NTC 220 - 50 Manual Rev00

NIKSA
Battery Charger / Rectifier

Model : NTC 220 – 50
Serial : 5788
Job Name :
Clients :
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NIKSA Battery Charger/Rectifier
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Thank you for selecting NIKSA Charger /Rectifier, the high reliability and
proven products to meet your needs.
The User’s Manual contains information about the operations of the

NIKSA Charger /Rectifier .
This manual is designed to help you :
• Understanding the basic operational principle .

• Understanding the additional features & alarms working with the charger.
• How to connect & install the system.
• Commissioning .
• Maintenance as well as trouble-shooting.
To ensure trouble-free operation ,this manual should always be read in

conjunction with the as-built drawings.
If you have problems with the operation of your battery charger /rectifier,
refer to chapter 4, ”troubleshooting”. If you need additional help, refer to
“Customer support” in chapter 4 for phone numbers to call for help.
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NIKSA Battery Charger/Rectifier
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SAFETY INSTRUCTIONS
The unit must be used as intended. Follow the instructions

given in this operating manual.
The Charger/rectifier must be installed by manufacture’s

technician or authorised personnel only.
If necessary, only original spare parts are allowed.
Dangerous voltage are present inside the unit.
Installation and use of this equipment must comply to all

national and local regulations and procedures.
To prevent overheating, do not obstruct the flow of air for

ventilation opening of the unit.
This equipment must be service and maintenance by

qualified personnel.
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CONTENTS
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Chapter 1 AN OVERVIEW OF BATTERY CHARGER / RECTIFIER 6
1.1 Introduction 7
1.2 Basic Elements In The Battery Charger / Rectifier 8
1.2.1 Understanding The Basic Operation 9
1.2.2 AC Power Failure and Restore Operation 10
1.2.3 DC Output Filter 10
1.3 Three Phase Battery Charger/Rectifier
Control Card and ISO – Driver Board 11
1.3.1 The Function of The Control Card 13
1.3.2 The Function of The ISO – Driver Board 15
1.4 Battery and Charging Operation 16
1.5 General Technical Specifications
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Chapter 2 WORKING WITH ADDITIONAL FEATURES 20
2.1 Alarm and Status Indications For Battery Charger/Rectifier 21

2.2 Multi-Alarm Card 22
2.3 Adjustment Of The Multi-Alarm Card 24
2.4 Typical System Configuration 25
Chapter 3 INSTALLING AND USING THE SYSTEM 29
3.1 Unpack Battery Charger/Rectifier 30

3.2 Safety Precaution Of handling The Battery 31
3.3 Determining Where To Install Battery & Charger/Rectifier 34
3.4 Installing The Battery & Charger/Rectifier 35
3.5 Commissioning and Start Up The System 40
3.6 Shut-Down The System 45
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CONTENTS
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Chapter 4 MAINTENANCE AND TROUBLESHOOTING 46
4.1 Maintain The Charger/Rectifier 47

4.2 Performing The Battery Maintenance 49
4.3 Basic Troubleshooting 50
Chapter 5 SYSTEM SCHEMATIC DIAGRAMS & MATERIALS LISTS 55
Chapter 6 FACTORY TEST REPORT 56
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CHAPTER 1
AN OVERVIEW
OF
BATTERY CHARGER
6
An Overview of Battery Charger / Rectifier
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1.1 Introduction
This Charger / Rectifier is designed to supply DC power to sensitive equipment at a onstant

uninterruptible voltage, free from the usual utility power line disturbances (noise, fluctuations,
momentary power disruption etc...). The rectifier normally float charges the battery in order to
maintain the battery to its full capacity as well as providing the DC power to the load. Upon an
AC failure, the battery charger system, due to the reserve energy in the battery, continues to
supply DC power to the load.
The scope of this manual includes :
Basic elements consists in the Battery Charger / Rectifier

Basic Operation of Charger/rectifier
Battery Charger/ Rectifier--Control & ISO-driver Board
Battery and Charging Operation
Summary of Technical Specification for NIKSA Charger / Rectifier
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1.2 Basic Elements Consists In Battery Charger / Rectifier
The basic Battery Charger /Rectifier consists of :
Input isolation transformer

Full controlled 6-pulse Thyristor Bridge
Output DC filter
Control & ISO-driver Printed Circuit Board
Enclosure
Alarm Unit
Battery ( not applicable for Rectifier)
Thyristor
Transformer Bridge Filter
Isolator
AC Supply Load
Isolated triggering
Rectifier voltage sensing Battery
Rectifier current sensing
Battery current sensing
Status LEDs
Charger On Battery temperature compensation
Float Summary
Hi-rate alarm
Current Limit Control Alarm remote
Crad contact
Alarm LEDs
Individual
Charger Fail remote
AC Fail alarm
Charger High Voltage
Charger Low Voltage
DC Earth Fault
Alarm input
Options : to be defined
at ordering
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1.2.1 Understanding The Basic Operation
The basic battery charger is isolated from the three phase AC supply via an isolation
transformer. A full controlled 6-pulse thyristor bridge module is used to rectify the AC power to
appropriate DC power, then this DC voltage is filtered by DC filtering circuit, consists of
inductor and electrolytic capacitor. The DC output voltage is always maintained at a constant
level irrespective of supply voltage fluctuations and loads changes, and the output current is
limited to avoid overload, which is controlled by the control printed circuit board.
Voltage spikes is elimated by Voltage Surge Arrestor which is installed across the primary of
the input transformer.
Independently adjustable modes of charging via potentiometer located on the control printed
circuit board for
Float (Trickle) Charge
Hi-rate (Boost) Charge
Commissioning Charge
Current Limit Setting
Under normal operation, a battery charger is used to Float (Trickle) charge the batteries bank
as well as supplying the required DC current to the load. In this mode a very low battery
charging current demand typically few mA per Ah, is required to maintain the batteries bank at
rated capacity. As long as the total DC output current does not exceed the output limit of the
rectifier, the output DC voltage is regulated at the constant level i.e. constant voltage
characteristics.
In abnormal operation, if the load current is higher than the preset rectifier current limiting
value, the battery charger is self protected by shifting to its current limit operation, whereby the
voltage will drop, the batteries bank will start to discharge and provide the additional current
required by the load. If the battery charger is at the current limiting mode more than 36
seconds, the charger will automatically shift to Hi-Rate (Boost) charge.
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1.2.2 AC Power Failure and Restore Operation
Upon an AC failure, the batteries shall deliver the required DC power to the load for the
required duration that the batteries bank was selected to perform.
When AC supply is restored, the charger shall automatically switch to a Hi-Rate(Boost) charge
condition. This is to speed up the charging time of the discharged batteries bank, as well as
regaining its full capacity. Upon completion of its charging process, the charger will
automatically revert back to its Float (Trickle) charged mode. As the charging process is fully
automatic, no human intervention is actually needed to continuously maintain DC supply to the
load.
1.2.3 DC Output Filter
The important element is designed and incorporated to the NIKSA battery charger. This
filtering design is to reduce the ripple current and provide a clean DC output. This filtering
increases the life of the connected batteries and also makes the battery charger possible to
operate without the battery connected.
The standard DC filter is made up of DC inductor and electrolytic capacitor as LC filtering

network, and to reduce the output voltage ripple to less than 5% of its nominal DC voltage
without batteries bank connected (typically 1% with the batteries bank connected).Optionally,
a 1% or 0.1% DC filter can be included in the design, for the telecommunication application, by
employing two stage DC filtering network, which consists of two sets of DC inductor and
electrolytic capacitor form as LCLC network.
This is normally employed to reduce noise level as required for sensitive electronic
instrumentation.
The filter is also designed to meet the ripple requirements of the telecom specification 876 type 3
24V dc = 1 mv ripple psophometrically weighted
48V dc = 2 mv ripple psophometrically weighted
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1.3 Three Phase Battery Charger/ Rectifier- Control & ISO-Driver Board
The control card can be divided into the following segments
Power Supply and Voltage Reference

Slow Start Circuitry
Zero-crossing detector for Synchronization of thyristor bridge
Current Amplification and Error Current
Voltage Feedback and Error Voltage
Modulator Circuitry
Thyristor Firing Pulses
Phase Unbalance Detection Circuitry
Charger /Rectifier Output Current Limit
High Voltage Monitoring Circuit
The Control Board is providing the following adjustments
Float(Trickle) Voltage P4
Hi-Rate (Boost) Voltage P5
Commissioning Charge P6
Balancing – Phase 1 P1
Balancing – Phase 2 P2
Rectifier Current Limit P7
Rectifier Mains Undervoltage Shutdown P3
High DC Voltage Shutdown P8
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Three Phase Control Card Schematic Diagram

P/N : EM713 - 9398C
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1.3.1 The Function of The Control Board
Control Board Power Supply
The AC voltage of 20V is applied from a tapping on the input transformer to the control card.
This voltage is rectified, filtered and then regulated to +15Vdc for the synchronization and
timing circuits. A more stabilised voltage reference, 5Vdc is also produced to be used as
reference voltage for voltage comparison. Function on the card which is operated in the event
of AC failure and supplied from the DC voltage through a DC/DC converter. A second AC
voltage of 20V is applied to the ISO-Driver card. This power is used to supply the rectifier gates
through a pulse transformer.
Slow-Start
The slow-start function is used to prevent high current surges during powering up of the
rectifier. This feature will reduce the power requirement of the AC source upon restoration of
power. The circuit only operate during the start-up of the rectifier.
Typically, the design is chosen to give the slow-start ramp of 10 seconds from start up.
Float & Hi-rate Voltage Adjustment
The Float and Hi-rate voltage reference levels can be adjusted using the following
potentiometers on this card:
Float voltage adjustment = P4

Hi-rate voltage adjustment = P5
Commissioning voltage adjustment = P6
Place the probes of the voltmeter (0.5% accuracy) at the battery terminals. Always make
adjustments to the Float voltage with the charger in Float mode. Allow the current and voltage
to stabilize as you make this adjustment slowly. Similarly, make adjustments to the Hi-rate
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voltage after you have completed the float voltage adjustment and with the charger in Hi-rate
mode. If the Hi-rate mode is not required, adjust the potentiometer P2 to the float charge level.
For Commissioning Charge is activated by connecting Jumper 9 to ON position.
Note : Adjustment of these two potentiometers is best conducted without battery connected.
Refer to the Factory Test Report for voltage to be adjusted.
A 0.5% accurate voltmeter is required for this procedure.
Current Limit Adjustment
The rectifier output current is protected by the current limit setting potentiometer P7. The preset
value is limited to avoid overload.
To make this adjustment, a load in excess of the rectifier current limit requirement is to be
connected at the load side of the equipment. Slowly increase the load until the rectifier current
exceeds the require set point. Then slowly turn the current limit potentiometer until the voltage
of the rectifier begins to drop.
Note : Adjustment of these two potentiometers is best conducted without battery connected.
Refer to the Factory Test Report for current limit value to be adjusted
Phase Unbalance
When a phase unbalance occurs, the output of the rectifier circuit will contain a 50Hz ripple
voltage that is proportional to the degree of unbalance. (Note : For six pulse systems at 50Hz
without a DC filter, the primary ripple voltage will be + 5% at 150 Hz under normal conditions).
The ripple measurement circuit will trip as a result of this 50Hz ripple and the rectifier output will
go to zero after a short delay. Adjustment of the phase unbalance is made by potentiometer P1
& P2. The standard settings allows for a maximum unbalance of 20% between the most
separate phases.
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Automatic Charge Control
The automatic charger control circuitry is used to trigger the charger to Hi-rate (Boost)
operation mode automatically. The ACC senses when the charger is operating in current limit
for more than 36 seconds, the charger will switch from float to Hi-rate charge. The charger will
remain in Hi-rate mode until the timer counts to zero or the float charge pushbutton has been
depressed.
The Hi-rate charge timer setting is set with Jumper S4 to S7 on Control Card as below:
Preset Period S4 S5 S6 S7
4 Hours ON OFF OFF OFF
8 Hours OFF ON OFF OFF
12 Hours OFF OFF ON OFF
24 Hours OFF OFF OFF ON
1.3.2 The Function of The ISO-Driver Card
The ISO-Driver card is used to galvanically separate and amplify the gate burst current from the
control card. It should be mounted as close to the thyristor bridge as possible. No adjustments
are required. There are six drivers for each thyristor in six pulse bridge configuration. Three
resistors R8 to R10 and three capacitors C2 to C4, connected in parallel, provide power to two
pulse transformers each. Since the switching signal operates at about 9610 Hz, there is no risk
of the transformer’s saturating. The resistors R8 to R10 make the system short-circuit proof.
High DC Voltage Protection
This feature is incorporated in the control board ,to detect the overvoltage across the DC filter
capacitor, in the event of possible fault with the charger, such as loss of voltage feedback
sensing cable, the rectifier will try to raise the output voltage to the maximum level, and this is
dangerous for the DC filter capacitor. The control circuitry is to inhibit the rectifier firing circuits,
to prevent the high voltage occurs.
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1.4 Battery and Charging Operation
Battery
The batteries bank is used to provide the back up power to the load in case of AC power
failure. The types of batteries to be installed to the systems can be Nickel Cadmium or Lead
Acid.
The duration of the batteries bank is able to back up the load is depends on the battery
capacity and its state of charge.
Charging Operation
When the AC power is restored, the charger is started to deliver it’s maximum output current
(limited only by the battery and charger current limit settings) until the battery voltage has risen
to the desired level.
The charger is capable of running at the maximum output current continuously. When the
desired voltage is reached, the charger supplies just enough current to feed the load and keep
the battery at this voltage. The float voltage level is selected according to strict battery
specifications, so it is important that before any change is made to these settings, the battery
specifications must be checked first.
The capacity of the battery charger is selected to recharge the battery in the required time and
simultaneously providing DC power to the load without damage to it. The charger will limit it's
maximum output current in order to protect the power components from damage.
As the battery continues to be charged, the voltage across it rises. A point is reached where
further increases in the voltage would cause excessive gassing of the battery and possible
battery damage. For this reason the charger has a circuit which limits the charging rate at a
certain voltage level.
Two charging rate is designed in the system

Float (trickle) charge
Hi-Rate (Boost) charge
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Both Charge modes are indicated by LED’s on the front panel.
Float (trickle) charge--the battery will remain at this voltage for the rest of it's life so it is
important that this voltage is selected to take account of long term effects on the battery.
Hi-Rate (Boost) charge--to recharge the battery to 100% capacity
In the situation the batteries are discharged even though the charger is still operating or
batteries are discharged due to the AC power failure. The Hi-Rate charge is automatically
activated. The battery voltage has lifted to a value above normal “Float “voltage. This “Hi-Rate”
charge voltage is held to restore the battery to it’s full capacity for a specific time, after which it
changes back to its normal "Float" value. The Hi-rate voltage and Hi-rate time depend on the
type of battery and the ambient temperature. The values of these voltages and charging times
are adjustable and are given in the factory test report.
Manual Hi-rate charging is also available on the front panel. If the battery reaches the Hi-rate
voltage within the set time then the charger will revert back to the Float voltage. This is a quick
way of checking the state of the charge of the Battery. The charger can be put back into the
Float charge at any time by depressing the float charge pushbutton.
2.4 135%
CELL VOLTAGE (V) 120%

2.3
CELL
VOLTAGE 105%
2.2
90 %
2.1
CHARGER (AH%)
2.0 75 %
60 %
0.4 C
CHARGER
0.3 C 45 %
CURRENT
30 %
0.2 C
CHARGER CURRENT (A)
0.1 C 15 %
0%
Battery Charging Characteristics
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1.5 General Technical Specifications
General Features:
Constant Voltage Regulation

Constant Current Regulation
Input:
AC Input voltage : 3 phase, 3 or 4 wires

380 + 10 % or as specified in the test report
AC input frequency : 50/60 Hz + 6%
Power Factor : Full Load 0.83 lag approx.
1/2 Load 0.93 lag approx.
Output:
Nominal DC voltage : 12, 24, 48, 110, 220V or other (refer to test
report)
Float voltage stability : + 1% from no load to full load with
AC input voltage variations of + 10% and
frequency variations of + 6%
Output ripple voltage : Max 5% rms of nominal DC voltage.
Typical 1% rms of nominal DC voltage with
batteries AH capacity 5 times higher than
rectifier rated current are connected.
(refer to as-built drawings and test report)
Current limit : Adjustable 20 - 110% of rated current.
Current stability : + 2% at current limit.
Controls : - Mode selector switch: Float & Manual Hi-
rate
- Reset push-button & LED test
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Meters : DC voltmeter, DC ammeter, 1.5% accuracy

Efficiency 220V : 94%
110V : 92%
48V : 86%
32V : 82%
24V : 80%
Operating Environment
Audible Noise : 55 dBA @1.5m

Temperature Range : -10oC to +40oC continuous from
+40oC to +50oC, output to be derated.
Humidity : 0 to 95% @ 25 degrees C
Altitude : Up to 1000m above sea level.
Above 1000m output current to be derated.
Protection : - AC and DC surge suppressers.
- Slow start circuit
- DC output fuse (or circuit breaker)
protection
Insulation voltage : 2000 V for 1 minute
Insulation resistance : > 10MΩ at 500 VDC
Earth Leakage : Sensitivity 10mA
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CHAPTER 2
WORKING WITH ADDITIONAL
FEATURES
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Workng With Additional Feature
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In some applications it is important to know the status of Battery Charger/Rectifier, therefore the
Multi Alarm Card is designed to monitor the fault for the user to take appropriate action and
avoid adverse effects on the system.
Also to meet the demands of industry, battery charger is suitable to work in parallel The
additional feature of dropping diodes control is to reduce and regulate the output voltage within
the specify limit.
This Chapter includes :
Alarm and status indication of Battery Charger /Rectifier

Multi Alarm Card
Adjustment of the Multi Alarm Card
Typical system configuration - Battery Chargers/ Rectifiers working in parallel
- Hi-Rate interlocking & Load sharing control
- Limit the output voltage by dropping diodes
- Extra feature
- Battery Current Limit Card
- Battery Temperature Compensation Card
2.1 Alarms and Status Indications for Battery Charger /Rectifier
Optional alarms can be included in the Battery Charger /Rectifier as follows :
Indicator Status Meaning
AC fail On AC incoming supply fail

Charger low voltage On Charger output voltage is low
Charger high voltage On Charger output voltage is high
Charger fail On Charger is not operating
Earth fault On Current leakage on the battery
Electrolyte level low On Battery electrolyte level is low
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Charger Overload On The charger is operating at current limit

Charger Temp. High On High temp. inside the chargers or semiconductor
Low load voltage On Low voltage at the load output
High load voltage On High voltage at the load output
Fan Failure On Fan has failed, only applicable to the system
with cooling fans
Main DC fuse blown On Main DC protection fuse has blown
MCB tripped On Circuit breakers have tripped
2.2 Multi-Alarm Card
The “Multi Alarm Card ” is designed to suit the basic requirement to monitor the status of
battery charger/ rectifier.
The Multi Alarm Card provides the following alarms:
Low voltage
Charger failure
High voltage
Earth fault
Four other auxiliary monitoring functions are normally provided for the following :
AC failure
Low electrolyte
Output fuse failure
Circuit breaker trip alarm
Note : All alarms and indicators are latched to alarms condition, and reset by alarms reset
pushbutton, If automatic alarm reset is preference, please defined it in your purchase order.
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Multi-Alarm Schematic Diagram

EM 711 - 9108D
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2.3 Adjustment of the Multi-Alarm Card
Low Voltage Alarm
Adjust the float voltage (using the main control card) to the low voltage alarm setting required.
Adjust the voltage trimpot R12 until the low voltage LED lights up and the common alarm relay
de-energizes. Re-adjust the float voltage back to the original level.
Charger Failure Alarm
This alarm has two adjustment settings, one for voltage and one for current. Adjust the float
voltage (using the control card) to the charger fail setting. Adjust the trimpot R32 until the
charger fail LED is lit. Check that the alarm relay de-energizes when the alarm is on. Now
increase the load until the charger is in current limit mode. Adjust R37 until the charger fail LED
goes off and the alarm relay energizes. Adjust the float voltage back to the original setting.
High Voltage Alarm
Switch the charger to “Manual Hi-Rate” mode. Adjust the Hi-rate voltage level (using the control
card) to the high voltage alarm setting required. Adjust trimpot R22 until the high voltage alarm
LED lights up and the common alarm relay de-energizes. Reduce the voltage back to the Hi-
rate level then press the alarm reset switch.
Negative Earth Fault
Connect a 1/2 watt resistor (resistor value = Float Voltage / 0.01 Ohms) from the negative of
the battery terminal to the chassis ground. With this resistor value, an earth fault current of
10mA will flow. Adjust R63 until the earth fault LED lights up and the common alarm relay de-
energizes. Remove the resistor then press the alarm reset switch.
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Positive Earth Fault
Connect a 1/2 watt resistor (resistor value = Float Voltage / 0.01 Ohms) from the positive of the
battery terminal to the chassis ground. With this resistor value, an earth fault current of 10mA
will flow. Adjust R63 until the earth fault LED lights up and the common alarm relay de-
energizes. Remove the resistor then press the alarm reset switch.
Common Alarm Relay
The common alarm contact is activated if any of the above alarms become active. The
standard system has no hold function for this relay. Normally-closed or normally-open
condition can be selected.
2.4 Typical System Configuration
In some applications, it is important for the systems that have a strict dc output voltage limit at
the load, but still require the batteries to be Hi-Rate charged. There are two most common
configurations used to limit the voltage seen at the load side, without sacrificing the need to
remove the essential high rate function.
Parallel operation of chargers with Hi-Rate interlocking feature

Limit the output voltage by the dropping diodes
Of course, DC/DC converters are also a solution, but a very expensive solution.
Battery Chargers/ Rectifiers working in parallel
In the parallel operations, the Hi-Rate interlocking feature is designed at only one time only
one charger is able to operate on Hi-Rate charge condition, the output is isolated from the load
by contactor, the other charger is force to Float charge condition and at the same time feed to
the load. A load sharing card is used for parallel charger systems. When both chargers are
supplying current to the load, this load sharing card is used to regulate and balance the current
output of each chargers. Depending upon the variability of the load, the load sharing control
card is accurate to approximately 10% of nominal output current.
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Adjust the Load Sharing for the current output of each charger
Before proceeding with the adjustment, ensure the Float and Hi-rate voltage settings are
correct for each charger. Load sharing balance is achieved using potentiometer P2 on this
card. To make any adjustment, load the two parallel chargers with equal resistive loads and
equal AC input voltage. Adjust P2 until the current output of each charger is approximately
equal. Allow the charger output to stabilize each time an adjustment is made. The maximum
allowed variation in voltage is + 1%.
Limit the output voltage by dropping diodes
The basic operation of the dropping diodes control is to reduce the output voltage at the load
when the system output voltage goes into Hi-Rate (boost) charge.
Number of diodes = [(Hi-rate voltage) - (Max load voltage) ] / 0.7
Number of control cards = [Number of diodes] / [(max load voltage) - (min load voltage)]
Whenever the charger voltage goes above the maximum voltage limit, a contactor is opened so
that the voltage control diodes are placed in series with the load. Approximately 0.8V is lost
across each diode. Whenever the charger output is below the maximum load voltage, the
contactor is closed so that the voltage control diodes are by-passed. As the operation is fully
automatic, the load voltage is regulated to within a safe voltage window, even when the voltage
seen at the battery side is high which is the Hi-Rate charge voltage. The control circuit
introduces a hysteresis voltage of 2V for switching the bypass contactor on and off.
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Rectifier Load
Relay 1 Relay 2 Output
Voltage Control Voltage Control

Card Card
Dropper Diode Voltage Control Card
Adjustment of the regulator card – To switch bypass contactor ‘On’ or “Off’
The charger output voltage is sensed via a voltage divider in which a potentiometer R8 is used
to set the required trigger voltage. The potentiometer R11 is used to adjust for hysteresis. The
voltage-free contact of RLY 1 is used to switch the external bypass contactor for the dropper
diodes. Whenever the charger output is below the acceptable maximum load voltage, the
dropper diodes will be by-passed so that no energy is lost in the output circuit.
PROCEDURES :
1. Disconnect the battery from the charger and connect a dummy load at the load terminals.
2. Adjust the potentiometers R8 and R11 clockwise until the bypass contactor is energized.
3. Adjust the float voltage (using the control card potentiometer P1) to the maximum
load voltage allowed.
4. Adjust R8 until the contactor de-energizes. The voltmeter will now show the reading which
includes the voltage drop across the diodes. The output voltage should be within the
Min/Max limits.
5. Reduce the float voltage until you reach 1 or 2 volts below the maximum voltage setting.
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6. Turn R11 until the contactor de-energizes again. This is the hysteresis adjustment.
7. Adjust the float voltage to a higher level and observe that the contactor de - energizes
again and the load voltage remains within the limits specified by the user.
8. Repeat this procedure for other dropper diode control cards installed in your system.
9. Repeat this procedure for other dropper diode control cards installed in your system.
Battery Current Limit Card
This card is inserted directly into the main control card, and is used mainly for systems which
use lead-acid batteries.
The battery current limit card limits the maximum current available to charge the batteries and
is independent of the total current limit of the charger. This function is particularly important for
systems which have a large load current relative to the battery current. The output signal from
this card is applied to the modulation circuit on the main control card. The battery current limit
is adjusted on this card using potentiometer P1.
Remove the battery bank or open the battery circuit breaker before making this adjustment.
Never make adjustments to the current limit in excess of 110% of the factory set current limit.
If the adjustment of P1 cannot reach the battery current limit setting required, you may need to
increase the charger current limit on the main control card.
Battery Temperature Compensation Card
This card in installed at X5 of the main control card. When sealed lead-acid batteries are used,
the floating charge voltage must be temperature compensated. Adjustment of the temperature
compensation is done with potentiometer P1 on this card.
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CHAPTER 3
INSTALLING AND USING
THE SYSTEM
29
Installing And Using The System
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Before getting to work and take full advantage of starting up the Battery Charger / Rectifier, it
is important for you to read this chapter.
This chapter includes :
Unpack Battery Charger /Rectifier

Safety Precautions Of Handling The Battery
Determining Where To Install Battery & Charger /Rectifier
Installing The Battery & Charger/ Rectifier
Commissioning And Start Up The System
3.1 Unpack Battery Charger /Rectifier
The charger and batteries are packed for transport by truck, train, ship, or plane. As a piece of
electronic equipment, the charger must be handled with care. Always use a fork-lift to move the
equipment and lift from under its bottom. The charger must be moved in an upright position.
There are labels on the packing which indicate the upright position.
If lifting eye-bolts are fitted, check that the bolts are screwed tightly and do not use them at an
angle wider than 45o.
The lifting capacity of the handling equipment must always be greater than the weight of the
equipment. For the equipment weights refer to the attached packing list.
Before Unpacking
The charger and batteries have been packed to withstand the vibrations that normally occur
during transportation, so as a rule, neither the packing nor the charger will have suffered any
damage during transportation. However, an inspection of the packing upon arrival is
recommended. If any damage has penetrated both the packing and the charger, or if it is not
received in an upright position, the shipper and the manufacturer should be notified
immediately. Before unpacking the charger, take out the delivery note and keep it to check that
the equipment is in accordance with the specifications on the note.
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Severely damaged packing or equipment should be left untouched until the shippers and the
insurance company have inspected it.
Unpacking
Unpack the charger in a clean, dry storage area.

Remove the screws which keep the lid of the packing in place.
Open the front sheet at the cabinet door and pull off the other sheets.
Remove the plastic bag and the polystyrene plates.
If the charger is not going to be used right away, leave the bags with moisture absorbing
material inside the cubicle and put the plastic bag over the charger again.
Store the charger in a dry and clean storage room free from aggressive gases. The
temperature in the storage room must be between -25 and +70 oC. The storage room should
be free from rodents and bugs and well ventilated.
3.2 Safety Precautions Of Handling The Battery
Handling the battery should be carried out by QUALIFIED PERSONNEL who is aware of
specific ELECTRICAL HAZARDS.
LETHAL VOLTAGES EXIST PERMANENTLY ACROSS THE BATTERY TERMINALS.
A BATTERY MAY RELEASE FLAMMABLE AND EXPLOSIVE GASES.
THE BATTERY MANUFACTURER’S SAFETY AND MAINTENANCE

RECOMMENDATIONS HAVE PRECEDENCE OVER THOSE CONTAINED
IN THIS MANUAL
31
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A. Keep Flame Away
Some explosive gas may be present in the battery cells even during storage or shipment. The
battery cells may also release flammable gas during Hi-rate charging. Therefore:-
Keep flames away from battery cells and out of the battery room.
Never smoke near the batteries.
Do not adjust connections while charging or within an hour Discharge any static electricity
from your clothing by touching a part connected to earth before entering the battery room.
Remove metal parts from your body and clothing which may come in contact with battery
terminals.
Never disconnect the battery when it is on load or charge.
B. Ventilation
Ventilate the battery room at all times to prevent the accumulation of explosive gases.
C. Safety Equipment
Use tools with insulated handles.

Wear full-face shields or goggles.
Wear rubber gloves, rubber boots, and rubber aprons. Wear long sleeved clothing.
D. Electrolyte
THE ELECTROLYTE CONTAINED IN LEAD-ACID OR NICKEL-CADMIUM BATTERIES

IS DANGEROUS TO THE SKIN AND CLOTHING.
If it is necessary to mix electrolyte for the battery cells, follow the safety precautions below:-
1. Lead-Acid Batteries
Never use equipment designed for Nickel-Cadmium batteries with Lead-Acid batteries.
Put water in the mixing vessel before the acid when diluting to avoid splashing and gas
emission.
32
____________________________________________________________________________________________________
1. Nickel-Cadmium Batteries
Never use equipment designed for Lead-Acid batteries with Nickel-Cadmium batteries. Use a
vessel of plastic or steel to mix the electrolyte. Never use a vessel of copper, aluminum or
galvanized iron. Pour water into the mixing vessel before carefully adding solid electrolyte to
avoid splashing and gas emission.
E. Handling
Keep and move the battery cells in an upright position. Never lift a battery by its terminals.
Lifting equipment used for carrying the battery must have capacity that exceeds the weight of
the batteries.
Do not place or drop metal objects on the top of the battery cells.
Never disconnect the battery when it is on load.
F. Waste Disposal
Neutralize all shipping caps, used vents etc. with a baking soda solution before disposing
them.
G. Emergency Measures
Make sure that water for washing is easily accessible around the battery area.
Wash immediately if electrolyte is splashed on skin or clothing.
Flood continually with water if electrolyte enters eyes, and quickly send for medical aid.
33
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3.3 Determining Where To Install Battery & Charger /Rectifier
To ensure that you get the best results of operating the Battery & Charger/ Rectifier,
Always use the following guidelines :
The ambient temperature must be between 0°C and 40°C.
For temperatures from 40oC to 55oC derate current rating by 1.25% per degree Celsius.
The relative air humidity must not exceed 95%.
The ambient air must be free from dust and aggressive gases.
The floor on which the battery & charger is going to be installed must be level so that the
cubicle and battery racks will not be twisted when it is bolted to the floor.
There must be a free space of at least 500 mm over the top and back of the cubicle.
The air flow through the charger must not be hindered. An extractor fan and/or an air inlet
on the front door or back provide the internal ventilation of the charger.
Sufficient clearance for the door(s) to open at least 90o.
External ventilation of the charger is not required provided the room temperature is
kept below the tolerated maximum working temperature (i.e. 40°C)
Be careful not to obstruct the natural air flow through the cabinet, leaving at least 500 mm
clearance at front, back, top and at louvers. This is to ensure compliance with the heat removal
required for the reliable operation of internal power electronic and magnetic devices. It is also
to ensure compliance regarding safe hydrogen dispersion into the ambient air when the
rectifier enclosure contains battery cells. Hydrogen is a gas which may be released by
charging battery cells. It is non-corrosive and not harmful if inhaled, but a high concentration of
hydrogen in the air forms an explosive mixture.
34
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3.4 Installing The Battery & Charger/ Rectifier
When planning the installation, arrange your cable ladder routing to deliver the cables for easy
entry into the cubicle, allowing sufficient space for bending.
Before start to install the system, ensure to check :
All external power supply to the system are in the OFF position.
All external protective devices (fuses, circuit breakers) are removed.
All internal circuit-opening devices (switches, circuit breakers) are in the OFF position.
Do not connect any external power cables or load to the system, until completing the
installation procedure in this chapter.
A. Battery Installation
It is recommended that a tray be placed under the battery rack to catch any electrolyte which
may be spilled from the battery cells.
Place the heaviest battery tray at the bottom and lightest at the top. Be sure to:
a) Alternate the (+) and (-) poles,

b) Use the accessories supplied by the battery manufacturer,
c) Tighten all connections to the torque values specified by the battery manufacturer.
The battery set consists of a series of battery cells where the negative (-) polarity of cell
number 1 is connected to the negative (-) polarity of the charger and where the positive (+)
polarity of cell number (last) is connected to the positive (+) polarity output of the charger. The
positive (+) polarity of cell number 1 is connected to the negative (-) polarity of cell number 2,
and so on. This is called a battery string.
INCORRECT POLARITY AT THE BATTERY CONNECTION MAY CAUSE SEVERE

DAMAGE TO THE EQUIPMENT.
35
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B. Cable Sizing
The cable sizing must comply with the applicable wiring rules.
The maximum current demand from the charger will normally occur after the battery has been
discharged. It is important to avoid unnecessary loss of regulation, due to the voltage drop
between the battery and the DC load.
We recommend that the voltage drop in all DC cables should not exceed 2% of the output
voltage, although in some applications this % of the value is reduced. Include the voltage drop
in both the (+) and (-) cables, and calculate it at the maximum output current.
If the resistance of the cable is unknown it can be approximated with the formula below:
Total length of wire (meters)

Resistance = ⎯ ⎯⎯⎯⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯⎯⎯⎯ x 0.02 Ohms
Cross-sectional Area of wire (mm sq)
C. Switchboard Circuit Breaker or Fuse
The circuit breaker on the switchboard feeding the rectifier needs careful attention. Firstly, this
circuit breaker needs to be able to support the maximum input current drawn by the rectifier.
Secondly, it must not trip each time the rectifier is turned on, or the AC is restored, due to input
transformer magnetizing current. This peak inrush current can be 10 times the maximum input
current, under worst conditions. It only lasts for a short time, decaying to steady state load
current after approximately 100 milliseconds.
To know whether the switchboard fuse of circuit breaker will trip, multiply the maximum AC
input current by 10 and check it against the time curves supplied for your circuit breaker or fuse.
These curves can easily be obtained from the supplier of the particular fuse or circuit breaker.
36
____________________________________________________________________________________________________
D. Fuse Discrimination
You may have fuses or circuit breakers on the output of the rectifier. When sizing these circuit
breakers or fuses it is necessary to ensure that the fuse or circuit breaker down stream of the
distribution breaker/fuse opens before the one upstream of it.
To ensure this happens, two aspects of the fuses and circuit breakers need to be considered.
The rating of the breakers/fuses, and

The time response of the breakers/fuses
It must also be remembered that it takes time for this fuse or circuit breaker to trip. When the
load is a switching application, power to the load may only be applied for a very short period,
maybe only milliseconds. In this case, the breaker/fuses can be rated lower than the full load
current. This also means that the cable sizes feeding the breakers/fuses can be smaller. To
work out the rating of the breaker or fuse, use the time response curves obtainable from the
supplier.
E. Cable Installation
The recommended cable sizes for installation of the battery & charger are shown on the single
line drawing(s) at the chapter 5.
NOTE : All AC and DC cables must be sized to allow for the maximum current capacity as
indicated by the rating of the input fuse or circuit breaker.
Pass the battery cables through the openings in the cabinet provided for this purpose. Always
use cable glands to prevent dust and dangerous vapors from passing through the cable entry
to the electronics. For the cable cross-sectional areas and appropriate protective features,
refer to the attached drawing package..
The input transformer has several tapping points to suit your mains voltage. The correct supply
voltage is marked on the transformer.
37
____________________________________________________________________________________________________
The AC input, battery, and output cables should be run separately to minimize mutual
interactions in the event of a fault. It is recommended that the positive and negative wires of
DC circuits be run in the same cable harness to avoid electrical interference with other circuits.
The same principle applies to wiring groups of AC cables.
The alarm and indication cables must be kept separate from power cables. A suitable distance
would be 100-300 mm. Signal cables which cross other cables that could cause electrical
interference must be placed at right angles.
Starting To Connect External Cables
Do not connect power to the system until instructions are given in “Initial Checks with
power on”.
NOTE : Leave all external switches and circuit breakers in the OFF position and remove the
battery fuse before making the following connections:
Connect the battery cables to the BATT (+) and (-) termination points at the front
of the cubicle.
Connect the earth cable to the earth terminal bar inside the cubicle.
Connect the AC power cables to the relevant input terminals in the charger.
Observe phase sequence.
Check that the rating of the load protection and disconnect devices are adequate.
Connect the cables for the load to the charger output terminal block.
38
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Temperature Compensation Probe (Option) Connection
The temperature probe consists of a precision transducer housed in a small isolating plastic
module. A two wire or a three wire transducer could be used (refer to section 4 engineering
drawings). These wires should NOT be connected to any battery terminal.
Attach the isolated temperature probe externally to the front of a cell which is located in the
middle of the Battery set. Clean and lightly roughten the cell surface with emery or sandpaper
(in a position below the "low electrolyte" mark, if possible). Use a two-part epoxy adhesive to
ensure permanent fitting.
Warning: Do not leave the probe disconnected or open if the temperature compensation card
has been installed. This could cause random voltage variation at the charger DC output which
may activate the over-voltage/under-voltage detectors and affect the battery life and
performance.
Note: Special considerations may be necessary where the battery is located more than 30
meters from the charger since the temperature compensation cable may not give a true
indication of the battery temperature. Consult our Customer Service Centre shown in chapter 4
for phone numbers to call for help.
Earth Leakage Detection (Option) Connection
Check that an Earth potential wire (1.5 mm2) is connected to one of the earth leakage
connections on the control card (refer to chapter 5 engineering drawings). Do not use this
option if one of the polarities of the battery or the DC load is intentionally grounded (Earthed).
Low Electrolyte Probe (Option) Connection
Connect a 1.5 mm2 wire to the low electrolyte terminal block on the control card (refer chapter 5
engineering drawings). Connect the other end of the wire to the electrolytic probe which must
be inserted into the most negative vented battery cell. The probe must touch the
electrolyte only when the level is equal to or above the "Min Level" indicated on the cell
container.
39
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3.5 Commissioning And Start Up The System
Initial Check With Power ‘OFF’
DO NOT SWITCH ON POWER UNTIL THE NECESSARY INITIAL CHECKS HAVE

BEEN PERFORMED
Refer to the schematic drawings in chapter 5 for the location and numbering of all
components.
Ensure the following before turning on the power:
Check that the charger characteristics (Voltage, Frequency, Power) match those
of the main supply, battery, and load.
Check that the information on the nameplate and test report are correct.
Check that the input transformer tap is suitable for your mains voltage. The
correct supply voltage is marked on the transformer.
Check any foreign objects and loose parts inside the cubicle.
Check that all connections are firmly secured.
Check for correct earthing and cabinet ground continuity.
Check that all fuses and circuit breakers are installed and correctly sized:-
a) AC input circuit breaker is in the OFF position.
b) Battery circuit breaker or battery fuse is in the OFF position.
c) Fan On/Off switch (if installed) is in the OFF position, and
d) All load output breakers and fuses are in the OFF position.
Using an Ohmmeter, check for short-circuit connections from phase-to-neutral.
Use the multimeter to check that the DC voltage for correct value and polarity
at the battery input terminals.
40
____________________________________________________________________________________________________
Initial Check With Power ‘OFF’
ONCE THE CHARGER HAS BEEN INSTALLED AND POWER ON, THE EQUIPMENT WILL
ALWAYS CONTAIN POTENTIALLY LETHAL VOLTAGES. TAKE RELEVANT SAFETY
PRECAUTIONS, AND AS A MINIMUM, FOLLOW THE LOCAL LEGAL AND SAFETY
PROVISIONS.
Start Up The Battery Charger/ Rectifier
Check that the load is ready to be powered up. Switch on the Charger/ Rectifier by
turning the input breaker ‘ON’.
Observe that the voltage shown on the voltmeter shall slowly swing to its float voltage.
Check that the battery polarity is correct. Close battery isolator (circuit breaker or fuses).
Press the “LED Test” button on the front panel and observe that all LED’s are ON.
Observe the battery voltage reading .If the charger output current is equal to the battery
current limit, the battery is recharging. Therefore, the battery voltage reading will be less
than the preset value and will rise slowly as the battery recharges.
Observe the charger current display and load current display. Check that they are within
the limits specified on the nameplate and test report.
Check that the load is ready to be powered up. Switch the load output circuit breaker (or
fuse) to the ON position. This will energize the DC Load.
Let the charger work for approximately 15 minutes with the normal load
connected.
Check that there are no alarms active.

Check the AC ripple voltage at the load terminals is within the specified values.
Inspect the batteries as instructed by the battery manufacturer’s maintenance manual.
41
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Performed Functional Test
During the following functional test, the batteries must be fully charged and operating at the
float voltage level. If you cannot afford to disconnect the DC load while testing the unit, do not
open the load circuit breaker or battery circuit breaker. Otherwise, switch these two circuit
breakers off now, and connect a dummy load to the load terminals. Then switch the two circuit
breakers on again.
Current Limit
After the battery voltage has stabilized, increase the DC load until the charger current reaches
the preset current limit and the battery voltage starts to drop.
If the charger mode is in the “Hi-rate” position, the charger will remain on for 8 hours and will
return to float level after the Hi-rate timer has counted down. To reset the Hi-rate timer,
switch the mode back to the float position.
Hi-rate Charging
With the charger still operating normally, move the charger mode to “Manual Hi-Rate” position.
The current should immediately rise and the voltage should also start to rise. After a while,
depending on the state of charge of the batteries, the voltage will stabilize. To reset the Hi-
rate timer, switch the mode to float position.
NOTE: 1. Certain batteries (e.g. sealed lead acid and some other models) are not intended
to be submitted to Hi-rate charging. In this case the Hi-rate voltage is set to the same level as
the float voltage.
2. Some DC systems are equipped with a load sensing device or interlocks which
will inhibit the Hi-rate voltage. In this case the interlocks must be disconnected to verify the Hi-
rate voltage.
42
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Dropping Diodes Regulator (if fitted, refer to the test report)
Activate the charger into “Manual Hi-Rate “position. When the battery voltage reaches the
maximum load voltage (refer to test report) the bypass contactor in the voltage dropping
network should de-energize. Switch back to the “Float Charge” position and the relay should
energize again when the voltage goes below the preset value (refer to test report). Measure the
battery voltage and the load voltage and compare the values with those in the test report.
Alarm Relays and LED’s
Connecting an ohmmeter across the corresponding alarm terminals. Under normal

circumstances the relay is energized and will de-energize (i.e. release) upon a fault.
High DC Voltage Alarm
If this alarm setting is below the Hi-rate voltage level (refer to test report), it is easy to check the
condition of this alarm circuitry. Simply by activating to the “Manual Hi-Rate”. As the voltage
goes above the alarm value, the high DC voltage alarm output is activated. This alarm level is
specified in the test report.
Charger Fail Alarm
Disconnecting the gate leads to the SCR’s on the Thyristor Bridge can activate this alarm.
Low Battery Voltage Alarm
To bring up this alarm, turn off the charger, and allow the batteries to discharge through the
load. After a while (depending on the size and state of charge of the batteries), the battery
voltage will drop to a point where the low battery voltage alarm will operate. When this occurs
compare the voltage with that in the test report. If the discharge is going to take too long,
disconnect a number of cells on the battery block. The setting for this alarm is specified in the
test report.
43
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Earth Leakage Alarm (if fitted, refer to the test report)
To activate this alarm an Earth leakage wire must be fitted. Check that the earth leakage alarm
LED on the front panel is not ON. If it is, push the RESET button. If the LED is still ON then
there is a fault in the battery circuit. If the LED is OFF, connect an impedance (e.g. 100 W,
240V lamp from the negative of the battery to the chassis) and the LED will come ON.
Remove the lamp and push the RESET button. Now connect the lamp from the battery positive
to the chassis and again the LED will come ON. Push the RESET button after disconnecting
the lamp.
Low Electrolyte Alarm (if fitted, refer to the test report)
To activate this alarm a low electrolyte probe must be fitted. Pull the low electrolyte sensor out
of the most positive cell of the battery (or disconnect it) and the low electrolyte alarm should
turn on.
Chargers Operating in Parallel (refer to the test report)
For dual (parallel) systems, check that the load is being equally shared between the two
chargers at 30% load and at 100% load. Check the response of the chargers when operating
at current limit. Some parallel system are installed with Hi-rate charge interlocks. Verify that
these interlocks work to prevent either charger going into Hi-rate mode (refer to the test report).
44
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3.6 Shut - Down The System
Check that the load is ready to be shut-down.

Switch all load circuit breakers to the OFF position.
NOTE: The DC capacitor bank may take several seconds to discharge.
Switch the AC input circuit breaker to the OFF position.

Using a multimeter, check that there is no voltage at the charger output terminal block.
If it is necessary to complete maintenance on the charger, switch off the battery
circuit breaker.
How To Take The System Out Of Commission
Activate the charger in Hi-Rate position and run the charger for 12 hours to ensure the
battery set is fully charged before taking the charger out of commission.
Open the output load circuit breaker(s) and fuses.
Open the charger AC input circuit breaker .
Open the battery circuit breaker (or battery fuses).
CAUTION !
STRICTLY OBSERVE THE STORAGE REQUIREMENTS (TEMPERATURE, HUMIDITY,

TIME ETC.) DEFINED BY THE BATTERY MANUFACTURER.
DO NOT LEAVE LEAD-ACID BATTERIES OFF-CHARGE FOR MORE THAN ONE

MONTH AS THIS COULD CAUSE IRREPARABLE DAMAGE TO THE BATTERIES
45
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CHAPTER 4
MAINTENANCE
&
TROUBLESHOOTING
46
Maintaining And Troubleshooting
____________________________________________________________________________________________________
To ensure excellent quality of your Battery Charger/ Rectifier, visual examination of the
equipment on a regular basis is essential. We recommend the equipment to be maintenance at
6-month intervals.
This Chapter includes :

Maintain the Charger/ Rectifier
Performing The Battery Maintenance
Basic Troubleshooting
Customer Support
4.1 Maintain The Charger/ Rectifier
The person performing the maintenance should understanding the principles of operation of
the equipment and should be a licensed electrician or be supervised by such a person. For a
routine maintenance agreement please contact AVATEC POWER PTE LTD.
As a general rule, the Charger/ Rectifier must always be maintained as follow :
Check that the air inlets and outlets are not obstructed.
Remove any dust from the internal components, especially the heat sinks and fan (if fitted),
using a brush and a vacuum cleaner fitted with a rubber tip.
If necessary, dry the components with compressed air.
Check for mechanically damaged components, overheated components and signs of
corrosion.
Check electrical connections: Tightness, terminal lugs and connectors in place, and all boards
are firmly secured.
Check for mechanical tightness and that all components are secure.
Check that the cooling fans (if fitted) are clean and run freely.
After three years of continuous service, it is recommended to replace the fans.
47
____________________________________________________________________________________________________
Procedure To Maintenance The Charger/ Rectifier
Battery Charger/ Rectifier Power On Maintenance
The purpose of this operation is to check the battery capacity by discharging it and checking
the measurements against the performance characteristics specified by the battery
manufacturer.
This Maintenance test should be conducted at least once every 12 months.
First of all, evaluate the normal backup time required for the system.
Check that the normal load is connected to the charger and is in service.
Press the “Test” button to test all LED’s.
Connect a millivolt meter across the battery shunt.
Connect a multimeter across the battery.
Turn off the rectifier using the input circuit breaker. Start a stop-watch.
Check that the charger output voltage measured across the load terminals is equal to the rated
voltage + 1% as indicated on the nameplate
When the battery voltage is at 85% of the rated value (Example: 93.5V for a 110V battery) or
at its end voltage, record the following:
a) The millivolt meter reading across the battery shunt, US

b) The discharge time in seconds, T
c) Battery shunt current rating (Amps), IS
d) Battery shunt voltage (mV), UM
Use the following formula to determine the average battery current discharge, ID = (IS x UM)/US
From the discharge current and time, check that the battery capacity still conforms to the
manufacturer’s specifications.
Turn on the rectifier and allow the batteries to charge for at least 10 minutes.
Press the “Reset” button if there are any red alarm LED’s on. If any of these LED’s remain on
after the reset button is pressed, refer to the troubleshooting section in this manual for
assistance.
48
____________________________________________________________________________________________________
4.2 Performing The Battery Maintenance
As a minimum perform the following checks at least once a year :-
Remove all dust from the batteries.

Clean the top of the battery cells, blowing off minerals or metal dust with compressed air.
If compressed air cannot be used, clean with a nylon brush.
Remove any trace of corrosion from the cell connections and the cable terminal lugs.
Isolate the batteries from the load and remove the connecting cables. Measure the
insulation resistance from each pole to Earth (the insulation resistance should be
greater than 15MΩ). If not, inspect for leaks and clean with distilled water.
Reconnect the cables.
Ensure that all inter-cell and inter-tray connections are correct and securely tightened.
Complete any other maintenance procedures recommended by battery manufacturer.
Nickel –Cadmium Battery Maintenance

Refer to the maintenance manual for specific maintenance procedures.
Sealed Gas Recombination / Maintenance Free Lead Acid Batteries

Refer to the maintenance manual for specific maintenance procedures.
Vented Lead-Acid Battery Maintenance

Check the level of electrolyte. If the level is below the "full" mark add
distilled/de-ionized water.
Use the Hydrometer to measure the Specific Gravity (SG) of the electrolyte.
This indicates the charging state of the battery. If the SG is less than 1.240 at
20oC contact the Battery Manufacturer.
The specific gravity must be in the range :-

1.245 + 0.005 At 20oC For Fully Charged Battery
1.140 + 0.005 At 20oC For Discharged Battery
49
____________________________________________________________________________________________________
Temperature corrector for specific gravity:-

Add 0.001 to hydrometer reading for each 1.5oC above 20oC
Subtract 0.001 from hydrometer reading for each 1.5oC below 20oC.
Use a multimeter to measure the voltages of the battery cells. The difference in voltage in
open battery cells must not exceed + 50 mV per cell. If the difference exceeds this value,
contact the battery manufacturer.
4.3 Basic Troubleshooting
CAUTION !
ALL OPERATIONS ON THIS EQUIPMENT MUST BE CARRIED OUT BY QUALIFIED

PERSONNEL, AWARE OF SPECIFIC ELECTRICAL HAZARDS AND PRECAUTIONS TO BE
TAKEN.
ALWAYS MAKE CONNECTIONS WITH THE EQUIPMENT DE-ENERGIZED.
NEVER REPLACE A FUSE WITH A FUSE OF A DIFFERENT RATING OR TYPE
LETHAL VOLTAGES EXIST PERMANENTLY INSIDE THE UPS AND ACROSS THE
BATTERY TERMINALS. NEVER MAKE ASSUMPTIONS AS TO THE PRESENCE OR
ABSENCE OF A VOLTAGE, CHECK USING A VOLTMETER.
A BATTERY MAY RELEASE FLAMMABLE AND EXPLOSIVE GASES. TAKE ALL

RELEVANT SAFETY PRECAUTIONS, AND AS A MINIMUM, FOLLOW THE LOCAL LEGAL
AND SAFETY PROVISIONS
50
____________________________________________________________________________________________________
WARNING !
When using an oscilloscope to measure the charger output voltage, the following precautions
must be taken:
If the oscilloscope is Grounded, use the probe(s) only on the hot side of the
charger output and not the ground lead.
If the oscilloscope is Not Grounded, use both probe leads on the hot and
neutral sides. However, be very careful not to touch the oscilloscope and the
charger cabinet and/or components.
Before replacing any modules, switch the charger completely off. (i.e. AC input
and battery). Wait for at least 2 minutes to let the DC capacitor bank discharge.
This trouble shooting guide covers the causes of disturbance most likely to appear. In our
experience, loose connections are the most common cause of failures.
In cases of malfunction, check the following first :-
Ensure all internal and external connections are securely tightened.

Verify all fuses and/or circuit breakers are operational.
Ensure proper polarity of the DC source. Connections should be positive to
positive negative to negative, and must be securely tightened.
Verify that proper input voltage, output voltage, frequency and load current are
Present as indicated on the nameplate.
If a battery set is part of the system, ensure that all inter-cell and inter-tray
Connections are correct and securely tightened.
If all the above checks are correct, use the following pages to locate the applicable
symptom and perform the corrective action as indicated.
51
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If the cause of a fault cannot be directly determined from the basic troubleshooting guide,
Consult your local NIKSA Customer Support Team for phone numbers.
Customer Support Department

AVATEC POWER PTE LTD
10, Ubi Crescent, #07-79

Singapore 408564
Tel : (65) 6749 1123
Fax : (65) 6841 3345
E-mail : avatec@singnet.com.sg
52
____________________________________________________________________________________________________
Basic Troubleshooting
Symptom Cause Solution
AC & DC Circuit breaker (or Wrong batteries connection Check battery cell to cell is
Fuses) trips, when Charger/ the polarity connection correct
Rectifier is switched ON and ?
battery is connected Fix correct correction ,and
replaced the blown fuse or
turn ON the breakers.
Thyristor Bridge Fail Replaced defective

semiconductors
DC filter capacitors short- Replaced defective capacitors

circuit
No DC output DC output breaker (or Fuse Replaced the blown fuse or

blown) in OFF position turn ON the breakers.
Battery voltage exceed the Normal condition, let the

charger output voltage battery discharge to the
setting setting voltage level as per
test report
Control card fail Replaced the control card
Thyristor Bridge Fail Replaced defective

semiconductors
Wrong output voltage and Load current is exceed the The charger is undersize for
Charger output current in Charger output current the load application. Please
current limit mode contact Customer Support
Department.
Battery cell damage Remedy as required
53
____________________________________________________________________________________________________
TROUBLESHOOTING FLOWCHART
Does the load YES This charger may be undersized for the
current exceed the load. If this state continues contact
rectifier output AVATEC POWER customer service
capacity ?
NO
Check for bad battery cells

and replace as required
Number of battery Consult battery

cells and cell NO brochure and remedy
types OK ? as required
YES
Allow charger to
Charger in Hi-rate raise battery
(Boost) mode ? voltage to
Hi-rate level
NO
Check Free-wheeling
Charger in float Diode and Dropper
voltage mode ? Diodes
(if installed)
NO
NO Check thyristor bridge
Press “LED Test” button. Is the ripple and DC filter for short
All LED’s should go on. voltage less than circuit
Replace if required. 5%
Refer to voltage
adjustment procedure
54
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CHAPTER 5
SCHEMATIC DIAGRAMS
&
MATERIAL LISTS
55
___________________________________________________________________________________________________
CHAPTER 6
FACTORY TEST REPORT
56

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NIKSA

Battery Charger / Rectifier

The User’s Manual contains information about the operations of the

This manual is designed to help you :

• Understanding the basic operational principle .

To ensure trouble-free operation ,this manual should always be read in

The unit must be used as intended. Follow the instructions

The Charger/rectifier must be installed by manufacture’s

If necessary, only original spare parts are allowed.

Dangerous voltage are present inside the unit.

Installation and use of this equipment must comply to all

To prevent overheating, do not obstruct the flow of air for

This equipment must be service and maintenance by

Chapter 1 AN OVERVIEW OF BATTERY CHARGER / RECTIFIER 6

Chapter 2 WORKING WITH ADDITIONAL FEATURES 20

2.1 Alarm and Status Indications For Battery Charger/Rectifier 21

Chapter 3 INSTALLING AND USING THE SYSTEM 29

3.1 Unpack Battery Charger/Rectifier 30

Chapter 4 MAINTENANCE AND TROUBLESHOOTING 46

4.1 Maintain The Charger/Rectifier 47

Chapter 5 SYSTEM SCHEMATIC DIAGRAMS & MATERIALS LISTS 55

Chapter 6 FACTORY TEST REPORT 56

This Charger / Rectifier is designed to supply DC power to sensitive equipment at a onstant

The scope of this manual includes :

Basic elements consists in the Battery Charger / Rectifier

1.2 Basic Elements Consists In Battery Charger / Rectifier

The basic Battery Charger /Rectifier consists of :

Input isolation transformer

1.2.1 Understanding The Basic Operation

1.2.2 AC Power Failure and Restore Operation

1.2.3 DC Output Filter

The standard DC filter is made up of DC inductor and electrolytic capacitor as LC filtering

The control card can be divided into the following segments

Power Supply and Voltage Reference

The Control Board is providing the following adjustments

Three Phase Control Card Schematic Diagram

1.3.1 The Function of The Control Board

Control Board Power Supply

Float & Hi-rate Voltage Adjustment

Float voltage adjustment = P4

A 0.5% accurate voltmeter is required for this procedure.

Current Limit Adjustment

Automatic Charge Control

1.3.2 The Function of The ISO-Driver Card

High DC Voltage Protection

1.4 Battery and Charging Operation

Two charging rate is designed in the system

Both Charge modes are indicated by LED’s on the front panel.

Hi-Rate (Boost) charge--to recharge the battery to 100% capacity

CELL VOLTAGE (V) 120%

Battery Charging Characteristics

1.5 General Technical Specifications

Constant Voltage Regulation

AC Input voltage : 3 phase, 3 or 4 wires

Meters : DC voltmeter, DC ammeter, 1.5% accuracy

Audible Noise : 55 dBA @1.5m

WORKING WITH ADDITIONAL

This Chapter includes :

Alarm and status indication of Battery Charger /Rectifier

2.1 Alarms and Status Indications for Battery Charger /Rectifier

Optional alarms can be included in the Battery Charger /Rectifier as follows :

Indicator Status Meaning

AC fail On AC incoming supply fail