Operation & Maintenance Manua

OPERATION & MAINTENANCE
MANUAL
UNIT : BATTERY CHARGER FOR 110V/2X1100AH VRLA BATTERY.
TYPE : DUAL FLOAT CUM BOOST: CP-CC: 110V/700A.
CLIENT : BHARAT HEAVY ELECTRICALS LIMITED HYDRABAD.
PROJECT : BINA REFINARY CAPTIVE POWER PLANT.
P.O.NO. : T707A058 DATED 04.06.2007.
SR.NO. : CE-1919 / CE-II 0801 /314
W.O.NO. : CE-1919.
MANUFACTURER :
Regd. Office & Factory : E-66, MIDC, Jalgaon - 425 003 (M.S.) QUALITY
ASSURED
Tel. : 91-257-2210626 / 27 / 28 Fax : 91-257-2213434 COMPANY
ISO:9001-2000
E-mail : chhabi_jal@sancharnet.in International Standards
Certifications
Lic. No. QAC/R91/0100
Visit us at www.chhabi-india.com
Mumbai Office : Bangalore Office : Delhi Office : Kolkata Office :

20, Anupam Indl. Estate no. 3, 120, First Floor, “Ajantha” F-12, First Floor, 16/1A, Bose Pukur Road,
L.B.S. Marg 6th C Main Road, Remco Layout Pankaj Grand Plaza, Kolkata - 700 042
Mulund (W) Vijayanagar 2nd Stage Mayur Vihar Phase-1, Ph : 91-33-2441 1375
Mumbai - 400 080 Bangalore - 560 040 (Karnataka) New Delhi - 110 091 Email : chhabikol@chhabi-india.com
Ph. : 91-22-2561 4435/5945 Ph : 91-80-2314 0031 Ph : 91-11-4215 1213 - 14
Fax : 91-22-2568 0513 Fax : 91-80-2314 0031 Fax : 91-11-4215 1215
Email : chhabi@mtnl.net.in Email : chhabiblr@chhabi-india.com Email : chhabindl@chhabi-india.com
CHHABI ELECTRICALS PVT. LTD. JALGAON – 425 003.SH.NO. : SH-4833 / 1 of 11

O P E R ATION AND M AINTENAN C E M ANUAL

P.O.NO. : T707A058 DATED 04.06.2007.
SR.NO. : CE-1919 / CE-II 0801 /314
W.O.NO. : CE-1919.
INDEX
Sr. # Description Sheet No.
1 Technical Specification SH-4833 / 3

2 Operational write-up for 110V battery charger. SH-4833 / 4
3 Erection and commissioning of equipment. SH-4833 / 5 to 8
4 Operation and Maintenance. SH-4833 / 9 to 11
5 Bill of material. LC 3158
6 Make of Components LC 3158 / 5 – 5
CIRCUIT DIAGRAM & GENERAL LAYOUT

Sr. # Description Drg. No.
1. Main circuit diagram for 110V/2X1100AH VRLA battery C10096A Rev.03
charger A&B.
2. Main circuit diagram for 110V/2X1100AH VRLA battery C10096B Rev.03
charger A&B.
3. Circuit diagram for 110V/2X1100AH VRLA battery C10096C Rev.04
charger A& B.
4. Circuit diagram for float cum boost charger A & B. C10096D Rev.03
5. Circuit diagram for 110V Micro controller based C10096E Rev.03
annunciation.
6. Legend print for Annunciation. C10096F Rev.02
7. General Layout for 110V/2X1100AH VRLA battery C10097 Rev.04
charger A & B.
8. General Layout for 110V/2X1100AH VRLA battery C10097A Rev.04
charger A & B.
PREPARED : A.S.G. CHECKED : A.S.B. APPROVED :D.J.P
CHHABI ELECTRICALS PVT. LTD. JALGAON – 425 003. SH.NO. : SH-4833 / 2 of 11

TECHNICAL SPECIFICATION
MAIN AC INPUT : 415V 10%, 50Hz, 5%, 3Phase, 4 Wire AC supply.
BATTERY DETAIL : a) Type of Battery : VRLA Battery.

b) No of Cells : 55 Nos.
c) AH capacity : 2X1100AH
d) Cell Voltage : 2.0 Volts / Cell.
TYPE : Float cum Boost Charger A & B.
DC OUTPUT : Battery Charger A & B :

a) Float Mode : Suitable to float 55 Nos. VRLA cells of 2500AH
capacity at 2.25V/cellas well as supplying a continuous load of
700A
b) Boost Mode : Capable to boost charge 55 Nos. VRLA cells of
2500AH capacity 2.3V/Cell at the maximum charging current of
700A
RIPPLE : Charger A & B - 1 % (RMS)
AMBIENT : 50° C Average ambient temperature.
SIZE : L = 4400mm H = 2000mm W= 1000mm
COLOUR : Inside & Outside RAL7032
CONSTRUCTION : a) Suitable for indoor operation and floor mounting.
b) Battery charging Equipment comprising of Duel float cum boost charger housed in a
common cubicle. Frame structure fabricated with 2 mm thick (CRCA) sheet steel for base
frame & front panel, 1.6mm for all other covers. It consists of AC I/P terminal, DC O/P
terminal for battery and load. Cable entry is provided at bottom through removable cable
gland plate. Charger is provided with Switch & Fuse and AC contactor of suitable rating at
AC input side & Switch & Fuse & DC contactor at DC O/P side respectively. LED’s are
provided on front panel to indicate the AC I/P supply ‘ON’, DC 'ON' & float, boost mode
‘ON’ and Control switches, potentiometer & Analog meters are provided on front panel of
battery charger.
Analog Meter:
VM1 A/B : Shows AC I/P Voltage of Battery charger A & B.
VM2 A/B : Shows the DC O/P Voltage of Battery charger A & B.
VM3 : Shows Battery1 &2, Battery tap voltage through selector switch.
AM1 A/B : Shows AC I/P current of Battery charger A & B.
AM2 A/B : Shows DC O/P current of Battery charger A & B.
AM3 : Shows charge /discharge current of battery.
AM4 : Shows Earth Leakage current.
Annunciation is provided on front panel to give audible, visible annunciation of the fault.
Controller cards CPC1A/B are provided from inside of the front panel. Rectifier stacks,
Contactors, FFD’S, Transformers & Chokes are mounted in MS cubicle at suitable places.

OPERATIONAL WRITE-UP FOR 110V BATTERY CHARGER.
(3 Phase Silicon Controlled Rectifier Equipment)
CHARGING EQUIPMENT:
The Battery Charging equipment consist charger A & charger B. Both the Chargers are
Float cum Boost charger. Both chargers normally will be in Float mode to supply station
load & trickle charge the Battery, by sharing the total load.
During an emergency, when AC power fails, the battery supplies the load & it discharges
to a certain extend depending upon duration of emergency. At this time, DC contactor C3
will be in energized condition.
When AC power is restored, the Battery needs to be Boost charged. Under such
condition, one charger will be supplying station load & operate another charger in Boost
mode for charging the battery. At this time, Battery positive bus & load positive bus will be
separated by DC contactor C3, C4 & C5.
CHARGER
FLOAT CUM BOOST CHARGER A & B :
The charger is fed from 3 phase, 4-wire AC supply & gives DC stabilized output at rated
full load current.
1) In Float mode: The variation in DC output voltage is limited to +/-1% for 0-100% load
variation, & simultaneously AC voltage variation of ±10% & frequency variation ±5%.
2) In Boost mode: The variation in DC output current is limited to +/-2% from 1.85 to
2.37V per cell & simultaneously for AC voltage variation of ±10% & frequency variation
of ±5%.
The rectification is obtained by using a 3-phase full controlled full wave bridge connected
Silicon rectifier stack comprising of 12 silicon controlled rectifiers (SCR), with surge
suppression RC network connected across each SCR.
WORKING OF CHARGER :
The circuit works on AC phase control principle. The SCR is a semiconductor device
with 3 terminals i.e. Anode, Cathode & Gate. The main load current is carried by Anode
& Cathode, while the control current flows through Gate and Cathode. The characteristic
of SCR is that, it blocks the forward voltage, when the gate current reaches to a specified
level. Therefore changing the instant at which the gate current or pulse is supplied can
control the instant, at which the SCR goes into conduction, or triggers. Once the SCR is
triggered it remains in conduction till Anode current is reduced to zero or reverse voltage
is applied to Anode. Thus changing the instant of firing can control the output voltage of
rectifier bridged / triggering the SCR. Potentiometer is used for adjusting the output
voltage setting. Shunt senses the load current. The signal proportional to this load current
is fed to the controller. In event of load current exceeding the rated full load current, the
output voltage starts drooping, thus limiting the load current. This inherent feature is
provided. A bleeder resistance is provided which provides the latching current for the SCR
under No load condition. A filter circuit comprising of Filter choke and Condenser is
connected in the output to limit the ripple content to the specified level.

ERECTION AND COMMISSIONING OF EQUIPMENT.
1.00 UNPACKING :
1. The equipment is covered with a layer of plastic and corrugated paper and then
packed in a wooden crate. Also read the instruction (FOR LIFTING THE
EQUIPMENT USE ALL LIFTING HOOKS) sticked on the unit carefully.
2. Dismantle the wooden crate carefully and then separate the layers of packing
papers. Also read the instruction (1. FOR LIFTING THE EQUIPMENT USE ALL
LIFTING HOOKS & 2. REMOVE SHORTINGS OF ALL METER'S TERMINAL
BEFORE USE ) sticked on the panel.
3. After unpacking observe the panel & components inside the charger after opening
of the door by use of door key provided (which is tied-up with door handle).
Intimate any damage during transportation if any, within 15 days to our Mumbai
office for insurance claim / for further process. Also remove meter terminal
shorting.
2.00 ERECTION AND COMMISSIONING OF BATTERY CHARGER :-
2.1) Install the equipment at indoor place suitably ventilated as per foundation details
shown in General layout drawing No. C10097 Rev.04 & C10097A Rev 04.
2.2) INSULATION RESISTANCE TEST (WITH 500V MEGGER) :-

2.2.1) Clean inside of the charger with the help of blower.
2.2.2) Ensure all the fuses are intact.
2.2.3) Take out the plugs of SCR controllers (CPC) & Electronics relays. Keep all
switches in ‘ON’ position.
2.2.4) Test the equipment I.R. before connection the AC & DC cables to the charger
terminal board.
2.2.5) Check I.R. in between following terminals one by one.
a) AC terminals and earth bus.
If IR value is more than 2MΩ then proceed further. If IR value is less than 2MΩ
refer following steps 1) Switch ‘OFF’ DC output switches/MCCB. 2) Keep AC input
switch/MCCB ‘ON’ and main contactor ‘OFF’ and check IR. 3) Keep AC input
Switch/MCCB and main contactor ‘ON’ and find out the point of leakage.
b) DC terminals and earth bus.
1) Switch ‘OFF’ AC input switch/MCCB and switch ‘ON’ DC output switch/MCCB
and check point of leakage.
c) AC terminals and DC terminals.
1) Switch ‘ON’ AC input switch/MCCB & switch ‘OFF’ DC output switch/MCCB and
check IR.
2) Switch ‘OFF’ AC input switch/MCCB & switch ‘ON’ DC output switch/MCCB and
check IR.
3) Find out the point of leakage. In each of the above 3 cases, I.R. should be more
than 2 Mega Ohms. If it is all right, proceed further, if not then, a) Keep space
heater always ‘ON’ to prevent the charger from moisture if charger is not in use.
b) Find out the point of leakage and rectify the same.
2.2.6) Switch ‘OFF’ all switches/MCCB’s and put the controller and relay plugs as it were.
2.3) Fix the cable glands to the removable cable gland plates, of charger after
terminating cables through the glands.
2.4) Lay down the cables of AC input & output i.e. load & battery. For cable sizes refer
Bill of Material. TB1A/B, TB2. Also connect the cables of remote annunciation.
2.5) Crimp cable lugs of suitable sizes to this cable to enable to connect these cables to
the charger terminal board.

3.00 POWER SUPPLY AND CONNECTION -
a. Connect the AC cables to the Charger Terminal Board TB1A/B.

b. Connect the charger earth bus to main earthing bus of the site.
c. Do not connect the Battery and load cables at present.
d. This equipment is designed to operate on AC mains of 415V ±10%, 50Hz ±5%, 3
Phase, 4 wire AC input.
4.00 LOADING ARRANGEMENT:-
Make the water load arrangement as described below.

1. Take two cables of suitable capacity.
2. Connect MS strip of suitable size to end of each cable.
3. Connect remaining ends of the wire to the terminals of the Float & Boost charger as
described in operation.
4. Arrange PVC Drum and fill up it with water and salt solution.
5. Keep one strip vertically dipped in Drum.
6. Dipping of second trip vertically in this Drum will form load. The distance between two
MS strips will decide the current drawn by this arrangement. As you decrease the
distance between two strips, current taken by this arrangement will go on increasing.
I) FLOAT CUM BOOST CHARGER A/B IN FLOAT MODE :

Charger has two modes of operation. A) Auto mode & B) Manual mode..
A) AUTO MODE :
Keep the following position of selector switch.

SW7A/B : CPC Auto/ Manual selector switch at Auto mode.
C2A/B&2A'/B' : Float / Boost selector auxiliary contactor will be at float position i.e. ’OFF’.
Switch ON AC input switch SW1A/B.
Charger AC ON’ indicating lamp `LP1-3’ A/B will glow.
Switch ON SW4A/B for closing contactor C1A/B.
SW7A/B : DC Output Switch A/B.
LP4 A/B : Observe float mode indicating lamp LP4 A/B starts to glow.
NO LOAD OPERATION:
Observe the output voltage on DC voltmeter VM2A/B. It shall increase gradually up to

123.7. (It is factory set @ 2.25V / Cell x 55 cells). If it is disturbed in transportation, reset it
123.7 with the help of voltage adjustment potentiometer (In Auto Mode) RV1A/B. The
voltage span in auto mode is 115V to 130V from minimum to maximum position of
potentiometer RV1 A/B.
Connect water load cables at TB3A/B Load terminals.
FULL LOAD OPERATION:
Increase the load current from zero, indicated by DC Ammeter AM2A/B & at the same
time, AC input current can be observed on the AC ammeter AM1A/B. Also AC input
voltage can be observed on the AC voltmeter VM1. Observe the floating voltage 123.7,
remains constant within ±1% up to 700A i.e from 0 to 100% of rated full load current.

CURRENT LIMITING FEATURE:
If you go on increasing load current above 700A, the output voltage starts to
decrease and limits the load current, thus allowing the battery to take extra load.
Changing the value of current control can vary this level of current limiting feature
resistance R3.
B) MANUAL MODE :

SW7 A/B : CPC Auto/ Manual selector at `Manual’ position.
RV3 A/B : Voltage control potentiometer in Manual mode, keep at minimum position.
Switch ÒN’ AC input switch SW1A/B.
Charger AC supply ÒN’ indicating lamp LP1-3 A/B glow.
Switch ON SW4 A/B to pick up contactor coil C1A/B.
Switch ÒN’ DC output Switch SW8A/B.
NO LOAD OPERATION :
Observe the output voltage on DC voltmeter VM2A/B. It should be near about zero. Turn
the voltage adjustment potentiometer (in Manual) RV3 A/B in clockwise and watch output
voltage. It will start increasing from 0V to 180V from minimum to maximum position of
RV3 A/B.
For load test: Turn back the RV3 A/B, at its minimum position.
Observe, Float mode indicating lamp LP4 A/B to glow.
FULL LOAD OPERATION :
Increase the voltage by RV3A/B; simultaneously increase the load current by

external water load arrangement, read on VM2A/B and AM2A/B respectively.
Maintain this floating voltage 123.7 at 600 A with the help of RV3 A/B.
NOTE : In manual mode, DC voltage is not regulated but only controlled by

potentiometer RV3 A/B manually.
Decrease the load current & voltage up to zero & switch ÒFF’ the AC, DC switches.
II) FLOAT CUM BOOST CHARGER A/B IN BOOST MODE:

C2A/B &C2A'/B': Float / Boost selector auxiliary contactor will be at Boost position (i.e. ON).
SW1A/B: Switch ON AC input switch.
LED1-3A/B: Charger AC ON’ indicating LED’s will glow.
SW7A/B: Switch ON DC Output Switch.
SW5: Charger A/B Priority selector switch at required position.
SW7A/B: CPC Auto/ Manual selector switch at auto mode
SW4A/B: Switch ON SW4 A/B for closing contactor C1 A/B.
Connect water load cables at TB2A/B Battery terminals. (Do not increase the Load.)
The Battery charger will operate in boost mode.
PB1A/B: Press Push button to operate the Charger in boost mode.
C3 & C4/ C5: Will open according to charger selected in boost mode.

NO LOAD OPEARTION :
Observe the o/p voltage on DC voltmeter. It shall increase gradually up to 126.5V (It is
factory set 2.3 V / Cell x 55 Cells). If it is disturbed in transportation Reset It 126.5V with
the help of voltage adjustment resistance R4 (in Auto mode) & observe the DC o/p
indicating lamp LP5 CC mode is ON.
The charger can be operated in n Boost mode by pushing PB1 A/B Manually or at auto
position of SW5 through ACOR. At this time, load positive bus will be isolated as
contactor C3, & C4/C5 gets de-energized.
After completion of boost charging, charger can be switched over to float through ACOR
or after laps of time set on the timer T1A/B.& energizing contactor C3 & C4/ C5. Share
the load.
FULL LOAD OPERATION :-
Increase the load current from zero, will shows on DC Ammeter AM2 A/B & at the
same time on Ammeter AM3. Also AC I/P current can be observe on AC ammeter
AM1 A/B & AC input voltage can be observed on the AC Voltmeter VM1 A/B.
Observe the Boost charging current 700A remains constant within +/-2% of set value for
102 V to 126.5V This Charging current can be set by potentiometer RV2 A/B.
decrease and limits the current, thus allowing the battery to take extra load.
Changing the position of RV2 current control potentiometer one can vary this level of
current limiting feature.
NOTE : In manual mode, DC voltage is not regulated but only controlled by potentiometer
RV3 A/B manually.
And keep close supervision on DC output voltage.
Decrease the load current and voltage up to zero and switch ÒFF’ the AC, DC switches
or MCCB’s.
5.00 CAUTIONS :
a) Do not keep the two strips with direct contact in any case. It may damage rectifier
stack or fuses may blown.
b) For diluting the solution, add water.
c) Increase requisite quantity of salt or electrolyte if required load is not being achieved
even after bringing the two strips nearer to each other.
6.00 Connect the battery, to battery terminals TB2A/B in correct polarity ie +ve at T5A/B,
+ve of tap cell at T6A/B & -ve at T7A/B.

OPERATION AND MAINTENANCE
1) FLOAT CUM BOOST CHARGER A/B IN FLOAT MODE :

A) AUTO MODE :
B) MANUAL MODE :
SW7A/B : CPC Auto/ Manual selector at `Manual’ position.
RV3A/B : Voltage control potentiometer in Manual mode, keep at minimum position.
II) FLOAT CUM BOOST CHARGER A/B IN BOOST MODE:-
Charger have two modes of operation. A) Auto mode & B) Manual mode.
SPECIAL FEATURE:
The float cum boost charger has special features as below:
Automatic Switching ON in Boost Mode:
Keep SW5 priority selector switch at position current control charger-A / Charger-B as
required. If AC Supply fails, the battery will supply the load & will discharge to the certain
extent depending upon the duration & load current. After restoration of AC supply, the
battery will take trickle charging current from the float charger. If this trickle charging
current increases beyond set value as sensed by ACOR ( Automatic changeover relay) of
the battery, float cum boost charger will operate automatically in boost mode & will charge
the battery. The boost charger will be switched over to float mode automatically after
completion boost charging through ACOR supported by the back up timer T1A/B.

2.00 PROTECTION :
1) Charger blocker diodes of suitable rating are provided to maintain one-way flow of
current. i.e. from charger to load battery (MR2 A/B).
2) Annunciation, Condenser are provided with HRC fuses of suitable rating.
3) Voltmeter is provided with glass fuse.
4) Fuse Failure Detector: FFD’s are provided to give annunciation in case of failure of
Rectifier fuses,Filter fuse , DC output fuses, battery fuses,
5) Battery tap diode `MR3’ is provided to maintain the continuity of supply for the
duration, DC contactor takes to pick up while AC mains fails during boost charging.
6) Auxiliary contactors CA1,CA2 A/B are provided to give annunciation if total AC mains
fail for charger A & B.
7) DC Under & Over Voltage Relay
a) DC Over Voltage Relay :
Due to any reason, DC output voltage of charger A/B goes above 102 this relay will
operate and gives annunciation. The resting voltage of relay is 110V.
b) DC Under Voltage Relay :
Due to any reason, DC output voltage of charger A/B goes below 128V; this relay
operates & gives annunciation. The reset voltage of this relay is 124V.
8) E/L (I.M.D.) : Earth Leakage Relay with suitable milli-ammeter (AM4) is provided
to indicate the leakage current. If in any case, the earth leakage current lies
between 1-7 mA, this relay will actuates and give annunciation.
3.00 ANNUNCIATION SCHEME FOR CHARGER :
If any of the following fault occurs, visual and audible annunciation will be there.
Accept the fault pushing push buttons. Hooter stops and only fault indicating
WINDOW will indicate the presence of fault. Fault indicating WINDOW stops glowing
when fault will be removed & after pushing reset push buttons.
LIST OF FAULTS:
Charger A AC mains fail Charger B AC mains fail
Charger A AC Fuse Blown Charger B AC Fuse Blown
Charger A Rectifier fuse blown Charger B Rectifier fuse blown
Charger A Filter Fuse Blown. Charger B Filter Fuse Blown.
Charger A DC Fuse Blown. Charger B DC Fuse Blown.
Charger A DC under voltage Charger B DC under voltage
Charger A DC over voltage Charger B DC over voltage
Charger A cubical temp. high Charger B cubical temp. high
Battery- 1 Fuse Blown Battery On Load
Battery -2 Fuse Blown. Battery Under Voltage
Battery Earth Fault.
4.00 SPECIAL ATTENTION WHILE OPERATING :

1) Generally operate the charger in Auto mode. Use manual mode in case of Auto mode
function failure. Before using manual mode keep voltage adjust potentiometer RV3 A/
B at its minimum position while operating the charger in Manual mode.
2) Always use HRC fuses of proper rating; use of wire fuses will cease our
Guarantee.
3) While changing the mode i.e Auto mode to Manual mode or vice versa. Switch ÒFF’
the charger and then change the position of Auto / Manual switch.

4) After meeting an emergency by battery, charge the battery by boost charger for
the period depending upon the duration of emergency the battery has met. After
boost charging is over, allow the battery across float charger for trickle charging.
5.00 INITIAL CHARGING OF BATTERIES :
1) Ensure that, battery cells are filled with electrolyte and sufficient rest is given to them
for cooling.
2) Connect battery cables to the charger terminal board `TB2A/B’ with proper polarity.
3) Keep SW6 A/B at “Auto” position. Switch ÒN’ the AC input switch SW1A/B.
4) Select the required charger to taken in boost mode with the help of SW5 , Press PB2
A/B for selection of Boost mode from any of the charger A/B. Observe the voltage and
current on VM2A/B, AM2A/B and AM3.
5) For charging the battery follow the procedure of charging according to Instruction
manual of Battery manufacturer. Boost charging current can be set at required value
with the help of Boost charger current limit potentiometer RV2A/B.
6) After completion of the charging cycles, allow the battery across float charger for
trickle charging. After this, battery will be ready to supply the load.
6.00 ROUTINE MAINTENANCE OF BATTERY CHARGER :
A) 1) Cleaning of panel from inside & outside by using blower : Weekly

2) Healthiness of indicating lamps. : Weekly
3) Tightness & healthiness of fuse links. : Quarterly
4) Electrical performance, Tightness of all connections, noise observation & complete
cleaning of equipment. : Half yearly
5) Calibration of meters. : Yearly
B) In addition to above daily reading book is to be maintained for reading.
C) Any fault occurring and rectification carried out/maintenance carried out to be recorded
in log book.
D) Ensure availability of necessary spares i.e. fuse links, thyristors, diodes, control cards
etc. At least one set of each.
7.00 TROUBLE SHOOTING :
1) If voltmeters does not show any reading then check

a) Fuses of voltmeter.
b) Voltmeter connections
c) Voltages at voltmeter selector switch.
d) Voltages at voltmeter.
e) Check voltmeter.
2) If ammeters does not show any reading then check
a) Ammeter connections
b) Current at Ammeter selector switch.
c) MilliVolts at Ammeter.
d) Check Ammeters.
3) If contactor does not pickup then check
a) Contactor coil fuse for C1A/B.
b) Contactor coil connections.
c) Contactor coil.
d) Check voltage at contactor coils

P.O.NO. : T707A058 DATED 04.06.2007.
SR.NO. : CE-1919 / CE-II 0801 /313
W.O.NO. : CE-1919.
MANUFACTURER :
ASSURED
Tel. : 91-257-2210626 / 27 / 28 Fax : 91-257-2213434 COMPANY
ISO:9001-2000
Certifications

Ph. : 91-22-2561 4435/5945 Ph : 91-80-2314 0031 Ph : 91-11-4215 1213 - 14
Fax : 91-22-2568 0513 Fax : 91-80-2314 0031 Fax : 91-11-4215 1215
CHHABI ELECTRICALS PVT. LTD. JALGAON – 425 003.SH.NO. : SH-4832 / 1 of 11

O P E R ATION AND M AINTENAN C E M ANUAL

P.O.NO. : T707A058 DATED 04.06.2007.
SR.NO. : CE-1919 / CE-II 0801 / 313.
W.O.NO. : CE-1919.
INDEX
Sr. # Description Sheet No.
1 Technical Specification SH-4832 / 3

2 Operational write-up for 110V battery charger. SH-4832 / 4
3 Erection and commissioning of equipment. SH-4832 / 5 to 8
4 Operation and Maintenance. SH-4832 / 9 to 11
5 Bill of material. LC 3158
6 Make of Components LC 3158 / 5 – 5
CIRCUIT DIAGRAM & GENERAL LAYOUT

Sr. # Description Drg. No.
1. Main circuit diagram for 110V / 2X1250AH VRLA battery C10096A Rev.03
charger A&B.
2. Main circuit diagram for 110V / 2X1250AH VRLA battery C10096B Rev.03
charger A&B.
3. Circuit diagram for 110V / 2X1250AH VRLA battery C10096C Rev.04
charger A& B.
4. Circuit diagram for float cum boost charger A & B. C10096D Rev.03
5. Circuit diagram for 110V Micro controller based C10096E Rev.03
annunciation.
6. Legend print for Annunciation. C10096F Rev.02
7. General layout for 110V / 2X1250AH VRLA battery C10097 Rev.04
charger A & B.
8. General layout for 110V / 2X1250AH VRLA battery C10097A Rev.04
charger A & B.

MAIN AC INPUT : 415V 10%, 50Hz, 5%, 3Phase, 4 Wire AC supply.
BATTERY DETAIL : a) Type of Battery : VRLA Battery.

b) No of Cells : 55 Nos.
c) AH capacity : 2X1250AH
d) Cell Voltage : 2.0 Volts / Cell.
TYPE : Float cum Boost Charger A & B.
DC OUTPUT : Battery Charger A & B :

a) Float Mode : Suitable to float 55 Nos. VRLA cells of
2X1250AH capacity at 2.25V/cell as well as supplying a
continuous load of 600A.
b) Boost Mode : Capable to boost charge 55 Nos. VRLA cells of
2X1250AH capacity 2.3V/Cell at the maximum charging current
of 600A.
RIPPLE : Charger A & B - 1 % (RMS)
AMBIENT : 50° C Average ambient temperature.
SIZE : L = 4400mm H = 2000mm W= 1000mm
COLOUR : Inside & Outside RAL7032
CONSTRUCTION : a) Suitable for indoor operation and floor mounting.
b) Battery charging Equipment comprising of Duel float cum boost charger housed in a
common cubicle. Frame structure fabricated with 2 mm thick (CRCA) sheet steel for base
frame & front panel, 1.6mm for all other covers. It consists of AC I/P terminal, DC O/P
terminal for battery and load. Cable entry is provided at bottom through removable cable
gland plate. Charger is provided with Switch & Fuse and AC contactor of suitable rating at
AC input side & Switch & Fuse & DC contactor at DC O/P side respectively. LED’s are
provided on front panel to indicate the AC I/P supply ‘ON’, DC 'ON' & float, boost mode
‘ON’ and Control switches, potentiometer & Analog meters are provided on front panel of
battery charger.
Analog Meter:
VM1 A/B : Shows AC I/P Voltage of Battery charger A & B.
VM2 A/B : Shows the DC O/P Voltage of Battery charger A & B.
VM3 : Shows Battery1 &2, Battery tap voltage through selector switch.
AM1 A/B : Shows AC I/P current of Battery charger A & B.
AM2 A/B : Shows DC O/P current of Battery charger A & B.
AM3 : Shows charge /discharge current of battery.
AM4 : Shows Earth Leakage current.
Annunciation is provided on front panel to give audible, visible annunciation of the fault.
Controller cards CPC1A/B are provided from inside of the front panel. Rectifier stacks,
Contactors, FFD’S, Transformers & Chokes are mounted in MS cubicle at suitable places.

OPERATIONAL WRITE-UP FOR 110V BATTERY CHARGER.
(3 Phase Silicon Controlled Rectifier Equipment)
CHARGING EQUIPMENT:
The Battery Charging equipment consist charger A & charger B. Both the Chargers are
Float cum Boost charger. Both chargers normally will be in Float mode to supply station
load & trickle charge the Battery, by sharing the total load.
During an emergency, when AC power fails, the battery supplies the load & it discharges
to a certain extend depending upon duration of emergency. At this time, DC contactor C3
will be in energized condition.
When AC power is restored, the Battery needs to be Boost charged. Under such
condition, one charger will be supplying station load & operate another charger in Boost
mode for charging the battery. At this time, Battery positive bus & load positive bus will be
separated by DC contactor C3, C4 & C5.
CHARGER
FLOAT CUM BOOST CHARGER A & B :
The charger is fed from 3 phase, 4-wire AC supply & gives DC stabilized output at rated
full load current.
1) In Float mode: The variation in DC output voltage is limited to +/-1% for 0-100% load
variation, & simultaneously AC voltage variation of ±10% & frequency variation ±5%.
2) In Boost mode: The variation in DC output current is limited to +/-2% from 1.85 to
2.37V per cell & simultaneously for AC voltage variation of ±10% & frequency variation
of ±5%.
The rectification is obtained by using a 3-phase full controlled full wave bridge connected
Silicon rectifier stack comprising of 12 silicon controlled rectifiers (SCR), with surge
suppression RC network connected across each SCR.
WORKING OF CHARGER :
The circuit works on AC phase control principle. The SCR is a semiconductor device
with 3 terminals i.e. Anode, Cathode & Gate. The main load current is carried by Anode
& Cathode, while the control current flows through Gate and Cathode. The characteristic
of SCR is that, it blocks the forward voltage, when the gate current reaches to a specified
level. Therefore changing the instant at which the gate current or pulse is supplied can
control the instant, at which the SCR goes into conduction, or triggers. Once the SCR is
triggered it remains in conduction till Anode current is reduced to zero or reverse voltage
is applied to Anode. Thus changing the instant of firing can control the output voltage of
rectifier bridged / triggering the SCR. Potentiometer is used for adjusting the output
voltage setting. Shunt senses the load current. The signal proportional to this load current
is fed to the controller. In event of load current exceeding the rated full load current, the
output voltage starts drooping, thus limiting the load current. This inherent feature is
provided. A bleeder resistance is provided which provides the latching current for the SCR
under No load condition. A filter circuit comprising of Filter choke and Condenser is
connected in the output to limit the ripple content to the specified level.

ERECTION AND COMMISSIONING OF EQUIPMENT.
1.00 UNPACKING :
1. The equipment is covered with a layer of plastic and corrugated paper and then
packed in a wooden crate. Also read the instruction (FOR LIFTING THE
EQUIPMENT USE ALL LIFTING HOOKS) sticked on the unit carefully.
2. Dismantle the wooden crate carefully and then separate the layers of packing
papers. Also read the instruction (1. FOR LIFTING THE EQUIPMENT USE ALL
LIFTING HOOKS & 2. REMOVE SHORTINGS OF ALL METER'S TERMINAL
BEFORE USE ) sticked on the panel.
3. After unpacking observe the panel & components inside the charger after opening
of the door by use of door key provided (which is tied-up with door handle).
Intimate any damage during transportation if any, within 15 days to our Mumbai
office for insurance claim / for further process. Also remove meter terminal
shorting.
2.00 ERECTION AND COMMISSIONING OF BATTERY CHARGER :-
2.1) Install the equipment at indoor place suitably ventilated as per foundation details
shown in General layout drawing No. C10097 Rev.04 & C10097A Rev 04
2.2) INSULATION RESISTANCE TEST (WITH 500V MEGGER) :-

2.2.1) Clean inside of the charger with the help of blower.
2.2.2) Ensure all the fuses are intact.
2.2.3) Take out the plugs of SCR controllers (CPC) & Electronics relays. Keep all
switches in ‘ON’ position.
2.2.4) Test the equipment I.R. before connection the AC & DC cables to the charger
terminal board.
2.2.5) Check I.R. in between following terminals one by one.
a) AC terminals and earth bus.
If IR value is more than 2MΩ then proceed further. If IR value is less than 2MΩ
refer following steps 1) Switch ‘OFF’ DC output switches/MCCB. 2) Keep AC input
switch/MCCB ‘ON’ and main contactor ‘OFF’ and check IR. 3) Keep AC input
Switch/MCCB and main contactor ‘ON’ and find out the point of leakage.
b) DC terminals and earth bus.
1) Switch ‘OFF’ AC input switch/MCCB and switch ‘ON’ DC output switch/MCCB
and check point of leakage.
c) AC terminals and DC terminals.
1) Switch ‘ON’ AC input switch/MCCB & switch ‘OFF’ DC output switch/MCCB and
check IR.
2) Switch ‘OFF’ AC input switch/MCCB & switch ‘ON’ DC output switch/MCCB and
check IR.
3) Find out the point of leakage. In each of the above 3 cases, I.R. should be more
than 2 Mega Ohms. If it is all right, proceed further, if not then, a) Keep space
heater always ‘ON’ to prevent the charger from moisture if charger is not in use.
b) Find out the point of leakage and rectify the same.
2.2.6) Switch ‘OFF’ all switches/MCCB’s and put the controller and relay plugs as it were.
2.3) Fix the cable glands to the removable cable gland plates, of charger after
terminating cables through the glands.
2.4) Lay down the cables of AC input & output i.e. load & battery. For cable sizes refer
Bill of Material. TB1A/B, TB2. Also connect the cables of remote annunciation.
2.5) Crimp cable lugs of suitable sizes to this cable to enable to connect these cables to
the charger terminal board.

3.00 POWER SUPPLY AND CONNECTION -
a. Connect the AC cables to the Charger Terminal Board TB1A/B.

b. Connect the charger earth bus to main earthing bus of the site.
c. Do not connect the Battery and load cables at present.
d. This equipment is designed to operate on AC mains of 415V ±10%, 50Hz ±5%, 3
Phase, 4 wire AC input.
4.00 LOADING ARRANGEMENT: -
Make the water load arrangement as described below.

1. Take two cables of suitable capacity.
2. Connect MS strip of suitable size to end of each cable.
3. Connect remaining ends of the wire to the terminals of the Float & Boost charger as
described in operation.
4. Arrange PVC Drum and fill up it with water and salt solution.
5. Keep one strip vertically dipped in Drum.
6. Dipping of second trip vertically in this Drum will form load. The distance between two
MS strips will decide the current drawn by this arrangement. As you decrease the
distance between two strips, current taken by this arrangement will go on increasing.
I) FLOAT CUM BOOST CHARGER A/B IN FLOAT MODE :

A) AUTO MODE :

NO LOAD OPERATION:
Observe the output voltage on DC voltmeter VM2A/B. It shall increase gradually up to

123.7. (It is factory set @ 2.25V / Cell x 55 cells). If it is disturbed in transportation, reset it
123.7 with the help of voltage adjustment potentiometer (In Auto Mode) RV1A/B. The
voltage span in auto mode is 115V to 130V from minimum to maximum position of
potentiometer RV1 A/B.
FULL LOAD OPERATION:
Increase the load current from zero, indicated by DC Ammeter AM2A/B & at the same
time, AC input current can be observed on the AC ammeter AM1A/B. Also AC input
voltage can be observed on the AC voltmeter VM1. Observe the floating voltage 123.7,
remains constant within ±1% up to 600 A. i.e from 0 to 100% of rated full load current.

decrease and limits the load current, thus allowing the battery to take extra load.
Changing the value of current control can vary this level of current limiting feature
resistance R3.
B) MANUAL MODE :

NO LOAD OPERATION :
Observe the output voltage on DC voltmeter VM2A/B. It should be near about zero. Turn
the voltage adjustment potentiometer (in Manual) RV3 A/B in clockwise and watch output
voltage. It will start increasing from 0V to 180V from minimum to maximum position of
RV3 A/B.
For load test: Turn back the RV3 A/B, at its minimum position.
Observe, Float mode indicating lamp LP4 A/B to glow.
Increase the voltage by RV3A/B; simultaneously increase the load current by

external water load arrangement, read on VM2A/B and AM2A/B respectively.
Maintain this floating voltage 123.7 at 600 A with the help of RV3 A/B.
NOTE : In manual mode, DC voltage is not regulated but only controlled by

potentiometer RV3 A/B manually.
Decrease the load current & voltage up to zero & switch ÒFF’ the AC, DC switches.


NO LOAD OPEARTION :-
Observe the o/p voltage on DC voltmeter. It shall increase gradually up to 126.5V(It is

factory set 2.3 V / Cell x 55 Cells). If it is disturbed in transportation Reset It 126.5V with
the help of voltage adjustment resistance R4 (in Auto mode) & observe the DC o/p
indicating lamp LP5 CC mode is ON.
The charger can be operated in n Boost mode by pushing PB1 A/B Manually or at auto
position of SW5 through ACOR. At this time, load positive bus will be isolated as
contactor C3, & C4/C5 gets de-energized.
After completion of boost charging, charger can be switched over to float through ACOR
or after laps of time set on the timer T1A/B.& energizing contactor C3 & C4/ C5. share
the load.
Increase the load current from zero, will shows on DC Ammeter AM2 A/B & at the
same time on Ammeter AM3. Also AC I/P current can be observe on AC ammeter
AM1 A/B & AC input voltage can be observed on the AC Voltmeter VM1 A/B.
Observe the Boost charging current 600A remains constant within +/-2% of set value for
102 V to 126.5V This Charging current can be set by potentiometer RV2 A/B.
decrease and limits the current, thus allowing the battery to take extra load.
Changing the position of RV2 current control potentiometer one can vary this level of
current limiting feature.
NOTE : In manual mode, DC voltage is not regulated but only controlled by potentiometer
RV3 A/B manually.
And keep close supervision on DC output voltage.
Decrease the load current and voltage up to zero and switch ÒFF’ the AC, DC switches
or MCCB’s.
5.00 CAUTIONS :-
a) Do not keep the two strips with direct contact in any case. It may damage rectifier
stack or fuses may blown.
b) For diluting the solution, add water.
c) Increase requisite quantity of salt or electrolyte if required load is not being achieved
even after bringing the two strips nearer to each other.
6.00 Connect the battery, to battery terminals TB2A/B in correct polarity ie +ve at T5A/B,
+ve of tap cell at T6A/B & -ve at T7A/B.

OPERATION AND MAINTENANCE
1) FLOAT CUM BOOST CHARGER A/B IN FLOAT MODE :

A) AUTO MODE :
LP4A/B : Observe float mode indicating lamp LP4 A/B starts to glow.
B) MANUAL MODE :


Charger have two modes of operation. A) Auto mode & B) Manual mode.
SPECIAL FEATURE:
The float cum boost charger has special features as below:

Automatic Switching ON in Boost Mode:
Keep SW5 priority selector switch at position current control charger-A / Charger-B as
required. If AC Supply fails, the battery will supply the load & will discharge to the certain
extent depending upon the duration & load current. After restoration of AC supply, the
battery will take trickle charging current from the float charger. If this trickle charging
current increases beyond set value as sensed by ACOR ( Automatic changeover relay) of
the battery, float cum boost charger will operate automatically in boost mode & will charge
the battery. The boost charger will be switched over to float mode automatically after
completion boost charging through ACOR supported by the back up timer T1A/B.

2.00 PROTECTION :
1) Charger blocker diodes of suitable rating are provided to maintain one-way flow of
current. i.e. from charger to load battery (MR2 A/B).
2) Annunciation, Condenser are provided with HRC fuses of suitable rating.
3) Voltmeter is provided with glass fuse.
4) Fuse Failure Detector: FFD’s are provided to give annunciation in case of failure of
Rectifier fuses,Filter fuse , DC output fuses, battery fuses,
5) Battery tap diode `MR3’ is provided to maintain the continuity of supply for the
duration, DC contactor takes to pick up while AC mains fails during boost charging.
6) Auxiliary contactors CA1,CA2 A/B are provided to give annunciation if total AC mains
fail for charger A & B.
7) DC Under & Over Voltage Relay
a) DC Over Voltage Relay :
Due to any reason, DC output voltage of charger A/B goes above 102 this relay will
operate and gives annunciation. The resting voltage of relay is 110V.
b) DC Under Voltage Relay :
Due to any reason, DC output voltage of charger A/B goes below 128V; this relay
operates & gives annunciation. The reset voltage of this relay is 124V.
8) E/L (I.M.D.) : Earth Leakage Relay with suitable milli-ammeter (AM4) is provided
to indicate the leakage current. If in any case, the earth leakage current lies
between 1-7 mA, this relay will actuates and give annunciation.
3.00 ANNUNCIATION SCHEME FOR CHARGER :
If any of the following fault occurs, visual and audible annunciation will be there.
Accept the fault pushing push buttons. Hooter stops and only fault indicating
WINDOW will indicate the presence of fault. Fault indicating WINDOW stops glowing
when fault will be removed & after pushing reset push buttons.
LIST OF FAULTS:
Charger A AC mains fail Charger B AC mains fail
Charger A AC Fuse Blown Charger B AC Fuse Blown
Charger A Rectifier fuse blown Charger B Rectifier fuse blown
Charger A Filter Fuse Blown. Charger B Filter Fuse Blown.
Charger A DC Fuse Blown. Charger B DC Fuse Blown.
Charger A DC under voltage Charger B DC under voltage
Charger A DC over voltage Charger B DC over voltage
Charger A cubical temp. high Charger B cubical temp. high
Battery- 1 Fuse Blown Battery On Load
Battery -2 Fuse Blown. Battery Under Voltage
Battery Earth Fault.
4.00 SPECIAL ATTENTION WHILE OPERATING :

1) Generally operate the charger in Auto mode. Use manual mode in case of Auto mode
function failure. Before using manual mode keep voltage adjust potentiometer RV3 A/
B at its minimum position while operating the charger in Manual mode.
2) Always use HRC fuses of proper rating; use of wire fuses will cease our
Guarantee.
3) While changing the mode i.e Auto mode to Manual mode or vice versa. Switch ÒFF’
the charger and then change the position of Auto / Manual switch.

4) After meeting an emergency by battery, charge the battery by boost charger for
the period depending upon the duration of emergency the battery has met. After
boost charging is over, allow the battery across float charger for trickle charging.
5.00 INITIAL CHARGING OF BATTERIES :
1) Ensure that, battery cells are filled with electrolyte and sufficient rest is given to them
for cooling.
2) Connect battery cables to the charger terminal board `TB2’ with proper polarity.
3) Keep SW6 A/B at “Auto” position. Switch ÒN’ the AC input switch SW1A/B.
4) Select the required charger to taken in boost mode with the help of SW5 , Press PB2
A/B for selection of Boost mode from any of the charger A/B. Observe the voltage and
current on VM2A/B, AM2A/B and AM3.
5) For charging the battery follow the procedure of charging according to Instruction
manual of Battery manufacturer. Boost charging current can be set at required value
with the help of Boost charger current limit potentiometer RV2A/B.
6) After completion of the charging cycles, allow the battery across float charger for
trickle charging. After this, battery will be ready to supply the load.
6.00 ROUTINE MAINTENANCE OF BATTERY CHARGER :-
A) 1) Cleaning of panel from inside & outside by using blower : Weekly

2) Healthiness of indicating lamps. : Weekly
3) Tightness & healthiness of fuse links. : Quarterly
4) Electrical performance, Tightness of all connections, noise observation & complete
cleaning of equipment. : Half yearly
5) Calibration of meters. : Yearly
B) In addition to above daily reading book is to be maintained for reading.
C) Any fault occurring and rectification carried out/maintenance carried out to be recorded
in log book.
D) Ensure availability of necessary spares i.e. fuse links, thyristors, diodes, control cards
etc. At least one set of each.
7.00 TROUBLE SHOOTING :
1) If voltmeters does not show any reading then check

a) Fuses of voltmeter.
b) Voltmeter connections
c) Voltages at voltmeter selector switch.
d) Voltages at voltmeter.
e) Check voltmeter.
2) If ammeters does not show any reading then check
a) Ammeter connections
b) Current at Ammeter selector switch.
c) MilliVolts at Ammeter.
d) Check Ammeters.
3) If contactor does not pickup then check
a) Contactor coil fuse for C1A/B.
b) Contactor coil connections.
c) Contactor coil.
d) Check voltage at contactor coils

BILL OF MATERIALS
W. O. NO. : CE-1919
REV NO. : 04
DATE : 14.08.08
UNIT : BATTERY CHARGER FOR 110V MF VRLA BATTERY.
TYPE : FLOAT CUM BOOST CHARGER A / B: CP - CV 110V
REF.DRG. NO. : C10096A - E.
CLIENT : BHEL HYDERABAD
PROJECT : 3 x 33 MW CFCB BASED CAPTIVE POWER PLANT-BORL, BINA M.P. PROJECT
P.O.NO. : T707A058 DTD 04/06/2007.
QUANTITY : 1 SET 1 SET
AH CAPACITY 110V/2 X 1250AH 110V/2 X 1100AH
SR. RATING RATING

CODE NO. DESCRIPTION
NO. 110V/600A 110V/700A
TERMINAL PLATES & LINKS
415V 3 Phase 4 wire AC input Terminal for incoming Suitable for 1x3½Cx185 Suitable for 1x3½Cx185
1 TB1A/B
power supply of charger. (R Y B N) (T1 -T4 A/B) sq.mm. AL Cable sq.mm. AL Cable
Suitable for 4x1Cx240 Suitable for 4x1Cx240

2 TB2A/B DC output Battery Terminals (T5,T6,T7A/B)
Sq.mm.Cu Cable Sq.mm.Cu Cable

3 TB3A/B DC output load terminals (T8,T9A/B) (+ve,-ve)
Sq.mm.Cu Cable Sq.mm.Cu Cable
Suitable for 1x2Cx1.5 Suitable for 1x2Cx1.5

4 TB4 Terminal for battery trouble (T10-11)
sq.mm. Cu Cable sq.mm. Cu Cable

5 TB5A/B Remote anuunciation terminal (T12-13A/B)

6 TB6A/B Terminal for interlocking purpose (T14-15)

7 TB7 Terminal for DC Control supply for Fuse Box (T16-17)
Terminal for interlock with BATT. Fuse box 1 & 2 Suitable for 1x2Cx1.5 Suitable for 1x2Cx1.5
8 TB8A/B
(T18-19A/B) sq.mm. Cu Cable sq.mm. Cu Cable
Terminal for Measuring for BATT.1 & BATT.2 Voltage Suitable for 1x2Cx1.5 Suitable for 1x2Cx1.5
9 TB9A/B
(T20-25) sq.mm. Cu Cable sq.mm. Cu Cable
FUSES
1 FS1-3A/B AC input HRC fuses 200A (CDFL1-200A) 250A (CDFL-250)
Glass cartridge fuses with suitable fuse fittings for the

2 FS4-6 A/B 100mA 100mA
VM1A/B.
3 FS7A/B HRC Fuse with suitable fuse fittings for the C1A/B. 4A (CNS4A, NSH20) 4A (CNS4A, NSH20)
4 FS8-19A/B Semiconductor fuses for the MR1&2A/B. GS1000/400A GS1000/400A
5 FS20A/B HRC fuse with suitable fuse fittings for FC1A/B. 250A (CDFL250) 250A (CDFL-250)
6 FS21-22A/B HRC fuses with suitable fuse fittings for DC output. 800A (CTLM800A) 800A (CTLM800A)
7 FS23-24A/B Glass cartridge Fuses with fitting for the VM2A/B. 100mA 100mA
FS25-27 &
8 Glass cartridge Fuses with fitting for the VM3. 100mA 100mA
FS25A-27A
HRC fuses with suitable fuse fittings for DC control
9 FS28 6A (CNS6A, NSH20) 6A (CNS6A, NSH20)
supply.
10 FS29A/B Glass cartridge fuse with suitable fuse fittings for lamp. 500mA 500mA
CHHABI ELECTRICALS PVT. LTD. JALGAON - 425 003 SHEET LC3158/ 1 OF 5

SR. RATING RATING
NO. 110V/600A 110V/700A
11 FS30A/B HRC fuse with suitable fuse fittings for 240V AC supply. 2A (CNS2A, NSH20) 2A (CNS2A, NSH20)
12 FS31A/B HRC fuse with suitable fuse fittings for Fan supply. 2A (CNS2A, NSH20) 2A (CNS2A, NSH20)
INDICATING LAMPS
1 LP1-3A/B ACÒN' indicating lamps. 230V AC 230V AC
2 LP4-5A/B FloatÒN'/Boost ÒN' indicating lamps. 110V DC 110V DC
3 LP6A/B Charger Trip indicating lamps. 110V DC 110V DC
4 L1 A/B Cubicle CFL lamps with fittings. 240V/11W 240V/11W
TRANSFORMERS, CHOKES & CT's
1 CT1-3 A/B Current transformers for AC ammeter AM1A/B 200/5A 250/5A
Double 'CU' wound impregnated naturally air cooled three 143.0 KVA 167.0 KVA
2 TR1A/B
phase mains transformer for float cum boost charger. 456/135V 456/135V
Auxiliary step down transformer for float cum boost

3 TR2,3A/B 50VA (150V/3X18-0-18) 50VA (150V/3X18-0-18)
charger controller card.
4 TR4 Auxiliary Tranformer for ACOR ckt. Supply. 20VA (270V/18-0-18V) 20VA (270V/18-0-18V)
5 CH1A/B Filter choke 750A 875A
6 IPT1A/B Inter Phase Transformer 375A 440A
RECTIFIERS & BLOCKER DIODES
250A/1000PIV 330A/1000PIV
R= 33E/25W R= 33E/25W
3phase, full wave rectifier bridge comprising of 6 Nos. of
C=0.47mfd/400V C=0.47mfd/400V
1 MR1,2A/B thyristors with suitable heat sink for float cum boost
(SKKT250/16E-3# Each, (SKKT330/16E-3# Each,
charger with balancing reactor.
HS=80AD-300mm-3# HS=80AD-300mm-3#
Each) Each)
760A/1000PIV (AR302-2# 760A/1000PIV (AR302-2#

Float cum boost charger silicon blocker diode with Each, Each,
2 MR3A/B
suitable heat sink connected 2 in parallel. HS=HK350-100mm-2# HS=HK350-400mm-4#
Each) Each)
1120A/1000PIV
Battery tap silicon blocker diode 'with suitable heatsink 1120A/1000PIV (AR302-4#,
3 MR4 (AR302-4#,
connected 2 in serires & 2 in parallel. HS=HK350-400mm-8#)
HS=HK350-400mm-8#)
RESISTANCES & POTENTIOMETERS
300V/300W - 4 Each 300V/300W - 4 Each

1 RB1A/B Bleeder Resistance
Connected in parallel Connected in parallel
Wire wound potentiometer for reference setting in auto

2 RV1A/B 10K/3W 10K/3W
mode (CPC Card)
Wire wound potentiometer to adjust the output voltage in
3 RV2A/B 10K/3W 10K/3W
Float mode.
Wire wound potentiometer to adjust the output voltage
4 RV3A/B 10K/3W 10K/3W
setting in boost mode.
Wire wound potentiometer to adjust the output current
5 RV4A/B 10K/3W 10K/3W
limit setting in float mode.
Wire wound potentiometer to adjust the output current
6 RV5A/B 10K/3W 10K/3W
setting in boost mode.
Wire wound potentiometer for reference setting in Manual
7 RV6A/B 10K/3W 10K/3W
mode (CPC Card)
5 RF1-3A/B Voltage Dropping resistance for FFD 2K/50W 2K/50W
6 RS1 A/B Voltage dropping resistance for DC U-O/V-R1A/B 2K/50W 2K/50W
5000MFD/200V -32# 5000MFD/200V -32#

7 FC1A/B Filter condensor
Connected in parallel Connected in parallel

SR. RATING RATING
NO. 110V/600A 110V/700A
METERS & SHUNTS (ACCURACY CLASS- 1.0%) 96 sq.mm. 90 deg. Deflection
AC moving iron Voltmeter to read AC incoming voltage of

1 VM1A/B 0-500V AC 0-500V AC
charger.
DC moving coil Voltmeter to read the charger output
2 VM2A/B 0-200V DC 0-200V DC
voltage
DC moving coil voltmeter to read battery & battery tap
3 VM3 0-200V DC 0-200V DC
voltage.
AC moving iron ammeter to read AC incoming current of
4 AM1A/B 0-200A 0-250A
charger.
DC moving coil ammeter to suitable shunt to read the
5 AM2A/B 0-700A 0-800A
charger o/p current.
DC moving coil Ammeter with suitable shunt to read the
6 AM3 700A-0-700A 800A-0-800A
discharge / /charge of the battery.
DC moving coil Ammeter to read the earth leakage
7 AM4 10A-0-10mA 10A-0-10mA
current.
CONTACTORS, PUSH BUTTONS & RELAY
225A/240V AC Coil 265A/240V AC Coil

1 C1A/B 3 pole AC input mains contactor.
(MNX225) (MNX265)
Auxiliary contactor for Float/Boost mode selection.& 4A/240V AC Coil

2 C2&2'A/B 4A/240V AC Coil
LP4-5A/B Float / Boost ON Indication. (MXO-22E)
DC contactor interlocked with AC mains contactor & DC 630A/110V DC Coil 630A/110V DC Coil
3 C3
output Contactor. (LC1-F630) (LC1-F630)
630A//240V AC Coil 630A//240V AC Coil

4 C4 & C5 DC Contactor interlocked with C2A/B.
(LC1-F630) (LC1-F630)
4A/415V AC Coil 4A/415V AC Coil

5 CA1&2A/B Auxiliary contactor for AC mains fail annunciation.
(MXO-22E) (MXO-22E)
4A/110V DC Coil 4A/110V DC Coil

7 CA3A/B Auxiliary contactor for DC fail & interlocking purpose.
(MXO-22E) (MXO-22E)
4A/110V DC Coil 4A/110V DC Coil

8 CA4A/B Auxiliary contactor for charger tripping.
(MXO-22E) (MXO-22E)
Auxilliary contactor for protection of reverse battery 4A/110V DC Coil 4A/110V DC Coil
9 CA5
connection. (MXO-22E) (MXO-22E)
10A/110V DC Coil
10 CA6 Auxilliary contactor for DC contactor interlocking purpose. 10A/110V DC Coil (LADN22)
(LADN22)
11 RL1A/B Auxilliary Relay for tempareture annunciation. 6A/240V AC 6A/240V AC
12 RL2A/B Auxiliay relay for cubicle temp. high annunciation. 110V DC 110V DC
13 PB1,2 A/B Push buttons for charger Float/Boost mode selection. 415V/4A 415V/4A
14 PB3 A/B Push buttons for charger reset. 415V/4A 415V/4A
15 PB4-6 A/B Push button for Accept, Test, Reset of annunciation. 0.5A/12V DC 0.5A/12V DC
SWITCHES
1 SW1A/B 3 pole ON/OFF AC incoming switch. 250A (CSSDF250D3) 250A (CSSDF250D3)
2 SW2A/B AC Voltmeter selector switch. 10A (SRP135VS) 10A (SRP135VS)
3 SW3A/B AC ammeter selector switch. 10A (SRP136MA60) 10A (SRP136MA60)
4 SW4A/B 1 pole ON/OFF toggle switch for C1. 10A (1021BY) 10A (1021BY)
2 pole 2 way No/OFF Cam type priority selector switch to

5 SW5 12A (2T26B/GB) 12A (2T26B/GB)
select charger in boost mode.
3pole 2 way No/OFF Cam type auto/manual mode

7 SW6A/B 12A (3T36B/GB) 12A (3T36B/GB)
selector switch for CPC controller.
4 Pole ON/OFF DC output isolator switch for Float cum

8 SW7A/B 630A (CSSD630K4) 630A (CSSD630K4)
Boost charger (Two Poles Connected in Parallel).
Single Pole ON/OFF toggle switch for earth leakage
9 SW8 10A (1021BY) 10A (1021BY)
ammeter.

SR. RATING RATING
NO. 110V/600A 110V/700A
10 SW9 Two pole Foure way NO OFFcam type switch for VM3. 10A (4S29D/YR) 10A (4S29D/YR)
11 SW10,11A/B 1 pole ON/OFF toggle switch for cubical lamp & Heater. 10A (1021BY) 10A (1021BY)
12 SW12A/B 1 pole ON/OFF toggle switch for Cublcal Fans 10A (1021BY) 10A (1021BY)
13 SW13A/B 1 pole ON/OFF toggle switch for Buzzer bypass 10A (1021BY) 10A (1021BY)
14 DOS1A/B Door Operated Switch for the Lamp. 10A 10A
3Pole On/Off Miniature circuit breaker for Power factor

15 MCB1A/B 16A (C16) 16A (C16)
capacitor.
PRINTED CKT.BOARD, ELECTRONIC RELAY, FFDS & CONTROL CARDS.
Fuse Fail Detector Circuit of solid state sensing type for

1 FFD1A/B 415V AC 415V AC
FS4-10A/B.
2 FFD2-5A/B 110 V 110 V
FS8-19A/B
3 FFD6 A/B 110V 110V
FS20A/B
4 FFD7A/B 110V 110V
FS21-22A/B
3-phase SCR controller for constant voltage/current
5 CPC1A/B 110V 110V
mode of operation.
Alarm annunciation ckt. with Accept, Test & Reset push
ANNUNCIA-
6 buttons (144sq.mm. Window type) with DC TO DC 110V DC 110V DC
TOR A/B
Converter.
U/V O/V U/V O/V
DC Under/over voltage Ckt. For charger U/V & O/V ACT 98V 123V ACT 98V 123V
7 DC U&O/V A/B
annunciation. REST 110V 122V REST 110V 122V
NORMAL 110V 110V NORMAL 110V 110V
U/V U/V
8 DC U/V DC Under voltage Ckt. For battery U/V annunciation ACT 94V ACT 94V
REST 99V REST 99V
NORMAL 110V NORMAL 110V
9 DC O/L DC overload relay for battery-On-Load annunciation 100A 100A
Automatic change-over relay for auto float/boost mode

10 ACOR 110V 110V
change-over
11 E/L Earth Leakage Relay of solid state sensing type. 110V 110V
MISCELLANEOUS
1 T1 A/B Solid state Timer to cut off boost charging 0-10Hr/240V (120DT4) 0-10Hr/240V (120DT4)
2 H1 A/B Space strip heater. 100W/240V 100W/240V
3 TH1 A/B Thermostat for the heater. 240V AC 240V AC
4 S1A/B 3 Pin socket with switch. 10A/240V AC 10A/240V AC
Metal oxide variator type surge supressor for primary of

5 SS1-3 A/B RDN320/20 RDN320/20
X'mer
6 SS4 A/B Metal oxide variator type surge supressor for DC output RDN150/20 RDN150/20
7 PFC1A/B Power Factor improvement capacitor 2KVAR -1# EACH 2KVAR -1# EACH
8 H2 Buzzer for Battery reverse polarity alarm
9 F1,2A/B Cubical forced Cooling fans 240V AC (8") 240V AC (8")
10 LED1 LED for Battery reverse polarity indication 10mA/110V 10mA/110V

MAKE OF COMPONENTS
SR. NO. DESCRIPTION MAKE
1 DC POWER ISOLATORS & AC SFU C&S / L&T / Schneider
2 CONTROL SWITCHES Kaycee
3 Fuse Links GE Power / Siemens / C&S
4 Contactor L&T / Siemens / Schneider / C&S
5 MCB Legrand (MDS)
6 Diodes/SCRS Hirect / Semikron / USHA
7 Meters AE / IMP
8 Filter Condenser Rescon / Alcon / SFPL
Electronic Controlled, Solid State Sensing Type Circuit

9 Chhabi (Our Own Make)
FFD, mV Amplifier, DC U/V, E/L, Annunciation
10 Filter Choke Chhabi (Our Own Make)
11 Transformer Chhabi (Our Own Make)
12 Push Button & Indicating Lamps Teknic
13 Control Terminals Connectwell / Elemex
14 Potentiometers Pankaj / Pawan
15 Timer L&T / Siemens
16 CT Indcoil
REV. 04
PREPARED : A.S.G.
CHECKED : M.S.A.
APPROVED : D.J.P.
DATE : 14.08.08
W.O.NO. : CE-1919
CHHABI ELECTRICALS PVT.LTD.JALGAON - 425 003 SHEET NO.LC3158 / 5 OF 5

UNIT : 500A CELL BOOSTER FOR 2X1250AH VRLA BATTERY.
TYPE : B1C (SP) 5 / 500A.
P.O.NO. : T707A058 DATED 04.06.2007.
SR.NO. : CE-1919 / CE-II 0801 / 316.
W.O.NO. : CE-1919.
MANUFACTURER :
ASSURED
Tel. : 91-257-2210626 / 27 / 28 Fax : 91-257-2213434 COMPANY
ISO:9001-2000
Certifications

Ph. : 91-22-2561 4435/5945 Ph : 91-80-2314 0031 Ph : 91-11-4215 1213 - 14
Fax : 91-22-2568 0513 Fax : 91-80-2314 0031 Fax : 91-11-4215 1215
CHHABI ELECTRICALS PVT.LTD. JALGAON - 425 003, SH : 4834 / 1- 4

INSTRUCTION MANUAL

TYPE : B1C (SP) 5 / 500A.
P.O.NO. : T707A058 DATED 04.06.2007.
SR.NO. : CE-1919 / CE-II 0801 / 316.
W.O.NO. : CE-1919.
INDEX
Sr Description Page No.

No.
1. Technical Specification. SH 4834 / 3
2. Operating Instructions & Maintenance and Fault Finding SH 4834 / 4
3. Bill of Materials LC 3159
4. Make of Components LC 3159 / 2-2
MAIN CIRCUIT & GENERAL LAYOUT
1. Main Circuit diagram & General layout for Cell Booster. C10098 Rev. 4

AC MAINS INPUT : 240V ±10%, 50Hz ±5% Single Phase AC Supply.
TYPE OF CELL BOOSTER : B1C (SP) 5 /500A.
DC OUTPUT : 500A Cell Booster suitable to charge cells as required.
AMBIENT : 50ºC average ambient temperature.
SIZE : L = 900mm, H = 1400mm, W = 800mm.
COLOUR : RAL 7032.
CONSTRUCTION : Suitable for Indoor operation.
The cell booster is equipment meant for charging battery at a maximum charging current of
500A. The unit having tapered charge current characteristics. For general layout, circuit
diagram and list of components refer Drawing No. C 10098 Rev. 4 & LC3159 Rev.4.
Double pole switch (SW1) & Fuse (FS1) is provided for AC Input side. LED (LED1)
indicates the AC supply 'ON' condition. Single phase, double wound mains transformer is
directly fed from single-phase regulator (REG1). The output of secondary of this
transformer is fed to the rectifier bridge. The rectifier bridge is full wave bridge comprising
of 4 Nos. Silicon diodes. Ammeter (AM1) reads the total charger output current. Fuse FS2
& switch (SW2) are used for DC output of the charger. Voltmeter (VM1) is used to read the
AC I/P voltage. Voltmeter (VM2) is used to read the DC O/P voltage.
Micro switch MS1 is provided in contactor coil supply. Also one NO contact of C1 is used in
parallel of this MS1. By this provision main contactor does not operate until regulator REG1
comes at its minimum position. Thus it avoids sudden rise in DC O/P voltage after booster
switched ON, if regulator REG1 will at its maximum position. IPT is provided for balancing
current of the regulator.
At minimum position of dimmer supply will go to contactor coil then contactor will pick up
and feed AC supply to dimmer.

OPERATING INSTRUCTIONS
1. Ensure that SW1 is in 'OFF' position and variac knob is in zero position. If it is not,
then turn it at its minimum position so as to pick up the main contactor C1.
2. Switch 'ON' SW1, Contactor C1 will get pick up. Turn the variac knob clockwise
gradually. Maintain DC output voltage 16V on voltmeter VM2.
3. Turn the variac knob to zero position, switch OFF SW1.
4. Switch ON SW1 & turn the variac in clockwise direction to maintain 14V DC at 500A
DC water load.
6. Complete the initial charging of battery following the instructions given by battery
manufacture.
7. While in operation the output current is controlled through variac.
MAINTENANCE AND FAULT FINDING
1. Periodic inspection and cleaning of the equipment will ensure trouble free operation
of the unit.
2. In case of no output check the fuse and replace, if necessary.
3. If fault is persistent, it can be traced by step-by-step by referring the circuit diagram.
4. In case of reduced output, disconnect and check the diodes individually and replace,
if Necessary.

TYPE : B1C (SP) 5 / 440A.
P.O.NO. : T707A058 DATED 04.06.2007.
SR.NO. : CE-1919 / CE-II 0801 / 315.
W.O.NO. : CE-1919.
MANUFACTURER :
ASSURED
Tel. : 91-257-2210626 / 27 / 28 Fax : 91-257-2213434 COMPANY
ISO:9001-2000
Certifications

Ph. : 91-22-2561 4435/5945 Ph : 91-80-2314 0031 Ph : 91-11-4215 1213 - 14
Fax : 91-22-2568 0513 Fax : 91-80-2314 0031 Fax : 91-11-4215 1215

INSTRUCTION MANUAL

TYPE : B1C (SP) 5 / 440A.
P.O.NO. : T707A058 DATED 04.06.2007.
SR.NO. : CE-1919 / CE-II 0801 / 315.
W.O.NO. : CE-1919.
INDEX
Sr Description Page No.

No.
1. Technical Specification. SH 4835 / 3
2. Operating Instructions & Maintenance and Fault Finding SH 4835 / 4
3. Bill of Materials LC 3159
4. Make of Components LC 3159 / 2-2
MAIN CIRCUIT & GENERAL LAYOUT
1. Main Circuit diagram & General layout for Cell Booster. C10098 Rev. 4

AC MAINS INPUT : 240V ±10%, 50Hz ±5% Single Phase AC Supply.
TYPE OF CELL BOOSTER : B1C (SP) 5 /440A.
DC OUTPUT : 440A Cell Booster suitable to charge cells as required.
AMBIENT : 50ºC average ambient temperature.
SIZE : L = 900mm, H = 1400mm, W = 800mm.
COLOUR : RAL 7032.
CONSTRUCTION : Suitable for Indoor operation.
The cell booster is equipment meant for charging battery at a maximum charging current of
440A. The unit having tapered charge current characteristics. For general layout, circuit
diagram and list of components refer Drawing No. C 10098 Rev. 4 & LC3159 Rev.4.
Double pole switch (SW1) & Fuse (FS1) is provided for AC Input side. LED (LED1)
indicates the AC supply 'ON' condition. Single phase, double wound mains transformer is
directly fed from single-phase regulator (REG1). The output of secondary of this
transformer is fed to the rectifier bridge. The rectifier bridge is full wave bridge comprising
of 4 Nos. Silicon diodes. Ammeter (AM1) reads the total charger output current. Fuse FS2
& switch (SW2) are used for DC output of the charger. Voltmeter (VM1) is used to read the
AC I/P voltage. Voltmeter (VM2) is used to read the DC O/P voltage.
Micro switch MS1 is provided in contactor coil supply. Also one NO contact of C1 is used in
parallel of this MS1. By this provision main contactor does not operate until regulator REG1
comes at its minimum position. Thus it avoids sudden rise in DC O/P voltage after booster
switched ON, if regulator REG1 will at its maximum position. IPT is provided for balancing
current of the regulator.
At minimum position of dimmer supply will go to contactor coil then contactor will pick up
and feed AC supply to dimmer.

OPERATING INSTRUCTIONS
1. Ensure that SW1 is in 'OFF' position and variac knob is in zero position. If it is not,
then turn it at its minimum position so as to pick up the main contactor C1.
2. Switch 'ON' SW1, Contactor C1 will get pick up. Turn the variac knob clockwise
gradually. Maintain DC output voltage 16V on voltmeter VM2.
4. Switch ON SW1 & turn the variac in clockwise direction to maintain 14V DC at 440A
DC water load.
6. Complete the initial charging of battery following the instructions given by battery
manufacture.
7. While in operation the output current is controlled through variac.
MAINTENANCE AND FAULT FINDING
1. Periodic inspection and cleaning of the equipment will ensure trouble free operation
of the unit.
2. In case of no output check the fuse and replace, if necessary.
3. If fault is persistent, it can be traced by step-by-step by referring the circuit diagram.
4. In case of reduced output, disconnect and check the diodes individually and replace,
if Necessary.

BILL OF MATERIALS
W. O. NO. : CE-1919
REV. NO : 04
DATE : 14.08.08
UNIT : 0.12V CELL BOOSTER FOR VRLA BATTERY.
TYPE : B1C (SP) 6
REF.DRG. NO. : C10098
P.O.NO. : T707A058 DTD 04/06/2007.
QTY. 1 NO. 1 NO.
RATING RATING
SR.NO. CODE NO. DESCRIPTION
440A 500A
TERMINAL PLATES
230V, 1 Phase AC input terminals for incoming power supply. Suitable for 1x3Cx16 Suitable for 1x3Cx16
1 TB1
(T1 - T3) ( L, N, E) sq.mm Cu Cable. sq.mm Cu Cable.

2 TB2 DC output Battery Terminals (T4-T5)
sq.mm Cu Cable. sq.mm Cu Cable.
FUSES :
1 FS1 AC input HRC fuses with suitable fuse fittings. 63A (CTIS63, SM63) 63A (CTIS63, SM63)
2 FS2 HRC fuse with suitable fuse fitting for DC output. 500A (CTTM500) 630A (CDFL630)
INDICATING LAMPS
1 LED1 AC input ON indicating LED with series resistance & diode. 230V 230V
2 LED2 DC output ON indicating LED with series resistance. 12V 12V
TRANSFORMERS, CHOKES
Single Phase double wound naturally air-cooled impregnated mains

1 TR1 264/20V (12.0 KVA) 264/20V (14.0 KVA)
transformer.
2 CH1 Ballast choke. 55A 60A
3 REG-1 Two coil Veriable Transformer (Auto transformer). 28A 28A
4 IPT Inter Phase Transformer 28A 30A
RECTIFIERS
D2- D5 =540A/1000PIV D2- D5 =540A/1000PIV

Full wave single phase rectifier Bridge comprising of 4 diodes with RC
1 MR1 (AR302-4#, (AR302-4#,
network.
HS=HK350-400mm-8#) HS=HK350-400mm-8#)
METERS (ACCURACY CLASS- 1%) 96 sq.mm. 90 deg. Deflection
1 VM1 AC moving iron voltmeter to read charger input voltage. 0-300V AC 0-300V AC
2 VM2 DC moving coils voltmeter to read charger output voltage. 0-20V DC 0-20V DC
DC moving coil ammeter with external shunt to read the charger

3 AM1 0-500A 0-600A
output current.
CONTACTORS
1 C1 2 Pole AC mains contactor for charger. 45A/240V AC (MNX45) 70A/240V AC (MNX70)
SWITCHES
1 SW1 2 Pole ON/OFF AC incoming switch. 63A (SRPM625) 63A (SRPM625)
2 SW2 2 Pole ON/OFF DC output switch. (two ploe connected in parallel) 300A (C3023) 300A (C3023)
3 MS1 Micro switch for interlocking between AC contactor & variac. 5A 5A
CHHABI ELECTRICALS PVT. LTD. JALGAON - 425 003 SHEET LC3159/1 OF 2

MAKE OF COMPONENTS
SR.NO. DESCRIPTION MAKE
1 AC SWITCH KAYCEE / HAVELLS
2 FUSE GE Power / Siemens / C&S
3 CONTACTOR L&T / Siemens / Schneider / C&S
4 DIODEs Semikron / USHA / Hirect
5 METERS AE / IMP
6 TRANSFORMER CHHABI (OUR OWN MAKE)
7 INDICATING LAMPS Teknic / CHHABI (OUR OWN MAKE)
Rev. 04 (Cell Booster)
W.O.NO. : CE-1919
PREPARED BY : A.S.G.
CHECKED BY : M.S.A.
APPROVED BY : D.J.P.
DATE : 14.08.08
CHHABI ELECTRICALS PVT.LTD.JALGAON - 425 003 SHEET NO.LC3159/ 2 OF 2

BILL OF MATERIALS
W. O. No. : CE-1919
REV. : 03 DTD. 14.08.08
UNIT : 110V BATTERY ISOLATION BOX A&B
REF.DRG. NO. : C10099
P.O.NO. : T707A058 DTD 04/06/2007.
QTY. 1 NO. 1 NO.
RATING RATING
SR.NO. CODE NO. DESCRIPTION
110V/600A 110V/700A
TERMINAL PLATES AND LINKS
Terminals for battery charger DC incoming supply. Suitable for 4x1Cx240 Suitable for 4x1Cx240
1 TB1A/B
(T1,T1A,T2) Sq. mm Cu. Cable. Sq. mm Cu. Cable.
2 TB2A/B DC output Battery terminals (TT3, T3A, T4)
Sq. mm Cu. Cable. Sq. mm Cu. Cable.
3 TB3A/B Terminal for battery fuse box DC supply (T5-6)
4 TB4A/B Terminal for interlocking purpose (T7-8)
5 TB5A/B Terminal for interconnection purpose (T9-10)
6 TB6A/B Terminal for Battery voltmeter VM3.(T11-13)
FUSES
1 FS1,2A/B HRC fuse with suitable fuse fitting for Battery 800A (CTLM800) 800A (CTLM800)
SWITCHES
4 Pole ON/OFF DC output isolator switch for

630A (ON-LOAD 630A (ON-LOAD
1 SW1A/B Battery Isolation (Two Poles Connected in
ISOLATOR) ISOLATOR)
Parallel).
ELECTRONIC CARD
Fuse Fail Detector Circuit of solid state sensing

1 FFD1A/B 110 V 110 V
type for FS1-2
CHHABI ELECTRICALS PVT. LTD. JALGAON - 425 003 SHEET LC3160 / 1 OF 2

MAKE OF COMPONENTS
SR. NO. DESCRIPTION MAKE
1 Switches Kaycee / Havells / HPL
2 HRC Fuses GE Power / Siemens / C&S
3 Electronic Controlled, Solid State Sensing Type Circuit FFD Chhabi (Our Own Make)
REV.03
PREPARED : A.S.G.
CHECKED : M.S.A.
APPROVED : D.J.P.
DATE : 14.08.08
W.O.NO. : CE-1919 (FUSE BOX)
CHHABI ELECTRICALS PVT.LTD.JALGAON - 425 003 SHEET NO.LC3160 / 2 OF 2

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OPERATION & MAINTENANCE

Mumbai Office : Bangalore Office : Delhi Office : Kolkata Office :

CHHABI ELECTRICALS PVT. LTD. JALGAON – 425 003.SH.NO. : SH-4833 / 1 of 11

UNIT : BATTERY CHARGER FOR 110V/2X1100AH VRLA BATTERY.

1 Technical Specification SH-4833 / 3

CIRCUIT DIAGRAM & GENERAL LAYOUT

PREPARED : A.S.G. CHECKED : A.S.B. APPROVED :D.J.P

CHHABI ELECTRICALS PVT. LTD. JALGAON – 425 003. SH.NO. : SH-4833 / 2 of 11

MAIN AC INPUT : 415V 10%, 50Hz, 5%, 3Phase, 4 Wire AC supply.

BATTERY DETAIL : a) Type of Battery : VRLA Battery.

TYPE : Float cum Boost Charger A & B.

DC OUTPUT : Battery Charger A & B :

RIPPLE : Charger A & B - 1 % (RMS)

AMBIENT : 50° C Average ambient temperature.

SIZE : L = 4400mm H = 2000mm W= 1000mm

COLOUR : Inside & Outside RAL7032

CONSTRUCTION : a) Suitable for indoor operation and floor mounting.

CHHABI ELECTRICALS PVT. LTD. JALGAON – 425 003. SH.NO. : SH-4833 / 3 of 11

CHHABI ELECTRICALS PVT. LTD. JALGAON – 425 003. SH.NO. : SH-4833 / 4 of 11

2.2) INSULATION RESISTANCE TEST (WITH 500V MEGGER) :-

CHHABI ELECTRICALS PVT. LTD. JALGAON – 425 003. SH.NO. : SH-4833 / 5 of 11

a. Connect the AC cables to the Charger Terminal Board TB1A/B.

4.00 LOADING ARRANGEMENT:-

Make the water load arrangement as described below.

I) FLOAT CUM BOOST CHARGER A/B IN FLOAT MODE :

Keep the following position of selector switch.

Observe the output voltage on DC voltmeter VM2A/B. It shall increase gradually up to

FULL LOAD OPERATION:

CHHABI ELECTRICALS PVT. LTD. JALGAON – 425 003. SH.NO. : SH-4833 / 6 of 11

Keep the following position of selector switch.

FULL LOAD OPERATION :

Increase the voltage by RV3A/B; simultaneously increase the load current by

NOTE : In manual mode, DC voltage is not regulated but only controlled by

II) FLOAT CUM BOOST CHARGER A/B IN BOOST MODE:

Keep the following position of selector switch.

CHHABI ELECTRICALS PVT. LTD. JALGAON – 425 003. SH.NO. : SH-4833 / 7 of 11

FULL LOAD OPERATION :-

CURRENT LIMITING FEATURE:

CHHABI ELECTRICALS PVT. LTD. JALGAON – 425 003. SH.NO. : SH-4833 / 8 of 11

1) FLOAT CUM BOOST CHARGER A/B IN FLOAT MODE :

CHHABI ELECTRICALS PVT. LTD. JALGAON – 425 003. SH.NO. : SH-4833 / 9 of 11

4.00 SPECIAL ATTENTION WHILE OPERATING :

CHHABI ELECTRICALS PVT. LTD. JALGAON – 425 003. SH.NO. : SH-4833 / 10 of 11

5.00 INITIAL CHARGING OF BATTERIES :

6.00 ROUTINE MAINTENANCE OF BATTERY CHARGER :

A) 1) Cleaning of panel from inside & outside by using blower : Weekly

7.00 TROUBLE SHOOTING :

1) If voltmeters does not show any reading then check

CHHABI ELECTRICALS PVT. LTD. JALGAON – 425 003. SH.NO. : SH-4833 / 11 of 11

Mumbai Office : Bangalore Office : Delhi Office : Kolkata Office :

CHHABI ELECTRICALS PVT. LTD. JALGAON – 425 003.SH.NO. : SH-4832 / 1 of 11

UNIT : BATTERY CHARGER FOR 110V/2X1250AH VRLA BATTERY.

Sr. # Description Sheet No.

1 Technical Specification SH-4832 / 3

CIRCUIT DIAGRAM & GENERAL LAYOUT

PREPARED : A.S.G. CHECKED : A.S.B. APPROVED :D.J.P

CHHABI ELECTRICALS PVT. LTD. JALGAON – 425 003. SH.NO. : SH-4832 / 2 of 11

MAIN AC INPUT : 415V 10%, 50Hz, 5%, 3Phase, 4 Wire AC supply.