Final Draft Ti SPC Psi 40 150 CHGR 1210
Final Draft Ti SPC Psi 40 150 CHGR 1210
Final Draft Ti SPC Psi 40 150 CHGR 1210
For battery charger for 110 Volt battery, 150 Ah (for 2x25
TI/SPC/PSI/ 40-150/CHGR/1210 kV)/40Ah (for 25kV) at SP/SSP for electric traction installation
TECHNICAL SPECIFICATION
FOR
(Effective from: )
ISSUED BY
SPECIFICATION FOR:Battery charger for 110 Volt battery, 150 Ah (for 2x25 kV)/40Ah (for
25kV) at SP/SSP for electric traction installation
0 TI/SPC/PSI/40-150/CHGR/1210 14
DATE
1.0 Scope
1.1 The specification applies to the design, manufacture, supply and erection &
commissioning of battery chargers for charging 110 V, 150 Ah lead acid batteries
installed at unattended 2X25 kV traction switching stations (SSP/SP/AT) and 40 Ah
lead acid batteries installed at unattended 25 kV traction switching stations (SSP/SP).
Separate battery charger shall be developed for 40Ah & 150Ah lead acid batteries.
1.2 The battery chargers shall be complete with all parts and accessories necessary for
their efficient operation. All such parts and accessories shall be deemed to be within
the scope of this specification whether specifically mentioned or not.
1.3 The “Make in India” Policy of Government of India shall be applicable.
1.4 This specification supersedes specification no. ETI/PSI/1 (06/81).
2.0 Service conditions:
2.1 The battery chargers are intended for use in moist tropical climate in India, with
following atmospheric conditions:
SN Description Value
i. Maximum ambient air Temperature 550C
ii. Minimum ambient air Temperature -100C
Maximum relative humidity 100% saturation during raining
iii. season
Maximum number of thunder storm days 85 days
iv. per annum
Maximum Number of dust storms days 35 days
v. per annum
vi. Altitude Not exceeding 2000 meters.
2.2 The battery chargers are required for installation in control rooms of unattended 25 &
2x25 kV switching station (SSP/SP). The charger shall also be suitable for effecting
quick charge of a discharged battery. The steady super-imposed load on the battery
charger will be maximum 2 Amp 40Ah battery charger and 4 Amp for 150 Ah
battery. Steady superimposed load will vary depend on type of SSP/SP and number
of lines. The control room cubicles are situated close to the Railway tracks and hence
the Panels are subjected to vibrations due to running trains.
2.3 The battery charger shall be suitable for operation on 240Volt single phase, 50 Hz
supply obtained from 25 kV / 240volts, 10 kVA LT supply transformer, the primary
of which is connected to the 25 kV switching station bus bars at one end and to earth
at the other. The 240V ac supply is, therefore, subject to fluctuations of voltage
between 170V and 270Volt.
3.0 Governing specification:
3.1 The battery charger and its main components shall comply with the following
specifications which shall be applied in the manner, altered, amended or
supplemented by this specification and the Indian Electricity Rules, where
applicable.: -
i. Mono-crystalline semiconductor rectifier assemblies IS: 4540-1968
and equipment. IS: 6619-1972
stacks.
iv. Electrical indicating instruments IS: 1248-1968
v. Miniature circuit breaker IS: 8828-1978
vi. Specification for HRC fuses IS:2208
vii. Specification for wiring IS:375/1963
viii. Air break contactor/switch IS:13947/1993
ix. Printed circuit board IS:5421/1981, IS:
5921
x. Safety code for semiconductor rectifier equipment IS:6619
xi. AC contactors for voltage not exceeding 1000V IS:2959
3.2 Any deviation from this specification calculated to improve the performance,
utility and efficiency of the equipment, proposed by the vendor, will be given due
consideration, provided, full particulars with justification thereof, are furnished. In
such a case the vendor shall quote according to this specification and the
deviations proposed by him shall be quoted as an alternative proposal.
4.0 Rating and other particulars:
4.1 The battery charger shall be designed for the following rating and other particulars:
i) Type Two-rate, mono crystalline semi-conductor Silicon
controlled rectifier type, suitable for floor mounting.
ii) Nominal primary 240V 50 Hz ac, subject to variation from 170 to 270V.
voltage
iii)Nominal output voltage. 110 V dc
iv) Charging characteristics:
a. Trickle charge Battery charger for 40Ah:
The output voltage of the charger shall be adjustable
between 115 to 127 V (2.1 to 2.3 V per Cell) by a
potentiometer provided on the PCB for smooth step less
control of trickle voltage. In this mode the charger will
operate in constant potential mode with current limit.
Battery charger for 150Ah:
The output voltage of the charger shall be adjustable
between 115 to 127 V (2.1 to 2.3 V per Cell) by a
potentiometer provided on the PCB for smooth step less
control of trickle voltage. In this mode the charger will
operate in constant potential mode with current limit.
Zinc Phosphating
Rinsing (Water wash)
Drying
Powder coating & curing
If any painted surface gets damaged during transit, the surface finish shall be
restored at site after erection by vendor.
5.3 The components of the battery chargers shall be appropriately mounted and
identified with identification labels. The layout of major components shall permit
easy access for maintenance. The charger shall be of robust construction. The
assembly shall be such that it will not be affected adversely by the vibrations
induced from nearby railway tracks. The clearances and creepage distances shall be
in accordance with clause 4 of IS: 6619-1972. The noise level shall be kept to the
minimum.
5.4 The rectifier transformer shall be double wound, vacuum impregnated, natural air
cooled and liberally rated. The core shall be made of low loss silicon steel
laminations. The winding shall be of copper with class F insulation.
5.5 Chokes shall be of copper winding with class-F insulation and shall be vacuum
impregnated.
5.6 The rectifier shall be of the half or full controlled bridge connection using silicon
thyristors or silicon thyristors and diodes with liberal ratings. The rectifier shall be
suitably protected against overloading due to short time heavy currents drawn
during closing of the circuit breakers, short circuits, over voltages and against
inrush currents when charging full discharged batteries.
5.7 The switches meters and fuses shall be flush mounted on the front panel and shall
be purchased from reputed manufacturers. These shall conform to relevant Indian
Standards specifications.
5.8 The volt meters and ammeters shall be of flush mounted type of accuracy class 2.5
as per IS: 1248-1968 or latest. Latest digital or Analog meter for each with better
accuracy shall be provided.
5.9 The control wiring inside the charger shall be with 1100 V grade PVC insulated
copper cable having a minimum cross-section of 2.5 sq. mm for current carrying,
0.75 sq. mm voltage sensing and 0.5 sq. mm for electronic portion confirming to lS:
694-2010. The size of wire for power circuit shall be as per battery charger rating.
The cables shall be suitably supported and provided with identification ferrules the
connecting points.
5.10 The AC input and the DC output terminals shall be of robust design and shall be
suitable for PVC copper cable connections. The polarity of output DC terminals
shall be clearly marked.
5.11 (i) The battery charger shall be provided with facility for both automatic and
manual control – which shall control both Float & Boost functions as to be
installed at unattended 25 kV & 2x25 kV switching stations
(ii) It shall have current limiting facility, if the voltage control is in an automatic
Page 7 of 14 Specification No. For battery charger for 110 Volt battery, 150 Ah (for 2x25
TI/SPC/PSI/ 40-150/CHGR/1210 kV)/40Ah (for 25kV) at SP/SSP for electric traction installation
mode and shall cause a gradual lowering of the output voltage when the DC load
current exceeds the load limiting setting.
(iii) The charger shall have an adjustable current limiting facility-brought about by
changing the charging voltage in gradual manner, also for safe guarding the
Battery.
(iv) Uniform and smooth adjustments of voltage setting (in both manual and
automatic modes) shall be provided.
(v) During Boost charging Battery Charger shall be in constant current mode and
operation shall be smooth and stepless.
(vi) The current limiting characteristics shall be such that any overload or short circuit
in the DC system shall not damage the charger, and will lower the output voltage
immediately to avoid blowing of any of the charger fuses. To prevent any failures
of the automation platform creating hazards in the field, it is recommended that
fuses blow rather than risk life and high voltage output.
(vii) A lead acid battery charger should switch to float charge when fully saturated
when operating in automatic mode.
(viii) Soft start feature shall be provided in the system.
5.12 Battery Charger shall have feature to communicate on MODBUS with SCADA
system for control (ON/OFF) battery charger, status monitoring, faults i.e. Battery
charger fail, input mains fail, input fuse fail/MCB trip, output MCB/MCCB
trip/fuse fail, DC over voltage, DC under voltage, earth leakage at RCC through
SCADA systems. The input and output voltage (Battery terminal and load
terminal) of battery charger shall also be communicated to RCC through SCADA.
6.0 Fittings and Accessories:
The following fittings and accessories shall be provided on the battery charger:
i) LED indication for input ON and out put ON
ii) LED indication for trickle status ON/OFF, Boost status ON/OFF
iii) A double pole miniature circuit breaker along with a backup slide lock type
HRC fuse on ac side.
iv) Two numbers slide lock type HRC fuses/MCB/MCCB of suitable rating on DC
side (Battery terminal).
v) Two numbers slide lock type HRC fuses /MCB/MCCB of suitable rating on
DC side (Load terminal)
vi) Analog or digital voltmeter 0-200 V on DC side.
vii) Analog or digital ammeter (0-5A/0-10A with 40 Ah battery charger or 0-
15A/0-30A with 150 Ah battery charger) separately or dual range for trickle
and boost current.
viii) Analog or Digital voltmeter 0-300 V on AC side.
ix) Auto/Manual selector switch
x) Step less smooth control through potentiometer for trickle voltage
adjustment in auto mode.
xi) Step less smooth control through potentiometer for Boost charge current
adjustment in auto mode.
Page 8 of 14 Specification No. For battery charger for 110 Volt battery, 150 Ah (for 2x25
TI/SPC/PSI/ 40-150/CHGR/1210 kV)/40Ah (for 25kV) at SP/SSP for electric traction installation
xii) Solid state automatic load voltage regulator to maintain the load voltage
of 110V±5 Volt DC. The rating of solid state transistorized dropping
device shall be 5A continuous and 20A for 30 Sec for 40Ah and 10A
continuous and 30A for 30 Sec for 150Ah.
xiii) Rating and diagram plate.
xiv) Two earthing terminals suitable for taking 8 SWG GI wires.
xv) RS 485 port for communication with SCADA to control, status and fault alarm
display at RCC
xvi) Fuse fail/MCB/MCCB trip LED indication load and battery terminal
xvii) PVC insulated PVC sheathed 1100 V grade 3 core cable with copper
conductors having a suitable cross section and conforming to IS: 694-2010
of suitable length fitted with a suitable 3 pin plug for connection to 240V ac
supply.
As battery charger is manual and automatic, accessories accordingly
shall be given in detail in the design drawing document submitted to RDSO
for approval.
7.0 Type tests:
Following type tests shall be carried out on the prototype complete charger.
7.1 Tests on complete charger:
7.1.1 Visual inspection:
The proper layout, mounting, identification, connections and construction shall
be checked.
7.1.2 No load test:
The test shall be carried out at input minimum voltage i.e. 170V and maximum
input voltage i.e. 270V adjusted through a variac at input side..
7.1.3 Load test with resistance load:
The test shall be carried out by applying the minimum input voltage i.e. 170 V and
maximum input voltage i.e. 270 Volts at input terminal through a variac at input side.
An adjustable resistance load shall be connected across the output terminals. Load
current shall be adjusted to the set value as nearly as possible at both minimum and
maximum input voltage. The tests shall be carried out individually for specific current
values specified under trickle and boost charge conditions.
7.1.4 Measurement of Ripple factor:
Ripple voltage on DC side shall also be measured during the load test (cl.
7.1.3) and the percentage ripple content shall be calculated.
7.1.5 Efficiency Test:
This test can be combined with no load test and load test for which details have
been indicated in Cl. 7.1.2 and 7.1.3 respectively. For this test, input current,
voltage and power on the AC side shall also be recorded at the minimum and
maximum output voltages. The efficiency and the power factor shall then be
computed from the test results.
Page 9 of 14 Specification No. For battery charger for 110 Volt battery, 150 Ah (for 2x25
TI/SPC/PSI/ 40-150/CHGR/1210 kV)/40Ah (for 25kV) at SP/SSP for electric traction installation
dimensioned drawings for the equipment offered as per Railways standard size
of 210 mm x 297 mm or any integral multiple thereof for approval by the
purchaser along with soft copy:
i) Outline general arrangement drawing (in three views) along with mounting
dimensions.
ii) Schematic diagram of connections along with technical details of
components.
iii) Cross –sectional views (showing location of major components).
iv) Table of guaranteed and other technical particulars.
After approval, six copies of approved drawings along with 2 sets of reproducible
copies shall be supplied to the purchaser.
9.4 Successful vendor shall also be required to furnish the design calculations for
the rectifier transformer rating, rectifier ratings and filter circuits for approval
by the purchaser.
Page 12 of Specification No. For battery charger for 110 Volt battery, 150 Ah (for 2x25
14 TI/SPC/PSI/ 40-150/CHGR/1210 kV)/40Ah (for 25kV) at SP/SSP for electric traction installation