220 V DC SYSTEM

index

Description

Battery Charger

System Description :

(a) Float Charger SCR Control

(b) Boost Charger - SCR Control

Battery Charger Annunciation Details

DESCRIPTION

220 V. DC power supply is provided in each unit to provide stable DC supply to

following:

1. Generator auxiliaries DC seal oil pump, Excitation Cubicle, Generator

2. Generator Relay Panel
3. Turbine auxiliaries
4. Boiler auxiliaries
5. 132KV, 6,6KV & 0.4 KV
switchgear
6. Emergency lighting
back up panel
Emergency lub oil pump, Jacking oil pump, Misc
solenoids
D.C. scanner air fan, FSSS panel & Misc solenoids
132KV Relay panel, 132KV control desk, 132KV
close trip operation, 6.6KV station & unit bus
C.B. close trip operations relay auxiliary supply
indications & annunciations.

All above loads are supplied from D.C. distribution board charged from Battery Bank
consisting of lead cells, constantly under charging by battery charger, Ac power to which
are supplied either from station auxiliary LT board (0.4 kV) and unit wise emergency
MCC.

D.C. System consists of following:

 a. One storage battery having 1500 AH capacity at 10 hour discharge rate consisting
of 110 Lead Acid cells for each unit.
b. One float charger per unit.
c. One float cum boost charger per unit.
d. One D.C.D.B. per unit.

The float charger will normally supply the load current & float charging current of
battery. Under this condition if AC feeder to charger fails, battery will supply the load
current. When mains restore, if battery takes more current than the float charging current,
float cum boost charger will be switched ON auto at float voltage. It will supply load
current as well as float charging current to the battery.

In case battery voltage comes down substantially or once in six month, float cum boost
charger con be taken in Boost mode to charge the battery upto the normal voltage.

BATTERY CHARGER

1. Make : Caldyne Automatics Pvt Ltd.

Type:

(a) Automatic float & float cum boost battery charger for 220v & 1500AH
batteries(SCR control)

(b) Automatic float & float cum boost battery charger for 24v & 1500AH batteries
(SCR control)

2. Capacity :

(a) 220v dc, 250A dc continuous

(b) 24v dc, 630A dc continuous

3. No of sets: (a) 220v charger 3 nos.

(b) 24v charger 6 nos.

4. Application:

(a) Charging of 220v station batteries and supplying station 220v dc load via DCDB

(b) Charging of 24v station batteries and supplying station 24v DC

load to electronic cards of DCS and BMS and relays via 24v boards.
5. Date of commissioning:

Station battery charger # 1.May 26

Station battery charger # 2.Nov 97

Swyd battery charger -- Feb 95

24v battery charger 1

Unit# 1 : 24v battery charger 2 Oct 96

24v battery charger 3

24v battery charger 1

Unit# 2 : 24v battery charger 2 Dec 97

24v battery charger 3

SYSTEM DESCRIPTION

FLOAT CHARGER SCR CONTROL :-

The float charger is meant for supplying the DC load and at the same
time float charging the battery to keep it in fully charged condition.
The float charger may either be operated in auto or manual mode. In
the automatic mode the output voltage is held constant at a preset
value whereas in manual position the output may be varied within
specified limits by an external potentiometer. The incoming supply of
the float charger will be fed into a 3 phase double wound step down
transformer thru suitably rated switch fuse unit. The secondary of the
transformer will then be fed to a 3 phase full wave full control
thyristorised bridges thru surge suppressor and high speed
semiconductor protection fuses. The bridge circuit consists of 6 nos.
thyristors, which are adequately protected by snubber circuit against
voltage transients and dv/df effect. The triggering of the thyristors are
controlled by A.V.R. unit which senses feed back from the output
voltage and current. These feedback signals are suitably processed
and compared with the reference generated in the A.V.R. circuits. Then
the error is amplified and phase compensated by high gain operational
amplifier. The incorporation of feedback ensures automatic correction
of any deviation oh the set voltage, which may arise due to line or load
fluctuations. The output of the final amplifier will be fed to triggering
circuits, which control the output voltage of the float charger by
adjusting the firing angle of the thyristors. With the help of the A.V.R
unit the regulation of the output voltage of the float charger may be
kept around + or - 1% against line or load fluctuations. Due to
incorporation of inner current loop by which the output voltage drops
as the rated load is increased there by automatically transferring the
load to the battery in order to avoid the overloading of the charger.

In this system as described a suitable DC filter is provided to bring

down the ripple to the required level at the output. Ammeter and
voltmeter are provided for monitoring output current and voltage
respectively. Necessary indications are provided for different status
and fault monitoring.

BOOST CHARGER -- SCR CONTROL :-

Then booster charger is basically meant for quick charging the battery
after heavy discharge, so as to restore the capacity of the battery
within minimum time. In this processed system the boost charger will
be normally in standby auto float charge mode and will cut into the
circuit automatically ( a) to provide occasional boost charge as
required (b) to take over of the function of the float charger in case of
the main float charger failure. The boost charger has also provision for
float and manual boost charging the battery thru manual selection.

In this system the boost charger is an automatic constant current

charger consisting of a suitably rated 3 phase double wound step down
transformer fed thru a suitably rated switch- use unit. The secondary
of the transformer is fed to 3-phase full wave full control thyristorised
bridge thru line surges suppressors and high speed semiconductor
protection fusses.

The bridge circuit consists of 6 nos. thyristors, which are adequately

protected by snubber against voltage transients. Triggering of the
thyristors is controlled by an ACR unit, which senses feedback from
output current. These feedback signals are suitably processed and
compared with the reference generated in the ACR circuit, then the
error will be amplified phase compensated by high gain operational
amplifier. The incorporation of the feedback ensures automatic
correction of any deviation of the set current, which may arise due to
line or load fluctuations.
When the battery draws 10 times of maximum recommended trickle
charging current, the battery charging starts at a starting rate which is
automatically monitored by electronic circuit. Once the battery voltage
reaches upto 2.35 v/cell, the charging current will automatically
reduced to the finishing rate by a current control circuit which adjusts
the current limit reference to the charger with increased in the battery
voltage. once the battery voltage reaches 2.75 v/cell the battery will
automatically be transferred to float charger and float charging
continues as usual manner.

In this system the battery will normally float across the floatcharger so
that in case of power failure the battery can maintain the load without
interruption.However after heavy discharge of battery, the battery is
placed on boost charger. Now if supply fails, the battery will be
connected to the bus by a N/O contact of the DC contactor which
remains de-energised when supply is present and battery is in boost
charging condition, thereby disconnecting the battery and the boost
charger from the load bus so as to maintain the load voltage within +
or 1% of the rated value, since boost charger output varies within
wide limits depending on the battery voltage. However if power supply
fails, while boost charging operation in progress the battery should be
connected to the load immediately to avoid any interruption. A diode is
incorporated between an intermediate cell and the load bus.

During normal operation the tap cell diode will be reversed biased. In
the event of power failure during boost charging with battery isolated,
the output voltage start dropping. As soon as it drops slightly lower
than the intermediate cell voltage, the diode will conduct thereby
maintaining voltage at the load bus, though lower in magnitude, to
avoid complete interruption of supply. However after this brief interval
the DC conductor will energises thereby connecting the battery to the
bus restricting the original load voltage. Thus this arrangement provide
an uninterrupted DC supply to the load.

The following modes of operation of the boost charger can be selected

with the help of mode selector switch:-

POSITION = 1

The boost charger will remain in de-energised condition with battery

bank in healthy condition across the float charger. However during
continuous floating operation, the cells in the battery bank tends to fall
out in steps, and float charging current increases and when it exceeds
preset limit, the auto equalising relay (RL 9) energises. Then the
boost charger switches on in auto equalising mode and charging
continues. When the battery voltage on charger increases to around
2.35 v/cell, the auto equalising relay (RL 9) de-energises thereby
tripping energising the boost charger. Thereafter the battery again
transfers to the float charger and float charging continues as usual
manner.

POSITION = 2

In position '2' of mode selector switch, the boost charger can be

operated as float charger provides the float sequence (C1) is off.

POSITION= 3

In position '3' the boost charging can be done manually thru external
current setting potentiometer (P2) provided on the front door of the
boost charge panel. This mode of control is normally necessary during
initial charging of the battery under manual supervision.

POSITION = 4

In position '4' the boost charging is done in automatic two step

charging mode i.e. at the starting and finishing rate of charge in
constant current mode.

BATTERY CHARGER ANNUCIATION DETAILS

Window What happens/

Facia
Corrective
Descrip When appears Remarks
No What does it mean action/Follow up action

AC INPUT Float/boost Charger Becomes 1. Nota AC input No automatic

UNDER inoperative.(Assuming that voltage action, if input Ac
VOLTAGE IF INPUT Inc supply has failed.) voltage has not
VOL< 370 failed; but there
V 2. Change source 1 is a voltage
to source 2 or surge.
vice-versa and
see if ann.
Disappears.

1 3. Check upstream
feeders at Mcab.