Charger Manual

Digitally signed
by TIKARAM
Date: 2010.04.16
10:35:24
GMT+05:30
Reason: CAT I
Location:
NTPCEOC
220V /400A BATTERY CHARGER FOR 990 AH NI-CD
UNIT :
BATTERY.
TYPE : FLOAT CUM BOOST: CP-CC 220 V / 400 A – 400A
CLIENT : LARSEN & TUBRO LIMITED ( ECC CONSTRUCTION GROUP )
PROJECT : NTPC,VALLUR THERMAL POWER PROJECT (3 x 500 MW )
P.O.NO. : ECCD/MAT/ E & GP / SKN/05 DTD 11.03.2009
SR.NO. : CE-2266/ CE II- 0909/281 ,282
W.O.NO. : CE-2266
MANUFACTURER :
Regd. Office & Factory : E-66, MIDC, Jalgaon - 425 003 (M.S.) QUALITY
ASSURED
Tel. : 91-257-2210626 / 27 / 28 Fax : 91-257-2213434 COMPANY
ISO:9001-2000
E-mail : [email protected] International Standards
Certifications
Lic. No. QAC/R91/0100
Visit us at www.chhabi-india.com
Mumbai Office : Bangalore Office : Delhi Office : Kolkata Office :

20, Anupam Indl. Estate no. 3, 120, First Floor, “Ajantha” F-12, First Floor, 16/1A, Bose Pukur Road,
L.B.S. Marg 6th C Main Road, Remco Layout Pankaj Grand Plaza, Kolkata - 700 042
Mulund (W) Vijayanagar 2nd Stage Mayur Vihar Phase-1, Ph : 91-33-2441 1375
Mumbai - 400 080 Bangalore - 560 040 (Karnataka) New Delhi - 110 091 Email : [email protected]
Ph. : 91-22-2561 4435/5945 Ph : 91-80-2314 0031 Ph : 91-11-4215 1213 - 14
Fax : 91-22-2568 0513 Fax : 91-80-2314 0031 Fax : 91-11-4215 1215
Email : [email protected] Email : [email protected] Email : [email protected]
CHHABI ELECTRICALS PVT. LTD, JALGAON - 425 003 SHEET NO. : SH 7126 / 1 - 13
OPERATION AND MAINTENANCE MANUAL
UNIT : 220V /400A BATTERY CHARGER FOR 990 AH NI-CD BATTERY.
TYPE : FLOAT CUM BOOST: CP-CC 220 V / 400 A – 400A
: LARSEN & TUBRO LIMITED ( ECC CONSTRUCTION GROUP )

CLIENT
: NTPC,VALLUR THERMAL POWER PROJECT (3 x 500 MW )
PROJECT
P.O.NO. : ECCD/MAT/ E & GP / SKN/05 DTD 11.03.2009
SR.NO. : CE-2266/CE II- 0909/ 281 ,282
W.O.NO. : CE-2266
INDEX
Sr. # Description Sheet No.

1 Technical Specification SH 7126 / 3 - 4
2 Operational write-up for battery charger. SH 7126 / 5 - 6
3 Erection and commissioning of equipment. SH 7126 / 7 - 11
4 Operation and Maintenance. SH 7126 / 12 - 14
5 Bill of material. LC 3719 / S11-S25
CIRCUIT DIAGRAM & GENERAL LAYOUT
Sr. # Description Drg. No.

1. Signal line diagram for FCB charger C11276A REV. 02
2. Main circuit diagram for220V/400A FCB charger C11276B REV. 02
3. Control circuit diagram for FCB charger C11276C REV. 02
4. Circuit diagram for Rectifier module C11276D REV. 02
5 Circuit diagram for Rectifier module C11276E REV. 02
6 Circuit diagram for Rectifier module C11276F REV. 02

7 Circuit diagram for DC Path of charger C11276G REV. 02
8 Circuit diagram for Annunciation with Legend C11276H REV. 02
9 General Layout for battery charger. C11277 REV. 02
10 General Layout for battery charger. C11277A REV. 02
PREPARED BY : P.V.P. CHECKED BY : H.R.P. APPROVED BY : D.J.P.
TECHNICAL SPECIFICATION
MAIN AC INPUT : 415V ±10%, 50Hz, ±3%, 3Phase, 3 Wire AC supply.
BATTERY DETAIL : a) Type of Battery : NI-CD

b) No of Cells : 169
c) AH capacity : 990 AH
d) Cell Voltage : 1.2 Volt
TYPE : FLOAT CUM BOOST: CP-CC 220V/400A - 400A
DC OUTPUT : Battery Charger

A) Float cum Boost Charger :
a) In Float Mode: Suitable to Float charge the 169 Nos.
cells of 990AH capacity at 1.4 V/Cell as well as supplying
a continuous load of 400A
b) In Boost Mode : Capable to boost charge 169 Nos. of cells
of 990 AH capacity at 1.7 V/Cell at the maximum
charging current of 400A
RIPPLE : Float cum Boost Charger: 1 % (RMS)
AMBIENT : 50° C Average ambient temperature.
SIZE : L = 2400 mm H = 2000 mm W= 800 mm
SHEET : Structure 2 mm & Other Panel 1.6 mm.

THICKNESS
CABLE ENTRY : Bottom and Rear.
COLOUR : Inside & outside : Shed No. RAL 9002 & Side Panel Shed No.
RAL5012
CONSTRUCTION :
a) Suitable for indoor operation and floor mounting.

b) Battery charging Equipment comprising of float cum boost charger housed in a
common cubicle. It consists of AC I/P terminal, DC O/P terminal for battery and load.
Control switches, potentiometers, Analog meters, Indicating lamps and Annunciation are
provided on front panel of battery charger.
TERMINAL BOARDS :
T1-3 : AC Input terminal Boards
T4- 5 : Terminal for DCDB interlock.
T6-7 : Terminal for Charger on in Boost mode potential free contact for
remote indication.
T8-9 : Charger DC Output terminal.
T10-11 : Terminal for Remote annunciation of Charger Trouble .
T 12-17 :Terminal for Transducer out put for DCS.
INDICATING LAMPS :
ACLEDP 1-3 : AC Input 'ON' Indicating lamps.

DCLED 1 : DC Output 'ON' Indicating lamps.
DCLED 2-3 : Boost mode ON indication LED.
POTENTIOMETERS :
RV 1 : Potentiometer to adjust the reference voltage .

(Auto mode of Controller card).
RV 2 : Potentiometer to adjust the DC output Voltage in float mode.
(Auto mode of Controller card).
RV 3 : Potentiometer to adjust the DC output voltage in Boost mode.
(Manual mode of Controller card).
RV4 : Potentiometer for Float mode current set.
RV5 : Potentiometer for Boost mode current set.
RV6 : Potentiometer meter for Manual mode voltage set.
CONTACTORS :
ACC 1 : AC Mains Contactor of Battery charger.

ACCA &2 : Auxiliary Contactor for AC Mains fail annunciation of Battery charger.
ACCA3 : Float /Boost operation contactor.
DCCA1 : Auxiliary Contactor for DC fail annunciation of Battery charger.
CONTROL SWITCHES :
ACSW 2 : Switch for Charger AC Contactor coil ON/OFF .

RSW 1 : Auto/ Manual mode selector switch of controller of Battery Charger
ACSW 4 : Switch for Charger Float / Boost mode operation selection.
Switch/SFU/MCB/MCCB/ACB:
ACSW 1 : AC Input “ON/OFF' switch of Battery Charger

DCSW 1 : DC Output “ON/OFF' switch of Battery Charger
ACSW 3 : AC Control supply ON/OFF switch.
ACSW 5,6 : Cubicle Lamp & Heater switches of Battery Charger
SETTINGS OF PROTECTIVE RELAYS FOR ANNUNCIATIONS :
a) DC Under & Over Voltage relay : (Float cum Boost Charger)

DC Under Voltage – Act.: 198 V, Reset: 220 V, Normal: 220 V,
DC Over Voltage – Act.: 243 V, Reset:238 V, Normal:220 V,
b) Earth Leakage Relay for annunciation: 220V
Annunciation as per legend is provided on front panel to give audio visual

annunciation of the fault. Controller cards are provided from inside of the front panel.
Rectifier stacks, Contactors, FFD’S, Transformers & Chokes are mounted in MS cubicle at
suitable places.
OPERATIONAL WRITEUP FOR BATTERY CHARGER.
(3 Phase Silicon Controlled Rectifier Equipment)
CHARGING EQUIPMENT :
The Battery Charging equipment comprises Float cum Boost charger.
Float cum Boost charger has two modes of operation i) Constant Voltage Float
Mode, ii) Constant Voltage / Current Boost Mode (as applicable as per the battery type).
Normally in float mode, charger will supply the trickle charging current required
for the batteries and will also feed the DC continuous load as required. During this time,
the charger and the battery are across the DC load terminals. If charger fails, the
battery will supply the load through DC contactor.
During an emergency when AC power fails, the battery supplies the load and
discharges to certain extent depending upon duration of emergency. When AC power is
restore, the battery needs to be boost charged for which operate Float cum Boost
charger in its boost mode.
When there is a power failure, the battery readily meets the DC loads. When the power
resumes, the battery has to be recharged for which operate the Float cum Boost charger
in Boost mode. During this period of boost charging, the DC contactor will gets open &
the load will be supplied through Battery Tap diodes or Voltage dropping device as per
logic provided in charger. Thus, higher voltage during boost charging will not appear
across the load.
The charger is fed from 3 phase, 3/4-wire (as applicable) AC supply & gives DC
stabilized output at rated full load current.
FLOAT CUM BOOST CHARGER :
1. In Float mode: The variation in DC output voltage is limited to ±1% for 0-

100% load variation & simultaneously AC voltage variation of ±10% &
frequency variation ±3%.
2. In Boost mode: The variation in DC output current is limited to ±2% for AC
voltage variation of ±10% & frequency variation of ±3%.
The rectification is obtained by using a 3-phase full controlled full wave bridge
connected Silicon rectifier stack comprising of six silicon controlled rectifiers (SCR), with
surge suppression RC network connected across each SCR.
WORKING OF CHARGER :
The circuit works on AC phase control principle. The SCR is a semiconductor
device with 3 terminals i.e. Anode, Cathode & Gate. The main load current is carried by
Anode & Cathode, while the control current flows through Gate and Cathode. The
characteristic of SCR is that, it blocks the forward voltage, when the gate current
reaches to a specified level. Therefore changing the instant at which the gate current or
pulse is supplied can control the instant, at which the SCR goes into conduction, or
triggers. Once the SCR is triggered it remains in conduction till Anode current is reduced
to zero or reverse voltage is applied to Anode. Thus changing the instant of firing can
control the output voltage of rectifier bridge / triggering the SCR.
Potentiometer is used for adjusting the output voltage setting. Shunt senses the
DC output current. The signal proportional to this DC output current is fed to the
controller and In the event of DC output current exceeds the rated full load current, the
output voltage starts drooping, thus limiting the DC output current. This inherent feature
is provided in the Battery Charger. A bleeder resistance is provided for the purpose of
the latching current required for the SCR under No load condition. A filter circuit
comprising of Filter choke and Condenser is connected in the output to limit the ripple
content to the specified level.
ERECTION AND COMMISSIONING OF EQUIPMENT
1.00 UNPACKING :
1. The equipment is covered with a layer of plastic and corrugated paper and then
packed in a wooden crate. Also read the instruction sticked on the unit carefully
(FOR LIFTING THE EQUIPMENT USE ALL LIFTING HOOKS).
2. Dismantle the wooden crate carefully and then separate the layers of packing
papers. Also read the instruction sticked on the panel (1. FOR LIFTING THE
EQUIPMENT USE ALL LIFTING HOOKS & 2. REMOVE SHORTINGS OF ALL
METER'S TERMINAL BEFORE USE).
3. After unpacking, observe the panel & components inside the charger after opening
of the door by use of door key provided (which is tied-up with door handle).
Intimate any damage during transportation if any, within 15 days to our Jalgaon
office for insurance claim / for further process as applicable. Also remove meter
terminal shorting.
2.00 ERECTION AND COMMISSIONING OF BATTERY CHARGER :
2.1) Install the equipment at indoor place suitably ventilated as per foundation details
shown in General layout drawing.
2.2) INSULATION RESISTANCE TEST (WITH 500V MEGGER) :-
2.2.1) Clean inside of the charger with the help of blower.

2.2.2) Ensure all the fuses are intact.
2.2.3) Take out the plugs of SCR controllers (CPC1&2) & Electronics relays. Keep all
Switches/SFU/MCB/MCCB/ACB in ‘ON’ position.
2.2.4) Test the equipment I.R. before connection the AC & DC cables to the charger
terminal board.
2.2.5) Check I.R. in between following terminals one by one.
a) AC terminals and earth bus.
If IR value is more than 2MΩ then proceed further. If IR value is less than 2MΩ
refer following steps,
1) switch ‘OFF’ DC output Switch/SFU/MCB/MCCB/ACB as applicable.
2) Keep AC input Switch/SFU/MCB/MCCB/ACB as applicable in ‘ON’ position
and main contactor if applicable in ‘OFF’ condition and check IR.
3) Keep AC input Switch/SFU/MCB/MCCB/ACB as applicable and main contactor if
applicable in ‘ON’ condition and find out the point of leakage.
b) DC terminals and earth bus.

Switch ‘OFF’ AC input switch and switch ‘ON’ DC output switch and check point
of leakage.
c) AC terminals and DC terminals.

1) Switch ‘ON’ AC input Switch/SFU/MCB/MCCB/ACB as applicable & switch
‘OFF’ DC output Switch/SFU/MCB/MCCB/ACB as applicable and check IR.
2) Switch ‘OFF’ AC input Switch/SFU/MCB/MCCB/ACB as applicable & switch
‘ON’ DC output Switch/SFU/MCB/MCCB/ACB as applicable and check IR.
In each of the above 3 cases, I.R. should be more than 2MΩ. If it is all right,
proceed further, if not then,
a) Keep space heater always ‘ON’ to prevent the charger from moisture if
charger is not in use.
b) Find out the point of leakage and rectify the same.
2.2.6) Switch ‘OFF’ all Switches/SFU/MCB/MCCB/ACB and put the controller and relay
plugs as it were.
2.3) Fix the cable glands to the removable cable gland plates of charger after
terminating cables through the glands.
2.4) Lay down the cables of AC input & output i.e. load & battery. For cable sizes Ref.
Bill of Material.
2.5) Crimp cable lugs of suitable sizes to this cable to enable to connect these cables to
the charger terminal board.
3.00 POWER SUPPLY AND CONNECTION :
1. Connect the AC cables to the Charger AC input Terminal Board as shown in GA

drawing.
2. Connect the charger earth bus to main earthing bus of the site.
3. Do not connect the Battery and load cables at present.
4. This equipment is designed to operate on AC mains of 415V ±10%, 50Hz±3%, 3
Phase, 3/4 wire (as applicable) AC input.
4.00 LOADING ARRANGEMENT :
Make the water load arrangement as described below.

1. Take two cables of suitable capacity.
2. Connect MS strip of suitable size to end of each cable.
3. Connect remaining ends of the wire to the DC output terminals of the charger as
described in operation.
4. Arrange PVC bucket / Drum and fill it up with water and salt solution.
5. Keep one strip vertically dipped in bucket.
6. Dipping of second trip vertically in this bucket / Drum will form load. The distance
between two MS strips will decide the current drawn by this arrangement. As you
decrease the distance between two strips, current taken by this arrangement will
go on increasing.
7. Alternatively the variable resistance load bank can be used to carry out the load
test.
I) FLOAT CUM BOOST CHARGER IN FLOAT MODE :
A) AUTO MODE :
Keep the Auto/ Manual selector switch of controller at Auto mode of operation.
Keep the Float/ Boost mode of operation selector switch at Float mode of operation
(Or operate charger in Float mode / Boost mode through push button as & if applicable)
Switch ON AC input Switch/SFU/MCB/MCCB/ACB as applicable
Charger AC ON’ indicating lamp / LED will glow.
Switch ON AC input contactor switch / MCB / Push Button as & if applicable.
NO LOAD OPERATION :
Observe the output voltage on DC voltmeter. It shall increase gradually up to the

factory set voltage. If it is disturbed in transportation, reset it to the set voltage with the
help of voltage adjustment potentiometer (In Auto Mode). The voltage span in auto
mode is ±5% maximum from minimum to maximum position of voltage adjustment
potentiometer.
Switch 'ON' DC Output Switch/SFU/MCB/MCCB/ACB as applicable

Observe DC voltage on voltmeter.
Observe the DC ON or float mode ON indicating Lamp / LED is ON as & if applicable.
Connect water load cables at DC Output terminals.
Switch ON the battery Switch/SFU/MCB/MCCB/ACB as & if applicable
FULL LOAD OPERATION :
Increase the DC current from zero, indicated by DC Ammeter & at the same time,
AC input current can be observed on the AC Ammeter if applicable. Also AC input voltage
can be observed on the AC Voltmeter if applicable. Observe the floating voltage as set at
No load operation remains constant within ±1% up to full load / rated current i.e. from
0 to 100% of rated full load current.
CURRENT LIMITING FEATURE :
If you go on increasing load current above the rated load current, the output
voltage starts to decrease and limits the load current, thus allowing the battery to take
extra load. The change in the value of the current limiting resistance can vary this level
of current limiting feature. The current limiting feature acts as the load current reaches
to the rated load & the excess current will get locked at 105% or 110% as applicable.
B) MANUAL MODE :
Keep the Auto/ Manual selector switch of controller in at Manual mode of operation.
Please keep Voltage control potentiometer in Manual mode at its minimum position.
Switch ON AC input contactor switch / MCB / Push Button as & if applicable.
NO LOAD OPERATION :
Observe the output voltage on DC Voltmeter. It should be near about

Zero. Turn the voltage adjustment potentiometer (in Manual) in clockwise and watch
output voltage. It will starts increasing from 0V to maximum output voltage as
applicable from minimum to maximum position of potentiometer.
For load test, Turn back the potentiometer at its minimum position.
Switch ÒN’ DC output Switch/SFU/MCB/MCCB/ACB as applicable
Increase the voltage by potentiometer, simultaneously increase the load current

by external water load arrangement. Please read the voltage on DC Voltmeter & current
on DC Ammeter respectively. Maintain the floating voltage as set at the rated load
current with the help of potentiometer.
NOTE : In manual mode, DC voltage is not regulated but only controlled by

potentiometer manually.
Decrease the load current & voltage up to zero & switch ÒFF’ the AC and DC
Switch/SFU/MCB/MCCB/ACB as applicable
III) FLOAT CUM BOOST CHARGER IN BOOST MODE :
A) AUTO MODE :
Keep the Auto/ Manual selector switch of controller in at Auto mode of operation.
Keep the Float/ Boost mode of operation selector switch at Boost mode of operation.
(Or operate charger in Float mode / Boost mode through push button if applicable)
Switch ON AC input contactor switch / MCB / Push button as & if applicable.
NO LOAD OPEARTION :
Observe the output voltage on DC voltmeter. It shall increase gradually up to the

factory set voltage. If it is disturbed in transportation, reset it to the set voltage with the
help of voltage adjustment resistance R4 (in Auto mode of controller).
Connect water load cables at DC Output terminals(Battery Terminals).
Switch on battery Switch/SFU/MCB/MCCB/ACB as applicable
Increase the DC current from zero, indicated by DC Ammeter & at the same time,
AC input current can be observed on the AC Ammeter if applicable. Also AC input voltage
can be observed on the AC Voltmeter if applicable. Observe the Boost charging current
as set remains constant within +/-2% of set value for fully discharged voltage of Battery
to fully charged voltage of the Battery. This Charging current can be set by
potentiometer current adjustment potentiometer.
CURRENT LIMITING FEATURE :
If you go on increasing load current above the rated load current, the output
voltage starts to decrease and limits the load current, thus allowing the battery to take
extra load. Changing the position of potentiometer can vary this level of current limiting
feature. The current limiting feature acts as the load current reaches to the rated load &
the excess current will get locked at 105% or 110% as applicable.
B) MANUAL MODE :
NO LOAD OPERATION :
Observe the output voltage on DC Voltmeter. It should be near about Zero. Turn
the voltage adjustment potentiometer (in Manual) in clockwise and watch output
voltage. It will starts increasing from 0V to maximum output voltage as applicable from
minimum to maximum position of potentiometer.
For load test, Turn back the potentiometer at its minimum position.
Switch ÒN’ DC output Switch/SFU/MCB/MCCB/ACB as applicable
Increase the voltage by potentiometer, simultaneously increase the load current

by external water load arrangement. Please read the voltage on DC Voltmeter & current
on DC Ammeter respectively. Maintain the floating voltage as set at the rated load
current with the help of potentiometer.
NOTE : In manual mode, DC voltage is not regulated but only controlled by

potentiometer manually.
Decrease the load current & voltage up to zero & switch ÒFF’ the AC and DC Switch/
SFU/MCB/MCCB/ACB as applicable
5.00 CAUTIONS :
1.Do not keep the two strips with direct contact in any case. It may damage rectifier
stack or fuses may blown.
1. For diluting the solution, add water.
2. Increase requisite quantity of salt or electrolyte if required load is not being
achieved even after bringing the two strips nearer to each other.
6.00 Connect the battery, to battery terminals in correct polarity i.e. +ve, +ve of tap
cell & -ve.
OPERATION AND MAINTENANCE
1) FLOAT CUM BOOST CHARGER IN FLOAT MODE :

Charger has two modes of operation. A) Auto mode & B) Manual mode..
A) AUTO MODE :
B) MANUAL MODE :
Keep the Float/ Boost mode of operation selector switch at Float mode of operation.
II) FLOAT CUM BOOST CHARGER IN BOOST MODE :-

Charger have two modes of operation. A) Auto mode & B) Manual mode.
A) AUTO MODE :
Observe the DC ON or boost mode ON indicating Lamp / LED is ON as & if applicable.
B) MANUAL MODE :
Observe the DC ON or boost mode ON indicating Lamp / LED is ON as & if applicable.
2 PROTECTION :
1. Charger blocker diodes of suitable rating are provided to maintain one-way flow of
current. i.e. from charger to load battery.
2. Annunciation, Condenser are provided with HRC fuses of suitable rating.
3. Voltmeters are provided with glass fuse.
4. Fuse Failure Detector: FFD’s are provided to give annunciation in case of failure of
AC input fuses/ DC output fuses/ battery fuses/ Semiconductor fuses/ Filter
capacitor fuses etc. as applicable.
5. Battery tap diode is provided to maintain the continuity of supply for the duration,
DC contactor takes to pick up while AC mains fails during boost charging.
6. Auxiliary contactors / relays are provided to give annunciation if AC mains fail.
3 ANNUNCIATION SCHEME FOR CHARGER :
If any of the following fault occurs, visual and audible annunciation will be there.
Accept the fault pushing push buttons. Hooter stops and only fault indicating will
indicate the presence of fault. Fault indication stops glowing when fault will be
removed.
4 SPECIAL ATTENTION WHILE OPERATING :
1. Generally operate the charger in Auto mode of controller. Use manual mode of
controller in case of Auto mode of controller function failure. Before using manual
mode keep voltage adjust potentiometer at its minimum position while operating
the charger in Manual mode.
2. Always use HRC fuses of proper rating; use of wire fuses will cease our
Guarantee.
3. While changing the mode i.e Auto mode of controller to Manual mode of controller
or vice versa. Switch 'OFF’ the charger and then change the position of Auto /
Manual switch.
4. After meeting an emergency by battery, charge the battery by charger in Boost
mode for the period depending upon the duration of emergency the battery has
met. After boost charging is over, allow the battery across charger in float mode
for trickle charging.
5 INITIAL CHARGING OF BATTERIES :
1. Ensure that, battery cells are filled with electrolyte and sufficient rest is given to
them for cooling.
2. Connect battery cables to the charger terminal board with proper polarity.
3. Keep the Auto/ Manual selector switch of controller in at Auto mode of operation.
4. Keep the Float/ Boost mode of operation selector switch at Boost mode of
operation. (Or operate charger in Float mode / Boost mode)
5. Switch ON AC input Switch/SFU/MCB/MCCB/ACB as applicable
6. Charger AC ON’ indicating lamp / LED will glow.
7. Switch ON AC input contactor switch / MCB / Push button as & if applicable.
8. Switch 'ON' DC Output Switch/SFU/MCB/MCCB/ACB as applicable
9. Observe DC voltage on voltmeter.
10.For charging the battery follows the procedure of charging according to
Instruction manual of Battery manufacturer. Boost charging current can be
set at required value with the help of Boost charger current limit potentiometer.
11.After completion of the charging cycles, allow the battery across float charger for
trickle charging. After this, battery will be ready to supply the load.
6 ROUTINE MAINTENANCE OF BATTERY CHARGER :-
A) 1) Cleaning of panel from inside & outside by using blower : Weekly

2) Healthiness of indicating lamps. : Weekly
3) Tightness & healthiness of fuse links. : Quarterly
4) Electrical performance, Tightness of all connections, noise observation &
complete cleaning of equipment. : Half yearly
5) Calibration of meters. : Yearly
B) In addition to above daily Log book is to be maintained for reading.
C) Any fault occurring and rectification carried out/maintenance carried out to be
recorded in log book.
D) Ensure availability of necessary spares i.e. fuse links, thyristors, diodes, control
Cards etc. At least one set of each.
CIRCUIT DIAGRAMS & BILL OF MATERIAL
Owner :NTPC LIMITED
Main Contractor : --
Sub-Contractor : --
Consultant Name : --
Project Name :NTPC, VALLUR THERMAL POWER PROJECT (3X500MW)
Customer Name :L & T LIMITED CHENNAI
Address :L & T CHENNAI HOUSE, 10, CLUB HOSE ROAD, ANNA SALAI, CHENNAI
Postal Code :600 002
Telephone No. :044-2846 0046 ( 9 LINES)
Telefax :044-2846 0060 / 62
LOI / P.O. No. :ECCD/MAT/E&GP/SKN/05 DATED 11.03.09
Work Order No. :CE2266
Unit :220V/400A BATTERY CHARGER
Rating :220V/400A SINGLE FCB CHARGER
Type :1 FCB ~ 220V/400A Qty. :06 NOS.
Chhabi Electricals Private Limited.

WEBSITE : www.chhabi-india.com
HEAD OFFICE & WORKS :
E-66, MIDC Area, Ajanta Road,
Jalgaon - 425 003 (Maharashtra) - India.
Tel. No. : 91-257-2210 626 / 627 / 628.
Fax No. : 91-257-2213 434.
E-Mail: [email protected]
MUMBAI OFFICE : DELHI OFFICE :
20, Anupam Indl. Estate No.3, L.B.S. Marg, F-12, First Floor, Pankaj Gland Plaza,
Mulund (W), Mayur Vihar Phase-1,
Mumbai - 400 080 (M.H.) India. New Delhi - 110 091 - India.
Tel. No. : 91-22-2561 4435 / 2561 5945. Tel. No. : 91-11- 4215 1213 / 1214
Fax. No. : 91-22-2568 0513. Fax. No. : 91-11- 4215 1215
E-Mail : [email protected] E-Mail : [email protected]
BANGALORE OFFICE : KOLKATA OFFICE :

120, First Floor, "Ajanta", 6th C Main Road,16/1,
Remco Layout, Vjaynagar 2nd Stage, "A" Bose Purkar Road,
Bangalore - 560 040 (Karnataka) - India. Kolkota - 700 042 (W.B.) - India.
Tel. No. : 91-80- 2314 0031 Tel. No. : 91-33- 2441 1375
Fax. No. : 91-80- 2314 0031 Fax. No. : 91-33- 2441 1375
E-Mail : [email protected] E-Mail : [email protected]
NTPC-TAMIL NADU ENERGY COMPANY LTD.

(A JOINT VENTURE COMPANY BETWEEN NTPC LIMITED & TNEB)
INDEX
SINGLE LINE DIAGRAM FOR FCB CHARGER S1
MAIN CKT. DIA. FOR 220V/400A FCB CHARGER S2
CONTROL DIAGRAM FOR FCB CHARGER S3
CKT. DIAGRAM FOR RECTIFIER MODULE S4
CKT. DIAGRAM FOR DC PATH OF CHARGER S7
CKT. DIAGRAM FOR ANNUN WITH LEGEND S8
GENERAL LAYOUT FOR 220V/400A CHARGER S9
GENERAL LAYOUT FOR 220V/400A CHARGER S10
BILL OF MATERIAL S11

* ALL DIMENSIONS ARE IN mm.
* ALL LOUVERS ARE PROVIDED WITH FINE BRASS
WIREMESH FROM INSIDE.
* CABLE ENTRY FROM BOTTOM WITH REMOVABLE
CABLE GLAND PLATES.
* ALL REMOVABLE PANELS HAVE SYNTHETIC RUBBER GASKET
* DEGREE OF PROTECTION =IP42
* DIMENSIONS OF THE EQUIPMENT WILL BE ACCURATE
WITHIN +/-10 mm.
* BACK DOORS WILL BE PROVIDED WITH LOUVERS.
* CRCA SHEET STEEL FOR FRAME 2 mm.
ALL PANEL BE 1.6MM AND M.S. GLAND PLATE BE 3MM.
* COLOUR OF FRONT PANEL, BACK PANEL & TOP PANEL,
INSIDE PANEL RAL 9002 & SIDE PANEL
RAL 5012. (POWDER COATING)
* FOR MAIN CKT. DIA. REF. DRG. NO. C11276A-H.
* ALL COMPONENTS MOUNTED ON THE FRONT &
INSIDE THE PANEL WILL BE SUITABLY LABELLED.
* POSITION OF INTERNAL COMPONENTS ARE SUBJECT
TO CHANGE WITHOUT NOTICE FOR SUITABLE
MODIFICATION .

Sheet No. :LC3719 File: CE2266R2_220V400A as CE-2163
BILL OF MATERIAL
Name Itemnumber Description
ACC1 AC2300ACZE0000CS PCONT F RANGE 300A3PAC-415VAC,C&S
ACCA1 BL94A00PGE0000LT ACONT MX0 22E, 4A,2NO+2NC, 415VAC,L & T
ACCA2 BL94A00PGE0000LT ACONT MX0 22E, 4A,2NO+2NC, 415VAC,L & T
ACCA3 AP94A00PD60000LT ACONT MX0 13E, 4A, 1NO+3NC, 240V AC, L&T
ACFB4 OTGLASS32MMNG000 GLASS FUSE HOLDER 32mm
ACFB7 GE11020GEOOOOOOF NSH20FRONT FUSEBASE,415V,GE
ACFFD1 FF3F2A0147AR2ACE FFD 3 FS W RELAY MODULE PCB NO 47AR2 CE
ACFS1 CD3892S22HCSOOOO CDFL315AFUSE LINK,500V,S2,HRC,C&S
ACFS4 OB4091BIGGOTOOOO 100mAFUSE LINK,415V,BIG,GLASS,OT
ACFS7 GD0601STGHGEOOOO NS2AFUSE LINK,415V,STAGTAG,HRC,GE
ACLED1 CLIRE24GAWCKCCTE CL LED IN RED P2PLBR4L 230VAC WCK G4W 22.5 TE
ACLED2 CLIYE26GAWCKCCTE CL LED IN YEL P2PLBR8L 230VAC WCK G4W 22.5 TE
ACLED3 CLIBL22GAWCKCCTE CL LED IN BLU P2PLBR6L 230VAC WCK G4W 22.5 TE
ACOL1 OLMNXR577LT00000 TH OL RELAY MNXR5 CTOP 180-300A, CS94229OOQO -L&T
ACR1 WW004K000R0500OT WIRE WOUND SI-COTED 4K-RADIAL 50W, OT
ACSW1 SFU00315C0FA20CS SFU 315A 3P ON/OFF 440V CSSF315D3 LEVER HANDLE C&S
ACSW2 SWT00010A0DC10KC TOGLE10A 1PON-OFF 240VAC KNOB HNDL PNLMTG-KC
ACSW3 SWC00012B0AC10KC CAM12A 2PON-OFF 415VAC KNOB HNDL PNLMTG-KC
ACSW4 SWR00016B1AO10KC ROT16A 2P2W NO-OF 415VAC CENTRE KEY LOCK PNLMTG-KC

BILL OF MATERIAL
ACT1 TME106C030F01LT0 TIMER ETX, 1CO, 240VAC/24VDC, 30HMS,ON-OFF DLY, 12ODT4 SERIES 175 LT
ACTR1 AXBV1332302CHH00 AUX XMER 1 Phase AC 456V/240V 500VA CHH
ADACCA3 CONADDONCS94033LT ADD-ON-BLOCK MX - A1 40E, NC, L&T
ANNUN1 WINDOWMOD12F0117 WINDOW INDICATOR MODULE LED 12F S144 117 CE
BD1 DIOB31209410RU00 RECT DIODE CAPSULE R650 550A 1000PIV RUTTONSHA
BZ1 BUZ24V80DBMARUMT BUZZER 24V DC,BLACK,80dB,MARUTI
CFL1 FLLAMP11W0000000 FLUORESCENT LAMP 11W CFL 240V AC
CH1 FC10G220060CE000 FILTER CHOKE 1% PTP 3 PH FULL CONT 220V 400A CE
CPC-1 COA04001234A3CE0 3 PHASE PRI. CONTROLLER CARD PCB NO 234AR3 CE
CPC-2 COA04001234A3CE0 3 PHASE PRI. CONTROLLER CARD PCB NO 234AR3 CE
CTR1 XDCAIA141115ARI0 TRANSDUCER DC/DC IP0-75mV OP 2 x 4-20mA AUX.24VDC -RISHABH
DAA1 DAA041612LCDANCE DAA MODULE 16DI/12DO/4AI, LCD2L, ANNUN, RS485 CE
DC TO DC1 CONADE179501AAC0 DC/DC CONV I/P 90-270V, O/P 24V-2.5A -AC
DC TO DC2 CONADE179501AAC0 DC/DC CONV I/P 90-270V, O/P 24V-2.5A -AC
DC U/O V1 DCUOVA01044R3ACE DC U & O VOLTAGE RELAY MODULE PCB NO 044R3 CE
DCCA1 P94A00PG20000LT ACONT MX0 22E, 4A, 2NO+2NC, 110V DC, L&T
DCFB1 V21630VAOOOOOOF FBO630ASOPEN SCREW,CIRCLIP FUSEBASE,415V,VAISHNOV
DCFB2 V21630VAOOOOOOF FBO630ASOPEN SCREW,CIRCLIP FUSEBASE,415V,VAISHNOV
DCFB3 OTGLASS32MMNG000 GLASS FUSE HOLDER 32mm
DCFB4 OTGLASS32MMNG000 GLASS FUSE HOLDER 32mm
DCFB5 GE11020GEOOOOOOF NSH20FRONT FUSEBASE,415V,GE
DCFB6 GE11020GEOOOOOOF NSH20FRONT FUSEBASE,415V,GE
DCFFD1 FF3F2A0147AR2ACE FFD 3 FS W RELAY MODULE PCB NO 47AR2 CE
DCFS1 GW1672S33HGEOOOO VST500AFUSE LINK,500V,S3,HRC,GE
DCFS2 GW1672S33HGEOOOO VST500AFUSE LINK,500V,S3,HRC,GE
DCFS3 OB4091BIGGOTOOOO 100mAFUSE LINK,415V,BIG,GLASS,OT
DCFS4 OB4091BIGGOTOOOO 100mAFUSE LINK,415V,BIG,GLASS,OT

BILL OF MATERIAL
DCFS5 GD0601STGHGEOOOO NS2AFUSE LINK,415V,STAGTAG,HRC,GE
DCFS6 GD0601STGHGEOOOO NS2AFUSE LINK,415V,STAGTAG,HRC,GE
DCLED1 CLIGR23FDWCKBCTE CL LED IN GRE P2PLBR3L 220VDC WCK G4W 22.5 TE
DCLED2 CLIGR23FDWCKBCTE CL LED IN GRE P2PLBR3L 220VDC WCK G4W 22.5 TE
DCLED3 CLIRE24FDWCKBCTE CL LED IN RED P2PLBR4L 220VDC WCK G4W 22.5 TE
DCSW1 SWI00320D0FA20HP ISOLTR320A 4PON-OFF 440VAC LEVER HNDLBSMTG-HPL
DR1 WW001K000R0500OT WIRE WOUND SI-COTED 1K-RADIAL 50W, OT
DR2 WW004K000R0500OT WIRE WOUND SI-COTED 4K-RADIAL 50W, OT
E/L1 EALE1A01034R2ACE EARTH LEAKAGE RELAY MODULE PCB NO 034R2 CE
FR1 RES1192090PH0000 2 WATT 150K CAR BON FILM RESISTANCE PH
H1 SP00000000AW50OT SPACE HEATER-FINNED STRIP 250V/100W-OT
HSBD1 ALUHS202SR400MM0 AL HEATSINK ANNOD,HK350 Tj.4,400mSA-1923,202BEH117
IPT1 IP01G220040CE000 INT PH TR NA 3 PH FULL CONT 220V 200A CE
LR1 WW004K000R0250OT WIRE WOUND SI-COTED 4K-RADIAL 25W,OT
LR2 WW004K000R0250OT WIRE WOUND SI-COTED 4K-RADIAL 25W,OT
LR3 WW004K000R0500OT WIRE WOUND SI-COTED 4K-RADIAL 50W, OT
MTR1 RTAV1355247CHH00 RECTIFIER XMER 3 Phase AC 456V/295V 167KVA CHH
PCARD-1 COA10001234B1CE0 PULSE CARD CARD PCB NO 234BR1 CE
PCARD-2 COA10001234B1CE0 PULSE CARD CARD PCB NO 234BR1 CE
PFC1 AC00A05230000EP0 METLP.P.CAP,BOX SCREW TERM-2KVAR 440VAC-EPCOS
R1 RES1192030PH0000 0.25WATT 150K CAR BON FILM RESISTANCE PH
R2 RES1132030PH0000 0.25WATT 4.7K CAR BON FILM RESISTANCE PH
R3 RES1056030PH0000 0.25WATT 180E CAR BON FILM RESISTANCE PH
R5 RES1116030PH0000 0.25WATT 2.7K CAR BON FILM RESISTANCE PH
R7 RES1102030PH0000 0.25WATT 1K CAR BON FILM RESISTANCE PH
RFB7 V21250ESOOOOOOB OFF-250, 250A OPEN TYPE FUSEBASE, 415V,ESSEN
RFC1 EA50034090000AL0 ELECTRO CAP,SCREW,50mm 2500MFD/200VDC-ALCON

BILL OF MATERIAL
RFFD1 FF3F2A0147AR2ACE FFD 3 FS W RELAY MODULE PCB NO 47AR2 CE
RFFD2 FF3F1A0147AR2ACE FFD 3 FS W/O RELAY MODULE PCB NO 47AR2 CE
RFFD5 FF3F1A0147AR2ACE FFD 3 FS W/O RELAY MODULE PCB NO 47AR2 CE
RFS1 GH0773AAASGEOOOO GS1000/400AFUSE LINK,660V,-,SEMICOND,GE
RFS2 GD0601STGHGEOOOO NS2AFUSE LINK,415V,STAGTAG,HRC,GE
RFS7 GU1532S11HGEOOOO VSF160AFUSE LINK,500V,S1,HRC,GE
RR1 WW004K000R0500OT WIRE WOUND SI-COTED 4K-RADIAL 50W, OT
RRB1 SP00000000CW70OT SPACE HEATER-FINNED STRIP 350V/300W-OTHER
RSH1 ID2AA9OOSTA000AE SHUNT EXT75mV SHUNT 0-500A -STDSIZE 1ACC-AE
RSW1 SWC00012D1AC10KC CAM12A 4P2W NO-OF 415VAC KNOB HNDL PNLMTG-KC
RTR1 AXAA3393010CHH00 AUX XMER 3 Phase AC 300V/3x18-0-18V 50VA CHH
RTR2 AXAA3393010CHH00 AUX XMER 3 Phase AC 300V/3x18-0-18V 50VA CHH
RV1 PT010K000T0030PK POTENTIOMETER 10K - 25mSHAFT 3W,PANKAJ

BILL OF MATERIAL
SC1 CAP5130885CT0000 CAPACITOR POLY, 0.47 MFD/ 1000VCT
SC2 CAP5130845CT0000 CAPACITOR POLY, 0.47 MFD/630VCT
SCR2&5 THYB30906910SK00 THYRISTOR CAPSULE MDT340(SKT340) 340A/1000PIV SEMIKRON
SCRHS1 ALUHS202SR450MM0 AL HEATSINK ANNOD,HK350 Tj.4, 450mm SA-1923,202BEH117
SCRHS4A1 ALUHS202SR200MM0 AL HEATSINK ANNOD,HK350 Tj.4, 200mm SA-1923,202BEH117

BILL OF MATERIAL
SOCKET1 SCKT2IN1000000 2 IN 1 SOCKET 6AMP 240V ANCHOR
SOCKET-1 PCB245AR3A0000CE PCB234AR3-A PRIMERY CONT. TERMINAL CARD SOCKET
SPD1 SSV20C3000OB0000 SURGE SUPPRESSOR V20 C3 OBO
SR1 WW033E000R0250OT WIRE WOUND SI-COTED 33E-RADIAL 25W,OT
T1 T300BBAL00000001 TERMINAL SUITABLE FOR 1 X 3C X 300SQ. MM AL CABLE
T4 T0100201W02036CW SCREW CLAMP TERMINAL CTS2.5 1W 2.5Sqmm 36A CW

BILL OF MATERIAL
T8 T630BBAL1C000000 TERMINAL SUITABLE FOR 1 X 1C X 630SQ. MM AL CABLE
T9 T630BBAL1C000000 TERMINAL SUITABLE FOR 1 X 1C X 630SQ. MM AL CABLE
T12 T2C205BBCU000000 TERMINAL SUITABLE FOR 1 X 2C X 2.5SQ. MM CU CABLE
TH1 THR00006A0DCA0SB THERMOSTAT-6A240VAC KNOB HNDL PNLMTG-SBIM
VTR1 XDCBRA141115ARI0 TRANSDUCER AC/DC IP 0-500V, OP 2 x 4-20mA, AUX. 24V DC -RISHAB
VTR2 XDCAQA251119ARI0 TRANSDUCER DC/DC IP 0-400V, 2 x 4-20mA, AUX. 24V DC - RISHABH


Charger Manual

Uploaded by

Copyright:

Available Formats

Charger Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Charger Manual

Uploaded by

Copyright:

Available Formats

Digitally signed

CLIENT : LARSEN & TUBRO LIMITED ( ECC CONSTRUCTION GROUP )

PROJECT : NTPC,VALLUR THERMAL POWER PROJECT (3 x 500 MW )

P.O.NO. : ECCD/MAT/ E & GP / SKN/05 DTD 11.03.2009

SR.NO. : CE-2266/ CE II- 0909/281 ,282

Mumbai Office : Bangalore Office : Delhi Office : Kolkata Office :

UNIT : 220V /400A BATTERY CHARGER FOR 990 AH NI-CD BATTERY.

TYPE : FLOAT CUM BOOST: CP-CC 220 V / 400 A – 400A

: LARSEN & TUBRO LIMITED ( ECC CONSTRUCTION GROUP )

Sr. # Description Sheet No.

CIRCUIT DIAGRAM & GENERAL LAYOUT

Sr. # Description Drg. No.

6 Circuit diagram for Rectifier module C11276F REV. 02

PREPARED BY : P.V.P. CHECKED BY : H.R.P. APPROVED BY : D.J.P.

MAIN AC INPUT : 415V ±10%, 50Hz, ±3%, 3Phase, 3 Wire AC supply.

BATTERY DETAIL : a) Type of Battery : NI-CD

TYPE : FLOAT CUM BOOST: CP-CC 220V/400A - 400A

DC OUTPUT : Battery Charger

RIPPLE : Float cum Boost Charger: 1 % (RMS)

AMBIENT : 50° C Average ambient temperature.

SIZE : L = 2400 mm H = 2000 mm W= 800 mm

SHEET : Structure 2 mm & Other Panel 1.6 mm.

CABLE ENTRY : Bottom and Rear.

a) Suitable for indoor operation and floor mounting.

ACLEDP 1-3 : AC Input 'ON' Indicating lamps.

RV 1 : Potentiometer to adjust the reference voltage .

ACC 1 : AC Mains Contactor of Battery charger.

ACSW 2 : Switch for Charger AC Contactor coil ON/OFF .

ACSW 1 : AC Input “ON/OFF' switch of Battery Charger

SETTINGS OF PROTECTIVE RELAYS FOR ANNUNCIATIONS :

a) DC Under & Over Voltage relay : (Float cum Boost Charger)

Annunciation as per legend is provided on front panel to give audio visual

The Battery Charging equipment comprises Float cum Boost charger.

FLOAT CUM BOOST CHARGER :

1. In Float mode: The variation in DC output voltage is limited to ±1% for 0-

ERECTION AND COMMISSIONING OF EQUIPMENT

2.00 ERECTION AND COMMISSIONING OF BATTERY CHARGER :

2.2) INSULATION RESISTANCE TEST (WITH 500V MEGGER) :-

2.2.1) Clean inside of the charger with the help of blower.

a) AC terminals and earth bus.

b) DC terminals and earth bus.

c) AC terminals and DC terminals.

3.00 POWER SUPPLY AND CONNECTION :

1. Connect the AC cables to the Charger AC input Terminal Board as shown in GA

4.00 LOADING ARRANGEMENT :

Make the water load arrangement as described below.

Observe the output voltage on DC voltmeter. It shall increase gradually up to the

Switch 'ON' DC Output Switch/SFU/MCB/MCCB/ACB as applicable

FULL LOAD OPERATION :

CURRENT LIMITING FEATURE :

Observe the output voltage on DC Voltmeter. It should be near about

FULL LOAD OPERATION :

Increase the voltage by potentiometer, simultaneously increase the load current

NOTE : In manual mode, DC voltage is not regulated but only controlled by

III) FLOAT CUM BOOST CHARGER IN BOOST MODE :

Observe the output voltage on DC voltmeter. It shall increase gradually up to the

FULL LOAD OPERATION :

FULL LOAD OPERATION :

Increase the voltage by potentiometer, simultaneously increase the load current