VAHAK ~OD-Pr: S(O Saeed INSTRUCTION MANUAL FOR REGULATED CHARGING RECTIFIER BEES 3 PR —30Gy OUTPUT VOLTAGE: 110V DC.1. APPLICATION — “IMPORTANT CONCLUSION Tl. GENERAL DESCRIPTION “PRINCIPLE OF CHARGER OPERATION II. OPERATING MODES FLOATING *HERATE TV. TECHNICAL SPECIFICATIONS V. INSTRUCTION FOR USE *CONNECTIONS “PUTTING IN SERVICE OPERATING VI. FRONT OUT LINE & MAIN COMPONENT LIST “FRONT VIEW OF BATTERY CHARGER ‘SIDE VIEW OF BATTERY CHARGER ‘MAIN COMPONENTS (INSIDE BATTERY CHARGER) Vil. ELECTRIC CIRCUIT DIAGRAM PAGE, 12 15nC 3a APPLICATION: This regulated charger, associated with a stationary battery forms a “No-break” DC supply to security, protection, and control circuits The use of a storage (industrial) battery provides the system with an independent operating capability, enabling safety functions and control operations to be carried out in the event of a power failure. As shown in the diagram below, the DC load is always supplied by DC current. Thus the rectifier and battery form an uninterruptable source of supply. Charger Transformer Rectifier 1 Battery AC mains | Wilt LOAD Current flow —— Mains present =—_====> = Mains absent IMPORTANT CONCLUSION: For applications as such the charger must be regulated, that 1) The output DC voltage should be constant. 2) The charging current should be electronically limited and will not exceed the rated value by more than 5% even at short circuits (A discharged battery will act as a short circuit on the charger). Also for power failures, forprolonged periods, the charger will operate safely when power isrestored, no matter how much the battery is dischargal due w its constant-cusrent characteristics3) 2-GENERAL DISCRIPTION ‘As can be seen in the block diagram shown below the the charger is composed mainly of:- TOBAT. TOLOAD 1) Input 3- phase circuit breaker CBI. 2) Operation mode selector switch. Power transformer T1. Thyristor rectifier bridge B1. Filter (smoothing) components (L1, CF). Electronic control unit E.C.U. Outgoing DC fuse Fo. Measuring instrument and indicators. 2PRINCIPLE OF CHARGER OPERATION: The charging rectifier is a constant voltage rectifier, with electrical construction characterized by a high degree of efficiency, many adjustment possibilities, and excellent operational reliability and, therefore, requires a minimum of maintenance. Looking to the block diagram, performance of the charger is explained to be as follows: The incoming ac voltage is switched to the main transformer T1 by the input breaker CB1, which has a thermal overload trip according to the rated current. T1 isolates the incoming ac voltage from the dc side and adopts this voltage to the battery and load voltage. The full controlled bridge B1 consisting of 6 thyristors rectifies and regulates the de output. The smoothing choke 11 will filter the rectified de to minimize the ripple content. For further ripple reduction an electrolytic capacitor CF is added. The electronic control unit checks the output voltage and current and compares these values with their respective adjusted reference values. Any voltage errors which occur during alterations in load will be measured by the regulating part of the electronic control unit ECU. As a result, control signals (pulses) generated in the ECU will be shifted in such a way that the output voltage and current are maintained at the reauired values 2:NAN nC Bay Thus control of the chargers output voltage can by achieved by changing the point in time (or phase ) at which the thyristors are fired > process well know as phase control technique , explained as follows When the output of the charger exceeds the desired value the control circuit ECU will send pulses to the thyristors at a large firing angle (illustrated as partially conducting in the diagram) a a FULL CONDUCTION PARTIALLYCONDUCTION SCR Such that the output is reduced to the desired value. Here the error is zero and the ECU will maintain pulses to the thyristors at this firing angle. Inversely, if the output of the charger is low, pulses will reach the thyristors at a small firing angle (illustrated as full conduction to increase the output till the desired value is reached . Consequently stability of output of high accuracy, in the range of + or— 1% can be achieved . 2:NTN nC Ba 3- OPERATING MODES: The current limited, constant voltage charger with an I-V characteristic as shown in the figure below has the following modes of operation. UCH U FL A) FLOATING: The floating voltage U FL (curve 1) applied to the battery is maintained constant at+or—1% against mains and load variations and enables: - -Maintaining the original charge of the battery by delivering a light current to compensate its internal losses. -Supply of the load under best voltage conditions. -Providing a slow charge to a partially discharge battery. The float Voltage varies according to the type of battery: For lead —acid cell V FL =2,25v. For alkaline cell V FL=1.4v The exact value is recommended by the battery manufacturer. Float voltages can be adjusted very accurately by the control potentiometer for ‘Float’ e.g: for alkaline cells the float voltage will be: 92x 14v = 128.8V DC Once this voltage is adjusted it will remain constant.NaN aC Day B) HIGH RATE: Also known as quick charge or charging, ‘The charging voltage UCH (curve 2) applied to the battery is maintained constant at+ 1% and against mains load variations and enables: - -Recharging of the battery within a limited time. -Supply of the load at a higher voltage than in floating but remaining within acceptable limits. The charging voltage varies according to type of battery: For lead —acid cell V CH =2.35v. For alkaline cell V CH = 1.5v. The exact value is recommended by the battery manufacturer.charging voltages can adjusted very accurately by the control potentiometers for * CHARGING”* in the electronic control unit. E.g.: for 174 alkaline cells the charging voltage will be 92.X 1,5 = 138 VDC Once this voltage is adjusted it will remain constant throughout operation. For both modes (Floating or charging) the charger current is limited to its rated current In (curve 3). This is the constant current mode. When the charger is in automatic mode (normal operation) the selection of Float or Hi-rate is controlled electronically according to the following process: - Hi-rate charging will be initiated automatically every time The Battery is discharged, because the Mode Selecting Unit MSU will detect a rise in output current >70% of rated which means that the Battery is discharged) and will select Hi-rate charging automatically. After charging is completed the MSU will return the operation To “Float” and stay so till the next discharge of Battery. 6VAHAK nC Bay TECHNICAL SPECIFICATIONS OF SOLID STATE SILICON RECTIFIER BATTERY CHARGER: RECTIFIER TYPE; 3PF-1-30 CV. INPUT VOLTAGE: 3 X 380V AC -15 % +10% INPUT FREQUENCY: 50 HZ+ OR -5% OUTPUT VOLTAGE; .V DC NOMINAL. FLOAT VOLTAGE: 92 X 1.4V /CELL =128.8V DC. ADJUSTABLE RANGE: FROM 90 TO 140V DC. HERATE VOLTAGE: 92 X 1,55V = 142.6V DC. ADJUSTABLE RANGE: FROM 130 TO 160 V DC. BOOST VOLTAGE: 92 X 1.65V/CELL = 151 DC. ADJUSTABLE UP TO 170 V DC. ACCURACY OF OUTPUT ADJUSTED VOLTAGE: + OR- 1% AGAINST: - A) INPUT VOLTAGE VARIATIONS — B)0- 100% LOAD RIPPLE VOLTAGE: LESS THAN 2% R.M.S (WITHOUT BATTERY) QUTPUT CURRENT: 30 A DC CONTINUOS AT 45 °C. CURRENT LIME HE OUTPUT CURRENT IS ELECTRONICALLY LIMITED TO THE RATED CURRENT EVEN AT SHORT CIRCUIT. THUS THE CHARGER IS PROTECTED AGAINST OVERLOADS AND SHORT CIRCUITS. PRINCIPLE OF OPERATION; CONSTANT VOLTAGE CURRENT LIMITED. CHARGE CHARACTERISTIC: IV, ACCORDING TO IEC 146 POWER CONVERSION: 6 PHASE RECTIFICATION USING SIX THYRISTORS IN A FULL CONTROLLED BRIDGE CONNECTION. PROTECTION: [P21 ACCORDING TO IEC 144. CABINET: FLOOR MOUNTED, SHEET STEEL CABINET, VENTILLATED BY NATURAL CONVECTION, WITH FRONT HINGED DOOR, ALLOWING EASY ACCESS TO MOST INNER COMPONENTS. DIMENSIONS: H=160 W=60 D=40 IN CM.CONNECTIONS: Connect the incoming AC 380V supply voltage to the input connectors with correct sequence as shown in the diagram (Frout view door open ) - Phase R To the Connector R - Phase S To the Connector S - Phase T To the Connector T - The Neutral To The Connector N - The Ground To The Connector E The size of the cable sholud not be less then 3 x 16 mm? +10 mm? copper cable. Before connecting the Battery put CBo off. - Connect the Battery bank to the output circuit breaker for Battery CB2 with correct polarity : - +ve terminal of Battery to +ve contact of CB2 for Battery: - -ve terminal of Battery to - ve contact of CB2 The cable size should not be less than 16 mmr - Connect the DC load to the output circuit beraker for load CB3 with correct polarity as above. - The cable size should not be less than 10 mm” (Asuming a DC load of maximam 20A DC) 2:¢ PUTTING IN SERVICE: Before operating and after all input/output connections are done as described, check the following: A) Perform a visual inspection of the equipment. B) Check the phase sequence of the supply is correct (clockwise): C) Check the ground is properly connected to Earth E. d) Check the presence ofthe 3ph. AC input voltage on the AC voltmeter V1 by voltmeter switch S2. e) Check correct battery connection by reading the battery voltage on the de voltmeter V2, e OPERATING - Ensure that the input 3 phase circuit breaker CB1 and the output circuit breaker CBo are off. - Set the Mode Selector Switch MS to "AUTO" - Apply input voltage 380 V AC 3PH and ensure it is correct by reading it on the input votmeter Vi and the selector switch $1 - Connect the output circuit breaker CBo. - Ensure output connections to Battery and lood are correct by reading the battery voltage on the DC voltmeter V2 ( the BAT /LOAD selector switch must be on BATTERY ) 2nC Da - Before operating disconnect the CBo - Operate the charger by putting CB1 on. The charger will operte at no lood giving the output Float voltage, as the mode selector unit will choose Float Mode. -After ensuring that charger operation is normal stop the charger to connect CBo and operate again. - Now the charger will give the output voltage and current which will start to folw according to the status of the Battery if the current is more then 70% of rated for 2 minutes , which means that the battery is partially or to tally discharged , hi-rate voltage will be automatically initiated. - After the charging cycle is completed, the current starts to decrease, because the charging of batteries is complete and the mode of operation will return to the normal Float mode. - Manual Selection of Floot or Hi-rate mode can be achieved by putting the mode selector switch (S) on "Manual " and choosing Floot or Hi- rate by the switch. 10oooo0o°0 HoeSIDE VIEW OF BATTERY CHARGER ss st CO VAHAK' O- onAWN er) 3PP-atey