INSTALLATION & OPERATION MANUAL

110V/60A BATTERY CHARGER

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1.1 IMPORTANT SAFETY INSTRUCTIONS FOR INSTALLER AND OPERATOR

1. Save these instructions.

2. Do not expose charger to rain or snow.
3. Only trained and qualified personnel may install and service this unit.
4. Do not operate charger if it has received a sharp blow, been dropped, or otherwise damaged
in any way; shut off power at the branch circuit protectors and have the unit serviced or
replaced by qualified personnel.
5. To reduce risk of electric shock, disconnect the branch circuit feeding the charger before
attempting any maintenance or cleaning. Turning off controls will not reduce this risk.
6. Working in the vicinity of a lead-acid or nickel-cadmium battery is dangerous. Storage
batteries generate explosive gases during normal battery operation. For this reason, it is of
utmost importance that each time before using your charger, you read this manual and
follow the instructions exactly.
7. To reduce the risk battery explosion, follow these instructions and those published by the
battery manufacturer and the manufacturer of any equipment you intend to use in the
vicinity of a battery. Review cautionary markings on these products and on the engine.

1.2 PERSONAL PRECAUTIONS

A. Someone should be within range of your voice or close enough to come to your aid when
you work near a storage battery.
B. Have plenty of fresh water and soap nearby in case battery electrolyte contacts skin,
clothing, or eyes.
C. Wear complete eye protection and clothing protection. Avoid touching eyes while working
near a storage battery.
D. If battery electrolyte contacts skin or clothing, wash immediately with soap and water. If
electrolyte enters eye, immediately flood the eye with running cold water for at least 10
minutes and get medical attention immediately.
E. NEVER smoke or allow a spark or flame in vicinity of battery or engine.
F. Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or short
circuit battery or other electrical part that may cause explosion. Using insulated tools
reduces this risk, but will not eliminate it.
G. Remove personal metal items such as rings, bracelets, necklaces, and watches when working
with a storage battery. A storage battery can produce a short circuit current high enough to
weld a ring or the like to metal, causing a severe burn.
H. Use this charger for charging LEAD-ACID or LIQUID ELECTROLYTE NICKEL-CADMIUM
batteries only. Do not use this battery charger for charging dry cells, alkaline, lithium, nickel-
metal-hydride, or sealed nickel-cadmium batteries that are commonly used with home
appliances. These batteries may burst and cause injuries to persons and damage to property.
I. NEVER charge a frozen battery

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 2.1 Do’s & Don’ts FOR BATTERY CHARGER

2.1.1 Do’s :

1 Always keep the Input Switch in off position while starting the battery charger

2 Operate auto / manual selector only after switching off the battery charger

3 Always keep manual mode potentiometer of current control in Max mode

4 When charger is switch on to boost mode for battery charging, ensure normal voltage at load
side and higher boost voltage at battery side check with voltmeter

5 Always keep charger in float mode for to supply the load to the battery when the battery is fully
charged

6 If auto mode is fail, switching off the battery charger. Kept auto / manual selector switch
(sw-“1”) at its manual position & ensure that manual mode potentiometer is in mid-range
position then switch on the charger, keep close supervision to maintain dc output voltage
constant along with variations in load current.

7 Keep charger clean every forth night, while cleaning switching off the ac supply.

8 Carry out preventive maintenance of the equipment after every six months. (check with manual)

9 Refer instruction manual for operation of the equipment.

2.1.2 Don’ts:

1 Never operate auto / manual selector switch without switching off the charger.

2 Don’t leave ‘manual start from minimum value or Maximum value

3 Don’t disturb presets provided in various electronics cards.

4 Don’t allow any metal objects to remain inside the charger.

Don’t expose equipment to any chemical / water.

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6 Don’t interconnect the charger to any other dc source equipment without consultation with
manufacture.

7 Don’t use the equipment to charge the batteries other than specified make & rating.

8 Don’ts use the components of other specifications than specified by the manufacturer in case of
replacement.

9 Never use water to cease the fire in the equipment.

3.2 GENERAL SPECIFICATIONS

3.2.1 INPUT VOLTAGE

(a) AC INPUT VOLTAGE:

Standard feature: 415V Single phase - 3 wire system

Permissible Variation: ±10 %

(b) AC INPUT FREQUENCY:

Standard feature: 50 Hz
Permissible Variation: ± 05 %

3.2.2 OUTPUT VOLTAGE:

(a) DC OUTPUT VOLTAGE:

Standard Feature: 110V DC, 60A

Permissible Variation: ±10%
(b) OUTPUT DC CURRENT:
Total current capacity:
Current :60A
FLOAT MODE:
Current limiting : 5A
TRICKLE MODE:
Current limit: 500mA

3.2.4 OUTPUT VOLTAGE REGULATION:

Regulation : ≥10%
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(a) STEADY STATE VOLTAGE REGULATION

Standard feature:
For higher voltage systems, namely, 110V systems, the steady state voltage
regulation of ± 10% (of operational voltage) is offered for ± 10% input voltage variation and
0 – 100% load variation both occurring simultaneously.
3.2.5 RIPPLE VOLTAGE:
Standard feature:
The ripple voltage is about 1% of the output voltage is offered as standard feature.
Ripple: ≤1%
3.2.7 METERING:
Standard feature:
The input AC voltmeter, DC voltmeter, Boost ammeter, load ammeter and trickle/float
ammeter are provided as a standard feature.
The type, size & accuracy class of meters are decided based on charger capacity, application,
system requirements & user’s specifications.
3.2.8 INDICATIONS AND ALARMS:
Following indications and alarms are provided as standard features:
Indications:
1. Under voltage
2. Over voltage
3. Earth fault +
4. Earth fault -
5. AC on
6. AC fail
7. Fuse fail

Alarm:
1. Under voltage
2. over voltage
3. Earth fault +
4. Earth fault –

3.2.9 OPERATION TEMPERATURE RANGE:

Standard feature:
The chargers are designed for + 10º C to 45º C as the standard feature.
For higher temperatures output current must be derated.
For +50 º C - derated 10%
For +55 º C - derated 18%

3.2.10 ALTITUDE:

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 Less than 1000 m over MSL 100% current.

2000 m over MSL 94% current.

3000 m over MSL 88% current.
4000 m over MSL 82% current.

3.2.11 PANEL:

Standard feature:

Protection grade of IP 20 is offered as standard feature.

Color shade of 631 light grey, as per IS: 5 is provided inside and outside with synthetic enamel
paint as standard feature.

3.2.12 MAGNETICS:

Standard feature:

Average winding temperature rise over ambient : 55 º C

Minimum insulation class : Class A
Insulation voltage breakdown : 2000V/min.

3.2.13 WIRING:

Insulation: 600V grade, PVC insulation is used. The wire sizes are decided based on design
calculation for current in respective circuits.

4.1 INTRODCTION

The Voltech battery charger is designed to supply a constant voltage for any load within its
rating. The battery charger is provided with a main transformer and buck & boost transformer
and for smooth variation a single phase variac is provide in the primary side
Diode –Diode module are employed and operated to obtain constant voltage. A full wave
bridge rectifiers are provides for rectification.

8.1.1 THREE PHASE RECTIFIER CIRCUIT:

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When the charger is connected to appropriate AC voltage source, voltage is connected to the
primary of the main transformer through the input switch. The transformer steps the voltage down
as required for the specific DC output voltage and isolates the commercial AC line for the battery
circuit. The transformers secondary is connected to the full wave bridge rectifier assembly.

The bridge is the heart of the power circuit. This assembly is a standard single phase full wave
bridge. The voltage control is accomplished by providing a variac in the primary side of the
transformer.

The bridge rectifier provides a DC voltage at its output.

The standard modules of series chargers have an inductance in the output circuit to bring down the
ripple voltage to 2% when the battery is connected to the charger.

8.2 CONTROL UNIT:

The battery charger consist of an annunciation card

The control rack consists
(i) AM card
The annunciation card is used for sensing fault occurrence in the circuit. The same is
identified by a led indication and buzzer.

8.2.1 BATTERY CURRENT LIMIT CONTROL:

It provide max limit for the battery charging current delivered by the rectifier. The current
limits are independently adjusted by the resistor R2 and R3 for float and trickle charging

8.2.3 CHANGE OVER FROM FLOAT TO TRICKLE AND VIES – VERSA:

FLOAT MODE:

The charger can be set in float mode using the rotary switch given in the front panel by switching
the rotary switch to position 2 and then by using the toggle switch(toggle switch should be in float
position) the charger can be set in float and the maximum current would be 5A

*Note: The rotary switch should not be set in position 1 when the charger is in the float mode

TRICKLE MODE:

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The charger can be set in float mode using the rotary switch given in the front panel by switching
the rotary switch to position 2 and then by using the toggle switch(toggle switch should be in trickle
position) the charger can be set in trickle mode and the maximum current would be 500mA

8.2.4 BOOST CHARGE CONTROL:

This feature is activated when the charger is set in boost mode, the charger can be set in
boost mode by using a rotary switch given in the front panel by switching the rotary switch to
position 1 the charger can be set in the boost mode. This mode enables the user to charge the battery
when it is fully discharge and charging current is indicated by the boost ammeter provided in the
front panel

8.2.5 SMOOTH VOLTAGE VARIATION:

The charger is equipped with a buck boost transformer and a variac to have a smooth
control over the voltage in the output DC side and the smooth variation enable the user to set a
exact voltage needed

8.3 ALARMS AND INDICATION GENERATED BY THE CARD:

INDICATION:

 Under voltage
 Over voltage
 Earth fault +
 Earth fault -
 AC on
 AC fail
 Fuse fail

ALARM:

 Under voltage
 Over voltage
 Earth fault +
 Earth fault –

8.3.1 AC ON:

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 When the charger is connected with 230 volt AC supply in the input terminal given, when
the AC I/P rotary switch is set in ON position the AC ON led glow

8.3.2 AC fail

When the input voltage connected to the charger fails the indication stating as AC fail will
glow in the front panel

8.3.3 under voltage

The Under voltage indication glow when the output voltage is below 99V DC

8.3.4 over voltage:

The Over voltage indication glow when the output voltage is above 145 V DC

8.3.5 Earth fault +/ Earth fault -

The Earth fault +/- glow when charge is

*Note: the float indication glow only when the charger is in auto mode

8.3.6 Fuse fail:

The fuse fail indication glow when the AC fuse blow off.

Alarm:

For every fault occurrence the Alarm would be triggered and alarm can be reset with the help of
reset button provided in the front panel
Note: * Reset button provided in the front panel will only break the alarm. Indication would be on
till the fault log is cleared
9.1 INPUT AND OUTPUT SIDE PROTECTION:

Various protections such as rotary switch for input and output, blocker diode, Relay and fuse
are provided for the protection of the charger

9.1.1 Rotary switch

For the protection of the charger there are two rotary switches provided one in the input side
which is a ON OFF switch and other is a DC switch which is 1 pole 2 way switch used to select the
battery in T/F mode or Boost mode

9.1.2 FUSE:
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 For the protection of the various equipment in the charger there are four fuses in the system
one is the input fuse with the specification of 32 Amp, the second is for the protection of diode-
diode module with the specification of 32 Amp, the third in the DC side with the specification of 50
Amp and the last for the protection of trickle/float current with the specification of 6 Amp.

9.1.3 Blocker Diode:

This blocking diode is used to prevent the reverse electrical current from flowing back from a
specified battery bank to the system with the specification of 1200V/50 Amp

9.1.4 Relay

There are two relay provided for the protection of batteries when they are wrongly connected
in the given battery terminal and only when the batteries are properly terminated in correct polarity
the charger will charge the battery.

10.1 INSTALLATION AND OPERATIONAL ROUTINES:

1) Do not install battery charger near heat generating equipment avoid location subjected to
corrosive fumes or extremes of dirt and moistures

2) The charger is cooled by natural convection. Hence sufficient clearances (Min 1mtr) to be
provided wherever the system is installed

3) Check the nominal output voltage of the charger shown on the name plate. It must correspond to
the battery voltage

4) To maintain proper voltage regulation at the battery, cables installed between charger and battery
must be sized to provide minimum voltage drop

5) Assembled battery according to battery layout drawing furnished by the battery manufacturer.
Check that all cells in the battery are installed properly with regards to polarity. Cell terminals are
connected positive to negative

6) Check the AC line for the input voltage, frequency to match the charger specification .The AC
cable must be sized to allow for maximum current capacity as indicated by the rating of the input
fuse

7) De- energizes the AC line and connects the cable to the power charger

8) Check only when the battery is in fully drained state put the charger in boost mode else use it in
float mode or manual mode

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9) In manual mode set the voltage as 110Volt and only if need increase the voltage by adjusting the
external pot else don’t increase the voltage beyond 110 Volts

10.2 INSTALLATION PROCEDURE:

1) Connect the input terminal of the battery charger to the input supply of 230 Volt single phases;
the input terminal is kept outside the charger box with the specification above the terminal.

2) Switch on the input by switching on the rotary switch to ON position

3) After switching on the rotary switch to ON position vary the variac to get the required output
voltage

4) Connect the load to the load terminal provided at the backside of the charger panel with the
notation “+output-“terminal

*Note: Make sure that the load is connected to the load terminal and not to the battery terminal

5) Connect the battery to the battery terminal provided at the backside of the charger panel with the
notation “+ battery terminal-“

*Note: make sure that you connect the battery in a proper way else there won’t be any DC volt in
the battery terminal.

7) To operate in Boost mode put the rotary switch in “1 st “position (DC on switch) and the Boost
ammeter will show you the charging current

*Note: for the safe use you can set the battery charger in float mode when the battery is fully
charged

8) To operate in float mode change the switch to position “2” (DC on switch) and put the toggle
switch in float mode. The maximum charging current in float mode would be 5A

9) To operate in Trickle mode change the rotary witch to position “2” (DC on switch) and put the
toggle switch in trickle mode. The maximum charging current in trickle mode would be 500m

Troubleshooting Steps to be performed:

 If there is voltage in the load terminal and there is no voltage in the battery terminal
1) Check if the battery terminal are properly connected to the positive and negative
terminal of the battery terminal provided at the backside of the panel
2) If the battery terminal are properly connected still you didn’t get the output voltage in
battery terminal check for the Relay provided in the battery charger

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 3) If boost charger is working and if float/trickle charging is not working check the fuse f4
(T/F fuse)
4) Check for the diode BD1
 If there is voltage in the Battery terminal and there is no voltage in load terminal
1. check for the discreet diode BD3

 If there is no voltage in both Load and Battery terminal, provided you have AC supply

1. Check for the fuse F3 (DC output fuse) and F2 (TX fuse).

2. Check for all the diode- diode module

 If AC fails indication glows

1. Check for the input terminal for the AC voltage

2. If the input terminal have a AC voltage check for the input fuse

 If Under voltage indication glows

1. Check for the input under voltage in the output terminal

2. Check if the variac is in minimum position, if it is so vary the input variac and set the DC
voltage above 100V DC

 If Over voltage indication glow

1. Check for the input over voltage in the input terminal

2. Check if the variac is in maximum position, if it is so vary the input variac and set the DC
voltage below 132

*Note: for the above two procedure connect the load and battery then check.

 If Earth fault +(or)- indication glow

Check for any fault in the earthing of the unit.

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