DC

1500

6-04

STANDARD RANGE AND TO NATIONAL GRID/SUPPLY AUTHORITY

SPECIFICATION NETWORK RAIL APPROVED

RECOGNISED AS LEADERS IN
STANDBY AND POWER SOLUTIONS

SERIES 1500 & 3500

Single & Three Phase Power Supplies
Automatic Constant Voltage Battery Chargers
Designed and manufactured in compliance with the relevant British & International standards,
PB Design offers a wide range of standard products and has extensive experience in the manufacture of equipment to meet the
specific requirements of customers. This experience in both standard and custom-built equipment extends to the following applications:Power Station Rectifiers - Safety and Security Systems Telecommunications - Telemetry and Instrumentation

Constant voltage charging for reduced maintenance

Digital metering of battery voltage and battery charge/discharge current
Modular alarm system with visual and audible indication
BMS facility via volt free changeover contacts
Nationwide inspection, commissioning and maintenance service
Comprehensive Quality Assurance System certified to BS EN ISO 9001
CE Mark to BS EN 50081-1

In any constant potential charging system the battery charge current will vary according to the battery demand as
determined by its state of charge/discharge. If the battery has been deeply discharged for a prolonged period
following a mains failure the resultant charge current upon restoration of the mains would be proportionally high in the
first instance and would reduce thereafter as the battery recovers and its terminals voltage rises.
To safeguard the charger from such high current demand and to optimise the rating of the charger, current limiting
circuitry is included within the system.
The charger characteristics changes from a current limited, constant current type at low battery voltage to a variable
current, constant potential type as the battery voltage recovers to its fully charged state. When fully charged the
battery is maintained constantly at its float voltage level while the charge current is reduced to a level sufficient to
offset system losses and maintain the battery in a fully charged condition.
In order to ensure that the correct charger system is selected to meet your requirements the minimum information
needed is as follows:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.

System application
System operating voltage, ie: number of cells in series.
The standing and/or intermittent load on the system.
Standby duration, ie: the number of hours the system is to support the load in iii. above following a mains failure.
The loads voltage limits, ie: maximum and minimum.
Battery type (NB: the ampere hour capacity may be specified if known).
The maximum time required for battery recharge in order to repeat the load duty.
The anticipated frequency of discharge imposed on the battery, ie: the charge/discharge cycling requirements.
The ambient operating/design temperature, eg: maximum, minimum, average maximum, average minimum, etc.

MODE OF OPERATION
Floating System
Provides a continuous DC supply at the load terminals at all times. By suitably sizing the charger the system can support a
directly connected load continuously when the mains supply is healthy providing a true NO-BREAK supply. With this mode of
operation a unique system is available that independently controls the battery charge current and the load current. This ensures
that the battery receives the correct charge at all times and therefore helps to maintain its operating life (refer to Manufacturer
for more details).

BATTERY SELECTION
There are three principle considerations when it comes to selecting a battery type, these being the INITIAL CAPITAL COST, the
batterys DESIGN LIFE and the MAINTENANCE REQUIREMENTS. It is necessary to make decisions such as whether a lower
initial cost is more important that the total cost over the anticipated life of the installation (including any maintenance
requirements). The above can best be summarised for each of the size battery types being offered by the following table:

Battery
Type
Cost Effective
Sealed Lead
Acid
Sealed Lead
Acid to BS6290
Tubular Plate
Lead Acid
Plante
Nickel
Cadmium
MainenanceFree Nickel
Cadmium

Initial Capital Outlay

Design Life

!!!!
!!!!
!!!!!!
!!!!!!!!
!!!!!!!!!!
!!!!!!!!!!

Maintenance
Requirement

STANDARD RANGE
1500 SERIES
SINGLE PHASE
VOLTS/AMPS

CUBICLE
SIZE/APPROX.
WEIGHT

INPUT/
KVA

3500 SERIES
THREE PHASE
VOLTS/AMPS

1500 SERIES
SINGLE PHASE
VOLTS/AMPS

CUBICLE
SIZE/APPROX.
WEIGHT

INPUT/
KVA

3500 SERIES
THREE PHASE
VOLTS/AMPS

12/3
12/6
12/10
12/12
12/16
12/20
12/30
12/40
12/50
12/60
12/75
12/100
12/125
12/150
12/200

2/10kg
2/15kg
2/18kg
2/22kg
4/28kg
4/34kg
4/46kg
4/52kg
5/60kg
5/70kg
5/80kg
5/92kg
6/110kg
6/120kg
6/146kg

.06
.12
.22
.26
.35
.44
.66
.88
1.1
1.3
1.6
2.2
2.7
3.3
4.4

3512/100A
3512/125A
3512/150A
3512/200A

220/20A
220/25
220/30
220/40
220/50
220/60
220/75
220/100

6/200kg
6X/240kg
6X/250kg
6X/265kg
8/390kg
8/420kg
8/500kg
9/560kg

7.3
9.2
11
14
18.4
22
27
37

35220/20A
35220/25A
35220/30A
35220/40A
35220/50A
35220/60A
35220/75A
35220/100A

24/3
24/6
24/10
24/12
24/16
24/20
24/25
24/30
24/40
24/50
24/60
24/75
24/100
24/125
24/150
24/200
24/225
24/250
24/275
24/300
24/400
30/3
30/6
30/10
30/12
30/16
30/20
30/25
30/30
30/40
30/50

2/20kg
2/26kg
2/34kg
2/38kg
4/46kg
4/50kg
4/60kg
4/65kg
5/70kg
5/78kg
5/100kg
6/120kg
6/140kg
6/170kg
6X/190kg
6X/210kg
6X/230kg
6X/260kg
6X/280kg
8/310kg
8/340kg
2/22kg
2/28kg
4/38kg
4/42kg
4/48kg
4/50kg
4/56kg
4/60kg
5/68kg
5/80kg

.12
.24
.43
.51
.68
.86
1.1
1.3
1.7
2.2
2.6
3.2
4.4
5.3
6.4
.6
9.6
10
11
13
17
.14
.28
.49
.56
.78
.98
1.2
1.4
1.9
2.4

3524/50A
3524/60A
3524/75A
3524/100A
3524/125A
3524/150A
3224/200A
3524/225A
3524/250A
3524/275A
3524/300A
3524/400A
3530/40A
3530/50A

50/3
50/6
50/10
50/12
50/16
50/20
50/25
50/30
50/40
50/50
50/60
50/75
50/100
50/125
50/150
50/200
50/250

2/25kg
2/34kg
4/40kg
4/42kg
4/48kg
5/60kg
5/64kg
5/78kg
5/100kg
5/130kg
6/160kg
6/170kg
6/200kg
6X/230kg
6X/280kg
6X/330kg
8/360kg

.26
.52
.86
1.0
1.3
1.7
2.1
2.6
3.4
4.2
5.2
6.4
8.2
10
13
17
21

3550/25A
3550/30A
3550/40A
3550/50A
3550/60A
3550/75A
3550/100A
3550/125A
3550/150A
3550/200A
3550/250A

110/3
110/6
110/10
110/12
110/16
110/20
110/25
110/30
110/40
110/50
110/75
110/100
110/125
110/150

4/32kg
4/42kg
5/50kg
5/55kg
5/75kg
5/100kg
5/120kg
6/150kg
6/200kg
6/220kg
6X/260kg
8/350kg
8/450kg
8/500kg

.5
1.0
1.7
2.0
2.7
3.4
4.3
5.1
6.8
8.6
13
17
22
26

35110/12A
35110/16A
35110/20A
35110/25A
35110/30A
35110/40A
35110/50A
35110/75A
35110/100A
35110/125A
35110/150A

220/3A
220/6A
220/10A
220/16

5/42kg
5/64kg
6/109kg
6/150kg

1.1
2.2
3.7
5.9

35220/6A
35220/10A
35220/15A

NOMENCLATURE
EXAMPLE
24 VOLT Charger/Battery system with single phase AC
mains input. Rated at 125A. The battery is to
comprise 10 year life Sealed Lead Acid cells to BS6290
part 4.
@100AH capacity.
PCV1#

024

0125

SL

100

OPTIONS

SERIES/MODEL
PCV1# = Single Phase Charger in Cubicle
PCV3# = Three Phase Charger in Cubicle
PCM1# = Single Phase Charger on Chassis
PCM3# = Three Phase Charger on Chassis
SYSTEM VOLTAGE
12v, 24v, 30v, 48/50v, 110v or 220v
CHARGER RATING
Charger Output Current in Amps
CELL TYPE
CL
- Cost Effective Sealed Lead Acid
SL
- Sealed Lead Acid to BS6290 part 4
TL
- Tubular Plate Lead Acid Monobloc
PL
- Vented Plante Lead Acid
VN
- Vented Nickel Cadmium
SN
- Maintenance-Free Nickel Cadmium
BATTERY CAPACITY
Stated in Ampere Hours for given rates of discharge
(NB: The quoted rates of discharge vary for each cell
type, eg: Vented Nickel Cadmium cells normally have
their capacity stated at the 5 hour rate of discharge
whereas Lead Acid cells normally have theirs stated at
the 10 hour rate of discharge).
OPTIONS
CCITT DD
FFA
LEA
BSI
EFA
LVD
*SB
*DB
*SF
*DF
RAU
AAR
SP
-

Telephone Smoothing on charger output

Dropper Diodes for Load Voltage Regulation
Fuse Failure Alarms
Low Electrolyte Alarm
Battery Monitor (battery disconnected)
Earth Fault Alarm
Low Voltage Disconnect
Single Pole Distribution Circuit Breakers
Double Pole Distribution Circuit Breakers
Single Pole HRC Distribution Fuses
Double Pole HRC Distribution Fuses
Remote Alarm Unit
Auxiliary Alarm Relay
Special Paint Finish

*Insert Quantity Required

Input Voltage
220/240v 6%, single phase (Series
1500) or 380/415v 6%, three phase
(Series 3500) (other voltages to special
order).
Input Frequency
50 or 60HZ 3%
Output Voltage
Charger
Max. Float Voltage Range
Voltage
12v
13
to
17v
24v
25
to
34v
30v
32
to
42v
48/50v
52
to
75v
110v
115
to
156v
220v
225
to
314v
Charger
Solid state thyristor controlled constant
voltage type with current limit and manual
boost. Inherently protected against low
battery voltage, reversed battery
connection and short circuit conditions.
Standards Approvals
BS EN 50081-1
1992
BS EN 50082-1
1992
BS EN 50081-2
1992
BS EN 50082-2
1992
BS EN 60950
BS EN 55014

1995-1
1993

National Grid Approved

Network Rail Approved
Certificate No. PA05/01939
Charger Output Regulation
Output characteristic is generally to DIN
41773 with float voltage controlled to
within 1% and output current controlled
to 2% irrespective of AC mains supply
variations as specified above and
charger output current variation from 0 to
100%. Improved voltage regulation is
available if required.
Float Voltage
Lead Acid: Normally 2.23-2.3v per cell
NiCad: Normally 1.4-1.5v per cell.
Boost Voltage
Lead Acid: Normally 2.6v-2.7v per cell
NiCad: Normally 1.6-1.7v per cell
NB: Sealed Lead Acid Cells do not
normally require boost charging.
Output Ripple Voltage
Ripple voltage is limited to a maximum of
2% rms of the system DC nominal
voltage. Improved charger output
smoothing is available if required, e.g.:
CCITT.
Efficiency
75-94% approximately depending upon
system voltage and current. Efficiency
increases as voltage and current levels
increase.
Power Factor
Approximately 0.8 lagging at float
voltage.
Component Rating
All components are designed and rated
for continuous operation with life
expectancy typically 35 years.
Recharge Time
Charger rated to provide 80% recharge
within 14 hours and full charge within 24
hours following a full rated discharge.
Refer to manufacturer if faster recharge
times are required.

Cooling
Air natural convection
Temperature Range
OIperating: -10C to 35C
Storage/transportation: -20C to 65C
(NB: Higher operational temperatures are
possible by suitably re-rating the charger.
Refer to manufacturer for details).
Instrumentation
Single Digital meter to indicate battery
voltage and battery current (charge and
discharge current) selectable via
pushbutton switch.
Indicators & Alarms
Functions
Mains on
Float
Boost (if applicable)
Charger healthy
Mains supply fail
Charger fail
Low volts
High volts
Reset-Silence-Test
System fault
Mini Alarm Module
Float
Boost
Charger healthy
Reset-Silence-Test
Charger fail
Low volts
High volts
Optional Extras
Battery Impedance
Earth Fault +/Circuit Breaker Fault
Battery Fault
Earth Fault

LED Colour
Amber
Green
Flashing Yellow
Green
Red
Red
Red
Red
Test Lamp Pushbutton
Flashing Red
Green
Yellow Flashing
Pushbutton
Green
Test Lamp Pushbutton
Red
Red
Red
Red
Red
Red
Red
Red

With each alarm condition being signalled

by an internal audible device.
Remote Alarm Facility
Single pole changeover volt free contact
rated at 0.5 amp at 240v ac/24v dc for
remote summary alarm purposes.
Individual alarm relays (AAR) available as
optional extra.
Fuses
Comply with the general requirements of
BS88 Part 2: 1975 mainly being of the
industrial H.R.C. type in withdrawable
carriers.
CUBICLE SIZE
2
5
X6
6
6X
7
8
9
10

HEIGHT (mm)
500
660
500
1250
1700
1700
1700
1700
1700

Switches & Protection

! Circuit Breaker for AC mains
supply.
! Float/Boost pushbutton selector
switch mounted internally.
! Audible alarm mute (only when
MAU fitted).
! Semiconductor fuses on
secondary of charger transformer.
! Suppression network protecting
power semiconductors.
! HRC fuse on charger output for
protection against reverse battery
connection.
! DC control fuse (voltmeter).
! Thyristor controller supply fuse.
Transformers
Double wound, earth screened to
BS171
Cubicles
Fabricated from minimum 1.6mm thick
zinc coated mild sheet steel of folded
construction to provide maximum
strength and rigidity. Channel sections
are fitted to the base of floor standing
cubicles in order to raise the cubicle off
the floor preventing damage from
moisture or corrosive material in
addition facilitating fork lift or pallet
truck.
Paint Finish
Standard Finish is stove enamelled
grey shade 381c631 semi gloss to
BS4800, other finishes are available
upon request at extra cost.
Cubicle Access
! Wall mounting via removable
covers and/or left hand hinged
lockable doors.
! Floor standing front access via
left hand hinged lockable doors.
Cable Access
! Wall mounting via two 20mm
conduit entry holes drilled in
bottom right hand side.
! Floor standing gland plate and
via four 20mm conduit entry holes
drilled in top right hand side. Top
or bottom cable entry may be
available if required (refer to
manufacturer).
Cubicle Ingress Protection
To BS5420: 1977 & IEC144: 1963
IP21 code. IP31 available upon
request at extra cost.

WIDTH (mm)
460
600
750
750
750
600
750
1000
750

DEPTH (mm)
265
440
455
455
455
630
820
820
650

CHASSIS SIZE
350 X 300 X 200
420 X 520 X 250*
420 X 520 X 250*
420 X 520 X 250*
420 X 520 X 250*
420 X 520 X 250*
420 X 520 X 250*

*Note: for larger units wound components supplied loose for accommodation elsewhere

Units 9/10, Hither Green Industrial Estate,

Clevedon, Bristol BS216XT
Tel: +44 (0) 1275 874411
Fax: +44 (0) 1275 874428
Email: sales@pbdesign.co.uk
Website: www.pbdesign.co.uk

CONTACT

STANDARD
SPECIFICATION

RECOGNISED AS LEADERS IN
STANDBY AND POWER SOLUTIONS

ADDITIONAL PRODUCTS Details are also available

on the following range of products & services.
AC Emergency Lighting Central Battery Systems
(Inverters) " DC Emergency Lighting Central Battery
Systems " AC Uninterruptible Power Supply (UPS) Inverter
Systems " Constant Voltage Chargers "
Telecommunications Battery & Charger Systems "
Standby Power Systems " Self-contained Emergency
Lighting Fittings " Installation, Commissioning, Service and
Maintenance.

This publication is issued for guidance and to provide outline information only and is not deemed to form part of any offer or contract. Our policy is
one of continued improvement and we reserve the right to vary details without prior notice.