Final Drawing

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CONFIDENTIAL DRAWING

CHANGE OR ALTERATIONS MESSRS.


NO DATE DESCRIPTION
1 Jan. 03, ‘11 APPROVAL
2 Apr. 01, ‘11 WORKING
3 Mar. 29, ‘12 FINAL
HYUNDAI MIPO DOCKYARD CO., LTD.
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FINAL
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DRAWING

BATTERY CHARGER AND


DISTRIBUTION BOARD

SHIP NO. S062/063

CLASS DNV

S E U N
ELECTRIC CO., LTD.
#797-5, GAMCHUN-DONG, SAHA-KU, BUSAN, KOREA
Http://www.seunelectric.co.kr E-mail : [email protected]
TEL. +82-51-208-4641, FAX. +82-51-208-4643

APPROVED BY Sungjin Jeong

CHECKED BY Sungjin Jeong

DRAWN BY Heesun Oh

ORDER NO.

DATE OF DRAWING March 29, 2012

DRAWING NO. SU-BC-H-S062

SEUN ELECTRIC CO., LTD. A4


BATTERY CHARGER

 INDEX

1. GENERAL SPECIFICATION………………………………………………………………………….2

2. ELECTRICAL SPECIFICATION……………………………………………………………………3

3. PART LIST………...……………………………………………………………………………………5

4. NAME PLATE LIST……………………………………………………………………………………6

5. SAFETY LABEL……………………………………………………………………………………….7

6. BATTERY CHARGER LAYOUT & DIMENSION…...………………………………………………8

7. CIRCUIT DIAGRAM…………………………………………………………………………………..9

8. FEEDER CIRCUIT…………………………………………………………………………………10

9. SPARE PART LIST……………………………………………………………………………………11

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SEUN ELECTRIC CO., LTD. A4
BATTERY CHARGER

1. GENERAL SPECIFICATION
A. NAME : BATTERY CHARGER AND DISTRIBUTION BOARD
B. MODEL : SU-BC-2008BS
C. Q'TY : 1set
D. DEVICE METHOD : THYRISTOR CONTROL
E. RATING : CONTINUOUS
F. THE CHARGER AND DISTRIBUTION BOARD TO BE COMBINED.

G. TEMPERATURE RISE
 REACTOR AND TRANS : 50℃
 SILICON RECTIFIER : 75℃
 POWER RESISTOR : 125℃

H. PANEL CONSTRUCTION
 FRONT : DOOR HINGED.
 SIDE : FIXED PLATE.
 TOP : FIXED PLATE.
 REAR : FIXED PLATE.
 BOTTOM : FIXED ANGLE. (COAMING HOLE)
 ENCLOSURE : IP23
 SEAT : SUPPLIED BY YARD

I. PANEL TYPE
 TYPE : SELF-STANDING
 MATERIAL & THICKNESS : SS400 2.3t
 PAINTING : RAL7032

J. THE CHARGER SHALL BE ATTACHED WITH FOLLOWING METERS.


 DC VOLTMETER : 1set
 DC AMMETER : 1set
 EARTH METER : 1set

K. NAME PLATE
 MATERIAL : PHENOL AND SUS
 LANGUAGE : ENGLISH
 METHOD : BLACK LETTER AND WHITE GROUND

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SEUN ELECTRIC CO., LTD. A4
BATTERY CHARGER

2. ELECTRICAL SPECIFICATION
A. ELECTRICAL SPECIFICATION
 RATING INPUT POWER : AC 440V 3 60Hz
 RATING SYSTEM VOLTAGE : DC 24V
 EQUALIZING VOLTAGE : DC 28V
 FLOATING VOLTAGE : DC 26.7~27.2V
 RATED CURRENT : DC 60A
 MAX. CHARGING CURRENT : DC 70A
 CHARGING RATE : CONTINUOUS
 EQUALIZING ALLOWANCE TIME : 1 HOUR
 EARTH LEAKAGE SETTING : 0.5M
 RIPPLE : 2% WITHIN

B. BATTERY
 TYPE : LEAD-ACID SEALED TYPE
 CAPACITY : DC 24V, 300AH
 RATING : 10 HOURS DISCHARGING

C. BUSBAR & CABLE COLOR CODE


a. BUSBAR MATERIAL : COPPER
b. AC
 POLE (R) - GREEN
 POLE (S) - YELLOW
 POLE (T) - BROWN
c. DC
 POLE (P) - RED
 POLE (N) - BLUE

D. INTERNAL WIRING MATERIAL


 POWER CIRCUIT : 660V SCP
 CONTROL CIRCUIT : 300V SYP(18AWG)

E. COMMON ALARM CONTACT (VOLTAGE FREE CONTACT) FOR EXTENSION TO BE


PROVIDED AS FOLLOWS.
 INPUT POWER FAIL
 EARTH LEAKAGE
 OVER CURRENT
 OUTPUT UNDER VOLTAGE
 OUTPUT OVER VOLTAGE
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SEUN ELECTRIC CO., LTD. A4
BATTERY CHARGER

F. INSULATION RESISTANCE SHALL BE MORE THAN 5M, WHEN MEASURED AT


DC500V MEGGER IMMEDIATELY AFTER LOAD TESTED.

G. DIELECTRIC STRENGTH : AC2000V/1min

H. THE CIRCUIT PROTECTION DEVICE TO BE SAFETY FUSE.

I. ALARM AND INDICATION LAMPS AS FOLLOWS.


 INPUT POWER FAIL (SETTING POINT : 50sec)
 EARTH LEAKAGE (SETTING POINT : 0.5M)
 OVER CURRENT (SETTING POINT : 63A)
 OUTPUT UNDER VOLTAGE (SETTING POINT : 22V)
 OUTPUT OVER VOLTAGE (SETTING POINT : 31V)

ALARM & DISPLAY MONITOR

FLOATING CHARGING

P/F

[V] O/C
H/V
L/V
[A] E/L

B/Z
E.Q/ DISPLAY
SET UP DOWN STOP/
FLOAT RESET MANU

ALARM SETTING MODE CHARGING OPERATING MODE

SYMBOL DESCRIPTION
ALARM BUZZER
P/F INPUT POWER FAIL ALARM
O/C OUTPUT OVER CURRENT ALARM
H/V OUTPUT HIGH VOLTAGE ALARM
L/V OUTPUT LOW VOLTAGE ALARM
E/L EARTH LEAKAGE ALARM

SEUN ELECTRIC CO., LTD.

<ALARM DISPLAY MONITOR>

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SEUN ELECTRIC CO., LTD. A4
BATTERY CHARGER

3. PART LIST

SPECIFICATION
NO. SYMBOL Q’TY REMARK
NAME SPEC. & MODEL TYPE
1 TR1 TRANSFORMER 3 4KVA AC440V/28/28/24 1
2 L1 CHOCK COIL 4mH 100A 1
3 EM EARTH METER 0~0.3~1~5~∞ M 1
INSULATION RESISTANCE
4 IRM SU-IR-2002 1
MONITOR UNIT
ALARM DISPLAY MONITOR
5 CM BH081130-1
& P.C.B
THYRISTOR CONTROL
6 SCR 081130 1
UNIT
7 SH1~4 SHUNT 100A 50mV 4
8 TH1~3 THYRISTOR MODULE TD90-16 3
9 DM1,2 DIODE MODULE DD100-16 2
10 C1 CAPACITOR 47000F/50WV 2
11 C2 CAPACITOR 47000F/50WV 1
12 R1 RESISTOR 50 50W 1
13 RY1,2 POWER RELAY YSPR25-2PC220A 2
14 VDR RELAY MY4 DC24 1
15 VD MAGNETIC CONTACTOR VF7-41H11 DC24V 70A 1
16 PL1,2 PILOT LAMP 25 DC24V 2
17 PB1,2 PUSH BUTTON 25 (1a1b) 250V/6A 2
18 MCCB1,2 BREAKER HiBS53/15A 2
19 MCCB3,4,5 BREAKER ABE 102b/100A 3
20 FEED FUSE & HOLDER TO FEEDER DWG. D.S TYPE
21 FAN FAN DC24V(92x92) 2
22 TS TEMPERATURE SWITCH R-45 1
23 MC1,2 MAGNETIC CONTACTOR HiMC20 AC220V 2
24 MC3,4 MAGNETIC RELAY HMX31 AC220V 2
25 F1,2 FUSE 5A 2
26 PL3,4 PILOT LAMP 25 DC24V, LED TYPE 2
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28
29
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BATTERY CHARGER

BATTERY CHARGER
OPERATION MANUAL

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SEUN ELECTRIC CO., LTD. A4
BATTERY CHARGER

OPERATING MANUAL FOR BATTERY CHARGER

 GENERAL SPEC. OF BATTERY CHARGER OPERATION

1. BATTERY CHARGING PART


THE MAIN CONTROL OF BATTERY CHARGER IS SCR CONTROL
SYSTEM(THYRISTOR CONTROL) AND THE INSIDE OF MAIN CONTROL,
THERE`S CONSTANT VOLTAGE, CONSTANT CURRENT SYSTEM.
1) CONSTANT VOLTAGE SYSTEM.
AFTER DETECTING FROM RECTIFIER`S CURRENT OUTPUT, THIS SYSTEM
SUPPLY STABLE VOLTAGE WITHIN ±2%
2) CONSTANT CURRENT SYSTEM
WHEN THE OUTPUT OF RECTIFIER IS OVER LOADED, FOR THE SAFETY
OF RECTIFIER, AUTO CONTROL SYSTEM WORKS DETECTING CURRENT
IN BOUNDARY OF SETTING CURRENT POINT WHICH IS SET UP BY SCR
CONTROL PCB.

2. DIODE CIRCUIT
FOR PROTECTING OVER VOLTAGE ON FEED LINE, THE DIODE 2SETS ARE
SERIAL STRUCTURE WITH DROP SYSTEM OF 2 LEVEL. AND SYSTEM
CONTROL DEVICE IS CONTROLLED BY PANEL DOOR`S OPERATION & ALARM
IND. PANEL AND SETTING MODE OF PANEL.
* THE DROP VOLTAGE PER DIODE IS 0.6V∼0.8V, THE SETTING POINT OF
DROP VOLTAGE IS THE FIRST LEVEL DC28V, THE SECOND LEVEL DC30V.

3. SCR CONTROL & OCR PCB


THE THYRISTOR CONTROL AND OVER CURRENT RELAY PCB IS DETECTING
CONSTANT VOLTAGE, CONSTANT CURRENT CONTROL AND OVER CURRENT. EACH
VOLUME FUNCTION IN PCB INSIDE IS AS BELOW.

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SEUN ELECTRIC CO., LTD. A4
BATTERY CHARGER

TG SG RG K0
J03
U5

U6

U7
R-GAN S-GAN T-GAN CH-ADJ VH-ADJ

VR6 VR7 VR8 VR9 VR10

U3

U4
U1 U2

C-ADJ
0-5V C-MAX

VR5
VR11 VR2 AUTO-ADJ EQ-ADJ
J01 J04 J02
VR1

R S T 0V N0 P0 NE N+ C1 V-MAX VR3 VR4 CO AO EC EB

1) THE MARKED "R-GAN" "S-GAN" "T-GAN" VOLUME (VR6, VR7, VR8)


THESE CONTROLS EACH PHASE CONTROL
IF EACH PHASE BALANCE IS NOT EXACT, THERE MAYBE A CHANCE TO
HAPPEN OVER LOAD IN R.S.T PHASE, SO MAIN TRANSFORMER AND SCR
MODULE WILL BE DAMAGED. SO IF POSSIBLE, WHEN THESE SHOULD BE
CHANGED, YOU MUST USE OSCILOSCOPE TO ADJUST PRECISELY.
2) "V-MAX" VOLUME (VR1)
AS MAX. OUTPUT VOLTAGE SETTING VOLUME, SET THE MAX. VOLTAGE
3) "C-MAX" VOLUME (VR2)
AS CONSTANT CURRENT LIMIT MAIN VR, THIS VR SET THE MAX BOUNDARY
OF CURRENT LIMIT.
4) "AUTO-ADJ" VOLUME (VR3) : AS FLOATING CHARGING VOLTAGE ADJUST VR
5) "EQ-ADJ" VOLUME (VR4) : AS EQUALIZING CHARGING VOLTAGE ADJUST VR
6) "C-ADJ" VOLUME (VR5) :
THE VR SET THE CURRENT LIMIT IN BOUNDARY OF C-GAN.
7) "CH-ADJ" VOLUME (VR9)
THE VR CONTROLS CURRENT LIMIT RESPONSE SPEED.
8) "VH-ADJ" VOLUME (VR10)
FOR CONSTANT VOLTAGE CONTROLLER, THIS VR CONTROLS THE SPEED
OF CONSTANT VOLTAGE KEEPING ABOUT OUTPUT VOLTAGE CHANGE.

- NOTICE -
ABOVE SCR CONTROL & OVER CURRENT RELAY PCB`S VR IS PRECISELY ADJUSTED
WHEN IT IS MADE, SO DONT ADJUST EXCEPT EQ ADJ, AUTO ADJ.

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SEUN ELECTRIC CO., LTD. A4
BATTERY CHARGER

4. OPERATING & ALARM DISPLAY BOARD

1) FUNCTION KEYPAD

ALARM & DISPLAY MONITOR

FLOATING CHARGING

P/F

[V] O/C
H/V
L/V
[A] E/L

B/Z
E.Q/ DISPLAY
SET UP DOWN STOP/
FLOAT RESET MENU

ALARM SETTING MODE CHARGING OPERATING MODE

SYMBOL DESCRIPTION
ALARM BUZZER
P/F INPUT POWER FAIL ALARM
O/C OUTPUT OVER CURRENT ALARM
H/V OUTPUT HIGH VOLTAGE ALARM
L/V OUTPUT LOW VOLTAGE ALARM
E/L EARTH LEAKAGE ALARM

SEUN ELECTRIC CO., LTD.

STORE VALUE IN DP BETWEEN SETTING OR MOVE TO


SET
NEXT MANU DISPLAY
ALARM
UP INCREASE VALUE / SCROLL UP
SETTING
MODE DOWN DECREASE VALUE / SCROLL DOWN
EQ/
CHARGING FLOAT
EQ / FLOAT CHARGING MODE
B/Z STOP/
ALARM BUZZER STOP / RESET
OPERATING RESET
MODE DISPLAY
DISPLAY MODE
MENU

2) GRAPHIC LCD DISPLAY


CHARGING MODE CLOCK

FLOATING CHARGING

VOLT P/F INPUT POWER FAIL ALARM


METER
[V] O/C OVER CURRENT
H/V HIGH VOLTAGE ALARM
AM L/V LOW VOLTAGE ALARM
METER
[A] E/L EARTH LEAKAGE ALARM

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SEUN ELECTRIC CO., LTD. A4
BATTERY CHARGER

3) ALARM SYMBOL

WHEN MAIN INPUT AC POWER IS FAIL OR


P/F POWER FAIL ALARM
MCCB IS TRIP.
WHEN THE CURRENT IS SUPPLIED TO
O/C OVER CURRENT ALARM
FEEDED & CONTROL CIRCUIT TO OVER.
WHEN THE VOLTAGE IS SUPPLIED TO
H/V HIGH VOLTAGE ALARM
FEEDED HIGH.
WHEN THE VOLTAGE IS SUPPLIED TO
L/V LOW VOLTAGE ALARM
FEEDED LOW.
WHEN BATTERY CHARGER OR DC POWER
E/L EARTH LEAKAGE ALARM
FEEDER WILL BE OF EARTH/GROUNDED

4) ALARM MEMORY
THE LCD DISPLAY MONITOR INCORPORATES A FIRST IN, FIRST OUT HISTORY
LOG. OF ALARM EVENTS THAT IS MAINTAINED WITH IN NON-VOLATILE MEMORY
THE MEMORY IS CAPABLE OF STORING AT LEST THE 100 EVENT WITH DATA
BEING STORED IN THE FOLLOWING FORMAT.
① ALARM NUMBER
② ALARM CONDITION(SYMBOL)
③ ALARM STARTED, DATE & TIME
④ ALARM ENDED, DATE & TIME
LCD DISPLAY

FLOATING CHARGING

P/F

[V] O/C
H/V
L/V
[A] E/A

5) ALARM SETTING METHOD

SET UP DOWN

ALARM SETTING MODE

* SET - STORE VALUE IN DP BETWEEN SETTING OR MOVE TO NEXT


MENU DISPLAY
* UP - INCREASE VALUE / SCROLL UP
* DOWN - DESCREASE VALUE / SCROLL DOWN

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SEUN ELECTRIC CO., LTD. A4
BATTERY CHARGER

FLOATING CHARGING 1. DROP HIGH


P/F
SET
PROTECTING OVER VOLTAGE ON FEED
[V] O/C
LINE, THE SETTING POINT DROP
H/V [V]
L/V
VOLTAGE IS THE DC28V. (DROP VOLTAGE
[A] E/A PER DIODE (2STEP)–Abt.2.8~3.2V)
SET

LCD DISPLAY 2. DROP LOW


THE FIRST PICTURE PROTECTING LOW VOLTAGE ON FEED
LINE, THE SETTING POINT DROP
[V] VOLTAGE IS THE DC27V. (DROP VOLTAGE
PER DIODE (1SETP) –Abt.1~1.4V)
SET

3. HI VOLT ALARM

HIGH VOLTAGE ALARM


[V] (SETTING POINT IS EQ-CHARGING x 105%[V]

SET

4. LO VOLT ALARM

LOW VOLTAGE ALARM


[V] (SETTING POINT IS 22V)

SET

5. OV CURRENT

OVER CURRENT ALARM


[A] (SETTING POINT IS RATED CURRENT x 105%)

SET

6. POWER FAIL DL

TIME DELAY SETTING FOR POWER FAIL


[ SEC ] ALARM (SETTING POINT IS Abt. 50SEC)

SET

7. HIGH VOLT DL

TIME DELAY SETTING FOR HIGH VOLTAGE


[ SEC ] ALARM (SETTING POINT IS Abt. 5SEC)

SET

8. LOW VOLT DL
TIME DELAY SETTING FOR LOW VOLTAGE
[ SEC ] ALARM (SETTING POINT IS Abt. 5SEC)

SET

9. OV CURRENT DL

10. EXIT SET TIME DELAY SETTING FOR OVER CURRENT


DOWN
[ SEC ] ALARM (SETTING POINT IS Abt. 5SEC)

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SEUN ELECTRIC CO., LTD. A4
BATTERY CHARGER

6) EQUALIZING CHARGING
OPERATION OF TIMER

FLOATING CHARGING EQUALIZING CHARGING 01 : 00 FLOATING CHARGING

P/F E.Q/ P/F P/F

[V] O/C [V] O/C [V] O/C


H/V H/V H/V
L/V L/V L/V
[A] E/A [A] E/A [A] E/A

LCD DISPLAY CHANGE BY EQUALIZING THE FLOAT CHANGE BY AUTO


THE FIRST PICTURE CHARGING MODE AFTER ONE HOUR

7) DISPLAY MODE
LCD DISPLAY LCD DISPLAY

FLOATING CHARGING FEED DISPLAY

P/F P/F

[V] O/C [V] O/C


H/V DISPLAY H/V
MENU
L/V L/V
[A] E/L [A] E/L

STANDARD MODE FEED DISPLAY MODE

BAT1 DISPLAY BAT2 DISPLAY

P/F P/F

[V] O/C [V] O/C

DISPLAY H/V DISPLAY H/V


MENU MENU
L/V L/V
[A] E/L [A] E/L

BAT1 DISPLAY MODE BAT2 DISPLAY MODE

*BAT2 DISPLAY MODE : OPERATION OF TWO BATTERY SYSTEM

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SEUN ELECTRIC CO., LTD. A4
BATTERY CHARGER

TROUBLE SHOOTING PART

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SEUN ELECTRIC CO., LTD. A4
BATTERY CHARGER

REPAIR METHOD

WHEN AN ACCIDENT OCCURS, CHECK THE FOLLOWING ITEMS.

SYMPTOM CAUSE MEASURE PART

VOLTAGE OUTPUT
SCR
IS OVER DC34V DEFFECTIVE MAIN
CHECK V-GAN VR CONTROL
AND CAN`T BE VR(V-GAN)
PCB
ADJUSTABLE

AUTO-ADJ VR
VOLTAGE CAN`T DEFFECTIVE SCR
CHECK THE
BE ADJUSTABLE AUTO VR(AUTO-ADJ) CONTROL
VOLTAGE
BELOW DC34V FEED BACK LINE SHORT PCB
FEED BACK LINE

EXCEPT ALARM
PCB`S SOURCE ALARM PCB OPERATING
ALARM PCB FUSE
LAMP AND INSIDE FUSE & ALARM
SHORT
INDICATOR CHECK IND. PANEL
DO NOT WORK

SETTING MODE OF
OPERATING
OPERATING &
MEMORY IC DEFECTIVE CHANGE 93C46 IC. & ALARM
ALARM IND. PANEL
IND. PANEL
CAN`T BE SAVED

WHEN EQUALIZING
EQUALIZING TIMER
CHARGING CHANGE TIMER
BROKEN
DOESN`T WORK

EVEN IF RESPONSE ACTION BUT DOESN`T WORK, PLEASE CONTACT MAKER

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SEUN ELECTRIC CO., LTD. A4
BATTERY CHARGER

1. EARTH LEAKAGE ALARM


 EARTH PUSH BUTTON TO BE PUSHED.
 THE EARTH LAMP WILL BE DARK IF ONE OF EARTH P OR EARTH N LINE IS
EARTHED.
 CHECK THE EARTHING PART DC LOAD SIDE OF BATTERY CHARGER ITSELF
FOLLOWING METHOD.
 LOAD SIDE
; TAKE OUT FUSE FROM DIST. BOARD P OR N LINE ONE BY ONE.
 BATTERY CHARGER SIDE
 REF TO FLOW CHART FOR EARTH LEAKAGE ALARM.

EARTH LEAKAGE DISPLAYED

YES
DC LINE GROUND

NO

YES
RESET

NO

YES
M-OHM METER
ABNORMAL

NO

NORMAL M-OHM INFORM ELTMINATE


METER TO SEUN GROUND
INFORM CAUSE
TO SEUN

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SEUN ELECTRIC CO., LTD. A4
BATTERY CHARGER

2. OVER CURRENT ALARM.


THE ALARM IS CAUSED WHEN CURRENT RANGE IS OVER THAN PRE
-SETTED CURRENT.
 AC MAIN SWITCH TO OFF POSITION.
 CHECKING THE SETTING CURRENT.
 CHECKING THE EACH DC LOAD LINE.
 CHECKING THE OC-ADJ FOR SCR CONTROL & OCR PCB.
 PLEASE NOTE, THAT FOLLOWING ALARM SETTING VALUE IS MAKER STANDARD.

OVER CURRENT DISPLAYED

DC LINE YES
OVER CURRENT

NO

YES
RESET

NO

YES OVER CURRENT


SETTING ABNORMAL

NO

YES
RESET

NO

ADJUST CHECK
NORMAL INFORM NORMAL
SETTING SETTING
TO SEUN
VOLUME VOLUME
INFORM INFORM
TO SEUN TO SEUN

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SEUN ELECTRIC CO., LTD. A4
BATTERY CHARGER

3. UNDER VOLTAGE ALARM


THIS ALARM IS LESS THAN 22V WHEN CHARGING POWER IS NOT SUPPLIED
TO BATTERY OR RECTIFIER VOLTAGE IS BELOW THAN BATTERY VOLTAGE.
 AC MAIN LINE.
 CHECKING MAIN LINE OF TRANSFORMER SECONDARY SIDE VOLTAGE.
 RECTIFIFR VOLTAGE.
 BATTERY CONDITION.

UNDER VOLTAGE DISPLAYED

AC FAIL OF FUSE
YES
BLOWN RECTIFIER FAIL
AND BATTERY
VOLTAGE DROP

NO

YES
RESET

NO

YES
MCCB TRIP
OR FUSE

NO

YES UNDER VOLTAGE


SETTING ABNORMAL

NO

CHECK LOAD ADJUST CHECK AC LINE


NORMAL CIRCUIT INFORM SETTING OR RECTIFIER
ELIMINTE TO SEUN VOLUME FIRE AND BAT-
TRIP CAUSE INFORM TERY VOLTAGE
TO SEUN FUSE BLOWN

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BATTERY CHARGER

4. POWER FAIL ALARM


 CHECK THE MAIN POWER.
 TRANSFORMER SECONDARY SIDE.

AC FAIL DISPLAYED

YES
AC LINE VOLTAGE
ABNORMAL

NO

YES
RESET

NO

YES AC CONTROL
POWER ABNORMAL

NO

YES
DAMAGED

NO

CHECK AC REPLACE INFORM NORMAL CHECK AC


CONTROL INFORM TO SEUN LINE
POWER TO SEUN VOLTAGE

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SEUN ELECTRIC CO., LTD. A4

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