TECHNICAL SEMINAR ON BATTERY CHARGER

FOR STANDBY APPLICATION

CONDUCTED BY SUMIT KUMAR BANERJEE
B.Sc.(Phy) B.Tech(Electronics) M.I.E., C.Eng.(I) Chief Technical Co ordinator Caldyne Automatics Ltd. Kolkata

BLOCK SCHEMATICS-DC UPS SYSTEM (OPTION 1) L+

AC

FLOAT CHARGER

(CV)

DC

TD

L-

SUPPLY
BOOST CHRGER

B+

(CC)

TC
(75% OF B+) B-

FIG-1

1. FLOAT CHARGER IS CONNECTED TO THE LOAD BUS DIRECTLY. 2. BOOST CHARGER IS CONNECTED TO THE BATTERY. 3. FLOAT CHARGER WILL SUPPLY DC LOAD AT CONSTANT VOLTAGE. (CV MODE) 4. BOOST CHARGE WILL QUICK (BOOST) CHARGE THE DISCHARGED BATTERY AT CONSTANT CURRENT RATE AS PER DATA SHEET (SINGLE STEP/ TWO STEP) UPTO A SPECEFIC VOLTAGE LEVEL. 5. DC CONTACTOR (DC) IS CONNECTED BETWEEN BATTERY & LOAD BUS. IT WILL CONNECT THE BATTERY TO THE LOAD AFTER COMPLETION OF THE BOOST CHARGE OR ON FAILURE OF THE FLOAT CHARGER OR ON FAILURE OF AC SUPPLY. 6. INTERMEDIATE CELL CONNECTED BLOCKING DIODE(CD) ENSURES AT LEAST 75% BATTERY VOLTAGE DURING PICK-UP TIME OF DC CONTACTOR (20-100ms). THUS THE ENTIRE SYSTEM ENSURES AN UNINTERRUPTIBLE DC POWER SUPPLY FOR CONNECTED DC LOAD.

BLOCK SCHEMATICS-DC UPS SYSTEM (OPTION 2) L+

AC

FLOAT CHARGER

(CV) SUPPLY

DC

TD

L-

B+
BOOST-CUM-FLOAT CHRGER

(CC/CV)

TC
(75% OF B+)

FIG-2
B-

1.THIS SYSTEM IS ALMOST SIMILAR TO FIG.1

2.SINCE THE ENTIRE SYSTEM IS FOR SUPPLYING DC LOADS, A STANDBY FLOAT CHARGER IS REQUIRED.

3.HERE BOOST CHARGER CAN ACT AUTOMATICALLY AS EMERGENCY FLOAT CHARGER ON FAILURE OF MAIN FLOAT CHARGER THROUGH THE DC CONTACTOR.

BLOCK SCHEMATICS-DC UPS SYSTEM (OPTION 3) L+

AC

FLOAT CHARGER

DC D D D D L-

(CV) SUPPLY

B+
BOOST-CUM-FLOAT CHRGER

(CC/CV)

FIG-3

B-

1.THIS SYSTEM IS ALMOST SIMILAR TO THE SYSTEM IN FIG.2

2.HERE ADDED ADVANTAGE IS SIMULTANEOUS OPERATION OF BOOST CHARGING & MEETING DC LOADS THROUGH THE BOOST CHARGER, ON FAILURE OF THE MAIN FLOAT CHARGER DURING BOOST CHARGING.

BLOCK SCHEMATICS-DC UPS SYSTEM (OPTION 4) DC

FLOAT-CUM-BOOST

L+

AC

CHARGER-1

(CV/CC) SUPPLY
FLOAT-CUM-BOOST CHARGER-2

TD

L-

B+

(CV/CC) TC (75% OF B+) B-

1.IN THIS SYSTEM FLEXIBILITY OF OPERATION IS ALMOST DOUBLE THAT OF THE SYSTEM SHOW IN FIG.1 2.TO SUPPLY DC CONTINUOUS LOADS THROUGH CHARGER-1 & TO BOOST CHARGE THE BATTERY THROUGH CHARGER-2 THE UPPER DC CONTACTOR IS TO BE KEPT ON. AFTER COMPLETION OF BOOST CHARGE BOTH CONTACTORS WILL BECOME ON.

3.IN THIS SEQUENCE OF OPERATION CHARGER-2 ACT AS STANDBY FLOAT CHARGER. REVERSE SEQUENCE OF OPERATION IS ALSO POSSIBLE.
4.COMPLETE OPERATION DESCRIBED ABOVE CAN BE MADE AUTOMATICS AS WELL AS MANUAL.

BLOCK SCHEMATICS-DC UPS SYSTEM (OPTION 5) L+ AC SUPPLY

FLOAT-CUM-BOOST CHARGER CONTROLLED DROPPER

L-

CONTROLLED DROPPER

B+ DC

DC

DC

B-

FIG.-5 D D D D D D

1. THIS IS A SPECIAL TYPE OF LOW COST CHARGER FOR LOWER VOLTAGE RANGES.

2. HERE ONLY ONE CONVERTER IS USED. UNDER FLOAT MODE THIS WILL CONNECT DIRECTLY TO THE LOAD BUS ALONG WITH THE BATTERY FLOATING TO MEET THE DC LOADS AT CONSTANT VOLTAGE. 3. UNDER BOOST MODE BATTERY WILL BE CHARGED AT CONSTANT CURRENT RATE.LOAD WILL BE CONNECTED THROUGH THE CONTROLLED DROPPER SO THAT IT WILL NOT BE AFFECTED BY THE BOOST VOLTAGE OF THE BATTERY (RANGE- 2.0V/CELL TO 2.75V/CELL).

4. CONTROLLED DROPPER MAY BE A DROPPER DIODE BANK WITH A FEW BYPASS DC CONNECTORS.

5. THIS SYSTEM IS SUITABLE FOR 24V AND 48V SYSTEM.