Operating and Maintenance Manual For Charger Unit

8/13/2019 Operating and Maintenance Manual for Charger Unit
CHLORIDE
Constant Potential
Battery Charger Handbook
Operating & Maintenance Manual
Project : Intel A9
Contract No. 20071214-E1”

“JOB NO.: SF2187”
Submitted by
Schneider Electric Overseas Asia Pte Ltd.
http://slidepdf.com/reader/full/operating-and-maintenance-manual-for-charger-unit 1/16
1. Application
The charger assembly, associated with a stationary storage battery, is intended for dc supply to
various types of loads such as :-
* Switchgear Closing Tripping
* Emergency Lighting
* Telecommunications
* Control and Monitoring Systems
* Microwave Links and Radio Installations
* Fire and Security Systems
The use of a storage battery provides the system with an independent operating capability by
supporting the load in the event of mains power failure.
2. General Principles
This standby power system is composed of 2 major sub-assemblies:
The Charger - supplied from the AC mains. It rectifies and controls the float and boost voltages for
the battery.
The Battery - works as an energy tank to feed the load when the mains fails or charger breaks down.
3. Brief Description of Charger
3.1 Rectification - Regulation

* a main transformer to adapt the mains to the battery voltage.
* a half-controlled bridge, consisting of diodes and thyristors, rectifies and regulates the dc
voltage.
* a smoothing circuit, consisting of electrolytic capacitor and choke (optional).
* adiagram
controller board
of the consisting
controller both
board a regulating
is as section
shown in Dwg. No.and an alarm section.A simplified block
9303007.
3.2 Protection
* ac input circuit breaker
* dc output fuse
* freewheel diode which acts as reverse polarity protection
3.3 Control and Signalling
* ac input circuit breaker
* Led indications for monitoring.
* Meters for measuring voltage and current.
4. Introduction :
The Chloride CBC-4 series standby power system charger is built for both lead acid and nickel
cadmium batteries. It offer a high degree of standarisation and reliability incorporating standard
features which include:-
i) Full automatic operation, correctly designed for long battery life and simplified maintenance.
ii) A ‘soft start’ feature which provides sufficient time for the current limit to operate on start up
even under short circuit conditions.
iii) Control cards are interchangeable ensuring continuous availability of spare parts.
The CBC-4 solid state constant potential charger is designed to float and boost charge nickel cadmium
and lead acid (sealed and vented) batteries in nominal voltages of 12, 24, 30, 48 and 110 volts.
1
5. General Specifications :
Input : Voltage - See test report.
Frequency - See test report.
Power Factor - Approximately 0.6 - 0.8.
Efficiency - Typically 70% - 80% at full load.
Output : Voltage - Nominal 12, 24, 30, 48 and 110 volts, which are determined
by control card programme module.
Voltage Stability - Better than +0.5% of voltage setting for simultaneous
excursion of +5% to -10% mains supply voltage.
Voltage Range - Float and boost voltages may be adjusted within any nominal
voltage range by individual potentiometers on the control card.
Output Voltage Adjustment Range
Nominal Float Boost
Voltage Voltage Voltage
12V 11.8 - 18.7 14.2 - 18.7
24V 20.5 - 36.2 25.9 - 36.2

30V 24.1 - 43.4 30.8 - 43.4
48V 46.8 - 88.8 61.4 - 88.8
110V 75.2 - 145.4 99.7 - 145.4
Float-Boost
Selection - Automatic Boost indicated by red LED indicator.
Current - See test report.
Current Stability - Output current held at preset level of +/-1% for simultaneous
changes in mains input voltage of +5% too -10% and load
variations from 0% to 100%.
Current Range - Adjustable from zero to 125% of full load current by
potentiometer on control card.
Smoothing - Ripple voltage better than 5% rms to average at full load
without battery.
Ambient Rating - Continuous full load operation up to 45 deg C ambient
temperature.
Soft Start - A fast resetting soft start feature minimizes in inrush current
surge both in turn-on and during intermittent mains
interruptions.
Standard Function
Indicators - A.C. On
Boost
Low Electrolyte
High Volts
Low Volts
Earth Fault
Charge Fail
Float
Mains Fail
Summary Alarm relay contacts and rating -1 changeover set rated D.C. 100V, 1
amp. 30 watt resistive; AC 240V,1A.
2
6. Installation :
6.1 Positioning -
After the cabinet has been unpacked it should be inspected for damage in transit. Take note of
cabinet paint condition, the voltmeter and ammeter faces, and internal connections, making
sure that all leads and components are intact.
The unit should be installed in a clean, well ventilated room, meeting the climatic requirements
of the specifications.
It must not be near a source of heat.
The ventilating louvers should not be obstructed and should have a side clearance of
approximately 300mm from walls or other obstructions to allow normal air flow.
The cabinet can be attached to the floor, which must be flat, so as not to stress the framework
(the cubicle must be levelled).
6.2 Connections -
6.2.1 External Protection :
The charger supply connections must be connected to the mains through an external
protection device such as circuit breaker or isolator.
6.2.2 Preliminary Precautions:
Ensure all protection devices are in off position.
6.2.3 Connection:
Connect the mains to the charger AC input terminals. Ensure the earth connection is
securely made.
Note : Input and Output voltages used in this system are HAZARDOUS. Do not use uninsulated tools
or touch uninsulated wires or terminals.
Battery is high current source, accidental short circuit can cause severe arcing, equipment
damage, battery explosion and personal injury.
Ensure that the correct number of cells are interconnected and that the polarity is observed. A
reverse polarity connection could damage the charger.
Battery - The battery positive lead should be connected to terminal B+ and the
negative lead to terminal B-.
Load - When single pole load distribution circuit breakers are fitted the positive
load connection should be made directly to the appropriate circuit breakers
and the negative load connection to the negative terminal provided. When
double pole distribution circuit breakers are fitted, the load connections
should be made directly to the circuit breakers. If no distribution circuit
breakers are fitted, the load connections should be made directly to the
load terminal studs. It is important the leads from the charger to the load
be of adequate cross section in order minimize the voltage drop in the line.
All circuit breakers are fitted with auxilliary contacts to provide a common
alarm in case of any circuit breaker trips.
Electrolyte
Sensing Probe - Remove the jumper wire located at the “Low E’lyte” terminal and connect
the ‘Low E’lyte sensing’circuit cable to the brown wire (wire 41) terminal.
The probe must be located in the most positive cell applicable to Nickel
Cadmium batteries.
NOTE:
The C.B.C. charger is designed for use on an unearthed battery system and is fitted with an earth fault detector, w
will operate on leakage currents from either positive or negative battery pole to earth of greater than 5m.a. Donot e
the battery.
If one side ofthe

disconnecting theconnection
battery must be earthed
between thethe
pin 33 of Earth Fault
control alarm
socket andcircuit cannot
the chassis be connection.
earth used and can be inhibited
3
7. Operating Instruction / Commissioning Procedure
7.1 Normal Operation (AC healthy)
1. Prior to connecting the battery as per section 6.2, the voltmeter indicated battery
2. voltage.
Charge-fail and low volts alarm indicator will only illuminate when the battery voltage
fall below its preset level .
3. Check for fault condition if exists.
4. Switch on the charger input circuit breaker and check that the A/C and boost indicators
illuminate.
5. Within a few seconds, the charger ammeter will show an increasing current under the
control of the soft start and rises to the full load current rating of the charger.
6. Close observation will show an increase in the battery voltage. The rate at which the
voltage rises is dependent upon the state of charge of the battery. The battery charging
current will start to fall as the battery voltage rises.
7. The charge fail and low volt alarm indicators are automatically reset when the battery
voltage rises above its preset level.
8. The charger is charging the battery at maximum rate.
9. For fully charged battery, the voltage will rise towards the boost voltage setting within
a short period. If this occurs, the charger will automatically revert to the float voltage
mode after a predetermined time.
10. If the battery is in a discharged or partially discharged state, the voltage will gradually
increase and the preset boost charge timer will continue the boost charge for the preset
time after the voltage rises to 90% of the preset boost voltage settings.
11. At the end of the boost charge period the charger will revert to float voltage mode.
12. When the charger is operating in the float mode, the boost indicator is extinguished.
13. Provided that the charger performs in accordance with the above, the load may be
14. connected as detailed

Load voltage in section
are maintained 6.2 and
within 110Vthe+16%/-10%
remainder of
viathe
theinstallation tested.
diode network.
7.2 AC Mains Fail
On Mains Fail, batteries will feed the load. Upon battery voltage being drops to their preset
voltage level settings of VS1; the respective diodes will be bypassed to maintain the output
voltage to 110V +16%/-10%.
4
9.2 Regulator Circuit

The regulator circuit comprises a voltage regulating IC, and two current regulating IC's whose
purpose is to override the voltage regulator in the event of excessive load being connected to
the output of the charger. The excessive load will cause the charger output voltage to fall
(back off).
The main CURRENT regulator is utilised as standard in all CBC-4 chargers whereas
BATTERY CURRENT LIMIT (BCL) is used in only certain charging applications eg. small
battery with large standing load.
In chargers not utilising BATTERY CURRENT LIMIT, the BCL setting potentiometer should
be wound fully clockwise, prior to setting the CURRENT potentiometer.
The voltage and current amplifier outputs are compared; and the one having the highest output
voltage will be in control of the firing circuit and hence the charger output.
Output voltage is set via the FLOAT and BOOST potentiometers which vary the feedback
signal level. Switching from one charging mode to the other is achieved as outline in the
BOOST CHARGE CIRCUIT.
Setting the CURRENT potentiometer positions the slider such that with rated output current
flowing the current amplifier is on the verge of dictating control over the firing circuit ( and
hence the output voltage.
9.3 Boost Charge Circuit
The two output voltage levels (i.e. float and boost) is controlled by the transistor. The
transistor is turned on, the FLOAT potentiometer is bypassed and the BOOST potentiometer is
in circuit. If the transistor is ‘off’ the FLOAT potentiometer is in circuit.
NB As these two potentiometers are in series, there is interaction between them. The BOOST
potentiometer must be set first, followed by the FLOAT potentiometer, whose range of control
has a maximum value equal to the actual BOOST potentiometer setting.
The standard CBC-4 mode of operation is for automatic initiation of a boost cycle with
automatic return to float at the end of the cycle.
Boost charge is initiated by any of the following :-
(i) Initial switching on the charger.
(ii) Restoration of mains to the charger after an outage.
(iii) Battery falling below approximately 90% of the float voltage setting - due, for example, to
application of a load in excess of the charger output rating.
Boost cycle will terminate in accordance with the following:

i) With only ‘long time’ switched in (i.e. only DIP Switch 3 or 4 closed)
Boost will terminate a preset number of hours after the battery voltage reaches 90% of the
Boost potentiometer setting.
ii) With ‘long time’ and ‘short time’ switched in (i.e. DIP Switch 3 or 4, plus Switch 5)
Boost will terminate approximately 40 minutes after initiation, if battery voltage has
reached 90% of the set BOOST level.
If battery voltage has not reached this 90% level at the end of 40 minutes, the boost mode
will continue.
end of When
this time the the
interval 90% level is
system reached,
will thefloat
return to ‘long time’ cycle will be initiated. At the
mode.
6
Boost Timer Options
DIP SW HOURS
1 1
2 2
3 4
4 8
5 * 40 mins
Test Points
TP1, TP2, TP3 - Test points to enable various operations to be checked. Shorting TP1 & TP2
forces charger from BOOST to FLOAT.
Shorting TP2 & TP3 forces charger from FLOAT to BOOST.
TP4, TP5 - Test points which when shorted speed up the clock pulse generator enabling
the timed circuit to cycle in seconds.
Charge Mode Options

The description above apply where the charger is placed in auto mode. There are two other
options; namely -
i) Boost Inhibited Charger
Where only single voltage charging is required - usually at the battery manufacturers
recommended FLOAT voltage level, controller pins 18, 21 & 22 are bridged permanently on
the edge connector.
This forces the charger to be permanently in float position.
ii) Manual Boost Initiation
A NO spring return switch is connected between controller pins 18 & 20.
Momentary closure of this switch forces the charger to go into boost charge state.
A timed BOOST cycle will follow in accordance with timer switch settings and time taken
for battery to reach the 90% setpoint - as detailed above.
At the end of this cycle, normal auto-boost charger operation is resumed.
9.4 Alarms
The alarm relay “AR” is driven by each of the following alarms:
High Volts
Low Volts
Charge Fail
Earth Fault
Low Electrolyte
Two sets of voltage free changeover contacts are brought out at pins 35 - 40, the relay being
energised in the event of an alarm i.e. the contacts change state in the event of an alarm.
In latching
switch alarm between
connected / manualpins
reset42units,
& 43. reset is achieved
Closing via awill
this switch normally opened
reset the alarmpushbutton
when the
charger is operating mode.
7
a) High Volts Alarm

The battery feedback voltage is compared with a portion of the reference voltage.
When battery voltage exceeds the set point voltage, the output of the high volts IC will go
high, lighting the HIGH VOLTS LED and energises the alarm relay.
The alarm is automatic resetting upon reduction of battery voltage to below the set point,
but can be converted to latching/manual reset by bridging link J5.
b) Low Volts Alarm

The battery feedback voltage is compared with a portion of the reference voltage. When the
battery voltage falls to the set point voltage, the output of the low volts IC will go high,
lighing the LOW VOLTS LED and energises the alarm relay.
The alarm is automatic resetting upon battery voltage rising to above the set point, but can
be converted to latching/manual reset by bridging link J6.
c) Charge Fail Alarm

The battery feedback voltage is compared with a portion of the reference voltage. When the
battery voltage falls to the set point voltage, the output of the charge fail IC to go high,
lighting the CHARGE FAIL LED & energises the alarm relay.
d) Earth Fault Alarm

No leakage from either battery pole the input to the comparator will remain low, the output
will be low and the earth fault led is inhibited.
Earth leakage currents from either pole to ground will result in an imbalance and the output
of the comparator will go high, illuminating the EARTH FAULT LED & energises the
alarm relay.
The alarm is automatic resetting upon removal of a fault, but can be made latching/manual
reset by bridging link J8.
e) Low Electrolyte Alarm

NB Electolyte level detection is not applicable to Sealed Lead Acid Batteries.
This alarm is for use in conjunction with a suitable conducting probe fitted into the
electrolyte of the MOST POSITIVE CELL only, of the battery. The probe will provide a
signal until such time as the electrolyte level drops and the probe fails to make contact;
LOW ELECTROLYTE LED illuminating and the alarm relay energises.
The circuit is automatic resetting upon rectification of the problem. It does not have a
latching facility as per the other alarms, as the nature of the feature is such that it requires
manual correcting once a problem has occurred.
For charger not requiring this alarm, edge connector pin 41 is permanently connected to
charger ‘positive’; forcing the circuit into a ‘healthy’ state.
8
Alarm Voltage Settings

Low Voltage Alarm
(1) Turn the selector switch to float position or momentarily short TP1 and TP2 on CBC-4
Controller Card.
(2) Float ‘LED’ should illuminate.
(3) Adjust the 'Low V' potentiometer fully anti-clockwise.
(4) Adjust the float potentiometer on the charger control card to the low volts alarm level.
(5) Slowly adjust the 'Low V' potentiometer clockwise until the 'LOW VOLT' LED just
start to illuminate.
Charge-fail Alarm
(1) Adjust the 'CHG FAIL' potentiometer fully anti-clockwise.

(2) Adjust the float potentiometer on the charger control card to the charge fail alarm
level.
(3) Slowly adjust the 'CHG FAIL' potentiometer clockwise until the 'CHG FAIL' LED just
start to illuminate.
High Volt Alarm
(1) Turn the selector switch to boost position or momentarily short TP2 and TP3 on CBC-
4 Controller Card.
(2) Boost 'LED' should illuminate.
(3) Adjust the 'HIGH V' potentiometer fully clockwise.
(4) Adjust the boost potentiometer on the charger control card to the high volts alarm
level.
(5) Slowly adjust the 'HIGH V' potentiometer in anti-clockwise until the 'High Volt' LED
just start to illuminate.
Earth Fault Alarm
Adjust the 'EF Sen' potentiometer to mid range. The earth fault alarm is activated when either
the positive or negative rail is shorted directly to earth or greater than 5mA.
NOTE:
The following potentiometer are optional and are not applicable to this system.
a. HI V CUT
b. LO V CUT
c. BCL
d. THRESH
11. Voltage Detection Module Adjustment
11.1 Voltage Sensing Module (VS1)
(1) Momentarily short TP1 and TP2 to force the charger to float mode.
(2) Adjust VR1 potentiometers on the voltage detection modules fully anticlockwise. The LED on
voltage detection modules are inhibited.
(3) Adjust the float potentiometer on the CBC-4 Controller to their respective voltage settings.
(4) Slowly adjust the VR1 potentiometer on the voltage detection module until the LED on the
modules just illuminate.

10
12. Maintenance:
12.1 General
As solid-state and integrated circuitry is used, maintenance is reduced to a minimum. To
obviate
kept in delays
stock. in repairs
When shouldita isfault
ordering occur,that
essential it isthe
recommended that a spare
full specifications showncontrol card1 be
on Page be
provided so that all adjustments can be effected in our factory prior to despatch.
12.2 Precautions
The CBC-4 series charger will only function correctly if connected to a battery or a simulated
battery made up of a large capacitance and a parallel load resistance.
A load resistor drawing about 1 amp at the nominal voltage of the unit would be suitable.
12.3 Fault Finding
The following table is a list of possible fault conditions observed when the charger is
connected to a battery and with any other load disconnected.
SYMPTOM POSSIBLE FAULT ACTION

Full load output No fault. The battery is discharged No action required.
current. and charger is functioning
correctly.
Less than full load (a) Power circuit faulty. Check :-
output current. (a) Mains circuit breaker.
(b) Transformer secondary.
voltage.(Approx. double nominal
D.C. output voltage.)
LOW Fault indicator on (c) Control card supply voltage at
pins 14 & 15 of connector plug
BATTERY (42 V.A.C).
(d) For broken connections.
VOLTAGE particularly those to control card
connector.
(b) Control card out of (e) Perform the adjustment
adjustment. procedures in section 10.
(c) Control card faulty. (f) Replace control card.
Fit correct voltage programme
module.
Perform adjustment procedure in
section 10.
(d) Faulty thyristor bridge. (g) If current still zero replace
thyristor bridge.

11
SYMPTOM POSSIBLE FAULT ACTION

Output current over full Faulty thyristor bridge. Remove control card.
scale. If no change in output current replace
thyristor bridge. If current is zero, control
Fault indicator on card is out of adjustment or faulty. Loss
of current feedback signal, check ammeter
HIGH to control card.
Current at or below full (a) Control card out of Perform the adjustment procedure in
BATTERY load output level. adjustment. section 10.
Fault indicator on (b) Control card faulty. Replace card. Fit correct voltage
VOLTAGE programme module. Perform adjustment
procedure in section 10.
(c) Sensing leads open If above checks do not eliminate fault, test
circuited. continuity of sensing leads from pins 16,
17 and 44 of control card connector.
Fault indicator on Cell electrolyte level low. Top up cells with distilled water.
LOW Charge-fail indicator Electrolyte level probe not Reposition probe and check connections.
on. correctly positioned in
ELECTRO- appropriate cell. Connecting
LYTE cable disconnected.
ALARM
Fault indicator on Earth leak connection to either Disconnect load to determine if earth fault
EARTH D.C. line, either inside charger is internal or external. Do not use a
or on external load or cabling. megger to test charger for earth faults.
FAULT Check visually or use an ohmmeter.
ALARM
Fault indicator on Loss of A.C. supply. Check breaker.

circuit A.C. supply to charger and input
CHARGE- Charger output fuse blown. Replace fuse cartridge.
Faulty thyristor bridge. Replace thyristor bridge.
FAIL Control card out of adjustment. Perform adjustment procedures in section
10.
ALARM Control card faulty. Replace card. Perform adjustment
procedure in section 10.
Broken connections. Check connections and correct.
Fault indication cannot Control card faulty. Replace control card.
be canceled or fault
located.
13. Spart Parts:-
To order spare parts it is necessary to nominate the item and the serial no. of the charger on which the
part is to be used and addressed to :
SERVICE DEPARTMENT
Chloride Batteries S.E.Asia Pte Limited
106 Neythal Road, Jurong
Singapore 628594
Tel : 6265-2444
Fax : 6265-1478 / 6266-0619

12

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8/13/2019 Operating and Maintenance Manual for Charger Unit

Operating & Maintenance Manual

Contract No. 20071214-E1”

This standby power system is composed of 2 major sub-assemblies:

3. Brief Description of Charger

3.1 Rectification - Regulation

24V 20.5 - 36.2 25.9 - 36.2

If one side ofthe

7. Operating Instruction / Commissioning Procedure

7.1 Normal Operation (AC healthy)

14. connected as detailed

7.2 AC Mains Fail

9.2 Regulator Circuit

9.3 Boost Charge Circuit

Boost cycle will terminate in accordance with the following:

Boost Timer Options

Charge Mode Options

i) Boost Inhibited Charger

ii) Manual Boost Initiation

A NO spring return switch is connected between controller pins 18 & 20.

At the end of this cycle, normal auto-boost charger operation is resumed.

The alarm relay “AR” is driven by each of the following alarms:

a) High Volts Alarm

b) Low Volts Alarm

c) Charge Fail Alarm

d) Earth Fault Alarm

e) Low Electrolyte Alarm

Alarm Voltage Settings

(1) Adjust the 'CHG FAIL' potentiometer fully anti-clockwise.

Earth Fault Alarm

11. Voltage Detection Module Adjustment

11.1 Voltage Sensing Module (VS1)

As solid-state and integrated circuitry is used, maintenance is reduced to a minimum. To

12.3 Fault Finding

SYMPTOM POSSIBLE FAULT ACTION

SYMPTOM POSSIBLE FAULT ACTION

Fault indicator on Loss of A.C. supply. Check breaker.

13. Spart Parts:-

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