DOC. NO.

:S-MAN-SEIL-208-18

INSTALLATION, COMMISSIONING
& SERVICING MANUAL
FOR
48V SMPS BASED POWER PLANT

INPUT VOLTS : 230 VAC (165-260V for RE, 90-300V for NRE)

NUMBER OF PHASE : SINGLE, 50Hz

OUTPUT VOLTS : 48V DC

OUTPUT AMPS : 50A

SPECIFICATION : RDSO/SPN/TL/23/99 VERSION-4.0

UNIT SERIAL NO. :

MANUFACTURED BY

STATCON ELECTRONICS INDIA LTD.

A-34, Sector-59, Noida-201 301

DISTT: Gautam Budh Nagar, (U.P.)
Phones : +91-120-3356101 FAX : +91-120-3356121
E-mail : info@sindia.co.in

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 DOC. NO. :S-MAN-SEIL-208-18

INDEX

SL. DESCRIPTION PAGE NO.

01. List of Abbreviations 03
02. Installation manual &site acceptance Tests (SAT) for 48VDC Power Supply 04
03. Safety Precautions 05
04. Preliminary checks on receipt at site 06
05. Installation Kit 07
06. Installation Kit for Power Plant 08
07. Main and Alarm terminals template (Upto 75A Ratings) 10
08. Main and Alarm terminals template (Above 75A Ratings) 11
09. Abstract 12
10. Introduction to 48V SMPS Based Power Plant System 13
11. Technical specification of switch mode rectifier system 14
12. Rectifier Module Status and alarm indication 16
13. Commissioning Test 17
14. Energizing the Power Plant 18
15. System Description for 48VDC Power supply 19
16. General Description of SMPS based FRBC module 22
17. Description of PFC Controller 23
18. Block Schematic of DC-DC Controller 24
19. Description of DSA Module 25
20. Operating Procedure of Micro Controller Based DSCA 26
21. System Alarms 27
22. Do’s and Don’ts 28
23. Routine Checks and Preventive Checks 29
24. Trouble Shooting 30
25. Customer Feedback Form 33
26. Enclosure 34

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 DOC. NO. :S-MAN-SEIL-208-18

LIST OF ABBREVIATIONS

01. A Amperes
02. AC Alternative Current
03. Ah Ampere Hour
04. dB Decibel
05. dBA Decibel Absolute
06. DC Direct Current
07. Deg. C Degree Celsius
08. DG. Diesel Generator
09. DOT Department of Telecommunication
10. E.M.F Electro Motive Force
11. FR-FC Float Rectifier cum Charger
12. FR-BC Float Rectifier cum Boost Charger
13. KG Kilo Grams
14. KHz Kilo Hertz
15. LED Light Emitting Diodes
16. LCD Liquid Crystal Device
17. MHz Mega Hertz
18. MOV Metal Oxide Varistor
19. MS Milli Seconds
20. PCB Printed Circuit Board
21. PF Power Factor
22. SMPS Switch Mode Power Supply
23. V Volts
24. VRLA Valve Regulated Lead Acid
25. LM Low maintenance

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 DOC. NO. :S-MAN-SEIL-208-18

INSTALLATION MANUAL

FUNCTIONAL DESCRIPTION
 Installation for power plant.
 This document describes the method of installation of power plant.

SITE ACCEPTANCE TESTS (SAT) for 48VDC Power Supply

Following points should be taken into account for SAT as a minimum:

1.) A well ventilated indoor area away from direct sunlight and heat. The dust shall be as
minimum as possible, while humidity shall be as per RDSO specification which is for safe
operation of the power supply equipment. (Please refer RDSO Specs)
2.) A pucca floor for erection (grouting etc.) for power supply equipment.
3.) Provision of a stable single phase or three phase input AC supply (utility) within the range as
specified.
4.) Provision of suitable earth as per latest earthing guideline of RDSO.
5.) Provision of suitable size of cables for Mains AC input supply, battery and (Load) telecom
equipment.
6.) Firm connection of AC, battery and load cables to the respective terminals.
7.) Proper placement of battery rack or battery bank.
8.) Firm and tight connection of inter row and inter tier of battery bank.
9.) Freshening charge of VRLA battery bank as per battery manufacturer’s recommendation.
10.) Switching-on of 48VDC SMPS battery charger and checking and setting of output voltage in
individual 48VDC SMPS modules. Checking and setting of output voltage and current
settings on the LCD display of the charger panel as given in the O&M manual.
11.) Checking of various protection parameters (factory set) on the LCD display with the help of
keypad.
12.) Note: Refer O&M manual for settings in individual 48VDC SMPS modules as well as on
LCD display of the charger panel using Keypad (this is DSCA controlled)..

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 DOC. NO. :S-MAN-SEIL-208-18

SAFETY PRECAUTIONS
Installation, testing, fault location and repair should only be attempted by authorized, qualified and
skilled electrical technician. This equipment carries dangerous voltages and stores electrical energy.
Statcon shall not be held responsible for electrocution of the personnel, in any way, while carrying
out any type of work in the equipment.

Before touching any live parts, remove metal objects, e.g. bracelets, rings or watch which comes
into contact with electricity carrying items. Carry out the following instructions.

1. Isolate the AC main supply external to the equipment.

2. Isolate the Battery and the load external to the equipment.

3. Check with a suitable scaled voltmeter, fitted with insulated test probes, that the equipment
does not carry any voltage at either the input or the output before commissioning work.

The above instructions (1) to (3) must always be followed before making any adjustment, and also
before making any electrical connections to the part of the equipment for the purpose of servicing.
Such connections should always be checked for safety before re-applying power.

The above instructions (1) to (3) must also be carried out before any connection is modified or
removed.

Note:

Adjustment should only be carried out with a non-conducting tool, taking care not to
touch any live part while doing so.

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 DOC. NO. :S-MAN-SEIL-208-18

PRELIMINARY CHECKS ON RECEIPT AT SITE

CONFORMITY WITH THE SPECIFICATION:

The installation and the connection of the equipment shall be checked before any action.

INSTALLATION CHECK

 Installation general aspect

 Equipment aspect (no spot, stripe, wrapping, oxidation, edge smoothing).

 Painting aspect

 Minimum clearance between side and walls: 800mm

CABINET CHECK

1. Check wiring, whether any of the connections are loose in transportation. Check especially the
cross-section of:
a. The link between 0V bus-bar and earth.
b. The link between cabinet earth and site earth network.
2 Check fixing of cabinet.
3 In case of false floor, cabinets should be fixed on metallic support on 4 points. In case of
concrete floor; cabinet is fixed directly on the ground on 4 points.
4 Check for easy opening of doors. In case of smaller racks, 3 modules or 4 module racks
accessibility is needed from the sides also.

EARTHING GUIDELINES
1. Earth terminal is provided at the top of the power plant near mains termination marked “E”.
2. Crimp the lugs with proper crimping tools.
3. Use at least 6 Sq. mm. Wires for the termination of earth to the power plant.
4. Measure the Earth resistance; it should be less than 2 Ohms.
5. Connect earth to the foundation bolts.
6. Separate earth should be used for 48VDC, +Ve grounding.
7. Scheduled watering of the earth pit is essential so that its resistance remains within limit.
8. Use only Copper/Lead Plates and bus-bars for earth connection.
9. Use at least four earth pits and short it with Main earth bus-bar to achieve good results.
10. Improper earth to the Power Plant may cause failure to it due to lightning.

RECEIVING THE EQUIPMENT

 Upon receipt of the equipment, inspect it for eventual shipping damage.
 Before disposing-off the package, check its contents against the packing slip.
 If damaged or partial loss is noticed, file a claim with the carrier without delay and any
necessary steps to protect your rights.
 For storage before installation, place the equipment in a dry ventilated place and keep away
from rain, water projection and chemical.

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 DOC. NO. :S-MAN-SEIL-208-18

INSTALLATION KIT
Kit definition
 The kit constitution depends on the uses.

Fixation Accessories
 Accessories needed for the floor fixation are as follows
 Bolt M8,
 Washers,
 Dowel for concrete,

Electrical accessories (Not part of the standard packing - to be procured by installer)

 AC mains cable,
 DC cable,
 Battery cable,
 Alarm cable,
 Link for grounding plates
 Braid for ground connection

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 DOC. NO. :S-MAN-SEIL-208-18

INSTALLATION KIT FOR POWER PLANT

Tools Required
 Multimeter,
 Standard tools for installation,
 Isolated screw driver,
 Isolated nut driver
 Torque wrench
 Before any installation, make sure that:
►The floor strength is compatible with the panel weight.
►The mains sizing is sufficient to power supply and other equipment (such as heater, air
conditioner, lights…)
► Site protection against lightning effect is properly dimensioned.

INSTALLATION AND FASTENING

 Before installation, provide sufficient clearance at the top of the cabinet for the cable
access.
 The securing of the cubicle to the floor is recommended. Refer to the appended drawings
for fixation hole distances and diameters (Refer Annexure-I).
 Ensure that the room space is sufficient to accommodate the cabinet dimension (length,
width, depth.
 Ensure that enough space is available all around the cabinet for maintenance, replacement
and cooling.
 Mark the location on the floor where the cabinet is to be erected.
 Mark on the floor the position of fixation holes axes.
 Ensure that no other equipment is likely to be damaged (Supply, pipe, water pipe…) before
drilling holes.
 Put on the dowels.
 Install the cabinet.
 Use the screws to fix the cabinet on the floor.

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 DOC. NO. :S-MAN-SEIL-208-18

CONNECTIONS (REFER TO THE DRAWING PACKAGE)

 The connections should be made with the system de-energized and the disconnecting
devices in the << open >> position:
► Mains input MCB’s of all the rectifier modules should be in OFF position.
► Battery fuses should be kept open.
► Load should be in OFF position

 Check that the associated batteries are installed and that the battery cells are connected in
correct polarity.
 All cables should be routed through the top of the cabinet.

Connection to the mains

 Connection to the mains from L.T. panel is made on terminal block provided at the rear side,
accessible from the rear side of the power plant. The input terminals in the higher ratings
(higher than 75A is from the front side. Cable entry is from the top.
 Make sure to connect the earth termination.

Single-phase connection of the mains to the system, from stage-1 suppressor

Connect the input cable of the stage-1 protection to the input of the Rack. Earth termination is
provided near the Mains input terminal inside the rack on the terminal blocks X1, X2, and X3.
Mains cable from L.T. Panel

DC Termination

 The termination of DC outputs of the power plant is provided at the rear side accessible from
the rear side of the power plant. Cable entry is from the top.
 The positive termination of batteries and the load is to be connected on the +ve terminal
block as shown in the diagram.
 The negative termination of load is to be terminated on the -ve Terminal block provided as
shown in the diagram.
 The Negative termination of the batteries is to be connected on the Terminal block as shown
in the diagram.

DC TERMINATION
Battery (+) Ve, Battery (-) Ve, Load (+) Ve, Load (-)Ve, Temp. Compensation (VRLA batt only).

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 DOC. NO. :S-MAN-SEIL-208-18

MAIN AND ALARM TERMINALS TEMPLATE (UPTO 75A RATINGS)

ALARMS
Two numbers of potential free contacts are provided in terminal block. Among them one is
redundant. This NO/NC contact operates at any fault conditions to extend alarm.

Relay contact breaking characteristics: 60VDC Maximum – 1 A.

BASE PLATE (REAR SIDE)

LINE NEUTRAL EARTH
LOAD PROBE
BATTERY
TERMINALS

CARD CC4 MOUNTED AT L.H.S. FROM REAR SIDE

FRFC FAIL MAINS FAIL DC U/V / LOAD VOLT. HIGH /

(NC C NO) (NC C NO) CUT OFF DC O/V
(NC C NO) (NC C NO)

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 DOC. NO. :S-MAN-SEIL-208-18

MAIN AND ALARM TERMINALS TEMPLATE (ABOVE 75A RATINGS)

ALARMS
Two numbers of potential free contacts are provided in terminal block. Among them one is
redundant. This NO/NC contact operates at any fault conditions to extend alarm.

Relay contact breaking characteristics: 60VDC Maximum – 1 A.

BASE PLATE (FRONT SIDE)

FRFC FAIL MAINS FAIL DC U/V / LOAD VOLT. HIGH /

LINE NEUTRAL EARTH
(NC C NO) (NC C NO) CUT OFF DC O/V
(NC C NO) (NC C NO)

TERMINAL PLATE (REAR SIDE)

LOAD PROBE
BATTERY
TERMINALS

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 DOC. NO. :S-MAN-SEIL-208-18

ABSTRACT

 DC power plant Commissioning.

 This document describes the procedure for commissioning of power plant.

MAIN SPECIFICATION FOR CABINET

MECHANICAL CHARACTERISTICS (Changes as per actual charger rating, refer GA diagram)

Cabinet PPSMCH0301R1
Width 578 mm
Depth 600 mm
Height 625+75 mm
Max. Number of rectifiers (25A). 3
Max. Weight of one module 10.5 Kg
Max. Total weight of fully equipped cabinet 83 Kg approx.

ENVIRONMENTAL CHARACTERISTICS

► Operation temperature : 0°C to 55°C

► Storage temperature : - 40°C to +70°C

►Relative humidity : 10 to 95% non-condensing

►Operating altitude : 0 - 1000 m

UPSTEAM CIRCUIT BREAKER TYPE AND CABLE DIAMETER

Size and tripping curve

Input Breaker To be matched with Input breaker of Power plant

Mains cable size As per current and distance

Battery Cable Size As per current and distance
Load Cable Size As per current and distance

TOOLS AND DOCUMENTS NECESSARY FOR COMMISSIONING

Documents needed for commissioning:

 Electrical diagram of system.

Test equipments needed for commissioning:

 1 Load Bank
 Digital Multimeter (DMM)
 Digital Ammeter

Note: All measurement tools must be calibrated by external national accredited laboratory.

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 DOC. NO. :S-MAN-SEIL-208-18

INTRODUCTION TO 48V SMPS BASED POWER PLANT SYSTEM

The 48V SMPS based power plant, designed as per customer’s load requirement and suitable
capacity of battery, is suitable for High Frequency Switched-Mode Technique for the use by Indian
Railways for Telecom Equipments i.e. Exchanges, Multiplexing Equipments, Microwave Radio
Equipments, GSM-R Equipments, TETRA Equipments, OFC Equipments etc.:

The panel consists of FRBC (float rectifier-cum-boost charger) modules, Distribution Supervisory
control & Alarm (DSA) unit and metering section. The advantages of SMPS based FRBC over
conventional types of controlled chargers are:
a) They are modular and therefore easily replaceable.
b) Works on wide input voltage range (165V AC–260VAC for RE, 90-300VAC for NRE) .
c) They have low current distortion and high power factor.
d) High efficiency.
e) Active current sharing in parallel operation.
f) Low output ripple and low noise.

The special features of this panel includes a coordinated set of class-B and class ‘C’ type of
lightening and power-line surge protection. This is thermal disconnecting type and equipped with
protection against SPD failure due to open & short circuit of SPDs connected between line & neutral.
Additional protection is provided against high or low input AC voltage by tripping the supply.

Page 13 of 34

TECHNICAL SPECIFICATION OF SWITCH MODE RECTIFIER SYSTEM
1. Type
2. AC Input Voltage
3. AC Input Frequency
4. DC Output Voltage setting
5. Load Voltage tolerance
6. Output Current Limit
7. Output Voltage regulation
8. Ripple (peak to peak)
9. Psophometric noise
10. Efficiency
11. Power factor
12. Noise Level
13. Dielectric levels
14. Insulation level
15. Switch gear
16. Protection
DOC. NO. :S-MAN-SEIL-208-18
: STATCON-48-25
: 230V AC rms, 1 phase, 2 wire system, permissible
variation 165V to 260V AC for RE and 90-300VAC
for NRE.
: 50 Hz. ± 2 Hz.
:
VRLA LM
Auto Float : 54.0V DC 52.8V DC
Auto Charge : 55.2V DC 57.6V-64.8 DC
: 44.4V to 56.0V DC
: 27.5A for each module up to 57.6V
: ± 1% of set value over specified input voltage
frequency variation and load variation of 25% to
100%.
: 300mV max. Peak to peak without battery
connected at full load.
: 2mV max. With battery connected or 4mV max.
without battery connected.
: a) Better than 85% at nominal input, output at
100% load.
b) Better than 80% for other specified input, output
conditions and load “between” 25% to 100%.
: a) 0.95 lag to 0.98 leading at nominal input &
output voltages and load 75% to 100%.
b) 0.90 lag to 0.90 lead in any other working
conditions and load between 25% to 100%.
: 60 dBA max. under all operating conditions at an
ambient noise level of 45 dBA.
: 1.5KV rms at 50 Hz. for 1 minute between AC input
to output, input to earth and output to earth.
: a) Greater than 2ME between AC input and earth.
b) Greater than 1ME between DC output and earth.
c) Greater than 5ME between AC input and DC
output.
: MCB at Main Input and individual module Input
: a) DC output high voltage
b) Overload / Short circuit
c) Input surge protection
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 DOC. NO. :S-MAN-SEIL-208-18

d) Soft start facility

e) Over Temp.

17. Indications : a) Mains

b) Float
c) Boost
d) DC voltage
e) DC current

18. Alarms (visual) : a) Load Voltage high

b) DC over voltage

c) DC under voltage

d) DC output overload.
e) FR-FC Fail
f) Temp comp. Fail
g) Mains fail
h) Mains out of range
i) Battery isolation

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 DOC. NO. :S-MAN-SEIL-208-18

RECTIFIER MODULE STATUS AND ALARM INDICATION

The indication LED’s are provided on the front of the rectifier module.
1. Mains : This indicates mains supply to the module is on.
2. Float : This indication shows the module is in float mode of charging.
3. Boost : This indication shows the module is in boost mode of charging.
4. Over Load / S.C. : This shows that the module is overloaded.
5. Under Voltage : This shows that the output DC voltage of the module is low.
6. Output Fail : This indication shows that the output DC of the modules is not
available.
7. Over Voltage : This shows that the output DC Voltage of the module have
exceeded normal output operating range.
8. Over Temp. : This indicates that the temperature of the module inside is more
o
than 75 C.

9. Fan fail : This indicates that module temperature goes to upto 85°C & fan
is not working.
10. Display (DPM) : Following parameters are displayed on the display of Module.
Output voltage
Output current
11. Voltage setting potentiometer: Potentiometer is provided at the right side of the module
accessible after pulling out the module from the rack.

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 DOC. NO. :S-MAN-SEIL-208-18

COMMISSIONNING TESTS

Check the measurements on System Display

 AC Voltage
 Load Voltage
 Battery Voltage
 Battery Current
 System Current

OPERATING CHECKS
 Float Voltage 54.0V ±1% for VRLA. 52.8VDC for LM

 Charge Voltage 55.2V ±1% for VRLA. 57.6-64.8V for LM

 Switch OFF mains, the system will change over from I/p Mains to battery, which will
generate alarm of “MAINS FAIL” with audible alarm.

 Decrease system Float voltage till 44.0 V. Rectifier under voltage operates and on FR/FC
alarm appears as “UNDER VOLTAGE”, FR/FC FAIL”. The same alarm is extended to DSA
as “FR/FC FAIL”.

 Switch OFF Battery contactor with the help of toggle switch, an alarm of “BATT
ISOLATED” is generated.

ALARM TERMINAL BLOCK

 Connection is made on terminal block provided on PCB (CC4),
 Loop ON/OFF characteristics: 60V max. – 1.0A
Alarm on terminal block:
There are four numbers of extendable alarms provided.
1. Load voltage High.
2. Battery Low.
3. AC out of range.
4. Module fail.
Extension of Each alarm is through potential free contacts of the relays.

Contacts definition:

 NO – Normally Open
 NC – Normally Close
 P - Pole

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 DOC. NO. :S-MAN-SEIL-208-18

ENERGIZING THE POWER PLANT

1. All disconnecting devices should be in the {open/off} position. Check that the mains
voltage and frequency is within the specified range of operation.
2. Do not insert the modules before the mains and battery wiring is completed.
3. For easy accessibility, remove the modules before operating the battery fuse (provided
by customer).
4. Switch ON Mains AC I/P & individual input of all the modules.
5. When load is connected to the power plant, a healthy module will indicate module DC
current on module front panel LED display when the push button is pressed. In un-
pressed condition of push-button the module DC voltage will be displayed.
6. Check for proper operation of the system according to technical data sheets.

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 DOC. NO. :S-MAN-SEIL-208-18

SYSTEM DESCRIPTION FOR 48VDC POWER SUPPLY

The SMPS based Float rectifier Float Charger (FRFC) or Float rectifier cum Boost charger Panel
(48V DC Power Plant) is designed and manufactured as per the RDSO specification
RDSO/SPN/TL/23/99 latest version.

48V DC Power Plant is based on high frequency switch mode technique for Indian Railways for
telecom equipments. The Power Plant having FRFC configuration is suitable to work with Lead Acid
VRLA batteries, while the FRBC is suitable to work with Lead acid LM batteries. It is capable of
meeting the output current requirement (equipment and battery bank)

The system is made at rack level using the basic modules of the same rating (48V/25A in this case).
To cater to the higher load requirement a number of SMPS charger modules are mounted in the
same rack and they shall be capable of working in parallel load sharing arrangement. The charger
panel consists of basic FRBC (float-rectifier cum float charger) modules, Distribution Supervisory
control & Alarm (DSA) unit and metering section. The advantages of SMPS based chargers over
conventional types of controlled chargers are: a) they are modular and therefore easily replaceable.
b) Works on wide range of input voltage. c) They have low current distortion and high power factor.
d) High efficiency. e) Active current sharing in parallel operation. f) Low output ripple and low noise.
Please refer the electrical circuit and schematic of the 48V battery charger. The mains input AC
supply as well as the battery banks are the main AC and main DC battery back-system.
The main components of 48VDC battery charger system consist of:
1. AC mains input cable connection terminals
2. Breaker at the main input supply for short-circuit protection
3. Class-B (Type-I) SPD for lightening protection
4. Class-C (Type-II) SPD for line surge protection
5. AC Mains under/over protection module
6. SMPS based FRBC charger modules
7. DSCA module
8. Current shunts to monitor output current as well as battery current
9. DC contactor in the battery path to isolate battery at battery under voltage level
10. Battery and Load cable connection terminals
11. Potential Free remote alarm terminals
12. Temperature Compensation probe terminals (in FRFC for VRLA batteries only)

The SMPS charger is rated according to number of FRBC modules connected in N+1 configuration
for FRFC and N+ 2 configuration for FRBC. Where ‘N’ is the number of modules as per system and
battery current. Each module is rated at 48VDC / 25A.
In the healthy and switched-on condition the FRFC/FRBC keeps the 48V DC battery bank in
charged (floating) condition as well as supply to the telecom equipment loads. In the switched-off
condition the load is floated across the battery. On resumption of Mains input supply to the
FRFC/FRBC it automatically start boost charging the battery to restore its charge.

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 DOC. NO. :S-MAN-SEIL-208-18

The Incoming supply is 230VAC, 50Hz, single phase, which is connected on the L, N & E terminals
which are provided inside the panel at the rear side. All the terminations are suitably protected
against accidental touch/contact from the working staff for their protection. The system works
satisfactorily with input voltage variation of 165-260VAC for RE and 90-300VAC for NRE. Frequency
variation from 47.5Hz to 52.5Hz. This supply is protected by input-breaker which also serves to
isolate the charger.

Class-B (type-I) type of surge protection device (SPD) is provided for protection against lightning,
while Class-C (type-II) SPD protects against any line surges. An AC under/over cut module (switch)
module is provided which disconnects the mains within 500ms to the rack whenever the input
voltage is beyond the specified range of operation. It will automatically re-connect the AC supply if it
comes back within the range of operation. A self restoring type of protection is provided at the input.

Now this input AC supply is fed to the SMPS based FRBC modules through individual single pole
MCBs for isolation and input supply short-circuit protection. Soft and slow start circuit is employed in
the charger so that the output voltage and therefore input current reaches its maximum value in 10
seconds and therefore prevents sudden in-rush current into the batteries or from the incoming side.
The modules run in active current sharing mode where the total DC load of (n-1) x 25 amps for
FRFC and (n-2) x 25A for FRBC is shared by n modules within +/-10% of the average current per
module when the load is within 50% to 100% of its rated capacity.

The 48VDC output from this is terminated on the output bus, through a system (total) current shunt
‘SH1’. This shunt monitors the total current drawn from the battery charger which is used to display it
on the LCD display as well as to set a limit on the drawn current. The output voltage of the chargers
is maintained within +/- 1% of the half load preset voltage in the range of 25% to 100% full load. The
output voltage starts drooping above the rated current of the charger or the limit set through keypad.
This feature is called current limiting feature of the charger. This feature also provides protection
from output overload and short circuit since it limits the output current at the same time drooping the
output voltage proportionate to the excess current. In this way there is no overheating of input/output
switchgears and accessories or devices and no risk of fire hazard. This monitoring and control is
done through DSCA module. An additional current shunt ‘SH2’ is connected in the battery path to
monitor battery path current in the same way. The purpose of this shunt is to continuously monitor
the battery current which is then used for displaying it on the LCD display as well as providing
battery path current limiting feature for battery health monitoring. The DSCA uses this current to
control “Auto Float-cum-charge mode” by which the charger either works as Float rectifier or float
charger.

The DSCA unit is provided for the ultimate rack capacity and it is also responsible for the battery
under voltage isolation of load, module failure alarm, system annunciation and various other
parameters display. It is done by sensing the output voltage, battery voltage, total system current
and battery current. The main function of the DSCA module is for temperature compensation, Float
to boost change over, battery current limit and battery depth of discharge alarms. In addition it
provides protection and alarms for AC under/over voltage, system overload and DC under voltage.
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 DOC. NO. :S-MAN-SEIL-208-18

A DC contactor is connected in the battery path, which operates only when the batteries are
connected in correct polarity therefore protects the unit in case of battery reverse connection. It also
isolates the battery bank in case batteries are discharged to under voltage level.

This SMPS charger panel also has facility of potential free contacts for “DC output fail”, “DC output
over voltage”, “DC output under Voltage” and “Mains fail” for the purpose of remote alarms.

All the alarms and status signals are concerted to RS-232 (optional) fitted inside the battery charger.

All the components fitted inside the panel are identified by their circuit codes. All the wiring is done
by PVC insulated copper wire and is neatly bunched and secured in PVC channels. Wires are
identified by ferrule marker rings.

The unit is sheet metal enclosed. The enclosure is stand-alone, floor mounted and suitable for dry
and well ventilated indoor area. It is to be installed away from direct sunlight and heat.

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 DOC. NO. :S-MAN-SEIL-208-18

GENERAL DESCRIPTION OF SMPS BASED FRBC MODULE

FRBC MODULE
DESCRIPTION OF MOTHER BOARD PCB
In this the Incoming supply is passed through RL1 & EMI filter consisting of L1, L2 & capacitor C10,
C11. MOV1 is for surge protection. BR1 is bridge to rectify the incoming AC. L3 is PFC choke. Q6,
Q8 are Mosfet for boosting the DC voltage. Boost Mosfet Q6, Q8 are driven by driver circuit. The
rectangular Pulses for Mosfet driving are set at 18V. D18, D19 are blocking rectifiers. PFC boost
voltage is used to charge capacitor C22- C25. Boost voltage is set at 395V. CT1 & CT2 are for
monitoring the current into the DC-DC converter bridge consisting of Mosfet Q1 – Q8. This operates
at frequency of 85 KHz. The gate drive to Q1-Q8 is square pulse of > 12V and can be monitored
between gate & source of Q1 – Q8. These are isolated by TXR1. Output of Q1 – Q8 bridge circuit is
fed to transformer TXR1. It has approximate amplitude of 395V. The output of TXR1 is
approximately 200V. This high frequency voltage is rectified in ultra fast recovery diode consisting of
diode D33-D35. L4, C11 is filtering circuit. L5 is common mode choke C12-C14 are filter capacitors.
Module O/P is available at L -Ve & L +Ve.

BLOCK SCHEMATIC OF MOTHER BOARD

TP3
RL1 L3 D18
L1 L2 395V
D19 TX2 TX2
MOV 1

Q1-Q8
C10 C11 BR1 Q6 Q8 C22-C25

CT1 CT2
EMI FILTER TXR1
TP1 GND

PFC DC-DC
CONTROLLER CONTROLLER
D33-D35
TX2

L4

C11

L5

C12-14
L L
+Ve -Ve

Page 22 of 34
 DOC. NO. :S-MAN-SEIL-208-18

DESCRIPTION OF PFC CONTROLLER

Function of PFC controller is to provide starting logic, generate PFC pulses. It senses the voltage
and gives starting command to PFC controller, with a delay. A soft start resistance for capacitor
charging is bypassed by relay RL1. It also has circuit to provide delay between PFC pulses & DC-
DC controller pulses. LED1, LED2 are provided to show status of card, LD1 “ON” shows PFC over
voltage. LD2 “ON” shows RL1 is operating.

BLOCK SCHEMATIC OF PFC CONTROL BOARD

RL1

STARTING
LOGIC
PFC PULSE TO MOTHER BOARD
GEN. FOR MOSFET DRIVE

LD1 LD2

PFC OVER VOLTAGE

LOGIC AND MIN.
AC SUPPLY LOGIC

DESCRIPTION OF DC-DC CONTROLLER.

Function of DC-DC control board is to provide voltage regulation, current limit, current sharing. It
also provides Battery current limiting, float / boost selection and protection for output over voltage,
under voltage, over load. This has indications for float, boost rectifier over voltage, mains on,
output fail & fan fail on this card and generate gate pulse for Mosfet. Block description of the
Circuit is as follows: Output voltage is fed to voltage divider & feedback processing network. This
also receives temperature compensation from DSA. A current signal from shunt on mother board
is processed in current amplifier & PI controller. The amplifier voltage is set at 5V at full load. This
voltage is varying with reference voltage which is set at 6V DC and over load voltage reference is
set at 5V for maximum current. DC under voltage & DC over voltage comparator compare the
output voltage and produce high signal at output with delay and provides alarm. Unit trips in case
of DC over voltage. In case of DC under voltage only alarm and indication comes. In case of Fan-
fail unit trips with indication & alarm comes on.
Battery signal from DSA is fed to current clamping circuit for providing current limit feature for all
modules as per battery requirement. Float & Boost command from DSA is for changing voltage
reference to set voltage in float or boost. Output voltage in float mode, boost mode and current in
float mode & boost mode is settable by preset on the front.

Page 23 of 34
 DOC. NO. :S-MAN-SEIL-208-18

BLOCK SCHEMATIC OF DC-DC CONTROLLER

VOLTAGE TEMP.COMP.
DRIVER & FROM DSA FOR DC-DC
FROM FEEDBACK GATE DRIVER MOSFET
O/P PROCESSING

TPS
REF.

TP3 MONITORING CKT. DISPLAY

FROM CURRENT
SHUNT AMPLIFIER
& PI

FROM OTHER
CURRENT MODE
TP2 TP3 TP15 SHARING

VOLTAGE
REF.
REF. SELECTOR
FLOAT
BOOST

CURRENT CURRENT BATTERY

REF. CLAMP LIMIT FROM DSA
FROM DSA

FROM
O/P DC O/V INDICATION
U/V &
ALARM CKT.
RESET CKT.

OVER LOAD

Page 24 of 34
 DOC. NO. :S-MAN-SEIL-208-18

DESCRIPTION OF DSA MODULE

DSA module is supervisory Module. It monitors input mains supply, system bus voltage, system
current. It provides temp. Compensation signal, Float boost voltage signal, DC low signal. It also
has battery current limit change over ckt. All alarms & indications for faults as per specification are
provided in it. Following is description of DSA ckt.

AC UNDER OVER CKT

In coming AC sample is rectified by U12, U13 & U14 and is compared with set reference level for
AC under and over voltage. Output is used in U29 for giving main out of range indication. If the AC
voltage is cutoff then the buzzer will start ringing and right most of LCD display shows FLT of the
blinking effect. If the Input voltage goes above 260V AC. Then the sensing signal goes to DSA to
show fault and make audio alarm..

SYSTEM OVER LOAD

Total system current is amplified in U20 and U21. It is compared with set reference in U29. When
the output current exceeds set value it gives alarm and indication for system overload. The system
bus voltage is buffered and compared by U29/4. If it exceeds set ref, “DC over voltage" indication
glows & alarm comes.

MAIN ON BATTERY DISCHARGING

When mains is ON & battery is discharging then the battery path signal is reversed, U9A monitors
this signal. The signal and its output swings giving indication & alarm for MOBD.

DC UNDER VOLTAGE
Battery voltage is monitored by U9B. It is compared with set reference value. If it exceeds set
value it extends alarm and indication.

FLOAT BOOST CKT

The battery current signal is compared with ref set by in U29/2. It this exceeds the set ref all
modules go to boost and when it falls below this, all modules comes to float.

POWER SUPPLY
Power supply for DSA from battery is generated by U1 and associated ckt. Its provides +12, -12V
& 5V supply.

BATTERY ISOLATION CKT.

Battery isolation is monitored by U29/34. The output is used for providing alarm.

FRBC FAIL.

FRBC fail is monitored by U29/15. The output is used for providing alarm.

Page 25 of 34
 DOC. NO. :S-MAN-SEIL-208-18

OPERATING PROCEDURE OF MICRO CONTROLLER BASED DSCA

1. The display in the system shows

st
a. AC voltage (left corner of the display at 1 line): This is the phase to neutral voltage
connected to the POWER PLANT.
st
b. DC Load Voltage (right corner of the display at 1 line):
nd
c. DC Voltage (left corner of the display at 2 line): This is the Battery voltage which is
common for both batteries.
nd
d. System current (Right corner of the display at 2 line): In normal mode, it shows “Load
current” with symbol “T”.
nd
e. Battery current (Right corner of the display at 2 line): To see the “Battery current”, press
“Increase” for 3 seconds. The system will display “Battery current” with symbol “B” within 10
seconds.
2. The system will display “FC” in Float mode and “BC” in Boost mode.
3. For any fault, the system will give alarm and display “FLT” with blinking effect till the fault
goes. Press “ENTER” to see the faults, the list of faults is displayed within 30 seconds &
buzzer will stop ringing.
4. To come to normal mode press “ENTER”.
5. To see the parameters values, press “SET” for 3 seconds.
6. The system will display “Login: User Set”.
7. Press “SET” again to choose “Fact set”.
8. To choose the “User Set Login” mode, press “ENTER”.
9. To choose the “Fact set Login” mode. Enter 4-digit password.
10. After entering press “ENTER” key in User set, display will show “Float voltage”, the first
parameter of the User Set.
11. Press “SET” button. At each subsequent pressing of set button, the display shows all the
parameter with its value one by one, which are ”FLOAT”, “BOOST”, “AC OV SET”, “AC UV
SET”, “AC SPAN”, “DC OV SET”, “DC UV SET”, “SYS CRNT”, “BCL”, “Load Voltage High”,
“TCS”, “F to B Current”, “B to F Current”, “RESTORE USER SET”.

12. Except “Float”, “Boost” and “BCL” all are factory settings. Do not disturb the settings.
13. To change the parameter values, first select the parameter.
14. To increase the value of selected parameter, press “INCREASE”.
15. To decrease the value of selected parameter, press ”DECREASE”
16. To register (store) the set value, press “ENTER”.
17. To restore the Default User setting first select the “RESTORE USER SET” in “user set”
Login mode then press “INCREASE” key and “DECREASE” key simultaneously for 4
seconds.

Page 26 of 34
 DOC. NO. :S-MAN-SEIL-208-18

SYSTEM ALARMS
1. When Mains AC is within the specified limits and still battery is discharging then “MOBD” is
displayed with audible alarm.

2. When the system current is more than 105% of the number of modules present excluding
redundancy then “SYSTEM OVER LOAD” alarm is generated.

3. Due to any reason, if module fails then “FR/FC FAIL” alarm is generated.

4. When Mains AC voltage is more than 265V or 300 then “AC O/R” alarm is generated. The
mains supply to the modules is isolated to switch them off. After the restoration of AC mains,
within the range, the modules are switched-on after a delay of 30 secs. (Hysterisis of 10V is
given to isolate and reconnect the modules.

5. When Mains AC voltage is less than 155V or 90V then alarm of “AC O/R” is generated. The
mains supply to the modules is isolated to switch them off. After the restoration of AC mains
within the range, the modules are switched-on after a delay of 30 secs. (Hysteresis of 10V is
given to isolate and reconnect the modules.

6. If the system voltage increases beyond the setting value (57.1) then “LOAD VOLT HIGH”
alarm is generated.

7. When battery is discharged below 44.4V then alarm of “DC U/V” will be generated. This
protection disconnects the batteries (through DC contactors) connected to the system. Now
battery will reconnect only when the system voltage rises above 44.5V & mains supply is
available.

8. When Battery is isolated manually with the help of Battery isolation switches then “BATT
ISOLATED” alarm is generated.

NOTE: Whenever any of the above alarm operates there is an audible as well as visual alarm.
To cut-OFF the audio alarm press ENTER key. Whenever audio alarm is cut OFF visual alarm
remains until the alarm is rectified.

Page 27 of 34
 DOC. NO. :S-MAN-SEIL-208-18

DO’S and DON’T’s

SMPS MODULE

DO’s
 Keep the entire module in on position.
 Set equal voltage in all modules for proper current sharing.
 Set battery path current to AH/10.
 Set battery voltage according to type of battery. For SMF battery Float is 2.25V/cell & Boost
is 2.3V/cell. For LM batteries float voltage is 2.2V and boost voltage is 2.4 to 2.7V/cell.
DONT’s
 Do not take out plugs of modules when working.
 Do not connect battery when modules are on.
 Do not connect battery in reverse polarity.
 Do not disturb battery under cut setting.

Page 28 of 34
 DOC. NO. :S-MAN-SEIL-208-18

ROUTINE CHECKS

The power plant does not need any elaborate routine checks as it has been designed for a rugged
application. For the purpose of longevity of the useful life of the Power Plant, some points are
enumerated below.

1. A general cleanliness should be maintained in the equipment room.

2. A logbook of battery current, load current, AC input voltage, load voltage and battery voltage
should be maintained.

3. The ventilation paths should not be obstructed for free flow of air in the room (over crowding of
the equipment room should be avoided).

4. Check the availability of clear and legible instructions in the vicinity of the power plant.

PREVENTIVE CHECKS

1. The batteries connected to the equipment should be monitored for the proper voltages with
the use of LCD display on the front panel and a log can be maintained.

2. It is recommended to apply rust free jelly to the connections given from bus bars to avoid
generation to contact resistance. The same can be applied to the points where the high
current carrying cables are connected to various points like loads, inputs and batteries etc.

3. The earth resistance to the Power Plant cabinet should be measured every six month and
should be maintained below 0.2 Ohm.

Page 29 of 34
 DOC. NO. :S-MAN-SEIL-208-18

TROUBLE SHOOTING

The power plant is compact in size and the assembly is in modular form, which makes the
servicing of the equipment very easy. The power plant has been provided with sufficient diagnostic
aids like 8 LED’s on front panel of the each rectifier module. The following tables gives some
commonly observed faults and remedies which may be referred before intimating the
manufacturer to help repair the equipment within the short period easily.

A. FRBC SMPS BASED POWER PLANT

i. Problem No. :-
Output is
not
available

YES Bring it within the

Main supply is
range, e.g.,
out of range
switch-on DG

NO

Input MCB is YES Switch-on the

off input MCB

NO

YES Replace input

Input fuse is
blown fuse

NO

YES Replace the

Module is not
working faulty module

Output is
available

Page 30 of 34
 DOC. NO. :S-MAN-SEIL-208-18

ii. Problem No. 2

Output is
low

Output is YES Wait for the current YES

drooping to reduce below the Battery current
limit-set is reduced

NO NO

YES Correct the Float Correct YES

Volt adjustment voltage and Boost voltages are set
is not proper voltage setting

NO

Correct O/P
voltage is
available

iii. Problem No. 3

Module is
tripping

Output voltage YES

Correct the output
setting is higher
voltage setting
than 67V DC

NO

Fan fail Fan or the YES

YES Replace faulty Fan
indication is temp. Sensor is
glowing or Sensor
faulty

Module is not
tripping

Page 31 of 34
 DOC. NO. :S-MAN-SEIL-208-18

iv. Problem No. 4

The current Current

sharing YES sharing is
between Module voltage Set equal voltage within 10-
modules is setting is not of each module 15% of equal
not proper equal
currents

Page 32 of 34
 DOC. NO. :S-MAN-SEIL-208-18

CUSTOMER FEDBACK FORM

Dear Sir,

We have supplied you IPS / Battery Charger / Battery Discharger to your esteemed
organization. Please give your feedback for our product performance & services.

Satisfactory Not satisfactory (With specific fault if any)

Suggestions (if any):

Site Name: __________________________

Customer Name: ______________________

Customer Sign: _______________________

Date: _______________________________

F-MKT-07-A (REV. 1)

Page 33 of 34
 DOC. NO. :S-MAN-SEIL-208-18

ENCLOSURE
I. G.A. Drawing of 48V Power Plant
ii. Power Circuit of 48V Power Plant
iii. Bill of Material of 48V Power Plant

Page 34 of 34