please do not change the setting of potentiometer/preset before switching
on the unit.

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 DOC.NO.: S-MAN-126-12

GUARANTEED TECHNICAL PARTICULARS - BATTERY CHARGER

S.No. DESCRIPTION
220V/450A 220V/450A
FLOAT CHARGER FLOAT CUM
BOOST CHARGER
B BATTERY CHARGER
1.0 General
1.1 Make STATCON POWER CONTROLS LTD
(STATCON Make)
1.2 Catalogue number NA
1.3 Type FC+FCBC
1.4 Reference standard As per specification
2.0 Rating
2.1 A.C. Input
a) Voltage + % variation V 415+/-10%
b) Phase 3 Phase,4Wire
c) Frequency + % variation 50 Hz.+/-5%
d) Input current at rated load including A 225A (Approx.) 275A (Approx.)
supply of battery charging current.
2.2 DC output
a) Voltage V/Cell 2.25 for Float Mode & 2.75 for Boost mode
2.75 ;110cells
b) Current A 450 450
2.3 Type of Cooling Natural Air Cooled
2.4 Maximum Temperature within cubicle
above 50o C ambient.
a) Rectifier Transformer
70 deg. C
b) SCR
60 deg. C
c) Choke
85 deg. C
3.0 Performance
3.1 Regulation for 0-100% rated load with + %
10% input voltage and + 5% input <+ / - 1 %
frequency variation.
3.2 Ripple content in DC output
a) with battery % < 1% RMS at nominal input voltage and
rated o/p
b) without battery % < 1% RMS at nominal input voltage and
rated o/p
3.3 Guaranteed efficiency at rated output % >85% >85%
3.4 Power factor at rated output % >0.8 lag at nominal input voltage
3.5 Rated output % 111.37 KW 136.12 KW
4.0 Miscellaneous
4.1 Charger provided with following features
a) Automatic Voltage Regulation Yes
b) Cuirrent limiting circuitry Yes
c) Smoothing filter circuit Yes
d) Soft start feature Yes
e) Is manual operation permissible ? Yes
4.2 SCR elements provided with
a) Surge protection Yes
b) Fast acting HRC Fuse Yes
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 DOC.NO.: S-MAN-126-12

5.0 AC Switch SFU USED

5.1 Make Refer Part & Make list
5.2 Type / Catalogue number Air break type
5.3 Reference standard IS 13947
5.4 Rated current A 315A 400A
6.0 AC Fuse
6.1 Make Refer Part & Make List
6.2 Type/catalogue number HRC
6.3 Reference standard IS 13703
6.4 Rated current
a) Continuous A 315 355
b) Interrupting kA 80
7.0 AC Contactor
7.1 Make REFER PART & MAKE LIST
7.2 Type/catalogue number Electromagnetic Type
73 Reference standard IS 13947
7.4 Rated current 250A 350A
7.5 Utilization category AC - 1
7.6 Thermal Overload with in-built single Seprate Single Phase Protection provided
phase preventer provided ? through SPP card
8.0 Rectifier Transformer
8.1 Make STATCON
8.2 Type/catalogue number Double Copper Wound Vaccum
Impregnated
8.3 Reference standard IS 2026
8.4 Ratings
a) kVA 141.1 172
b) Voltage ratio 415 : 221 415:270
c) Vector group Delta- Delta
d) % Z at 75 deg. C 5%
8.5 Class of insulation Class – F with temperature rise limited to
class - 'B'
8.6 Method of cooling Natural Air cooled
9.0 Controlled Rectifier (SCR)
9.1 Make Refer Part & Make List
9.2 Type / Catalogue number Monocrystalline Silicon
9.3 Reference standard
9.4 RMS current rating A 900 900
9.5 Surge current
a) One cycle kA 9 9
b) Repetitive cycle A Data not
Data not available
available
9.6 Peak inverse voltage
a) Continuous V 1200 V
b) Surge V Data not available
10.0 Filter Choke
10.1 Make STATCON
10.2 Choke rating mH 0.7 0.9
10.3 Quantity 1 1
10.4 Class of insulation CLASS – F
11.0 Filter Capacitor
11.1 Make and type Refer Part & Make List
11.2 Voltage class 315V
11.3 Capacitance rating uF 16000uF/350V or
13000uF/350V or eqv.
eqv.

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 DOC.NO.: S-MAN-126-12

11.4 Quantity
Total value to be split as per availability
12.0 DC Fuse
12.1 Make Refer Part & Make List
12.2 Type/catalogue number HRC
12.3 Reference standard IS 13703
12.4 Current Rating
a) Continuous A 500 500
b) Interrupting kA 33
13.0 DC Contactor
13.1 Make as per make list
13.2 Type/catalogue number Electromagnetic Type
13.3 Reference standard IS 13947
13.4 Rated current 500A
13.5 Utilization category DC1
14.0 Blocking Diodes
14.1 Make Refer Part & Make List
14.2 Type/catalogue number Monocrystalline Silicon
14.3 Reference standard
14.4 Current Rating 800A Iav 800A Iav
a) 10ms kA 7 7
b) Oned hour A 800 800
14.5 Peak inverse voltage v 800
15.0 Indication Lights
15.1 Make Refer Part & Make List
15.2 Type/catalogue number Bright led clustered
15.3 Reference standard
15.4 Wattage W 2.5 2.5
15.5 Series Resistor Ω in-built
16.0 Meters
16.1 Make Refer Part & Make list
16.2 Type/catalogue number LCD display and Analog panel meter
16.3 Reference standard
16.4 Size 96 X 96 sq mm for analog meter and
168 X 128 for LCD
16.5 Accuracy Class – 1.0
17.0 Alarm Facia LCD Provided
17.1 Make Refer Part & Make list
17.2 Type/catalogue number Panel Mounted
17.3 Reference standard
17.4 Number of Window per facia N.A
18.0 Changeover Switch, if applicable
18.1 Make as per make list
18.2 Type/catalogue number rotary changeover
18.3 Reference standard IS 13947
18.4 Rating 500A
18.5 Number of Poles THREE
18.6 Key interlock furnished.
19.0 DC Switch SFU USED
19.1 Make Refer Part & Make list
19.2 Type/catalogue number Air break switch
19.3 Reference standard IS 13947
19.4 Rating A 630 630
19.5 Number of Poles 3 3
19.6 Key interlock furnished. N/A NA
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 DOC.NO.: S-MAN-126-12

20.0 Charger Panel

20.1 Make STATCON
20.2 Type/catalogue number Floor Mounted free standing cubicle
20.3 Reference standard
20.4 Enclosure
a) Degree of protection IP – 42
b) Sheet Steel thickness 2.0mm
20.5 Panel Provided with
a) internal lamp with door switch Yes
b) space heater with thermostat Yes
c) 3-Pin 5A receptacle Yes
20.6 Internal wiring
a) Material Copper Wire
b) Insulation PVC
c) Voltage grade 1100V
d) Minimum conductor size 2.5 sq mm for Power wiring, 0.5 sq mm for
electronics, 2.5 sq mm for control wiring
e) Conductor whether solid/stranded Stranded
20.7 Power Terminal
a) make Refer Part & Make list
b) size / catalogue number 60x10 Al.(I/P ter.),50x6 cu.(load ter.),50x6
cu.(Batt. ter.)
20.8 Control terminal
a) make Refer Part & Make list
b) Size/cataqlogue number 2.5 sq mm
c) 10% spare terminal furnished yes
20.9 Ground terminal size: 50 X 6 sq mm G.I
20.10 Overall dimension (HxWxD)
(2200+100)Hx(1200+650+1200)Wx1000D
20.11 Approx. Weight 2000Kg for 1set.
20.12 GA drg. furnished yes
20.13 All accessories as specified furnished
with battery charger? Provided
20.14 Painting
Colour
RAL 7032
Finish Powder coated
Details of painting
20.15 Whether schematic diagramof the charger
has been enclosed? Enclosed
21.00 Load terminal voltage on float mode 247.5V
22.00 Gasket material Neoprene
23.00 Busbar material copper
24.00 Battery capacity/type 2250Ah/plante (L-A)

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FRONT PANEL DOOR: CONTROLS, INDICATIONS AND DISPLAY
FLOAT CHARGER
DISPLAY: PARAMETER
ƒ AC VOLTAGE:
ƒ AC CURRENT:
ƒ CHARGER VOLTAGE:
ƒ CHARGER CURRENT:
ƒ LOAD VOLTAGE:
ƒ LOAD AMPS:
KEYPAD CONTROLS:
ƒ FLOAT VOLTAGE:
ƒ SYSTEM CURRENT LIMIT:
DISPLAY ANNUNCIATION:
ƒ AC UNDER/OVER VOLTAGE:
ƒ INPUT FUSE FAIL:
ƒ SCR FUSE FAIL:
ƒ OUTPUT FUSE FAIL:
ƒ DC UNDER VOLTAGE:
BHEL DOC.NO.: PE-V0-373-508-E019
DOC.NO.: S-MAN-126-12
The LCD displays R, Y, B phase voltage of
415VAC three supply input supply.
The LCD displays R, Y, and B line current of
415VAC three phase input supply.
The LCD displays the float charger output DC
voltage.
The LCD displays the Output current which is
delivered by the float charger.
The LCD displays the load voltage.
The LCD displays the load current.
The float voltage of the charger within limit is set
through key pad.
Using the key pad the limit of the current (up to the
rated current) that can be drawn from the float
charger is set.
The LCD will display “AC Under/Over Voltage” fault
if the 415VAC input three phase supply is out of
specified range of operation.
The LCD will display “Input fuse fail” fault if the
fuses connected in input supply blows.
The LCD will display “SCR Fuse fail” fault if the
fuses connected in Rectifier Bridge of float charger
blows.
The LCD will display “Output fuse fail” fault if the
fuse connected in output DC circuit blows
The charger will display “DC UNDER Voltage” fault
if the output DC voltage of the charger or the
Page 10 of 37
 DOC.NO.: S-MAN-126-12

battery is lower than 1.85V/cell (battery discharged

level).

ƒ DC OVER VOLTAGE: The charger will display “DC OVER Voltage” fault if
the output DC voltage of the charger is higher than
set limit.

ƒ DC EARTH FAULT: The LCD will display “DC EARTH FAULT” is there
is earth leakage at the charger output DC side.

ƒ FILTER FUSE FAIL: The LCD will display “Filter Fuse Fail” fault if the
fuse(s) connected in filter capacitor circuit of float
charger are blown.

ƒ PHASE FAIL/REVERSE: The LCD will display “Phase fail/reverse” if there is

a missing phase or phase reversal of the three
phase input supply.

ƒ CHARGER FAIL/OFF: The LCD will display “CHARGER FAIL/OFF” if the

output voltage of the float charger fails due to any
reason.

ƒ MAINS FAIL: This indicates failure or off condition of mains AC

supply.

ƒ DC OVERLOAD: This indicates over load at the DC output side of

the Float charger.

INDICATIONS:

ƒ R, Y, B PHASE ON: This indicates that AC input supply (R, Y, B,

phase) is ON at the input of float charger.
ƒ DC ON: This indicates that the output DC voltage of the
float charger is available.
ƒ CONTROL SUPPLY ON: This indicates that the control supply is available.

CONTROL SWITCH:

ƒ START CONTROL SWITCH: This switch is used to ON/OFF input AC contactor.

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 DOC.NO.: S-MAN-126-12

CONTROLS & POTENTIOMETER PROVIDED INSIDE AT THE FRONT

FLOAT CHARGER

CONTROLS:
ƒ CHANGEOVER SWITCH: This switch is used to select one of the two input
supply sources.

ƒ INPUT SFU: This SFU connect or disconnect 415V AC 3-Ph

input supply to the float charger.

ƒ OUTPUT SFU: This SFU connect and disconnect float charger

output with load and battery.

ƒ SPACE HEAT SWITCH: This switch is used to switch-On/Off the AC supply

to the thermostatically controlled space heater.

ƒ LAMP ON /OFF SWITCH: This switch is used to switch–on/off the AC supply

to the panel lamp. Lamp glows only when the
panel door is opened.

POTENTIOMETER

ƒ MANUAL VOLT SET POT. : This potentiometer sets the voltage in manual
mode of operation of float charger.

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 DOC.NO.: S-MAN-126-12

FRONT PANEL DOOR: CONTROLS, INDICATIONS AND DISPLAY

FLOAT-CUM-BOOST CHARGER

DISPLAY: PARAMETER
ƒ AC VOLTAGE: The LCD displays R, Y, B phase voltage of
415VAC three supply input supply.

ƒ AC CURRENT: The LCD displays R, Y, and B line current of

415VAC three phase input supply.

ƒ CHARGER VOLTAGE: The LCD displays the boost charger output DC

voltage.

ƒ CHARGER AMPS: The LCD displays the Output current which is

delivered by the boost charger.

ƒ BATTERY VOLTAGE: The LCD displays the Battery Voltage.

ƒ TAP-CELL VOLTAGE: The LCD displays the voltage of the 85% tap-cell
(counting from the negative) of the battery bank.

ƒ BATTERY AMPS: The LCD displays the battery charging/discharging

current.

KEYPAD CONTROLS:
ƒ FLOAT VOLTAGE: The float voltage of the charger within limit is set
through key pad.
ƒ BOOST VOLTAGE: The boost voltage of the charger is set through the
key pad.
ƒ SYSTEM CURRENT LIMIT: Using the key pad the limit of the current (up-to the
rated current) that can be drawn from the charger
is set.
ƒ BATTERY CURRENT LIMIT: Using the key pad the limit of the current that can
be drawn by the battery can be set.

DISPLAY ANNUNCIATION:

ƒ AC UNDER/OVER VOLTAGE: The LCD will display “AC Under/Over Voltage” fault
if the 415VAC input three phase supply is out of
specified range of operation.

ƒ INPUT FUSE FAIL: The LCD will display “Input fuse fail” fault if the
fuses connected in input supply blows.

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 DOC.NO.: S-MAN-126-12

ƒ SCR FUSE FAIL: The LCD will display “SCR Fuse fail” fault if the
fuses connected in Rectifier Bridge of float charger
blows.

ƒ OUTPUT FUSE FAIL: The LCD will display “Output fuse fail” fault if the
fuse connected in output DC circuit blows

ƒ DC UNDER VOLTAGE: The charger will display “DC UNDER Voltage” fault
if the output DC voltage of the charger or the
battery is lower than 1.85V/cell (battery discharged
level).

ƒ DC OVER VOLTAGE: The charger will display “DC OVER Voltage” fault if
the output DC voltage of the charger is higher than
set limit.

ƒ DC EARTH FAULT: The LCD will display “DC EARTH FAULT” is there
is earth leakage at the charger output DC side.

ƒ FILTER FUSE FAIL: The LCD will display “Filter Fuse Fail” fault if the
fuse(s) connected in filter capacitor circuit of float
charger are blown.

ƒ PHASE FAIL/REVERSE: The LCD will display “Phase fail/reverse” if there is

a missing phase or phase reversal of the three
phase input supply.

ƒ CHARGER FAIL/OFF: The LCD will display “CHARGER FAIL/OFF” if the

output voltage of the float charger fails due to any
reason.

ƒ MAINS FAIL: This indicates failure or off condition of mains AC

supply.

ƒ DC OVERLOAD: This indicates over load at the DC output side of

the Float charger.

INDICATIONS:

ƒ R, Y, B PHASE ON: This indicates that AC input supply (R, Y, B,

phase) is ON at the input of boost charger.

ƒ DC ON: This indicates that the output DC voltage of the

boost charger is available.
ƒ CONTROL SUPPLY ON: This indicates that the control supply is available.

CONTROL SWITCH:

ƒ START CONTROL SWITCH: This switch is used to ON/OFF input AC contactor.

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 DOC.NO.: S-MAN-126-12

CONTROLS & POTENTIOMETER PROVIDED INSIDE AT THE FRONT

FLOAT-CUM-BOOST CHARGER

CONTROLS:
ƒ CHANGEOVER SWITCH: This switch is used to select one of the two input
supply sources.

ƒ INPUT SFU: This SFU connect or disconnect 415V AC 3-Ph

input supply to the float charger.

ƒ OUTPUT SFU: This SFU connect and disconnect float charger

output with load and battery.

ƒ SPACE HEAT SWITCH: This switch is used to switch-On/Off the AC supply

to the thermostatically controlled space heater.

ƒ LAMP ON /OFF SWITCH: This switch is used to switch–on/off the AC supply

to the panel lamp. Lamp glows only when the
panel door is opened.

POTENTIOMETER

ƒ MANUAL VOLT SET POT. : This potentiometer sets the voltage in manual
mode of operation of Boost charger.

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TERMINALS PROVIDED IN THE BATTERY CHARGER

INPUT AC SUPPLY TERMINAL: “R, Y, B & N” terminals are provided for connecting

Incoming supply 415v AC ±10%, 3 phase, 50 Hz

through Source-1 and Source-2

LOAD TERMINAL: X8-X9 are Load terminals, provided to connect the

load or DCDB.

REMOTE ALARM “TS1”: Potential free contacts of charger-fail relay are

terminated on this terminal which is then wired up
to the user’s control board for attending to the
charger group fault.

MOD BUS CONNECTOR “TS2”: This MOD BUS connector is RS-232

communication interface for SCADA. The charger
output parameters and faults are displayed on the
customer’s computer system when the program is
installed.

COMMON CONTROLS, INDICATION & METER

ƒ LOAD DC ON: This indicates that the DC supply is available on

Load terminals.

ƒ DC AMMETER : This meter shows Load current and Battery current

by selecting through DC Ammeter selector switch.

ƒ DC VOLMETER : This meter shows Load voltage and Battery

voltage by selecting through DC Voltmeter selector
switch.

ƒ DC AMMETER SELECTOR : This switch selects Load current and Battery

current to display on DC Ammeter.

ƒ DC VOLMETER SELECTOR : This switch selects Load voltage and Battery

voltage to display on DC Voltmeter.

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 DOC.NO.: S-MAN-126-12

INITIAL INSTALLATION AND OPERATING INSTRUCTIONS

a) Connect firm earth to the panels.

b) Connect input supply (Source-1 and Source-2) with neutral on the input supply
terminals ‘R, Y, B and N’ provided in the charger.

FOR FLOAT CHARGER

1. Switch on the charger with the help of input SFU. Switch-on the on/off control switch
provided on th front panel door. The charger will switch-on and the LCD will display
logo of Statcon.

2. Next the display will automatically show “charger volts”, “charger amps” and “float” in
first screen. The “load volts’ in second screen. In third screen it will show “R-Y volts, R-
phase amps”, “Y-B volts, Y-phase amps” and “B-R volts, B-phase amps”.

3. Switch-off the charger.

FOR FLOAT-CUM-BOOST CHARGER

4. Switch on the charger with the help of input SFU. Switch-on the on/off control switch
provided on th front panel door. The charger will switch-on and the LCD will display
logo of Statcon.

5. Next the display will automatically show “charger volts”, “charger amps” and “float” in
first screen. The “battery-volts”, “battery amps”, “tap-cell volts” in second screen. In third
screen it will show “R-Y volts, R-phase amps”, “Y-B volts, Y-phase amps” and “B-R
volts, B-phase amps”.

6. Switch-off the charger and connect battery; positive, negative and tap-cell on the
battery terminals provided inside the battery charger.

7. Switch-on the charger. The battery will draw current, which should be 10% of the
battery Ah capacity.

8. Switch –off the charger and connect load on the load terminals provided in float charger
unit.

The charger is now installed.

The charger parameter display and setting procedure is given in following pages. voltages
once set during installation should never be disturbed, unless the size and type of
battery or system voltage requirements varies.

NOTE: - Please see the flow chart diagram for keypad control for operation of this charger.

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OPERATING PROCEDURES

The parameters shown in the figure may vary from actual requirement. The actual
requirement can be referred to from the respective GTP.
The whole unit of microcontroller charger consists of two no. of charger one is the
FLOAT CHARGER and other is the FLOAT CUM BOOST CHARGER. The FLOAT
CHARGER feeds the load & FLOAT CUM BOOST CHARGER used for charging the
battery. The front view of the door of panel is shown below in Figure:-1

Figure:-1 FRONT VIEW OF THE CHARGER PANEL

The upper part of the front panel door shows four indication lamps/ LEDs (1) Red LED
indicates RY-phase presence (2) Yellow LED indicates YB-phase presence (3) Blue
LED indicates BR-phase presence (4) Green LED indicates DC voltage presence
In the middle it carries display unit and keypad unit.

Figure:-2 LARGE VIEW OF THE DISPLAY AND KEYPAD UNIT

NOTE: - Values shown in diagrams are only for reference.
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 DOC.NO.: S-MAN-126-12

Display Unit
Display unit is a Graphical LCD display as shown in Figure:-2 used for displaying the
input and output parameters of the charger. We can also check the settings of the
charger parameters and fault annunciation and alarm settings

Keypad Unit
Keypad unit consists of five keys as shown in Figure:-2
(1) Increase key shown as ‘+ ‘
(2) Decrease key shown as ‘- ‘
(3) Mode key shown as ‘MODE ‘
(4) Set key shown as ‘SET ‘
(5) Enter key shown as ‘ENTER‘

Home position of Display

When the charger system is switch- on, the graphical LCD Display of the system will first
show the LOGO of the STATCON for the moment and then it will start displaying the
input or output parameter of the charger, battery and load voltage status.

The home position of the display is split into 3-parts; Disp#1, Disp#2 and Disp#3 as
shown below in figure: 3, figure: 4 and figure: 5, respectively. By default they change
automatically in a cyclic manner

By Pressing the DEC key the automatic change in displays can be disabled. The
manual change of displays can be done by pressing the SET key. This is again changed
to automatic change by pressing DEC key.

Note: Follow the instruction given in the operating procedure flow chart.

Figure:-3 Disp# 1 (in the home position)

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 DOC.NO.: S-MAN-126-12

Figure:-4A Disp# 2 (in the float charger home position)

Figure:-4B Disp# 2 (in the boost charger home position)

Figure:-5 Disp# 3 (in the home position)

Procedure to Select the Setups

To enter into mode of setups Press MODE key, “Float Boost Charging Setup” will
appear in display. There are six setups
1) Float and Boost charging setup (shown below in figure :-6 )
2) Annunciation and alarm setup (shown in Figure:-7)
3) Charger Output Rating Setup (shown in Figure:-8)
4) Battery test Setup (shown in Figure:-10)

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 DOC.NO.: S-MAN-126-12

5) Communication Setup (shown in Figure:-11

6) Calibration Setup (shown in Figure:-9)

By Pressing INC key or DEC key we can select the above given six setups one by one.

Note: Follow the instruction given in the operating procedure flow chart.

Figure:-6

Figure:-7

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 DOC.NO.: S-MAN-126-12

Figure:-8

Figure:-9

Figure:-10

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 DOC.NO.: S-MAN-126-12

Figure:-11

Procedure Of Changing The “Charging Mode” Setting

Action 1:- In the home position of display [Press MODE key]

“Float Boost Charging Setup” option will appear in display
Action 2:- [Press MODE key] again to enter into the setup, Cursor would be on “Type
Of Cell”.
Action 3:- [Press SET key], Cursor would be shifted to “Number of Cells.”
Action 4:- [Press SET key] again, Cursor would be shifted to “Charging Mode”.
Action 5:- [Press INC key or DEC key] to select the one of desired Charging Mode
These are “Auto mode”, “Manual Float”, “Manual Boost” and “Equalize Mode”.
Action 6:- [Press ENTER key]. It will come out from Setup.
Action 7:- [Press ENTER key] again. It will come to Home Position of Display.

Note: Follow the instruction given in the operating procedure flow chart.

Procedure Of Changing The “Float Voltage” Setting

Action 1:- In the home position of display [Press MODE key]

“Float Boost Charging Setup” option will appear in display
Action 2:- [Press MODE key] again to enter into the setup, Cursor would be on “Type
Of Cell”.
Action 3:- [Press SET key], Cursor would be shifted to “Number of Cells.”
Action 4:- [Press SET key] again, Cursor would be shifted to “Charging Mode”.
Action 5:- [Press SET key] again, Cursor would be shifted to “Float Voltage”.
Action 6:- [Press INC key or DEC key] to set the desired Float Voltage.
Action 7:- [Press ENTER key]. It will come out from Setup.
Action 8:- [Press ENTER key], again. It will come to Home Position of Display.

Note: Follow the instruction given in the operating procedure flow chart.

Procedure Of Changing The “Boost Voltage” Setting

Action 1:- In the home position of display [Press MODE key]

“Float Boost Charging Setup” option will appear in display
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 DOC.NO.: S-MAN-126-12

Action 2:- [Press MODE key] again to enter into the setup, Cursor would be on “Type
Of Cell”.
Action 3:- [Press SET key], Cursor would be shifted on “Number of Cells”.
Action 4:- [Press SET key] again, Cursor would be shifted to “Charging Mode”.
Action 5:- [Press SET key] again, Cursor would be shifted to “Float Voltage”.
Action 6:- [Press SET key] again, Cursor would be shifted to “Boost Voltage”.
Action 7:- [Press INC key or DEC key] to set the desired Boost Voltage.
Action 8:- [Press ENTER key]. It will come out from Setup.
Action 9:- [Press ENTER key], again. It will come to Home Position of Display.

Note: Follow the instruction given in the operating procedure flow chart.

Procedure Of Changing The “Battery Current Limit” Setting

Action 1:- In the home position of display [Press MODE key]

“Float Boost Charging Setup” option will appear in display
Action 2:- [Press MODE key] again to enter into the setup, Cursor would be on “Type
Of Cell”.
Action 3:- [Press SET key], Cursor would be shifted to “Number of Cells”.
Action 4:- [Press SET key] again, Cursor would be shifted to “Charging Mode”.
Action 5:- [Press SET key] again, Cursor would be shifted to “Float Voltage”.
Action 6:- [Press SET key] again, Cursor would be shifted to “Boost Voltage”.
Action 7:- [Press SET key] again, Cursor would be shifted to “Extended Voltage”.
Action 8:- [Press SET key] again, Cursor would be shifted to “Cell Capacity”.
Action 9:- [Press SET key] again, Cursor would be shifted to “Boost to Float
Changeover Time”.
Action 10:- [Press SET key] again, Cursor would be shifted to “Battery Current Limit”.
Action 11:- [Press INC key or DEC key] to set the desired Battery Current Limit.
Action 12:- [Press ENTER key]. It will come out from Setup.
Action 13:- [Press ENTER key] again. It will come into Home Position of Display.

Note: Follow the instruction given in the operating procedure flow chart.

Procedure Of Changing The “System Current Limit” Setting

Action 1:- In the home position of display [Press MODE key]

“Float Boost Charging Setup” option will appear in display
Action 2:- [Press MODE key] again to enter into the setup, Cursor would be on “Type
Of Cell”.
Action 3:- [Press SET key], Cursor would be shifted to “Number of Cells”.
Action 4:- [Press SET key] again, Cursor would be shifted to “Charging Mode”.
Action 5:- [Press SET key] again, Cursor would be shifted to “Float Voltage”.
Action 6:- [Press SET key] again, Cursor would be shifted to “Boost Voltage”.
Action 7:- [Press SET key] again, Cursor would be shifted to “Extended Voltage”.
Action 8:- [Press SET key] again, Cursor would be shifted to “Cell Capacity”.
Action 9:- [Press SET key] again, Cursor would be shifted to “Boost to Float
Changeover Time”.
Action 10:- [Press SET key] again, Cursor would be shifted to “Battery Current Limit”.

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 DOC.NO.: S-MAN-126-12

Action 11:- [Press SET key] again, Cursor would be shifted on “System Current
Limit”.
Action 12:- [Press INC key or DEC key] to set the desired System Current Limit.
Action 13:- [Press ENTER key]. It will come out from Setup.
Action 14:- [Press ENTER key], again. It will come into Home Position of Display.

Note: Follow the instruction given in the operating procedure flow chart.
The float voltage set will be 2.25 volt per cell
The boost voltage set will be normally 2.35 to 2.4 volt per cell.
The equalize voltage setting will be 2.75 volt per cell.
The battery current limit will be 10% of the Ah capacity of battery.
The system current limit will be up to the rated current of the charger.

Procedure of Changing the “ANNUNCIATION AND ALARM” User Setting

Action 1:- In the home position of display [Press MODE key]

“Float Boost Charging Setup” option will appear in display.
Action 2:- [Press INC key], “Annunciation and Alarm Set up” option will
appears in display.
Action 3:- [Press MODE key] to enter into the setup, Cursor would be on “User
Login”.

Action 4:- [Press MODE key], Cursor would be on “AC over voltage”.
Action 5:- [Press INC key or DEC key] to set the desired value.
Action 6:- [Press SET key], Cursor would be shifted to “Latching”.
Action 7:- [Press INC key or DEC key] to set the desired value.
Action 8:- [Press SET key], Cursor would be shifted to “Trip”.
Action 9:- [Press INC key or DEC key] to set the desired value.
Action 10:- [Press SET key], Cursor would be shifted to “AC under voltage”.
Action 11:- [Press INC key or DEC key] to set the desired value.
Action 12:- [Press SET key], Cursor would be shifted to “Latching”.
Action 13:- [Press INC key or DEC key] to set the desired value.
Action 14:- [Press SET key], Cursor would be shifted to “Trip”.
Action 15:- [Press INC key or DEC key] to set the desired value.

Note: - Similarly follow operating procedure attached with manual, to set other
annunciation and alarm.

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 DOC.NO.: S-MAN-126-12

GENERAL DESCRIPTION AND OPERATION OF 220 VOLTS

FLOAT AND FLOAT-CUM-BOOST CHARGER

Offered battery charger shall be of the thyristor controlled automatic constant voltage type
with current limit facility and shall be suitable for supplying the normal constant load, at the
same time maintaining the battery to which it is connected in a fully charged condition. The
equipment shall be naturally ventilated.

All the equipments for the charger shall be contained in a sheet steel cubicle. The charger
cubicles may be installed any where in a well ventilated area. The general arrangement
drawing showing dimensions, layout of front panel mounted components; cable entry etc. is
furnished in the submitted documents.

The chargers are designed for operation from a three –phase, 4-wire AC supply and it shall
maintain the float charge voltage automatically for all DC loads between 0-100%, irrespective
of voltage and frequency variation of 373V to 456V and 47.5Hz to 52.5Hz, respectively. Let
us understand the circuit of Boost charger.

The input supply 415V ± 10%, 50Hz ± 5%, 3 phase – 4 wire is connected at the marked R, Y,
B and N terminals. It is coming from two source is selected by the “Main Changeover Switch”
which is mounted in float charger panel. ‘SFU1’ is input supply disconnector having air break
protection. ‘CT1’ to ‘CT3’ are current transformers which pass current signal to the
microcontroller card to read input line current on the display provided on the front panel door
of the battery charger. Apart from this the voltage signal is also fed to read AC voltage. ‘C1’ is
input contactor which operates when the input supply is available and ‘SFU1’ is ON. It trips
automatically through the auxiliary trip relay which operates after a fault. ‘e1’ is thermal
overload relay which operates after an input overload or unbalance condition. The main
transformer ‘TX1’ is a step down, copper wound transformer, dry type and vacuum
impregnated. It shall be designed to operate continuously at full load and maintain the
specified set voltages within ± 1% regulation for specified variation in voltage and frequency
without the need for any tapping.

SCR ‘TH1’ to ‘TH6’ are rectifier devices, rated for 200% charger rating, mounted on
aluminium heat sinks for better device cooling. ‘RC1’ to ‘RC6’ are snubber circuits for dv/dt
protection of the device. ‘F4’ to ‘F9’ is SCR device protection fuses connected in each arm of
the rectifier connection.

The charger can be operated without damage to itself and system. Filter choke ‘L4’ and
capacitor bank ‘K4’, ‘K5’, ‘K6’ keep the output voltage ripple less than the specified limit
without battery connected.

The limit of the charging current can be set at any value within the range of 50% to 100% of
the maximum battery charging current which is normally 10% of the battery Ah capacity.
Controlling the gate-firing angle of the thyristors stabilizes the output DC against line voltage

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 DOC.NO.: S-MAN-126-12

and load current variation. The firing pulses for the thyristors are generated and controlled in
main controller card ‘CC1’ which is microcontroller based solid state. For This sample of
output voltage, output current and battery voltage is fed to these cards. The sample of the
output current is fed in the form of a proportionally generated mV signal across current
shunts. These shunts are provided separately for monitoring the total current, load current
and battery current drawn. The generated pulses are fed through small pulse transformers
mounted on card ‘CC11’. From the keypad console the maximum charging current, which
can be drawn by the batteries can be set. The battery charging current can be adjusted from
50%-100% uniform and step-less by this. This feature is achieved by providing load limiter
having drooping characteristic, which shall cause when the voltage control is in automatic
mode, a gradual lowering of the output voltage when the DC load current exceeds the load
limiter setting of the charger. Any sustained overload or short-circuit in DC system shall not
damage the charger.

The battery can be charged in three modes, viz., Float, Boost and equalizing mode by using
the keypad selection. Setting the output of float/ equalizing / boost charge shall be
independent of each other so that setting of one voltage/current shall not require resetting
other. In Auto mode the batteries can be charged automatically in Float and Boost modes by
sensing the charging current requirement.

Annunciation of different faults as listed on the SLD and GA drawing submitted is provided by
card ‘CC10’. This card receives various AC/DC fault voltages and converts it to DC fault
signal. This signal is then send to the microcontroller card ‘CC1’ which then show it on the
display with an audio alarm sound. The settings for various trip levels on the key pad for
example AC under and over voltage, DC under and over voltage etc., is done through
microcontroller. Potential free remote alarms for “earth fault” and 4-20mA analog signals for
output voltage, battery voltage and output current is provided in the battery charger.

The circuit of Float charger is identical to the Boost charger, except a few differences. For
example it doesn’t have boost voltage or battery current display or settings.

The battery charger system consists of a set of Float Charger (FC) Float cum-boost Charger
(FCBC). The function of the FC is to feed the respective DCDB. It also trickle charge the
batteries in case FCBC is fail or switched-off.

The function of the FCBC is to charge the Batteries in trickle mode or in Boost mode,
manually selecting or automatically. With the help of keypad the voltage/current can be set
whichever is required for starting current & finishing current, it will have to do manually not be
automatically. It also feeds the DCDB in trickle mode when FC fails or switched-off. Than
failure of FC is sensed by the FCBC and it becomes emergency Float-Charger and supplies
to the battery. If the battery is charged it trickle charge it. During occasional boost charging
requirement of the battery the FCBC automatically make a switchover to boost mode to
charge the battery and reverts back to Float mode when the batteries are charged. Let us
understand the system with the help of the circuit diagram.

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DC CONTACTOR OPERATION IN DIFFERENT MODE.

AC FC BC BATTERY DCDB ‘C3’

1. on on on (boost mode) bc fc open
2. on on on (float mode) fc/ bc fc/bc closed
3. on off/fail on (float mode) bc bc closed
4. on on off/fail fc fc closed
5. on off/fail off/fail discharging battery closed
6. off off off discharging battery closed

Point no.2 when the BC is in float mode, ‘C3’ closes.

Point no.3 When the FC fails, its voltage starts falling. When this voltage reaches just below
the tap-cell voltage of the battery, tap-cell diode switches-on (forward biased). Now the
voltage across the DCDB terminals is supplied through tap-cell of the battery.

Meanwhile, failure of FC is sensed by the FBBC and it becomes emergency Float-Charger.

This is done by disabling its Float-Boost circuit. Sensing which, the contactor ‘C3’ operates.
Now the voltage across DCDB terminals is maintained through ‘C3’ and full battery voltage in
float mode.

Point no.4 Failure of BC also operates the ‘C3’ by operating its charger fail relay’RL7’.

The Charger enclosure is sheet steel floor mounted and suitable for use in indoor application,
well ventilated area. The controls critical to the operation of the charger are provided on the
front panel door. All the components are identified by their circuit codes and are easily
accessible for repair or replacement. The wires are identified by their ferrule numbers.

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DESCRIPTION OF MAIN CONTROL CARD CC1 (SPCL-312V3)

Charger is completely automatic and this is controlled by digital controller. Purpose of the
main control card is to produce 16-bit digital signal for SCR firing. The function of main-
control card is to provide voltage regulation, to provide current limit and to provide limit in
battery current. It also provides under voltage and over voltage protection. The Trip and
Latch function of the faults is user settable and also the under voltage and over voltage of
the faults is user settable. All these functions are incorporated in one control card and their
functions are explained below.

POWER SUPPLY SECTION: - This section ± 12V DC supply from separate power supply
cards provided in the charger and converts it to +5 volts. This supply is provided to all the
IC’s on the board and also to the LCD. ‘CN1’ connector receives the ± 12V DC supply
generated from AC source and ‘CN2’ from DC battery source. The two supplies are then
ORed and given to the +5V voltage regulator.

SENSING CKT:-

(a) Charger Sensing: Connectors ‘CN11/1’ – ‘CN11/2’ receives the Charger Voltage
sensing. ‘R145’ and Preset ‘P3’ make the divider circuit for op-amp ‘U23’ which gives the
signal corresponding to the Charger voltage. This signal is within +5V and is given to the
Microcontroller IC ‘U3’ pin no. 3.

(b) Load Sensing: Connectors ‘CN11/3’ – ‘CN11/4’ receives the Load Voltage Sensing.
‘R144’ and Preset ‘P2’ make the divider circuit for op-amp ‘U23’ which gives the signal
corresponding to the Load voltage. This signal is within +5V and is given to the
Microcontroller IC ‘U3’ pin no. 4.

(c) Battery Voltage Sensing: Connectors ‘CN11/5’ – ‘CN11/6’ receives the Battery Voltage
Sensing. ‘R146’ and Preset ‘P4’ make the divider circuit for op-amp ‘U12’ which gives the
signal corresponding to the Battery voltage. This signal is within +5V and is given to the
Microcontroller IC ‘U3’ pin no. 10.

(d) Total Current Sensing: Connectors ‘CN12/3’ – ‘CN12/4’ receives the signal from total
current Shunt. Op amp ‘U21’ and ‘U22’ operates in differential mode. This signal from ‘U22’ is
within +5V and is given to the Microcontroller IC ‘U3’ pin no. 5.

(e) Battery Current Sensing: Connectors ‘CN11/7’ – ‘CN11/8’ receives the signal from
Battery Current Shunt. Op-Amp ‘U10’ and ‘U13’ provides the Battery +ve signal. Op- Amp
‘U10’, ‘U17’ & ‘U19’ provides the Battery –ve signal. Both the signal is within +5V. The signal
goes to Microcontroller IC ‘U3’ pin no. 9.

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 DOC.NO.: S-MAN-126-12

FAULT SENSING & AC SENSING: - Connector ‘CN3’ receives the fault signals, AC
Voltage signals and AC current signals from opto annunciation card ‘SPCL326V1’. The
Signal then goes to IC ‘U4’, which sends the signal one by one to Microcontroller IC pin no.
8.

DIGITAL FIRING PULSES:- Connector ‘CN8’ receives the digital pulses for the Firing Card
‘SPCL-333V1’. The Microcontroller IC ‘U4’ sends the signal to IC ‘U7’ & ‘U8’. This in turn
sends this signal to the SCR through connector ‘CN8’.

KEY PAD INTERFACE: - Connector ‘CN6’ receives the keypad interface. Five Keys are
provided, namely, “MODE”, “SET”, and “INC”, DEC”and“ENTER. Through this key pad
whole function of the charger can be controlled.

SERIAL COMMUNICATION PORT: - Connector ‘CN10’ receives the serial communication.

The Data on the can be transferred through the serial port. All the parameters can be seen
and also changed through the Computer Interface.

AC CONTACTOR TRIP SIGNAL :- Connector ‘CN9’ receives the contactor trip signal,
charger fail signal, DC over voltage( at load) sensing signal.

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 DOC.NO.: S-MAN-126-12

DESCRIPTION OF AUTO FIRING CARD CC2 (SPCL-333V1)

Purpose of this controller is to produce firing pulses for SCR in synchronized fashion. This
card gets the digital signal from the Main Card and also senses the 3 phase synchronous
signal from Auxiliary transformer and then accordingly gives the pulses to Pulse
Transformer Card SPCL-263.

POWER SUPPLY: The power supply for this card also is received from ± 12V DC power
supply cards. The +5V supply is received from main controller card.

3 PHASE AC SYNC SIGNAL: - Connector ‘CN1’ gets the 3 phase AC Sync signal from
Auxiliary transformer and the gate pulses are phase shifted in proper sequence and given to
the SCR. ‘P1’, ‘C1’ provides the phase shifting signal for 1st phase, ‘P2’ & ‘C2’ for the 2nd
Phase and ‘P3’ & ‘C3’ for the 3rd Phase. All the signals are phase shifted by 30 degree.

SCR FIRING PULSES :- Connector ‘CN4’ receives the required SCR Firing pulses .The 12
signals from the Microcontroller ‘IC4’, ‘U5’ & ‘U6’ provides the required firing pulses. ‘U4’
provides the firing pulses for the 1st Phase SCR, ‘U5’ provides firing pulses for the 2nd phase
of SCR and ‘U6’ provides firing for the 3rd phase of SCR. This signal is then amplified in 2
stage by ‘Q7’, ‘Q8’ 1st pair, ‘Q9’, ‘Q10’ 2nd pair, ‘Q11’, ‘Q12’ 3rd pair, ‘Q13’, ‘Q14’ 4th pair, and
so on.

+24 V UNREGULATED SUPPLY: - CN3 gets +24 V unregulated supply for pulse supply
and it goes to the PTX Card through the connector CN4.

ZERO CROSSING SENSING: - ‘U1’ gets the attenuated AC supply. This signal is then
converted to the square pulses of 50Hz. These pulses are then pass through the Low pass
filter and converted to pulses, this pulse after inversion goes to the Microcontroller ‘U4’ and
generates zero crossing signals for 1st phase, similarly ‘U2’ gives zero crossing signal of 2nd
phase for ‘U5’ and ‘U3’ gives zero crossing signals for 3rd phase for ‘U6’.

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DETAILS OF PRESET OF AUTO FIRING CARD (SPCL-333V1)

P1. Used for adjusting the 30 deg phase shift for 1st phase.

P2. Used for adjusting the 30 deg phase shift for 2nd phase

P3. Used for adjusting the 30 deg phase shift for third phase.

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 DOC.NO.: S-MAN-126-12

DESCRIPTION OF MANUAL FIRING CARD CC7 (SPCL-404V1)

Purpose of this controller is to produce manual firing pulses for SCR in synchronized
fashion. The Output Voltage is controlled through the Manual Volt Set Potentiometer which
is separately provided the charger.

POWER SUPPLY: - The card needs ±12V DC supply which is provided from the separate
power supply cards.

SCR FIRING PULSES. :- Connector ‘CN2’ provides the required SCR Firing pulses .The 12
signals from the Microcontroller IC4, ‘U1’ provides the required delay for the firing of the
SCR’s

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DESCRIPTION OF MAINS SENSING CARD CC3 (SPCL-326V1)

This card senses the input voltage from small power supply transformers, input current
signal from CTs and fault signals from Op to annunciation card. The AC voltage and current
signals are converted to corresponding DC signals (0-5V). These signals along with faults
signals received from opto annunciation cards are sent to main control card (SPCL-312V3)
through flat cable connector CN8.

POWER SUPPLY -: Connector CN7 is the connector terminal for the card. The card
requires ±12V DC supply to operate which is received from power supply cards.

DESCRIPTION OF OPTO CARD CC10 (SPCL-343V1)

This card gets the all fault signals from the charger. These fault signals are optically
isolated. When a fault is received the corresponding opto IC switches on gives a signal.
This signal is then sent to mains sensing card ‘CC3’ through flat cable connector ‘CN11’.

DESCRIPTION OF POWER SUPPLY CARDS (SPCL-148V4)

The power supply cards are used to supply ±12V DC to various other controller cards. The
input of cards ‘CC5’ & ‘CC6’ is 230VAC while that of card ‘CC8’ is output DC supply of the
battery charger. This is done to have redundancy of power supply so that even if AC supply
fails it gets its supply from DC.

DESCRIPTION OF PHASE REVERSAL CARD CC4 (SPCL-129V3)

In case of wrong phase sequence or a missing phase of input three phase AC supply, an
alarm is generated and charger is tripped. This fault is displayed on the graphical LCD.

DESCRIPTION OF PULSE TRANSFORMER (PTX) CARD CC11 (SPCL-263)

In this card pulses are received from auto firing card & there are two pulses for one cycle.
Through connectors pulses are reached to gate of the corresponding SCR.

DESCRIPTION OF RELAY CARD CC9 (SPCL-344V1)

In this card signals come from control card to operate this card. These signals are used to
operate the AC contactor & pick up the relay7 and relay8/relay3.

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 DOC.NO.: S-MAN-126-12

TROUBLE SHOOTING

The best way to trouble shoot is to check for any physical damage and replace the part
immediately after ascertaining that fault was not due to this. The quality of rework must
match original work. Given below is procedure for trouble shooting.

(COMMON TO FLOAT CUM BOOST CHARGER)

OBSERVATION POSSIBLE CAUSE REMEDY

Charger output is not (a) Mains supply is not available. Check and connect mains
available supply.

(b) Input MCCB/switch/SFU is off. Check and

MCCB/switch/SFU on the
same.

(c) Ac contactor is not operating. Check voltage at its coil. If

available, within the range,
coil is faulty, replace the
same. If not available,
check if any fault indication
is glowing.

(d) Glass fuses GF1-GF3 have Check and replace if blown.

blown

(e) Sync transformer and/or Check these small

power supply transformers are transformers. Replace if
faulty faulty.

(f) Main Controller card is Check main controller card,

as per the test point wave
Faulty.
shape and voltage details,
given on separate pages.
Replace if values are not
matching. DO NOT
DISTURB ANY SETTING.

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 DOC.NO.: S-MAN-126-12

(g) Initialization relay may not be Check voltage across its

coming on coil. If not, check transistor
Q1 on Relay card SPCL-
344. Replace if faulty.

Output is not proper (a) Voltage setting is not proper. Check and correct volt
settings with the help of key
pad .

(b) Voltage feedback is faulty. Replace main controller

card SPCL-312V3.

Voltage drops when (a) Charger is overloaded Check current settings of

load is connected the main controller card or
wait for the batteries to be
charged.

(b) Rectifier device(s) are faulty. Check and replace if found

so.

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 DOC.NO.: S-MAN-126-12

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 DOC.NO.:S-MAN-DCH-126-12

OPERATION AND MAINTENANCE MANUAL

FOR

220VDC/230A FOR 2300AH BATTERY

DISCHARGE RESISTOR BANK

INPUT VOLTS : 220VDC

OUTPUT AMPS : 230A

TYPE : MANUALLY SELECTED STEPPED

UNIT SERIAL NOS. : 13B08226

CLIENT : BHARAT HEAVY ELECTRICALS LIMITED

OWNER : WEST BENGAL POWER DEVELOPMENT CORPN. LTD.
CONSULTANT : DEVELOPMENT CONSULTANTS PVT. LTD., KOLKATA
PROJECT : SAGARDIGHI THERMAL POWER PROJECT UNIT-3 & 4
(2X500MW)

MANUFACTURED BY
Statcon Power controls Ltd.
A-34, SECTOR-59, NOIDA,G. B. NAGAR - 201301 (U.P.)
TELE: 0120-3851760, FAX: 0120- 3851796
Email: info@stat-con.com, Web site : www.stat-con.com

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CONTENTS

Sl. No. PARTICULARS PAGE NO.

1. INTRODUCTION 3

2. SAFETY PRECAUTIONS, HEALTH & SAFETY 4

3. INSPECTION AND INSTALLATION 5

4. TECHNICAL PARTICULARS 7

5. PANEL CONTROLS, INDICATIONS & METERS 7

6. OPERATING INSTRUCTIONS 8

7. GENERAL DESCRIPTION OF DISCHARGE RESISTOR BANK 9

8. TROUBLE SHOOTINGS 10

9. CUSTOMER FEED BACK FORM 11

10. ENCLOSURES

a. MECHANICAL DRAWING

b. ELECTRICAL DRAWING

c. BILL OF MATERIAL

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INTRODUCTION

All protection circuits work on a D.C. Source. This is generally stationary Ni-Cd battery. Once the
battery is charged it requires to be kept on float to meet internal losses of the battery. Also it needs
recharging in case of battery is drained. This is accomplished with the help of battery charger. To meet
the load demand, the D.C source of power should be a highly stable and reliable. It should be Durable
and maintain its capacity to deliver. Now if the batteries are kept on float charge only and load current is
also very low as compared to battery Ampere-Hour capacity the current delivering capacity of the
batteries can not be ascertained, for example, if the load is increased or a long outage of mains supply.
Here comes the need of a discharge resistor bank. It can be used once in a year or so depending upon
the actual load current, criticality of load and main supply condition (for recharging of drained batteries
after load test). The load test may be carried out for a shorter period of time and, say, 5% of Ah
capacity.

STACON’S discharge resistor bank is designed to meet all these requirements.

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SAFETY PRECAUTIONS
HEALTH & SAFETY

Installation, testing, fault location and repair should only be attempted by authorized, qualified and
skilled electrical technician. Statcon shall not be held responsible for the electrocution of the personnel
carrying out any activity in the battery charger.

This equipment carries dangerous voltages and stores electrical energy.

Before touching, remove metal objects, e.g., metal bracelets, rings or necklaces which come into
contact with electricity carrying items. Carry out the following instructions.

1. Isolate the AC main supply external to the equipment.

2. Isolate the Battery external to the equipment.

3. Check with a suitable scaled voltmeter fitted with insulated test prods that the equipment does not
carry any voltage at either the input or the output before commissioning work.

The above instructions (1) to (3) must always be followed before making any adjustment, and also
before making any electrical connections to the part of the equipment for the purpose of servicing. Such
connections should always be checked for safety before re-applying power.

The above instructions (1) to (3) must also be carried out before any connection is modified or removed.

Note:

Adjustment should only be carried out with a nonconducting tool taking care not to touch
any item carrying electricity while doing so.

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INSPECTION AND INSTALLATION

Initial inspection and preliminary check out procedure are recommended for safe operation. Please
follow step-by-step procedure described in the chapter.

INITIAL INSPECTION:

Inspect the package for external evidence of damage and inform company handling in transit. Notify the
damage and inform company immediately if any. Do not destroy or remove any of packing materials
used in damaged shipment.

After unpacking unit inspect through visual check to detect any transit damage to any component on the
front panel or inside the cubicle. If any loose or broken connections are noticed set them right.

MECHANICAL INSTALLATION:

The panels are free standing steel structure and should be installed in dust free well ventilated place.

Clean the equipment properly to remove dust particles settled on the components and the equipment.

ELECTRICAL INSTALLATION:

1. Connect AC input supply on terminal/strip provided in this equipment.

2. Connect Battery on the battery terminals provided in this equipment.

3. Connect the firm earth to the panel.

4. Push all the fuses; they might have become loose in transit.

5. Check that all the PCB or metering connections are proper.

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BATTERY DISCHARGE RESISTANCE BANK

GAURANTEED TECHNICAL PARTICULARS

Battery bank rating - 220 DC / 2300Ah

Open-circuit bank voltage - 220V DC

Type of battery - Lead -Acid Plante

Number of cells - 110

Open-circuit Voltage per cell - 2.0

End cell voltage - 1.85 volt/cell

Discharge bank rating - 220V / 230A

Type of bank - Load selected in steps

Load selection device - Rotary on/off switches

Tolerance in load current - ± 10%

Type of cooling - Forced air using fans

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PANEL CONTROLS, INDICATIONS & METERS

CONTROLS:
ƒ INCOMING MCCB : This MCCB connect / Disconnect battery supply to
the equipment.

ƒ LOAD SWITCHES : These switches are for step selection of loads as per
requirement.

METERS:

DC Voltmeter : This meter reads the battery voltage.

DC Ammeter : This meter reads the battery discharging
current.

TERMINAL DETAILS:

Battery Terminals : These terminals are used to connect input

cables from the battery bank.
AC supply Terminals : These terminals are used to connect 230V AC,
50Hz, 1 phase supply for fan and input MCCB
U/V coil.

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OPERATING INSTRUCTIONS

1. Ensure that all the load bank switches mounted on the front panel door are in off
position. Keep the input MCCB in off position.
2. Connect a fully charged (220V battery) across the battery terminals provided
inside the panel at the front.
3. Connect 230VAC, ± 10%, 50Hz single-phase supply to the 230VAC aux supply
terminals for fan and MCCB coil supply.
4. Switch-on the input MCCB.
5. Switch-on the load bank resistance one by one to set it at rated current (max.). A
few lower current steps are provided to keep the discharge current maintained at
the rated current during discharging of the battery.
6. The discharging is done up to 1.85V (per cell). After this the total Ah is calculated
by multiplying the discharge current (Amp) by total run time (hour).

Caution:
Fan is provided for cooling of the discharge bank. It is necessary that fan should run
throughout the running time of discharging. Interlocking is provided such that if the AC
supply to the MCCB coil is interrupted MCCB is tripped.

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GENERAL DESCRIPTION OF BATTERY DISCHARGE RESISTOR BANK

The 220V DC battery bank is connected on the battery terminals provided inside the panel.
Main input ‘MCCB’ fitted with 240V AC-under-voltage release-coil is for connecting and
disconnecting the connected battery bank. The MCCB can be switch-on only when the
240VAC is available across the coil and trips when this AC supply is interrupted. A cooling
fan is provided in the equipment for load bank. This cooling fan is necessary for long life of
the bank. The operating supply for this fan is 240VAC, 50Hz, single phase.

The load bank consists of a number of special types of punched steel resistors divided into
different branches to select the discharging current in steps. The selection is made by on/off
switches provided on the front panel door of the equipment. Since, with the lowering of
voltage the set discharge current starts decreasing, additional small steps are provided for
discharging stage.

A DC voltmeter is provided to read the battery voltage, while an Ammeter is provided to read
the discharging current.

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TROUBLE SHOOTING

The best way to trouble shoot is to check for any physical damage and replace the part immediately
after ascertaining that fault was due to this. The quality of work must match original work. Given below
is procedure for trouble shooting.

OBSERVATION POSSIBLE CAUSE REMEDY

Discharge current (a) Battery is not connected properly. Check and make proper
output is not available connection of battery supply
on the battery terminals.

(b) Input MCCB is off. Check and switch on the

same.

(c) AC supply to the MCCB coil is Check 240VAC supply on the

interrupted. terminals. Check control fuse.
Set it right. Otherwise the coil
may be faulty.

(d) Cable connection from the battery Check cable connection in this
terminals to the load switches path and set it right.
through input MCCB is loose.

Load current is not a) The switch is faulty. Check and replace if the
adding up when a continuity of the switch is not
switch is kept in on made. (Check after tripping the
position. input MCCB).

b) The corresponding resistor branch

The resistance of the resistor
is faulty.
branch is checked by a
multimeter.

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