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( Industrial Electronics Division)

R-508, TTC Industrial Area, MIDC, Rabale, Navi Mumbai 400708 Tel.: (022) 6516 6318, 6516 6319, 6516 6504 Fax ; (022) 2764 2444 E-mail: customercare@raychemrpg.com Website: www.raychemrpg.com

OPERATION & MAINTENANCE MANUAL FOR THYRISTOR CONTROLLED BATTERY CHARGER Rating: 110V DC / 40A (Max. DC 110V, max. Current 40Amps)

CLIENTS NAME

:-

M/s FURNACE FABRICA (INDIA) LTD.

CLIENTS P. O. NO. :-

2009/200815/545 File Reference IE0068 09G43

DT. 22.05.2009

SR. NO. MODEL

::-

3BCH110V 40A (THY.CONTROLLED)

Raychem RPG Ltd.


R-508, TTC Industrial Area, MIDC, Rabale-400708 Navi Mumbai
Tel: 30916501

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

TYPE: CAPACITY: INPUT: OUTPUT:

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

WORKING CONDITIONS: Maximum Ambient temperature 45 C

II. GENERAL DESCRIPTION

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:

CONTROL CARD - Type 105DJ1


This card generates the line-synchronized pulses required to trigger main SCRs connected on the secondary side of the main transformer TR1. There are three firing circuits in the unit. All the three circuits are identical. The Pulse generator receives the control signal from the buffer output stage (explained below). The pulses produced by the firing card are synchronized to Mains AC cycle by using synchronizing circuits. The pulses from each firing circuit in the card are synchronised to relevant phases. The Pulse generator card receives line synchronising signals from secondary windings of the control transformers TR2.The control transformer TR2 provides the synchronization of R Phase signal for controlling the R Phase SCRs, Y Phase signal for controlling the Y Phase SCRs & B Phase signal for controlling the B Phase SCRs. The control voltage governs the position of the synchronized pulses with respect to the start of each line half cycle. Thus, by changing this control voltage, the firing angle of the main SCRs can be changed, which in turn gives rise to control of the rectified output voltage, thereby controlling the DC output voltage of the unit. The card also senses the AC supply voltage and the sequence of the same from the supply received thru the secondary of control Transformers TR2. If the sequence of AC signal is reversed or if the level of input voltage falls (under voltage) below the preset limit, all the three pulses on this card are automatically shut down to make the DC output from the unit to zero. This feature prevents mismatch firing of thyristers thereby ensuring proper control. Three Red LEDs have been provided on this card to indicate normal functioning of the card. These LEDs (normally dimly lit) indicate the presence of pulses corresponding to the three phases generated by the card. All the three pulse-generating sections in the firing card are completely independent of each other.

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.

Pulse Driver card Type 118B (Dual)


This card amplifies the pulses produced by the firing card (105DJ1) to a level required for reliable and steady firing of the SCRs. This card also provides isolation between the pulses produced by the firing card and the gates of the main SCRs. Two separate pulse transformer mounted on a PCB along-with LEDs have been provided on this card to indicate pulse output from this card to individual SCRs. Such 3 pulse driver cards are provided for relevant phases.

DC over voltage & over current Type 19C


This card consists of a DC voltage & DC current sensing logic, on card auxiliary Transformer & two on card Relays. This card has two independent comparators for voltage & current. This card receives voltage signal from the unit output and DC current signal from the shunt. The voltage comparator stage on this card continuously compares the DC O/P voltage signal to the reference level set by the voltage preset on this card. Whenever the DC O/P voltage increases beyond the value set by the voltage preset, a relay on this card is energised to provide a change over contact for over-voltage condition. A delay of about 4/5 seconds is introduced after the overvoltage condition is sensed. The over-voltage indication level can be set anywhere from 10V to 30V by means of the voltage preset marked as V/S. Similarly, The current comparator stage on this card continuously compares the DC O/p current signal to the reference level set by the current preset on this card. Whenever the DC O/P current increases beyond the value set by the current preset, a relay on this card is energised to provide a change over contact for over-current condition. A delay of about 4/5 seconds is introduced after the over-current condition is sensed. The over-current indication level can be set anywhere from 10mV to 75mV by means of the current preset marked as C/S. Two red LEDs have been provided on this card to indicate operation of the voltage & current comparators. The respective LEDs glow when the individual comparators are energised due to over-voltage or over-current condition. An alarm is provided for the above fault and an acknowledge push button is provided for the same to acknowledge the same. The indications will continue as long as the fault is not been rectified. Reset push button is clubbed along-with the off push button by the OFF push button.

f) Function of Auto-change over


In event of the batteries getting charged beyond 130V DC during Boost working, the charger switches over to float mode. This is affected by sensing over voltage of the Battery by an over voltage card. The over voltage card senses 130Volts across the battery and effects the above operation. This results in charger running in float mode as long as the battery voltage drop down below 115.0V, Moment the battery voltage drop below 115.0V the charger goes in boost mode and charge the battery in constant current mode. This is affected by sensing under voltage of the Battery by an under voltage card. The under voltage card senses 115Volts across the battery and effects the above operation. This results in charger running in boost mode and vice-versa.

a) INSTALLATION & COMMISSIONING

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.

c) Keep the Constant current potentiometers in zero position.

d) Connect 415 Volt AC 3 Phase. 50 Hz supply to the input terminals.

e) Switch ON the MCB. The mains on indication lamp will light. Switch on the control supply by ON push button.

f) Slowly the output voltage will rise to 118 Volts.

g) Switch off the supply and connect some dummy load.

h) With the constant current potentiometer (on front panel) at minimum, switch ON the unit and adjust the DC output current with the Potentiometer.

i) Switch off the supply and connect the actual load.

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.

Check the connections tightness once every month.

Check the wires for snapped connections from time to time.

For the faults of malfunctioning, you will have to refer to the circuit diagram and the description thereby.

c) FAULT FINDING AND RECTIFICATION


FAULT NO VOLTAGE OUTPUT POSSIBLE CAUSES Rectifier not AC supply. getting METHODS OF RACING FAULT Check input fuses, control box supply and actual input to the rectifier. RECTIFICATION Self-explanatory.

Control not getting ON

a) Check the polarity phase failure LED. b) Check the wiring

and

1) Correct the same if LED glows. 2) Correct the same.

RECTIFIER DELIVERING VOLTAGE CURRENT

NOT OR

Control Transformer a) not setting fully b)

Check control fuses Check wiring

the the

Restore the same.

Thyristors not getting pulses

Check the wires connected to the gate of each thyristors

Restore if found snapped

DC OVERLOAD TRIPPING.

Shorting in the load

Check the load.

Self explanatory

Settings of overload must have been changed.

Set the over load setting to max and slowly increase the current.

Make new settings.

RECTIFIER I/P MCCB IS TRIPPING

Short-circuit some where in the unit. a) Transformer has shorted.

a) Isolate Transformer primary and secondary and check individual coils with a Dimmerstat.

a)

If faulty, replace transformer coils.

b)

One of thyristors shorted.

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.

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