DC 125V Charger / Rectifier System

Model : NRT 125-180(D)

Model : NRT 125-144(D)
Model : NRT 125-108(D)
Model : NRT 125-72(D)
Model : NRT 125-54(D)
DC 125V Charger / Rectifier System

figure 1.1
 DC 125V Charger / Rectifier System

• The dual DC Charger/Rectifier system is connected in parallel with

single battery charging configuration

• Each system employs N+1 configured rectifier modules to increase

the output power to 180A, 144A, 108A, 72A, 54A DC, there by
provides redundancy output

• It delivers a constant DC power to sensitive load which is free from

utility power line disturbances (EMI, noise, fluctuations, momentary
power disruption, etc...)

• It charge the battery at optimum level in different mode in order to

maintain it to its full capacity

• It maintains a continuous and conditioned power to the critical

loads both during utility presence or absence
 DC 125V Charger / Rectifier System

The intelligent microprocessor controlled Charger / Rectifier is

mainly comprises of the following:

• Rectifier Modules
• Central Control and Alarm module
• User Interface Board(UIB)
• Battery
• Power Distribution Unit
 DC 125V Charger / Rectifier System (Rectifier Module)

Rectifier module is the main power unit , which accept AC input from mains,
filters out incoming noise, performs power factor correction (PFC) to achieve
optimum input PF. Then it converts this incoming AC into a steady high voltage
DC. A DC-DC converter converts high DC into required DC voltage level suitable
for load. The delivered DC output is regulated and controlled irrespective of
input voltage disturbances.

Other functions incorporated into the module are as follows :

High/Low Input Voltage Protection:

Above +/-10% of nominal AC input voltage, the rectifier will automatically cut off from power,
and will be power on automatically once the input voltage comes within the input range

High Output Voltage Protection:

Incase of output voltage exceeded voltage high limit, module will shut down automatically
to protect the system as well as the battery bank.
 DC 125V Charger / Rectifier System (Rectifier Module)

Current Limit:
Current limit self-protection is incorporated to prevent overload of the module or short
circuit at the output of the system.

Current share:
Advanced current share circuitry is in- built in each module. This function enable the
rectifier module to share it’s output and current according to load demand.

Shared Communication:
All rectifier responds equally to the main controller through a shared communication cable,
which runs parallel to the main controller.
 DC 125V Charger / Rectifier System (Control Module)

The central control module is the controlling and monitoring center of Charger /
Rectifier system. Its task is to monitor the work of each rectifier module in the
whole system. It collects different information of rectifiers and system to
activate alarm.

It monitor parameters such as

• System mains voltage
• System output voltage
• System output current
• Battery charging and discharging current
• Ambience temperature.

Basic functions :
• Display of system parameters ( For voltages, currents and temperature)
• Display and record of alarm information ( For system and Rectifier)
• Any alarms such as general Alarm, DC low voltage, Rectifier failure, Battery fault, DC
high voltage etc.. can be configured through relay interface
 DC 125V Charger / Rectifier System (Control Module)

Basic functions :

• System ON/OFF
• Remote control by remote communication interface

Battery Management is possible, which include :

• Auto / Manual boost charge
• Periodical boost charge
• Battery current limit
• Battery Discharge test
• LVDS integration

In the control module, there is several volt-free dry contact relay output for
remote alarm. Auxiliary external equipment can be connected to the control
module using the internal relay for specified control function. External interface
such as fuses blown, breaker trip monitoring and others can be done too.
 DC 125V Charger / Rectifier System (Control Module)

SYSTEM OK ü Green LED

234A 54.5V
FL ALARM ! Amber LED

SMR SHUTDOWN û Red LED

Display :
It is a two-line by 16 character alphanumeric display of a back-lit LCD type.
The 5mm high characters normally display output voltage and current as well as
the system status - Float (FL) or Equalise (EQ). This is the default or “home”
screen.
 DC 125V Charger / Rectifier System (Control Module)

Basic LED Indications & Buzzer :

Green LED : ON/OFF Status

OFF : No output current from any SMR
ON : There is output current

Amber LED : Alarm Status

OFF : No alarm
ON : There is alarm

Red LED : Shut Down

OFF : No Shut down
ON : SMR is Shut down

Buzzer
When there is alarm, the buzzer sounds
 DC 125V Charger / Rectifier System (Control Module)

System Menus :
There are 4 menus in the Control panel display, which can be used to modify,
read, and configure the SMR parameters and data. These are :
 Home menu : It contains general system information
 SMR menu : It contains all the parameters relating to the rectifiers
 Battery menu : It contains all the parameters relating to the batteries
 Alarms Log : It contains chronological record of the last 1000 alarms.

If no button has been pressed for two minutes, the display will revert back to the Home
screen.

To move to any menu, corresponding menu button is pressed momentarily.

To scroll through any menu from the first screen to the last, press the INC button and to
scroll from bottom screen to first press the DEC button.
 DC 125V Charger / Rectifier System (Control Module)

System Menus :

Home Menu
a) Ambient temp
b) Security & password
c) Indicators & Display test
d) System type
e) Date and Time
f) Alarm information setting
g) Battery breaker status
h) AC monitoring

SMR Menu
a) SMR Data & Information
b) SMR Parameter Setting
c) SMR Alarm info & Setting
d) SMR Sleep mode
 DC 125V Charger / Rectifier System (Control Module)

Battery Menu
a) Batt Status
b) Batt Parameter
c) Battery Charging Duration
d) Battery cutoff Alarm
e) Battery Protection
f) Battery Test data

Alarm Menu
a) Alarm Status
b) Alarm Log
 DC 125V Charger / Rectifier System (Powering ON)

Powering ON
(DO NOT SWITCH ON POWER UNTIL THE NECESSARY INITIAL CHECKS HAVE BEEN PERFORMED. IT
SHOULD BE HANDLED BY TRAINED & PROFESSIONAL PERSON)

Initial Check With Input Power ‘OFF’

Ensure the following before turning on the power:

• Check and match the technical data mentioned on the nameplate and test report
• Refer Schematic drawing to locate components and understand
• Check and tighten all the components in the system
• Check any foreign objects and loose parts inside the cubicle
• Check that all connections are firmly secured and tight
• Check for correct earth is available and cabinet is grounded
• Check all the fuses are available in fuse holders
• Check AC input circuit breaker is in OFF position
• Check Battery breaker or battery fuse is in OFF position
• Check all load output breakers are in OFF position
• Check Fan On/Off switch (if installed) is in OFF position
 DC 125V Charger / Rectifier System (Powering ON)
Start-Up
(Check that the load is ready to power ON)

• Close the input fuse to switch on the Charger/ Rectifier.

• Switch on each rectifier module input breaker one by one..
• Observe that the voltage shown on the LCD display shows DC VOLT, DC current and
mode of operation as FL(Float)
• Check in multimeter the DC voltage is of correct polarity.
• Repeat the above procedure on other set of Rectifier, if the battery charger is DUAL in
nature.
• Close charger out put fuse (Repeat on other charger also if it is DUAL)
• Check that the current sharing between the units to within +/- 5% to 10% of the average
rectifier current. Clear if any alarm log.
• Observe the LCD display and browse through it using the guidelines given in operation
procedure.
• Check that the battery polarity is correct on battery terminals
• Close battery circuit breaker or fuses.
 DC 125V Charger / Rectifier System (Powering ON)
Start-Up
(Check that the load is ready to power ON)

• Switch the load output circuit breaker 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.
 DC 125V Charger / Rectifier System (Powering OFF)

Shut down
(Check that the load is ready to power OFF)

• Check that the load is ready to be powered OFF.

• Switch the load output circuit breaker to the OFF position. This will isolate the DC Load.
• Open battery circuit breaker or fuses.
• Open charger out put fuse (Repeat on other charger also if it is DUAL)
• Check in multimeter that there is no DC voltage at output or battery terminals.
• Switch off each rectifier module input breaker one by one.
• Observe that no voltage and data shown on the LCD display
• Repeat the above procedure on other set of Rectifier, if the battery charger is DUAL in
nature.
• Open the input fuse to completely switch off the Charger/ Rectifier.
• Using a multimeter check that there is no voltage at the charger output

(Note – DC capacitors inside the rectifier module may take time to discharge fully.
Wait few minutes before maintenance work to start)
 DC 125V Charger / Rectifier System (Maintenance)

Charger / Rectifier Maintenance

NIKSA Charger/Rectifier is a smart power supply system meant for un-man duty
operation. Thus maintenance tasks are reduced.

In general the following normal maintenances are recommended :

• 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 or dust out the components with compressed air
• Check for mechanically damaged components, overheated components and signs of
corrosion
• Check electrical connections, terminal lugs are tight
• Check for mechanical tightness and that all components are secure
• Check that the cooling fans (if fitted) are clean and run freely
 DC 125V Charger / Rectifier System (Maintenance)

Charger/Rectifier Maintenance

NIKSA Charger/Rectifier is a smart power supply system meant for un-man duty
operation. Thus maintenance tasks are reduced.

In general, the following specific maintenances are recommended :

• Checking and adjustment of the system voltage once in half a year

• Checking and recording of battery measurement data once in half a year
• Checking and ensuring environmental condition like temperature, humidity, moisture
once in half year
• Maintaining a system failure record (if any) for future reference, which may be helpful for
service personnel in fault finding.
 DC 125V Charger / Rectifier System (Maintenance)

Battery Maintenance

Basic Safety Requirement

• Use tools with insulated handles

• Wear goggles, rubber gloves, rubber boots, rubber aprons, long sleeved clothing
• Remove metal parts from your body and clothing to avoid contact with battery terminals
• Never adjust connections while battery are charging
• Never disconnect the battery when it is on load or charging
• Never lift a battery by its terminals
• Always keep and move the battery cells in an upright position.
• Keep flames away from battery cells
• Never smoke near the batteries
• Do not place or drop metal objects on the top of the battery cells
 DC 125V Charger / Rectifier System (Maintenance)

Battery Maintenance

Basic Recommendations for Maintenance

• As a minimum perform the following checks at least once a year

• Take voltage measurements of all cell
• Discharge the battery till 30% to 50% of battery capacity and charge it back
• 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, use a clean brush
• Remove any trace of corrosion from the cell connections and the cable terminal lugs
• Ensure that all inter-cell and inter-tray connections are correct and securely tightened
• Complete any other maintenance procedures recommended by battery manufacturer
 DC 125V Charger / Rectifier System (Troubleshooting)

Basic Troubleshooting

This trouble shooting guide covers the likely causes of disturbance may appear.
Normally, loose connections are the most common cause of failures. In the cases of
malfunction, check the following first :

• Ensure all internal and external connections are securely tightened

• Check that the air inlets and outlets are not obstructed and airflow is smooth and free
• Check for mechanically damaged or overheated components and signs of corrosion
• Ensure proper polarity of the DC source
• Verify all fuses and/or circuit breakers are good
• Verify that proper input voltage, output voltage, frequency and load current are present
as indicated on the nameplate
• Ensure that all inter-cell connections are correct and securely tightened
• Remove any dust from the internal components around the module and Controller

Note : Follow the trouble shooting chart provided in next page to identify and perform
the corrective action as indicated to rectify the fault.
 DC 125V Charger / Rectifier System (Troubleshooting)
Abnormal Description & Checkpoint Solution
No AC power to SMR Check AC supply to SMR; if necessary reset
UNIT OFF CB supplying SMR
SMR faulty Replace SMR

Check AC supply and confirm condition; If

AC Fail (SMR alarm) Total AC power failure or AC voltage not
AC is OK replace SMR units if only two
within operating limits
show alarm condition

Ambient Temperature is too high Reduce temperature.

Temperature sensor is faulty Check and replace if necessary

Amb Temp High
Connection to UIB7 is faulty Repair connection

Set point is too low Check Amb Temp High threshold level and
re-adjust if necessary
SMR fault Replace SMR

Volts High Float level set too high on NCU 4000 Check and adjust if necessary

NCU 4000 fault Replace NCU 4000

 DC 125V Charger / Rectifier System (Troubleshooting)
Abnormal Description & Checkpoint
AC power has failed; system on battery
power
All SMRs are off due to NCU 4000 Inhibit
signal, system on battery power
Volts Low
Battery charging current limiting due to
faulty battery current signal . This will
depress float voltage
Unit not current sharing (if only one
showing power limit)
Power Limit
Load current too high (if more than one
unit showing alarm)
SMR Heat sink temperature too high
H/S Temp High Ambient temperature is too high
Microprocessor card is faulty
Solution
Restore AC power if possible
Check reason for signal; if necessary
replace NCU 4000
Check battery currents. If one of them
shows figure higher than Batt Chg Curr
Lim set point, check corresponding
current transducer; check connections to
transducer; check UIB7 connections
Replace SMR
Reduce load
Reduce battery charging current limit if it
is too high
Check air intake to SMR is not blocked
Try to reduce ambient temperature
Replace SMR
 DC 125V Charger / Rectifier System (Troubleshooting)
Basic Troubleshooting

Removal of of Rectifier Module

• It is advisable to first switch off the unit power while unplugging it. This is done to
prolong the life of the rear “hot pluggable” connector
• Lift the securing latch in the centre divider adjacent to the module and pull the module
out of the Power shelf
• If the ambient temperature is high and the unit has been operating at maximum load,
pull the unit halfway out of the magazine and let cool for 2-3 minutes before handling.

Re-plugging of Rectifier Module

• It is advisable to first switch off the unit power while plugging it. This is done to prolong
the life of the rear “hot pluggable” connector
• Carefully slide the rectifier into the magazine. Press the unit into the magazine until it is
flush and the spring retaining clip clicks down
• Switch on the relevant AC circuit breaker in the AC distribution module. The rectifier will
start automatically and connect itself to the DC bus at the appropriate time
 End of
Charger System Training
Thank You