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OPERATION & MAINTENANCE MANUAL FOR THYRISTOR CONTROLLED BATTERY CHARGER Rating: 110V DC / 40A (Max. DC 110V, max. Current 40Amps)
CLIENTS NAME
:-
CLIENTS P. O. NO. :-
DT. 22.05.2009
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INDEX
1. Brief Specification. 2. General Description. 3. Technical Description. 4. Protections & Indications. 5. Installation & Commissioning. 6. Maintenance. 7. Faultfinding & rectification. 8. Drawings. General arrangement drawing (External) Wiring circuit Diagram Wiring circuit Diagram (Controller) IE0068-01 (sheet 1 of 1) IE0068-04 (sheet 1 of 2) IE0068-04 (sheet 2 of 2)
I. BRIEF SPECIFICATION
THYRISTOR CONTROLLED BATTERY CHARGER. 5.6 KW 415 Volts 3 Phase.50Hz. AC (Nom) 110 Volts DC 40 Amps DC Max.
DETAILS: a) TRANSFORMER-RECTIFIER UNIT: Air cooled b) Solid state controller c) Constant current settable d) Voltage limit maximum e) Meters provided on main unit. f) MCB Provided on Main unit. g) DC Over voltage, DC under voltage & Battery low protections as per Circuit diagram. h) Ripple less than 2% at full voltage and full load. from 0% to 100% 140Volts DC
The battery charger is designed to provide constant voltage variable current supply of 110-140 Volt at 40 Amps max.
The charger is a thyristor-controlled equipment, having high capacity, thyristors connected on the secondary side of the transformer, in 3-phase full wave Bridge configuration.
The unit is fully automatic; the output voltage & current can be adjusted over the range of 105-140V & 0-40A with potentiometer on the front panel for manual working. The output DC current in the manual mode can be adjusted from 0-4Amps by selecting a low current range selection switch inside the cubicle.
Separate sets of potentiometers are provided inside the charger for setting Voltage and current in float mode & boost mode independently. The setting made in the float mode and in boost mode applies directly in the auto mode wherein the charger selects the working mode (Float/Boost) depending upon the state of battery voltage.
III. TECHNICAL DESCRIPTION The battery charger set has been designed to give you satisfactory working in all the working conditions and following circuitry has been incorporated for the same. Kindly refer to the following circuit diagrams: IE0068-04 (sheet 1 of 2 & 2 of 2) a) Main Transformer The main Transformer has been designed with copper conductors & class F insulation. The temperature rise is maintained below Class F permissible limits. It is mounted towards rear, left hand side and is accessible on opening the rear door. The secondary connections are taken directly to the Three - phase
Thyrister Bridge. b) Rectifier assembly The rectifier assembly is having 6 thyristors connected in three-phase Bridge configuration. The Thyristors have been selected with over 2 times average rating, mounted on aluminium heat sinks. The assembly is designed for natural cooling, however fans are provided for additional cooling. The assembly is streamlined by using fiberglass angles and partitions. The RC is provided for each thyristor, and gate cathode terminals are provided for each thyristor separately, with facility to disconnect gate terminal while carrying out the check. Actual connections to the thyristor blocks are done by flexible copper wire to avoid any tension on the elements.
c) Filter Choke To reduce the peak currents during process, a choke is provided, mounted by the side of the transformer. It is wound with copper, and is having suitable cable connections. The winding has been done with class F insulation with class F temperature rise. The choke has been designed to reduce the ripple content in the output to be less than 2% at full voltage and current condition along-with suitable Filter capacitors. d) Protections And Indications An MCB rated for 32Amps on the incoming side An MCB rated for 40Amps on the outgoing side Battery low indication. Under voltage indication. Over voltage indication. Over load indication. Under voltage change over from float to boost. Over voltage change over from boost to float. Indications for float ON Indications for Boost ON Indications for charger ON Indications for Mains ON Indications for thyrister fuse fail. Indications for Output MCB trip.
e) Controller The power for the control has been derived from mains by using an isolation control transformer. The controller provides pulses to the phase
controlled thyristor assembly. It is having following different functions. Provides pulses, which are synchronized in line with the input phase. Pulses are shifted automatically to adjust the desired output current. Feedback signals are compared with the reference signals for output parameters adjustments. The main controller provides control for the pulses as follows:
The card controls the DC output voltage and current of the unit. The error amplifier in this card receives a reference voltage from potentiometer (P1) for setting the output voltage maximum limit, this potentiometer is provided inside the controller unit. This card receives voltage feedback through the potential divider card consisting of resistances connected across DC output. The amplifier stage 1 on this card compares both the signals. Similarly, reference voltage from potentiometer (P2) for setting the output current is provided on the front panel. This card also receives current feedback from the shunt connected in series on the DC output. The millivolt signal from the shunt is amplified tot the desired level (1000times) and is compared with the reference voltage of potentiometer (P2). The amplifier stage 2 on this card compares both the signals. The amplified voltage from stage1 (CV) & stage 2 (CC) is again compared for constant voltage or constant current control. Depending upon the load conditions and the settings of the above potentiometers (P1 & P2) the controller automatically controls either the voltage or current output. The DC output voltage can be set anywhere from 0V to the full rated value by varying the control voltage fed by potentiometer. The current signal after processing is fed to the control logic on this card through current setting potentiometer. Whenever the DC voltage exceeds the limit set by the CV potentiometer, any further increase in current signal tends to retard the firing pulses thereby reducing the DC output voltage to maintain the current at this limiting value of voltage. Thus the unit operates in voltage limiting and holds the voltage constant at the set limit. The voltage control logic overrides the current control signal and maintains the output voltage at the limit value irrespective of the setting of CC potentiometer. This feature is useful in protecting the rectifier unit from delivering higher voltage. The control card gets AC supply through secondary winding of auxiliary transformer TR2. Two LEDs are provided on this card to indicate normal functioning of the card. The green LED indicates that the card is energised while the red LED indicates the presence of control signal from this the card.
a) Install the unit, sufficiently away from any wall. Proper ventilation must be ensured in the room, where the unit is installed.
b) The unit must be installed away from chemical fumes and dust particles.
e) Switch ON the MCB. The mains on indication lamp will light. Switch on the control supply by ON push button.
h) With the constant current potentiometer (on front panel) at minimum, switch ON the unit and adjust the DC output current with the Potentiometer.
b) MAINTENANCE The equipment should be installed in a place, which is having free ventilation from all the side. It should be installed sufficiently away from a wall, such that the natural flow of air may not get obstructed.
The equipment has been designed for maintenance free service, however for trouble free service, timely check up and maintenance will increase the life of the equipment considerably as follows.
Wipe the dust from contactor, MCB and potentiometers once every month with a smooth cloth.
Remove the dust from the PCBs, Thyristor and Heat Sinks by using vacuum cleaner.
For the faults of malfunctioning, you will have to refer to the circuit diagram and the description thereby.
and
NOT OR
the the
DC OVERLOAD TRIPPING.
Self explanatory
Set the over load setting to max and slowly increase the current.
a) Isolate Transformer primary and secondary and check individual coils with a Dimmerstat.
a)
b)
the has
b) After the above steps check each thyristors with multimeter and isolate the faulty one.
Replace the faulty one. While replacing the thyristors proper polarity of the new thyristors must be ensured before fitting. They must match with the old polarity.