Master Drawing of Battery Chargers o & M Manuals

DOC. NO. REV. NO.
PLL-GVK-PEE-212-W-001 0
Total Sheets 20
O&M MANUALS FOR DC SYSTEM - MAIN PACKAGE

SUPPLIER - STATCON
0 FOR INFORMATION 26.03.2012

REV. NO. DESCRIPTION PRED. BY CHKD. BY DATE
PROJECT 2x270 MW, COAL BASED TPP

GOINDWAL SAHIB PUNJAB
OWNER
GVK POWER (GOINDWAL SAHIB) LIMITED
OWNER'S
CONSULTANT CONSULTING ENGINEERS LIMITED,
BANGALORE
BOP
CONTRACTOR PUNJ LLOYD LIMITED,
95 INSTITUTIONAL AREA, SECTOR 32.
GURGAON 122-001.
BOP
CONSULTANT FICHTNER Consulting Engineers (India) Private Limited
Chennai
INDEX SHEET
SR.NO. DESCRIPTION PAGE NO.

1. 220 V / 50 A Float Cum Boost Charger 2 – 74
2. 220 V / 120 A Float Cum Boost Charger 75 - 146
3. 220V DC 2500Ah (250A) Discharge 147 – 160

Resistor Bank
4. 2V or 4V DC 2500Ah (250A) Discharge 161 – 173

Resistor Bank
5. 220V DC 900Ah (90A) Discharge Resistor 174 – 186

Bank
6. 2V or 4V DC 900Ah (90A) Discharge 187 - 216

Resistor Bank
DOC.NO.: S-MAN-180A-10
OPERATION AND MAINTENANCE MANUAL

FOR
220V/500A FLOAT-CUM-BOOST CHARGER
INPUT VOLTS : 415 VAC ± 10%, PHASE-3, FREQ. : 50 Hz. ± 5%
OUTPUT VOLTS : FLOAT: 237.6V BOOST: 291.6V
OUTPUT AMPS : FLOAT: 500.0 A BOOST: 500.0 A
UNIT SERIAL NOS. : 11J00826 - 11J00829
PROJECT 2x270 MW, GVK (GOINDWAL) THERMAL POWER PROJECT,

GOINDWAL SAHIB, PUNJAB
OWNER
OWNER'S
BANGALORE
BOP
GURGAON 122-001.
BOP
Chennai
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
E:\SPC-10\SPC-180-10-(C)\ASBUILT\180A\S-MAN-180A-10.doc Page 1 of 31
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 FCBC 8
6. CONTROLS & POTENTIOMETER PROVIDED INSIDE AT THE FRONT FCBC 10
7. TERMINALS PROVIDED IN BATTERY CHARGER 11
8. INITIAL INSTALLATION AND OPERATING INSTRUCTIONS 12
9. OPERATING PROCEDURE 13
10. GENERAL DESCRIPTION & OPERATION OF 220V FLOAT-CUM- BOOST CHARGER 21
11. DESCRIPTION OF MAIN CONTROL CARD CC1 (SPCL-312V3) 23
12. DESCRIPTION OF AUTO FIRING CARD CC2 (SPCL-333V1) 25
13. DETAILS OF PRESET OF AUTO FIRING CARD (SPCL-333V1) 26
14. DESCRIPTION OF MANUAL FIRING CARD CC7 (SPCL-404V1) 27
15. DESCRIPTION OF MAINS SENSING CARD CC3 (SPCL-326V2) 28
16. TROUBLE SHOOTINGS 29
17. CUSTOMER FEED BACK FORM 31
18. ENCLOSURES
a. MECHANICAL DRAWING
b. ELECTRICAL DRAWING
c. BILL OF MATERIAL
d. CONTROL CARDS & B.O.M.
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.
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.
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.
GUARANTEED TECHNICAL PARTICULARS - BATTERY CHARGER
Sr. No. Description Unit Client Offers

Specification Specification
1 Stationary Lead Acid Storage IS 1651
battery (Tubular)
2250Ah
1.1 Application Unit / Station/ Unit
Water System
Area
1.2 NO. of battery Bank required Nos. 4 Sets
1.3 Reference ambient Deg. C 50 50
temperature for design of
electrical devices
1.4 DC System voltage V 220V 220V
1.5 Ampere hour capacity of Ah 2500
battery at 27 deg. C
temperature for 10 hours rate
to give final cell voltage of 1.75
volts/ cell
1.6 Discharge duty considered for Yes
battery sizing
1.7 a) Required area of Depends Upon
battery and charger Room Layout
room
b. Battery orientation/ Single tier for
mounting batteries above
arrangement 1000Ah capacity
1.8 Charging method proposed Constant current
constant voltage
1.9 Battery charger rating required 300A
to charge the battery in 10 hrs
from fully discharged
conditions (both Voltage and
current range to be specified)
1.10 No. of cells per set 108
a. Short time load
b. Continuous load.
c. Starting current of
largest connected DC
motor
1.11 Battery charger current and
voltage rating
a. Float 237.6V, 500 A
b. Boost 291.6V, 500A
1.12 Float/ Tricle charging current of 2500mA(min)
battery 10000mA(max)
1.13 Max. Boost charging current of Amp, 300A (starting)
battery. 150A (finishing)
Max. Boost charging Voltage of Volt. 2.7V/cell
battery
1.14 Max. time for Boost charging of Hours 10 10 hours
battery
1.15 AC system date

a. Supply V, Hz 415V, 3ph, 3 wire 415V, 3ph, 3 wire
50 Hz 50 Hz
b. Variation in supply %
±10% in voltage ±10% in voltage
±5% in ±5% in
c. Short circuit level kA Frequency Frequency
d. Type of earthing 50 kA for 1 sec 50kA

non effectively
e. Pf at 415VAC and earthed
Reated load (boost
mode) 0.8 lag
1.16 Efficiency at 415VAC and rated >85%

load (boost mode)
1.17 Ripple at 415VAC and rated <3% rms

load (boost mode) (without battery)
<±1% rms
(with battery)
1.18 Regulation for 0-100% load <±1%
and ±10% variation in input
voltage, ±5% variation in input
frequency
FRONT PANEL DOOR: CONTROLS, INDICATIONS AND DISPLAY
FLOAT-CUM-BOOST CHARGER
DISPLAY: PARAMETER
AC VOLTAGE: The LCD displays R, Y, B phase voltage of
415VAC three supply input supply.
AC CURRENT: The LCD displays R, Y, and B line current of

415VAC three phase input supply.
CHARGER VOLTAGE: The LCD displays the boost charger output DC

voltage.
CHARGER CURRENT: The LCD displays the Output current which is

delivered by the boost charger.
BATTERY VOLTAGE: The LCD displays the Battery Voltage.
LOAD VOLTAGE: The LCD displays the Load voltage of the battery
charger.
BATTERY CURRENT: The LCD displays the battery charging/discharging

current.
KEYPAD CONTROLS:
FLOAT VOLTAGE: The float voltage of the charger within limit is set
through key pad.
BOOST VOLTAGE: The boost voltage of the charger is set through the
key pad.
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.
BATTERY CURRENT LIMIT: Using the key pad the limit of the current that can
be drawn by the battery can be set.
DISPLAY ANNUNCIATION:
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.
AC MCCB TRIP/OFF: The LCD will display “AC Input MCCB Trip/Off”
fault if the Input MCCB connected in input supply
Off.
SCR FUSE FAIL: The LCD will display “SCR Fuse fail” fault if the
fuses connected in Rectifier Bridge of float charger
blows.
DC MCCB TRIP: The LCD will display “DC MCCB Trip” fault if the
Output MCCB connected in output DC circuit trip.
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).
DC OVER VOLTAGE: The charger will display “DC OVER Voltage” fault if
the output DC voltage of the charger is higher than
set limit.
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.
SINGLE PHASING/REVERSE: The LCD will display “Phase fail/reverse” if there is

a missing phase or phase reversal of the three
phase input supply.
CHARGER FAIL/OFF: The LCD will display “CHARGER FAIL/OFF” if the

output voltage of the float charger fails due to any
reason.
AC MAINS FAIL: This indicates failure or off condition of mains AC

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

the Float charger.
INDICATIONS:
R, Y, B PHASE ON: This indicates that AC input supply (R, Y, B,

phase) is ON at the input of boost charger.
DC ON: This indicates that the output DC voltage of the

charger is available.
CONTROLS:
CONTROL SWITCH: This switch is used to select the input supply
source for space heater, lamp and socket supply.
CONTROLS & POTENTIOMETER PROVIDED INSIDE AT THE FRONT
CONTROLS:
INPUT MCCB: This MCCB connect or disconnect 415V AC 3-Ph
input supply to the Battery charger.
OUTPUT MCCB: This MCCB connect and disconnect float charger

output with load and battery.
SPACE HEATER SWITCH: This switch is used to switch-On/Off the AC supply

to the thermostatically controlled space heater.
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
MANUAL VOLT SET POT. : This potentiometer sets the voltage in manual
mode of operation of Boost charger.
TERMINALS PROVIDED IN THE BATTERY CHARGER
INPUT AC SUPPLY TERMINALS: “R, Y, B ” terminals are provided for connecting
Incoming supply 415v AC ±10%, 3 phase, 50 Hz
LOAD TERMINALS: 220vdc load terminals for connecting load.
BATTERY TERMINAL: Battery terminals, for positive, negative and tap-cell

are provided to connect the battery.
REMOTE ALARM “TS1”: Potential free relay contact of charger-fail, DC

under voltage, Output MCCB and Input MCCB are
terminated on the terminal which is then wired up
to the user’s control board for attending to the
charger group fault.
Analog signals 4-20mA of output current and

voltage are terminated for remote signalling.
INITIAL INSTALLATION AND OPERATING INSTRUCTIONS
a) Connect firm earth to the panels.
b) Connect 415VAC +/- 10%, three-phase input supply on the input supply terminals ‘R, Y,
B’ provided in the charger.
1. Switch on the charger with the help of input MCCB “MCCB1”. Switch-on the on/off
control switch provided on the 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 “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”.
3. Switch-off the charger and connect battery; positive, negative and tap-cell on the
battery terminals provided inside the battery charger.
4. Switch-on the charger. The battery will draw current, which should be 10% of the
battery Ah capacity.
5. 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.
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.
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)
Figure:-4A Disp# 2 (in the float charger home position)
Figure:-4B Disp# 2 (in the boost charger 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)
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.
Figure:-6
Figure:-7
Figure:-8
Figure:-9
Figure:-10
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.
Procedure Of Changing The “Float Voltage” Setting

Of Cell”.
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 8:- [Press ENTER key], again. It will come to Home Position of Display.
Procedure Of Changing The “Boost Voltage” Setting

Of Cell”.
Action 3:- [Press SET key], Cursor would be shifted on “Number of Cells”.
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.
Procedure Of Changing The “Battery Current Limit” Setting

Of Cell”.
Action 3:- [Press SET key], Cursor would be shifted to “Number of Cells”.
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 13:- [Press ENTER key] again. It will come into Home Position of Display.
Procedure Of Changing The “System Current Limit” Setting

Of Cell”.
Changeover Time”.
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 14:- [Press ENTER key], again. It will come into Home Position of Display.
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

“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 8:- [Press SET key], Cursor would be shifted to “Trip”.
Action 10:- [Press SET key], Cursor would be shifted to “AC under voltage”.
Note: - Similarly follow operating procedure attached with manual, to set other
annunciation and alarm.
GENERAL DESCRIPTION AND OPERATION OF
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, 3-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 47Hz to 51Hz,
respectively. Let us understand the circuit of the FCBC.
The input supply 415V ± 10%, 50Hz ± 5%, 3 phase – 3 wire is connected at the marked R,
Y, B, terminals. ‘MCCB1’ is input supply breaker MCCB. ‘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 ‘MCCB1’ is closed. 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
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 this card. The sample of the
output current is fed in the form of a proportionally generated mV signal across current
shunts ‘SH1’ and ‘SH2’. These shunts are provided separately for monitoring the total
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 two modes, viz., Float and Boost by using the keypad
selection. 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 charger- fail, MCCB trip AC fail is provided
on the remote alarm terminal. 4-20mA analog signal for DC output voltage and DC output
current is also terminated on the terminals for remote signaling.
The Function of the FCBC is to charge the battery, in float or boost mode depending on the
battery requirement, as well as supply the loads. During float charging the contactor C2 will
remain closed and FCBC will trickle charge it’s respective battery Bank. In case the
batteries needs boost charging. Than FCBC shall be selected in boost charging mode to
boost charge battery. During boost charging the contactor C2 shall remain open and load
shall be feed by Tap Cell. In case of FCBC complete failure than load supply feed by tap
cell diodes.
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.
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
(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
(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.
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.
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’.
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.
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
DESCRIPTION OF MAINS SENSING CARD CC3 (SPCL-326V2)
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.
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 is off. Check and MCCB/switch 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.
(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.
DOC.NO.: S-MAN-180B-10

FOR
INPUT VOLTS : 415 VAC ± 10%, PHASE-3, FREQ. : 50 Hz. ± 5%
OUTPUT VOLTS : FLOAT: 237.6V BOOST: 291.6V
OUTPUT AMPS : FLOAT: 120.0 A BOOST: 120.0 A
UNIT SERIAL NOS. : 11J00832 - 11J00833

OWNER
OWNER'S
BANGALORE
BOP
GURGAON 122-001.
BOP
Chennai
MANUFACTURED BY

TELE : 0120-3851760 ,FAX: 0120- 3851796
E:\SPC-10\SPC-180-10-(C)\ASBUILT\180B\S-MAN-180B-10.doc Page 1 of 31
CONTENTS
1. INTRODUCTION 3
4. GUARANTEED TECHNICAL PARTICULARS- BATTERY CHARGER 6
5. FRONT PANEL DOOR CONTROLS, INDICATIONS AND DISPLAY FCBC 8
6. CONTROLS & POTENTIOMETER PROVIDED INSIDE AT THE FRONT FCBC 10
7. TERMINALS PROVIDED IN BATTERY CHARGER 11
8. INITIAL INSTALLATION AND OPERATING INSTRUCTIONS 12
9. OPERATING PROCEDURE 13
10. GENERAL DESCRIPTION & OPERATION OF 220V FLOAT-CUM- BOOST CHARGER 21
11. DESCRIPTION OF MAIN CONTROL CARD CC1 (SPCL-312V3) 23
12. DESCRIPTION OF AUTO FIRING CARD CC2 (SPCL-333V1) 25
13. DETAILS OF PRESET OF AUTO FIRING CARD (SPCL-333V1) 26
14. DESCRIPTION OF MANUAL FIRING CARD CC7 (SPCL-404V1) 27
15. DESCRIPTION OF MAINS SENSING CARD CC3 (SPCL-326V2) 28
18. ENCLOSURES
c. BILL OF MATERIAL
d. CONTROL CARDS & B.O.M.
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.
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.
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.
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.
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.
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.
GUARANTEED TECHNICAL PARTICULARS - BATTERY CHARGER
Sr. Description Unit Client Offers

No. Specification Specification
1 Stationary Lead Acid IS 1651
Storage battery (Tubular)
650Ah
1.1 Application Unit / Station/ Station and WTP
Water System
Area
1.2 NO. of battery Bank required Nos. 2 Sets
1.3 Reference ambient Deg. C 50 50
temperature for design of
electrical devices
1.4 DC System voltage V 220V 220V
1.5 Ampere hour capacity of Ah 900
battery at 27 deg. C
temperature for 10 hours
rate to give final cell voltage
of 1.75 volts/ cell
1.6 Discharge duty considered Yes
for battery sizing
1.7 a) Required area of Depends Upon
battery and charger Room Layout
room
b. Battery orientation/ Single tier for
mounting batteries above
arrangement 1000Ah capacity
1.8 Charging method proposed Constant current
constant voltage
1.9 Battery charger rating 90A
required to charge the
battery in 10 hrs from fully
discharged conditions (both
Voltage and current range to
be specified)
1.10 No. of cells per set 108
a. Short time load
b. Continuous load.
c. Starting current of
largest connected
DC motor
1.11 Battery charger current and
voltage rating
a. Float 237.6V, 120 A
b. Boost 291.6V, 120A
1.12 Float/ Tricle charging current 900mA(min)
of battery 3600ma(max)
1.13 Max. Boost charging current Amp, 108A (starting) 54A
of battery. (finishing)
Max. Boost charging Volt. 2.7V/cell
Voltage of battery
1.14 Max. time for Boost charging Hours 10 10 hours
of battery
1.15 AC system date

a. Supply V, Hz 415V, 3 ph, 3 wire 415V, 3 ph, 3 wire
50 Hz 50 Hz
b. Variation in supply %
±10% in voltage ±10% in voltage
±5% in Frequency ±5% in Frequency
c. Short circuit level kA
50 kA for 1 sec 50Ka
d. Type of earthing non effectively
earthed
e. Pf at 415VAC and rated
load (boost mode) 0.8 lag
1.16 Efficiency at 415VAC and >85%

rated load (boost mode)
1.17 Ripple at 415VAC and rated <3% rms

load (boost mode) (without battery)
<±1% rms
(with battery)
1.18 Regulation for 0-100% load <±1%
and ±10% variation in input
voltage, ±5% variation in
input frequency
FRONT PANEL DOOR: CONTROLS, INDICATIONS AND DISPLAY
DISPLAY: PARAMETER
AC VOLTAGE: The LCD displays R, Y, B phase voltage of
415VAC three supply input supply.
AC CURRENT: The LCD displays R, Y, and B line current of

415VAC three phase input supply.
CHARGER VOLTAGE: The LCD displays the boost charger output DC

voltage.
CHARGER CURRENT: The LCD displays the Output current which is

delivered by the boost charger.
BATTERY VOLTAGE: The LCD displays the Battery Voltage.
LOAD VOLTAGE: The LCD displays the Load voltage of the battery
charger.
BATTERY CURRENT: The LCD displays the battery charging/discharging

current.
KEYPAD CONTROLS:
FLOAT VOLTAGE: The float voltage of the charger within limit is set
through key pad.
BOOST VOLTAGE: The boost voltage of the charger is set through the
key pad.
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.
BATTERY CURRENT LIMIT: Using the key pad the limit of the current that can
be drawn by the battery can be set.
DISPLAY ANNUNCIATION:
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.
AC MCCB TRIP/OFF: The LCD will display “AC Input MCCB Trip/Off”
fault if the Input MCCB connected in input supply
Off.
SCR FUSE FAIL: The LCD will display “SCR Fuse fail” fault if the
fuses connected in Rectifier Bridge of float charger
blows.
DC MCCB TRIP: The LCD will display “DC MCCB Trip” fault if the
Output MCCB connected in output DC circuit trip.
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).
DC OVER VOLTAGE: The charger will display “DC OVER Voltage” fault if
the output DC voltage of the charger is higher than
set limit.
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.
SINGLE PHASING/REVERSE: The LCD will display “Phase fail/reverse” if there is

a missing phase or phase reversal of the three
phase input supply.
CHARGER FAIL/OFF: The LCD will display “CHARGER FAIL/OFF” if the

output voltage of the float charger fails due to any
reason.
AC MAINS FAIL: This indicates failure or off condition of mains AC

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

the Float charger.
INDICATIONS:
R, Y, B PHASE ON: This indicates that AC input supply (R, Y, B,

phase) is ON at the input of boost charger.
DC ON: This indicates that the output DC voltage of the

charger is available.
CONTROLS:
CONTROL SWITCH: This switch is used to select the input supply
source for space heater, lamp and socket supply.
CONTROLS & POTENTIOMETER PROVIDED INSIDE AT THE FRONT
CONTROLS:
INPUT MCCB: This MCCB connect or disconnect 415V AC 3-Ph
input supply to the Battery charger.
OUTPUT MCCB: This MCCB connect and disconnect float charger

output with load and battery.
SPACE HEATER SWITCH: This switch is used to switch-On/Off the AC supply

to the thermostatically controlled space heater.
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
MANUAL VOLT SET POT. : This potentiometer sets the voltage in manual
mode of operation of Boost charger.
TERMINALS PROVIDED IN THE BATTERY CHARGER
INPUT AC SUPPLY TERMINALS: “R, Y, B ” terminals are provided for connecting
Incoming supply 415v AC ±10%, 3 phase, 50 Hz
LOAD TERMINALS: 220vdc load terminals for connecting load.
BATTERY TERMINAL: Battery terminals, for positive, negative and tap-cell

are provided to connect the battery.
REMOTE ALARM “TS1”: Potential free relay contact of charger-fail, DC

under voltage, Output MCCB and Input MCCB are
terminated on the terminal which is then wired up
to the user’s control board for attending to the
charger group fault.
Analog signals 4-20mA of output current and

voltage are terminated for remote signalling.
INITIAL INSTALLATION AND OPERATING INSTRUCTIONS
a) Connect firm earth to the panels.
b) Connect 415VAC +/- 10%, three-phase input supply on the input supply terminals ‘R, Y,
B’ provided in the charger.
1. Switch on the charger with the help of input MCCB “MCCB1”. Switch-on the on/off
control switch provided on the 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 “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”.
3. Switch-off the charger and connect battery; positive, negative and tap-cell on the
battery terminals provided inside the battery charger.
4. Switch-on the charger. The battery will draw current, which should be 10% of the
battery Ah capacity.
5. 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.
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.
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.
Figure:-4A Disp# 2 (in the float charger home position)
Figure:-4B Disp# 2 (in the boost charger 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)
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.
Figure:-6
Figure:-7
Figure:-8
Figure:-9
Figure:-10
Figure:-11
Procedure Of Changing The “Charging Mode” Setting

Of Cell”.
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 7:- [Press ENTER key] again. It will come to Home Position of Display.
Procedure Of Changing The “Float Voltage” Setting

Of Cell”.
Action 6:- [Press INC key or DEC key] to set the desired Float Voltage.
Procedure Of Changing The “Boost Voltage” Setting

Of Cell”.
Action 3:- [Press SET key], Cursor would be shifted on “Number of Cells”.
Action 7:- [Press INC key or DEC key] to set the desired Boost Voltage.
Procedure Of Changing The “Battery Current Limit” Setting

Of Cell”.
Changeover Time”.
Action 11:- [Press INC key or DEC key] to set the desired Battery Current Limit.
Action 13:- [Press ENTER key] again. It will come into Home Position of Display.
Procedure Of Changing The “System Current Limit” Setting

Of Cell”.
Changeover Time”.
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 14:- [Press ENTER key], again. It will come into Home Position of Display.
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

“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 10:- [Press SET key], Cursor would be shifted to “AC under voltage”.
Note: - Similarly follow operating procedure attached with manual, to set other
annunciation and alarm.
GENERAL DESCRIPTION AND OPERATION OF
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, 3-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 47Hz to 51Hz,
respectively. Let us understand the circuit of the FCBC.
The input supply 415V ± 10%, 50Hz ± 5%, 3 phase – 3 wire is connected at the marked R,
Y, B, terminals. ‘MCCB1’ is input supply breaker MCCB. ‘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 ‘MCCB1’ is closed. 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 M1 to M3 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’ 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
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 this card. The sample of the
output current is fed in the form of a proportionally generated mV signal across current
shunts ‘SH1’ and ‘SH2’. These shunts are provided separately for monitoring the total
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 two modes, viz., Float and Boost by using the keypad
selection. 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 charger- fail,MCCB trip AC fail is provided
on the remote alarm terminal. 4-20mA analog signal for DC output voltage and DC output
current is also terminated on the terminals for remote signaling.
The Function of the FCBC is to charge the battery, in float or boost mode depending on the
battery requirement, as well as supply the loads. During float charging the contactor C2 will
remain closed and FCBC will trickle charge it’s respective battery Bank. In case the
batteries needs boost charging. Than FCBC shall be selected in boost charging mode to
boost charge battery. During boost charging the contactor C2 shall remain open and load
shall be feed by Tap Cell. In case of FCBC complete failure than load supply feed by tap
cell diodes.
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.
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
(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
(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
(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.
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.
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’.
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.
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
DESCRIPTION OF MAINS SENSING CARD CC3 (SPCL-326V2)
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.
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)
Charger output is not (a) Mains supply is not available. Check and connect mains
available supply.
(b) Input MCCB/switch is off. Check and MCCB/switch 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.
(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.
DOC.NO.:S-MAN-DCH-180A-10
FOR
220VDC 2500Ah (250A)

DISCHARGE RESISTOR BANK
INPUT VOLTS : 220VDC
OUTPUT AMPS : 250A
TYPE : MANUALLY SELECTED STEPPED
UNIT SERIAL No. : 11J00830

OWNER
OWNER'S
BANGALORE
BOP
GURGAON 122-001.
BOP
Chennai
MANUFACTURED BY

TELE : 0120-3851760 ,FAX: 0120- 3851796
E:\SPC-10\SPC-180-10-(C)\ASBUILT\DISCHARGER\S-MAN-DCH-180A-10.doc Page 1 of 11
CONTENTS
1. INTRODUCTION 3
4. TECHNICAL PARTICULARS 7
5. PANEL CONTROLS, INDICATIONS & METERS 7
6. OPERATING INSTRUCTIONS 8
7. GENERAL DESCRIPTION OF DISCHARGE RESISTOR BANK 9
10. ENCLOSURES
c. BILL OF MATERIAL
INTRODUCTION
All protection circuits work on a D.C. Source. This is generally 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. 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.
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.
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.
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.
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.
2. Connect Battery on the battery terminals provided in this equipment.
4. Push all the fuses; they might have become loose in transit.
5. Check that all the PCB or metering connections are proper.
GENERAL TECHNICAL PARTICULARS
Battery bank rating - 220 DC / 2500Ah
Open-circuit bank voltage - 216V DC
Type of battery - Lead -Acid
Number of cells - 108
Open-circuit Voltage per cell - 2.0
End cell voltage - 1.85 volt/cell
Discharge bank rating - 216V / 250A
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
PANEL CONTROLS, INDICATIONS & METERS
CONTROLS:
INCOMING MCCB : This MCCB connect / Disconnect battery supply to
the equipment.
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.
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.
GENERAL DESCRIPTION OF BATTERY DISCHARGE RESISTOR BANK
Refer electrical ckt diagram S/ELECT/DCH-180A-10

The 220V DC battery bank is connected on the battery terminals provided inside the
panel. Main input DC MCCB ‘MCCB1’ fitted with 240V AC-under-voltage release-coil
is for connecting and disconnecting the connected battery bank. The ‘MCCB1’ 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
230VAC, 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 Ah integrator is

provided to read real time current and accumulated Discharging Ah of battery.
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.
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.
DOC.NO.:S-MAN-DCH-180B-10
FOR
2V or 4V DC 2500Ah (250A)
INPUT VOLTS : 2V/4V DC
OUTPUT AMPS : 250A
UNIT SERIAL No. : 11J00831

OWNER
OWNER'S
BANGALORE
BOP
GURGAON 122-001.
BOP
Chennai
MANUFACTURED BY

TELE : 0120-3851760 ,FAX: 0120- 3851796
E:\SPC-10\SPC-180-10-(C)\ASBUILT\DISCHARGER\S-MAN-DCH-180B-10.doc Page 1 of 11
CONTENTS
1. INTRODUCTION 3
10. ENCLOSURES
c. BILL OF MATERIAL
INTRODUCTION
SAFETY PRECAUTIONS
HEALTH & SAFETY
Note:
INITIAL INSPECTION:
Battery cell rating - 2V or 4V DC / 2500Ah
Number of cells - 1 or 2
Discharge bank rating - 2v or 4V / 250A
Type of bank - Solid state electronic
Load selection device - Step-less by potentiometer
CONTROLS:
INCOMING SWITCH : This SWITCH connect / Disconnect battery supply to
the equipment.
METERS:

current.
TERMINAL DETAILS:

U/V coil.
1. Ensure that the potentiometers mounted on the front panel is in min position. Keep
the input swotch in off position.
2. Connect a fully charged 1 cell / 2 cells in correct polarity across the battery
terminals provided
terminals for fan.
4. Switch-on the discharge resistance bank by switching on the ON-Off switch
provided on the front panel.
5. Rotate the current set potentiometer coarse and fine to adjust the discharging
current..
Refer electrical ckt diagram S/ELECT/DCH-180B-10

The 2V or 4V DC battery cell(s) is connected on the battery terminals provided on the
front panel cover of box. The discharger is a controlled electronic resistive load. The
control supply for this load is derived from mains supply.
Incoming supply is switched-on/off by ‘SW1’, while ‘F1’ is short circuit protection fuse.
The transformer ‘TX1’ is for providing control supply as well as supply for deep
discharging. Relay ‘RL1’ is for reverse polarity protection. Transistor assembly
consisting of series pass elements (NPN transistors) connected in parallel. The base
drive for transistor is generated by control card ‘CC1’.SH1’ sense the discharging
current. Potentiometers ‘P1’ and ‘P2’ are for coarse and fine setting of the current.
The control is done in such way so as to keep the discharging current constant.
‘RL1’ is battery reverse operated relay. If the battery is connected in reverse polarity
then ‘RL1’ is operated and disables the coil of contactor ‘C1’.
TROUBLE SHOOTING
(b) Input Switch is off. Check and switch on the

same.
(c) Cable connection from the battery Check cable connection in this
terminals to the load through input path and set it right.
switch is loose.
d) The switch is faulty. Check and replace if the

continuity of the switch is not
made.

e) The corresponding resistor branch
is faulty.
multimeter.
Load current is not

adding up when a
switch is kept in on
position.
DOC.NO.:S-MAN-DCH-180C-10
FOR
220VDC 900Ah (90A)

OUTPUT AMPS : 90A
UNIT SERIAL No. : 11K1093

OWNER
OWNER'S
BANGALORE
BOP
GURGAON 122-001.
BOP
Chennai
MANUFACTURED BY

TELE : 0120-3851760 ,FAX: 0120- 3851796
E:\SPC-10\SPC-180-10-(C)\ASBUILT\DISCHARGER\S-MAN-DCH-180C-10.doc Page 1 of 11
CONTENTS
1. INTRODUCTION 3
10. ENCLOSURES
c. BILL OF MATERIAL
INTRODUCTION
SAFETY PRECAUTIONS
HEALTH & SAFETY
Note:
INITIAL INSPECTION:
CONTROLS:
the equipment.
requirement.
METERS:

current.
TERMINAL DETAILS:

U/V coil.
Caution:
Refer electrical ckt diagram S/ELECT/DCH-180C-10


TROUBLE SHOOTING

same.

may be faulty.

is faulty.
multimeter.
FOR
220VDC 900Ah (90A)

OUTPUT AMPS : 90A

OWNER
OWNER'S
BANGALORE
BOP
GURGAON 122-001.
BOP
Chennai
MANUFACTURED BY

TELE : 0120-3851760 ,FAX: 0120- 3851796
CONTENTS
1. INTRODUCTION 3
10. ENCLOSURES
c. BILL OF MATERIAL
INTRODUCTION
SAFETY PRECAUTIONS
HEALTH & SAFETY
Note:
INITIAL INSPECTION:
CONTROLS:
the equipment.
requirement.
METERS:

current.
TERMINAL DETAILS:

U/V coil.
Caution:
Refer electrical ckt diagram S/ELECT/DCH-180C-10


TROUBLE SHOOTING

same.

may be faulty.

is faulty.
multimeter.
DOC.NO.:S-MAN-DCH-180D-10
FOR
2V or 4V DC 900Ah (90A)
INPUT VOLTS : 2V/4V DC
OUTPUT AMPS : 90A

OWNER
OWNER'S
BANGALORE
BOP
GURGAON 122-001.
BOP
Chennai
MANUFACTURED BY

TELE : 0120-3851760 ,FAX: 0120- 3851796
E:\SPC-10\SPC-180-10-(C)\ASBUILT\DISCHARGER\S-MAN-DCH-180D-10.doc Page 1 of 11
CONTENTS
1. INTRODUCTION 3
10. ENCLOSURES
c. BILL OF MATERIAL
INTRODUCTION
SAFETY PRECAUTIONS
HEALTH & SAFETY
Note:
INITIAL INSPECTION:
Battery cell rating - 2V or 4V DC / 900Ah
Number of cells - 1 or 2
Discharge bank rating - 2v or 4V / 90A
Type of bank - Solid state electronic
Load selection device - Step-less by potentiometer
CONTROLS:
INCOMING SWITCH : This SWITCH connect / Disconnect battery supply to
the equipment.
METERS:

current.
TERMINAL DETAILS:

U/V coil.
1. Ensure that the potentiometers mounted on the front panel is in min position. Keep
the input swotch in off position.
2. Connect a fully charged 1 cell / 2 cells in correct polarity across the battery
terminals provided
terminals for fan.
4. Switch-on the discharge resistance bank by switching on the ON-Off switch
provided on the front panel.
5. Rotate the current set potentiometer coarse and fine to adjust the discharging
current..
Refer electrical ckt diagram S/ELECT/DCH-180D-10

The 2V or 4V DC battery cell(s) is connected on the battery terminals provided on the
front panel cover of box. The discharger is a controlled electronic resistive load. The
control supply for this load is derived from mains supply.
Incoming supply is switched-on/off by ‘SW1’, while ‘F1’ is short circuit protection fuse.
The transformer ‘TX1’ is for providing control supply as well as supply for deep
discharging. Relay ‘RL1’ is for reverse polarity protection. Transistor assembly
consisting of series pass elements (NPN transistors) connected in parallel. The base
drive for transistor is generated by control card ‘CC1’.SH1’ sense the discharging
current. Potentiometers ‘P1’ and ‘P2’ are for coarse and fine setting of the current.
The control is done in such way so as to keep the discharging current constant.
‘RL1’ is battery reverse operated relay. If the battery is connected in reverse polarity
then ‘RL1’ is operated and disables the coil of contactor ‘C1’.
TROUBLE SHOOTING
(b) Input Switch is off. Check and switch on the

same.
(c) Cable connection from the battery Check cable connection in this
terminals to the load through input path and set it right.
switch is loose.
d) The switch is faulty. Check and replace if the

continuity of the switch is not
made.

e) The corresponding resistor branch
is faulty.
multimeter.
Load current is not

adding up when a
switch is kept in on
position.

Master Drawing of Battery Chargers o & M Manuals

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Master Drawing of Battery Chargers o & M Manuals

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DOC. NO. REV. NO.

O&M MANUALS FOR DC SYSTEM - MAIN PACKAGE

0 FOR INFORMATION 26.03.2012

PROJECT 2x270 MW, COAL BASED TPP

SR.NO. DESCRIPTION PAGE NO.

2. 220 V / 120 A Float Cum Boost Charger 75 - 146

3. 220V DC 2500Ah (250A) Discharge 147 – 160

4. 2V or 4V DC 2500Ah (250A) Discharge 161 – 173

5. 220V DC 900Ah (90A) Discharge Resistor 174 – 186

6. 2V or 4V DC 900Ah (90A) Discharge 187 - 216

OPERATION AND MAINTENANCE MANUAL

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

OUTPUT VOLTS : FLOAT: 237.6V BOOST: 291.6V

OUTPUT AMPS : FLOAT: 500.0 A BOOST: 500.0 A

UNIT SERIAL NOS. : 11J00826 - 11J00829

PROJECT 2x270 MW, GVK (GOINDWAL) THERMAL POWER PROJECT,

STATCON POWER CONTROLS LTD.

Sl. No. PARTICULARS PAGE NO.

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 FCBC 8

6. CONTROLS & POTENTIOMETER PROVIDED INSIDE AT THE FRONT FCBC 10

7. TERMINALS PROVIDED IN BATTERY CHARGER 11

8. INITIAL INSTALLATION AND OPERATING INSTRUCTIONS 12

10. GENERAL DESCRIPTION & OPERATION OF 220V FLOAT-CUM- BOOST CHARGER 21

11. DESCRIPTION OF MAIN CONTROL CARD CC1 (SPCL-312V3) 23

12. DESCRIPTION OF AUTO FIRING CARD CC2 (SPCL-333V1) 25

13. DETAILS OF PRESET OF AUTO FIRING CARD (SPCL-333V1) 26

14. DESCRIPTION OF MANUAL FIRING CARD CC7 (SPCL-404V1) 27

15. DESCRIPTION OF MAINS SENSING CARD CC3 (SPCL-326V2) 28

16. TROUBLE SHOOTINGS 29

17. CUSTOMER FEED BACK FORM 31

d. CONTROL CARDS & B.O.M.

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

i. It should operate on AC commercial mains available.

iii. It should meet full load demand.

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

HEALTH & SAFETY

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

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

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

INSPECTION AND INSTALLATION

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

2. Connect the firm earth to the panel.

GUARANTEED TECHNICAL PARTICULARS - BATTERY CHARGER

Sr. No. Description Unit Client Offers

1.15 AC system date

d. Type of earthing 50 kA for 1 sec 50kA

1.16 Efficiency at 415VAC and rated >85%

1.17 Ripple at 415VAC and rated <3% rms

FRONT PANEL DOOR: CONTROLS, INDICATIONS AND DISPLAY

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

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

 CHARGER CURRENT: The LCD displays the Output current which is

 BATTERY VOLTAGE: The LCD displays the Battery Voltage.

 BATTERY CURRENT: The LCD displays the battery charging/discharging

 SINGLE PHASING/REVERSE: The LCD will display “Phase fail/reverse” if there is

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

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

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

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

CHARGER VOLTAGE: The LCD displays the boost charger output DC

CHARGER CURRENT: The LCD displays the Output current which is

BATTERY VOLTAGE: The LCD displays the Battery Voltage.

BATTERY CURRENT: The LCD displays the battery charging/discharging

SINGLE PHASING/REVERSE: The LCD will display “Phase fail/reverse” if there is

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

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

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

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

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

OUTPUT MCCB: This MCCB connect and disconnect float charger

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

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