PB Design Charger

It contains

 Isolation Transformer
 Controlled Bridge Rectifier
 Capacitor filter smoothing
 Thyristor Charger Controller
 Common Distribution Board
o Controller Interlocked input contactors
o Control Section
o Busbar Voltage Monitoring
o Outgoing MCB Distribution – 2 Bus Bars with a bus coupler

MCB1 – Door Interlock Circuit Breaker

MCB2 – Charger Output Circuit Breaker

F5, F6 – Load Fuse in charger

PCB9 – ROM Board – All LEDs shall be illuminated

Procedure for following at initiation of Charger:

Boost Charging
There is a manual push button for setting boost charging. This is inside the front panel board. The boost
operation will be continued for pre-defined time interval until timer is expired. To stop the boost charging,
press and hold reset button for more than 10s.

Boost Charging Time is set on Multi Alarm Unit module.

All alarm conditions are self cancelling when the alarm condition is cleared. But for High Voltage case,
alarm shall be reset manually.

Distribution Cubical Operation :

Basic Construction

System has a Isolation Transformer then to a Thyristor Bidge. Thyristors are controlled by adjusting their
phase angle conduction from 1 phase compact controller. Output chokes and capacitors are there to
provide necessary smoothed output.

Supply to Charge controller is via TR2 providing 15V AC supply. Switch mode power supply is use to
convert 5V and 24V voltages required for other controlling.

Current limit measurements are taken from the shunt SH1 also used for ammeter.

Lamp Test will only work in manual mode and once entered to the manual mode, operation indicators
will light up. When manual key switch to position 1, system healthy and Lamp test Buttons will light up.
In auto mode, in normal operation bus coupler will be closed.

Details of PCBs:

Inside Charger:

 PCB1 – 95MB Mother Board

 PCB2 – 1 phase compact controller – Generate phase angle for thyristor operation. Power
supply is derived from 15V AC. This rectified and one section fed into a 12V regulator for logic
supply, the other section fed to the Output Drive. Green LED indicates the healthy 12V supply
Voltage settings for float voltage and boost voltages are set here.
Float Voltage – R19 Potentiometer
Boost Voltage – R20 Potentiometer

Current Controlling also done through a Balance Whestone Bridge in here. Current control is the
balanced adjustment of this bridge.
Current Limit 1 – R6 Potentiometer
Current Limit 2 – R14 Potentiometer
 PCB3 – Multiple Alarm Unit – Monitor all other alarms and provide timing functions for delayed
alarm initiation. This has 5V and 24V supply requirement. D45 Green LED indicates that 24V
supply is healthy and D44 Green LED indicates 5V supply is healthy.
If JP10 is not linked, boost charging cannot be done. Boost Time is set on JP 7. Default value in
2hours.
This units provide below alarm conditions.
o Mains Fail
o Charger Fail
o High Volts – Triggering Threshold can be adjusted by potentiometer R27
o Low Volts – Triggering Threshold can be adjusted by potentiometer R28
o This facilitate 5 other additional alarm conditions
 PCB4 – Switch Mode Power Supply – 30W – should be for control operation. Creates 5V and 24V
supply. A green LED D7 is on when the power supply is operating
 PCB5 – Front Panel Board
 PCB6 – Charger Output Digital Meter
 PCB7A + PBC7B – Controlled Bridge Rectifier
 PCB8 – Earth Fault Alarm – Monitors earth leakage and feeds any alarm signal in to mother
board / alarm board via the Aux 3 and Aux 4 inputs
 PCB9 – Relay Output Module – provides volts free contacts for external indication and is fed
directly from the Mother Board / Alarm Board
Module has 8 channels, each channel has an input line, an output relay with LED indicator, a
delay enabled link and a software timer which operates in minutes. Depend on the state of
input line, output line state will be changed. Output line can be programmed to be active or
inactive or active after a specific time.
 PCB10 – AC and DC Filter Card

Inside Distribution Control

 PCB301 – Control Module

  PCB302 – 8 x Input / Output
 PCB303 – 8 x Input / Output
 PCB304 – Voltage Monitor
 PCB305 – Voltage Monitor
 PCB306 – Voltage Monitor
 PCB307 – Voltage Monitor
 PCB308 – Aux Diode
 PCB309 – Aux Diode
 PCB310 – Isolated Power Supply

Operation of Charger:
Operation of Distribution Cubical:
Basic Connections:

Charger Connections

Distribution Cubical Connections:

Connections between Charger and Distribution Cubical:

Physical Arrangement in Charger:

Physical Arrangement of Distribution Cubical: