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JACOBS H&G

SPECIFICATION NO: Z00-MZBS-001-01

TITLE: SPECIFICATION FOR MANUAL BATTERY CHARGER

PROJECT REFERENCE:

- Project No: BC-2718

-
- Project Title: Retail outlets
- Client: Reliance Industries Ltd.
-

- Project Manager Authorisation: Mr.Shivprakash Date: 24.05.06

-
- Client Authorisation: Mr. Kiran Shinde / A. B. Shah Date:

APPROVALS
Rev. Issue Pages Revision Description By Check Approve
No. Date

02 24.05.2006 5 Issued for purchase PG JNS JNS

01 03.02.2003 5 Issued for purchase BM TNS RBD
00 23.09.2002 5 Issued for Enquiry VM TNS RBD
0A 09.05.2002 5 Issued for Client’s Approval MSJ TNS RBD
; Entire Specification SPECIFICATION ISSUED FOR:
Issued this Revision † In-house Review ; Purchase

† Revised Pages Only † Client’s Approval † Construction

Issued this Revision † Enquiry †

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DATE : 25-May-06 TIME : 5:16 PM

 JACOBS H&G
PROJECT NO: BC-2718 SPECIFICATION NO:Z00-MZBS-001
TITLE: SPECIFICATION FOR MANUAL BATTERY
CHARGER PAGE 2 OF 5

TABLE OF CONTENTS

1.0 SCOPE

2.0 APPLICABLE STANDARDS

3.0 SERVICE CONDITIONS

4.0 DETAILS OF DESIGN

5.0 MAJOR COMPONENTS

6.0 DRAWINGS AND DATA

7.0 QUALITY ASSURANCE

8.0 INSPECTION AND TESTING

9.0 DEVIATIONS

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 JACOBS H&G
PROJECT NO: BC-2718 SPECIFICATION NO:Z00-MZBS-001
TITLE: SPECIFICATION FOR MANUAL BATTERY
CHARGER PAGE 3 OF 5

1.0 SCOPE
1.1 This specification covers the design, manufacture, testing, supply and transportation to site of
battery charger.
2.0 APPLICABLE STANDARDS
All equipment shall comply with the following standards, including amendments and addenda.
IS 9224 Fuses for protection of semiconductor devices.
IS 1248 Electrical Indicating Instruments.
IS 694 (IEC 228) PVC Insulated Cables for Switchgear and Control gear
wiring.
IS 3895 Specification for Rectifier equipment in general.
IS 2147 Degree of protection for cubicles.
IS 375 Specification for wiring and Busbars.
IS 4540 Monocrystalline semiconductor rectifier
assemblies and equipment.
IS 6619 Safety code for semiconductor rectifier equipment.
IS 2959 AC contactors for voltage not exceeding 1000V.
IS 4327 General requirement for switch gear & control
gear for voltages not exceeding 1000V.
IS 4064 & 4047 Air break switches and fuse combination units.
IS 6005 Code of practice for phosphating for iron and steel.
IS 5 Colour for ready mix paints.
IS 2026 Transformers
3.0 SERVICE CONDITIONS
The battery charger shall be suitable for '-5° C to +55° C ambient temperature, altitude of 1000
meter above MSL and 90% Relative humidity.
4.0 DETAILS OF DESIGN
4.1 The charger shall suitable for charging 24V lead acid maintenance free (12 Nos of 2V/Cell)
Automobile battery at a maximum charging current of 25A. The Battery charger is intended to
operate from 240V, +/-10%, 50HZ, +/-3% single phase AC supply.
4.2 Battery chargers shall be sized for recharging the automobile battery to full capacity for the rated
duty within 5 hours. Battery charger shall be fabricated as per the attached schematic diagram.
4.3 The charger shall deliver pure DC charging current (ripple less than 3%).
4.4 The components shall be housed in a well ventilated sheet steel cubicle of thickness 2 mm, for
floor mounting complete with internal wiring and input/ output terminals within the cubicle.
4.5 On the input side 6 sq.mm PVC insulated copper wire shall be provided and on the output side 3
meter cable each for positive (Red) and negative(Black) with suitable battery clamp shall be
provided. The wires on output side shall be 6.0 sq.mm PVC insulated flexible copper wire.
4.6 DP Miniature Circuit Breaker (MCB) of adequate rating shall be provided on the input side.
4.7 High rupturing capacity fuses in the output circuit.
4.8 All internal wiring shall be carried out in 650V grade PVC insulated copper wires.
4.9 Cable terminating facilities and terminals shall be suitable for the specified cable type, gland and
conductor size.
4.10 All non-current carrying metal work shall be bonded together and connected to an adequately
sized earth bus provided within the panel. Facility for external earth connection shall be provided
at two points of the earth bus.
4.11 The unit shall be provided with all necessary labels, having black letters on a white background.
Warning labels shall have white letters on a red background.
4.12 All components shall be identified by providing labels.
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 JACOBS H&G
PROJECT NO: BC-2718 SPECIFICATION NO:Z00-MZBS-001
TITLE: SPECIFICATION FOR MANUAL BATTERY
CHARGER PAGE 4 OF 5

4.13 The battery charger cubicle shall be painted with Epoxy powder coated paint of shade no. 632 as
per IS 5. It shall be free standing with IP 55 enclosure.
4.14 Indicating instruments shall be of 96mm X 96 mm size and square faced flush mounting type.
5.0 MAJOR COMPONENTS
The major components within the charger shall be as indicated below.
Components Rating Make
1 Double pole ON/OFF AC input Miniature Circuit 32 A Siemens / MDS /
Breaker at the incoming. Havell’s / S&S /
Indo Asian /L&T
2 AC pilot lamp to indicate AC mains ON condition 240 V L&T/ Siemens /
(LED type of Size 22.5 mm) Teknic
3 AC input contactor to be interlocked with variac so 25 A L&T/Seimens / GE /
that contactor will be switched ‘ON’ only when Schneider
variac is in minimum position to avoid in rush input
current. The contactor shall be with 240 V AC coil.
4 Single phase, naturally air cooled, manually 15A Reputed Make with
operated, auto transformer Variac. IS mark
5 240/120 volts, Single phase, double wound, with 3.33 KVA Reputed Make with
Copper winding, Class B insulation, naturally air IS mark
cooled, mains transformer.
6 Ballast choke to limit output voltage fluctuation. 27.75 A Reputed Make with
IS mark
7 Single phase full wave rectifier bridge comprising 40 A Usha/IOR/Hirect
of silicon diodes (1000 PIV) complete with
suitable heat sinks (K3) with RC surge
suppression network
8 Bleeder Resistance 3 K / 50 W Escol / SURE
9 Filter choke to reduce the output ripple to 1% 25 A Reputed Make with
IS mark
10 Filter condenser (2 numbers) 2500 mfd/ Rescon / Elcon
200 volts
11 Filter condenser HRC fuse base with fuse link 16A L&T/Seimens / GE /
Schneider
12 Moving coil DC ammeter (size 96 sq.mm) to read 0-30A IMP/AE/Rishab
output current
13 Moving coil DC voltmeter (size 96 sq.mm) to read 0-150V IMP/AE/Rishab
output voltage
14 HRC fuse base with fuse link to protect DC 2A L&T/Seimens / GE /
voltmeter Schneider
15 HRC fuse base with fuse link to protect DC output 25A L&T/Seimens / GE /
Schneider
16 Battery reverse polarity indicating LED with series 80V Mimic / Teknic
resistance and Diode
17 Input terminals 10 sq.mm Connectwell/Elmex
18 3 meter cable with clamp for each positive and 10 sq.mm Polycab/ Finolex
negative terminals
6.0 DRAWINGS AND DATA
6.1 The manufacturer shall provide drawings and data in accordance with “Vendor Document
Requirements”
7.0 QUALITY ASSURANCE
7.1 Quality Assurance shall follow the requirements of Jacobs H&G Limited QA documents

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 JACOBS H&G
PROJECT NO: BC-2718 SPECIFICATION NO:Z00-MZBS-001
TITLE: SPECIFICATION FOR MANUAL BATTERY
CHARGER PAGE 5 OF 5

7.2 QA involvement will commence at enquiry and follow through to completion and acceptance thus
ensuring total conformity to owner's requirements.
8.0 INSPECTION AND TESTING
8.1 The manufacturer shall provide test certificates for type and routine check tests and calculations to
verify performance.
8.2 Tests on equipment shall include the following:
8.2.1 Voltage regulation test from 0-100% load with+/-10% input voltage variation.
8.2.2 Ripple Content Measurement.
8.2.3 Heat run test (10 Hrs.).
8.2.4 Insulation Resistance Test.
8.2.5 HV test at 2.5KV for one minute.
8.2.6 Carry out operational and visual checks.
8.3 The owner reserves the right to witness all the above tests.
8.4 The manufacturer shall give two weeks' notice of tests prior to commencement.
8.5 All apparatus, instruments, etc. required for tests shall be provided by the manufacturer and shall
have been checked and tested for accuracy during the twelve months prior to the tests.
8.6 The owner reserves the right to inspect the equipment at the manufacturer's works prior to
dispatch.
9.0 DEVIATIONS
9.1 Vendor shall give in his offer, clause wise confirmation against each clause. Deviations from the
specification must be stated in writing at the quotation stage, clause wise and in case of absence
of such a statement, it will be assumed that the requirements of the specification are met without
exception.

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