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Operating & Maintenance Manual: 48V/100A Float Cum Boost Charger

This document provides an operating and maintenance manual for a 48V/100A float cum boost battery charger. It includes: 1. A general description of the charger components and specifications for voltage, current, and modes of operation. 2. A table of contents listing sections that describe the charger's technical specifications, installation, controls, protections, theory of operation, instructions, maintenance, troubleshooting, and drawings. 3. Details on the charger's AC and DC ratings, meters, indicators, protections, controls, special features, construction, and ambient temperature range. 4. Instructions for unpacking and installing the freestanding cabinet charger in an area away from heat and

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100% found this document useful (1 vote)
3K views23 pages

Operating & Maintenance Manual: 48V/100A Float Cum Boost Charger

This document provides an operating and maintenance manual for a 48V/100A float cum boost battery charger. It includes: 1. A general description of the charger components and specifications for voltage, current, and modes of operation. 2. A table of contents listing sections that describe the charger's technical specifications, installation, controls, protections, theory of operation, instructions, maintenance, troubleshooting, and drawings. 3. Details on the charger's AC and DC ratings, meters, indicators, protections, controls, special features, construction, and ambient temperature range. 4. Instructions for unpacking and installing the freestanding cabinet charger in an area away from heat and

Uploaded by

Mushahary Anup
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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OPERATING & MAINTENANCE MANUAL

48V/100A FLOAT CUM BOOST CHARGER

J.O. No. : 0758-10

Rating : 48V/100A FLOAT CUM BOOST CHARGER

S.O. No. : PKOLS/000020/10-11

Customer : UNITEK PROJECT & SYSTEMS / GUWAHATI

Project : OIL INDIA LTD / GUWAHATI

SL.NO. : 01100758000010101 TO 01100758000160101

REV. 00

AMARA RAJA POWER SYSTEMS LTD.


RENIGUNTA–CUDDAPAH ROAD, KARAKAMBADI–517 520
TIRUPATI (A.P.)
Tel : 0877- 2265000
Fax : 0877-2285600 / 2285899
TABLE OF CONTENTS

==================================================================
SL.NO. CONTENTS
-------------------------------------------------------------------------------------------------------------------

01. GENERAL DESCRIPTION

02. TECHNICAL SPECIFICATIONS

03. UNPACKING AND INSTALLATION

04. CONTROLS & INDICATORS

05. PROTECTIONS

06. CHARGER THEORY

07. OPERATING INSTRUCTIONS

08. MAINTAINENCE & TROUBLE SHOOTING

09. ALLIGNEMENT & ADJUSTMENT

10. BILL OF MATERIALS

11. SCHEMATIC DRAWINGS

12. DIMENSIONAL DRAWINGS

=================================================================

2 of 14
1.0 GENERAL DESCRIPTION

1.1 The Battery Charger (Float cum Boost Charger) is for charging the Battery
bank in Float/Boost modes and to meet the load requirement. The Battery
Charger basically consists of AC Input MCB, Double Wound Input
Transformer, Full-wave Full controlled rectifier bridge, L-C Filter circuits, DC
output MCCB and control and protection circuits.

1.2 All these circuits are housed in freestanding cabinet of folded sheet steel
construction. The cabinet is provided with front and back double leaf doors for
easy accessibility. All meters, meter selector switches, Annunciator Panel is
provided on the top panel and mode selector switches are provided on the
middle panel. The input and output switches are provided on middle switch
panels. The cable terminations are provided behind the bottom panels.

1.3 The Float cum Boost charger works on 415V AC, 3 phase, 50Hz supply. The
Battery charger is capable of delivering the full rated load at the specified
voltage at the output terminals. The set output voltage is maintained for AC
variation of ± 10% and load variation from 0-100% of rated full load.

*****

3 of 14
TECHNICAL SPECIFICATION
TYPE : FLOAT CUM BOOST CHARGER
FULL WAVE FULL CONTROLLED TYPE
RATINGS : 48V/100A Float cum Boost Charger
(Suitable for NVRLA battery)
2.1 AC INPUT
a. Voltage : 415VAC + 10%, -10%
b. Frequency : 50Hz ± 5%
c. Phase : 3 Phase, 4 Wire

2.2 DC OUTPUT
a. Float Voltage : 52.8V DC adjustable by +2%, -5%(2.2*24)
b. Boost Voltage : 66.0V DC adjustable by +2%, -5% (2.75*24)
c. Regulation : Better than ± 1% of set value
d. Ripple : Less than 1% Peak to Peak
e. Current : 100A
f. DC output : 52.8VDC after DD Ckt.

2.3 METERS : Following Analog type meters of 96*96Sq. mm with 90°


deflection are provided in the system for measuring the
respective parameters.
a. DC Voltmeter
b. DC Ammeter
c. AC Voltmeter}selector switch
d. AC Ammeter}
e.
2.4 INDICATIONS : 1. Pilot lamps are provided at AC input for mains ON condition.

2. ‘LED’ indicators are provided for the following


Conditions with audio alarm abnormal conditions.
a. Charger ON
b. Battery discharge*
c. Battery over voltage/over charge
d. Mains fail *
e. Rectifier fuse fail
f. Charger fail*
g. Float ON
h. Boost ON
i. Phase fail*
j. Filter fuse fail
k. Equipment DC over voltage
l. Equipment DC under voltage
m. DC Earth leakage
n. DC CB trip
o. Alarm board fuse fail
p. Battery under voltage*
NOTE : PFC contacts will be provided for * marked conditions

2.5 PROTECTIONS : Following protections are provided in the system


a. AC input MCB
b. DC output MCCB
c. Fast semiconductor fuses for Rectifier Bridge.
d. Over voltage cutback
e. Charger over load/short circuit
f. Battery charging current limit
g. Blocking Diode
h. Battery under Voltage Protection

4 of 14
2.6 CONTROLS & SWITCHES : Following Controls & Switches are provided in the
system.
a. AC input source MCB
b. DC output MCCB
c. Float/Boost mode selector switch
d. Float & Boost voltage variable potentiometers.
e. Manual voltage adjustment potentiometer
f. Lamp push button
g. Alarm Silence push button
h. Battery current adjust potentiometer
i. Heaters Power supply switch
j. Socket Power supply switch
k. Door lamp power supply switch

2.7 SPECIAL FEATURES : The following features are provided in the system.
a. Soft start on DC side.
b. Class-F insulation for all magnetics.
c. Filter circuit to eliminate ripple.
d. Charger current limit
e. Built in auto phase reversal of operation

2.8 GENERAL :
1. Cabinet : Free standing cabinet, floor mounting type, sheet steel
Construction, easy access for installation and maintenance,
cable entry at bottom.

2. Paint : Shade 631 of IS - 5

3. Protection : IP – 42 as per IS 13947

4. Ambient Temperature : 0-50 Deg. C


range of operation

5. Relative humidity : 0 - 95% non - condensing

UNPACKING AND INSTALLATION


All external wrapping and packing materials should be removed and discarded. Care should be
exercised in removing at front as all the meters, push buttons and control switches are located on
front panel. This would include cardboard, plywood packing and plastic film. The unit should be
opened and carefully inspected for wooden braces used to block internal components as well as
adhesive tapes, which are often used to restrain plug in components such as relays. Internal
packing materials may be discarded, since they will be of no further use.

A good deal of consideration should be given to the location selected such that the area is free
from dropping or falling substances which may penetrate through ventilated openings. Care
should be exercised to locate the unit away from heat producing equipment, which may cause the
ambient in the area of the system to be higher than the specified value. Generally, the system
(cabinets) are supplied with free standing bottom

5 of 14
INPUT/OUTPUT CABLING

The equipment is designed to accept cables from the bottom of the cabinet. Entrance areas for
these cables have been provided at front/back of the cabinet. The terminal connection areas are
generally behind the doors at about 3" to 6" below the cable entry openings.
The maximum current ratings of input/output connections are presented below.
AC INPUT : 4 Wire (R,Y,B & N)
DC OUTPUT : 2 Wire
BATTERY INPUT : 2 Wire

Care should be taken when selecting the size of the cable and load components to co-ordinate
with the input and output current requirements of the system.

CONTROLS & INDICATIONS


The following are the controls provided in the system for different operating conditions. The
functions are briefed below with front panel inscription.
CONTROLS
===================================================================
CKT.DES FRONT PANEL DESCRIPTION FUNCTION
INSCRIPTION
------------------------------------------------------------------------------------------------------------------
CB 401 AC INPUT AC Input circuit Connects the three phase
Breaker AC input supply to the charger
Input transformer.

CB 402 DC OUTPUT DC output circuit Connects DC output to the


Breaker battery and to the load

SW 405 MODE SELECT Charging mode Selects the charging modes Auto/
selector switch Float/ Boost depending upon
the switch position manually.

SW 3 DC VOLT SEL DC Voltage Selects the DC output


Selector switch depending upon the switch
position manually.

PB 1 LAMP TEST Lamp Test By pressing the push button the


Push button LED indicators directed through
the alarm board will glow.
PB 2 ALARM SILENCE Alarm silence When depressed the fault audio
push button alarm gets silenced.

R 401 FLOAT VOLT Float voltage It is used to adjust to get the


ADJUST adjust POT required float voltage of the
Charger (52.8V DC).

R 402 BOOST VOLT Boost voltage It is used to adjust the boost


ADJUST adjust POT voltage of the
Charger (66.0V DC).
6 of 14
INDICATIONS
The following indications are provided in the system for different conditions. The indications are
briefed below with front panel description.

TITLE INDICATION ALARM DESCRIPTION

MAINS ON (PILOT LAMP) Yes ---- Indicates that the AC Input supply is
available at charger input.

FLOAT ON Yes ---- Indicates that the charger is in


Float mode and battery is float
charged by charger.

BOOST ON Yes ---- Indicates that battery is in


Boost charging mode.

AC SUPPLY FAIL Yes Yes Indicates that the AC Input Power


Supply Fail at Charger Input.

CHARGER ON Yes ---- Indicates that the DC output is


available at charger output.
CHARGER FAIL Yes Yes Indicates that the Charger fails to
give rated DC output through AC
Mains is available at AC Input.

EQUIPMENT UNDER Yes Yes Indicates that the Voltage at load


VOLTAGE bus is lower than the set value 48V
DC

EQUIPMENT OVER Yes Yes Indicates that the voltage at the


VOLTAGE load bus is higher than the set value
54V DC

BATTERY UNDER Yes Yes Indicates that the Voltage at Batt.


VOLTAGE bus is lower than the set value 44V
DC

BATTERY OVER Yes Yes Indicates that the voltage at the


VOLTAGE load bus is higher than the set value
67.5V DC

DC EARTH Yes Yes Indicates that the either +VE of the


FAULT system or –VE of the system is
leaking to earth
RECTIFIER FUSE Yes Yes Indicates that SCR fuse is failed
FAIL

FILTER FUSE Yes Yes Indicates that Filter fuse is failed


FAIL
PHASE FAIL Yes Yes Indicates that any one of the phase
fail
DC CB TRIP Yes Yes Indicates that dc output MCCB
trip/off
7 of 14
BATTERY OVER LOAD Yes Yes Indicates that Batteries are over
loaded
BATTERY DISCHARGING Yes Yes Indicates that Battery is under
discharge condition

PROTECTIONS
DC OVER LOAD/SHORT CIRCUIT PROTECTION
The Charger is current limited at 105%. The shunt SH 401 provides the current feedback to the
control board PC 401, which causes the unit to go into current limit beyond the set value.
Whenever the current exceeds this point (set level) the charger control board PC 401 senses this
overload and reduce the output DC voltage. So that the output current does not exceed the preset
value.
OVER VOLTAGE PROTECTION
The charger control board (PC 401) is having build in over voltage protection for any failure in
regulating circuit. In this the operational amplifier compares the output voltage over a reference
voltage. If the output voltage is more than the set one, the OP. AMP inhibits the firing pulses to
the charger SCRs. Thus avoiding over voltage at charger output. Thus the output voltage never
goes beyond a set value. The reference voltage set at factory itself.

SOFT START
The equipment is provided with soft start feature and this makes the DC output voltage to rise
gradually to its rated value over duration of 6-10 seconds, whenever the charger is powered or at
the time of restoration of mains failure. This avoids the sudden application of full voltage to the
drained battery and DC capacitors. Also the equipment restarts automatically in Float mode and
goes to boost mode based on the battery condition.

BATTERY UNDER VOLTAGE CUT OFF

This equipment is also provided with battery under voltage cut off protection to avoid battery
deep discharge during mains fail or charger fail condition in turn increases the life of the battery.
During battery discharge, battery voltage will be monitored through control PCB to isolate the
battery from load terminals.

OPERATING INSTRUCTIONS
The battery chargers are designed to operate unattended without the need for periodic adjustments.
Before switching on the equipment make sure that:
1. All the Input / Output connections are made properly.
2. Rated voltages are present at all input terminals.

SYSTEM OFF CONDITION

The system total OFF condition with all controls in initial status is presented below:

BREAKER / SWITCH POSITION

1. AC INPUT (CB 401) OFF

8 of 14
2. DC OUTPUT (CB 402) OFF

3. DC VOLT SELECT (SW3) CHARGER


4. MODE SELECT (SW405) AUTO

CHARGER FUNCTIONAL CHECK

The charger may be checked for its functional operation before connecting the Battery and
Load. Make sure that all the above conditions (Charger OFF) prevail before powering the
charger. The functional checks are as follows.

a. Ensure that DC VOLTS SELECT switch (SW 3) is in charger position.

b. Make sure that MODE SELECT switch (SW 405) is in FLOAT position

c. Throw AC INPUT Breaker (CB 401) to ON position and observe DC VOLTS meter
reading.

d. The charger output voltage should gradually increase to its rated Float value 52.8VDC.
If the meter does not show the rated voltage, the FLOAT potentiometer R401 should be
adjusted to get the required voltage.

e. Throw MODE SELECT switch (SW 405) to BOOST position. The DC VOLTS meter
should gradually increase to rated BOOST voltage 66.0V DC. If the meter does not show
then rated voltage the BOOST potentiometer R 402 should be adjusted to get the required
Voltage.

f. Throw MODE SELECT switch (SW405) to AUTO position. The meter should read the
rated FLOAT voltage.
g. Throw AC INPUT breaker (CB 401) to OFF position.
h. Observe the reading of DC VOLTS meter, which gradually comes to zero voltage.
Now the battery and load can be connected to the system and the operation of the system is
merely a matter of starting the unit and shutting it down properly.

START UP PROCEDURE

a. Ensure that the MODE SELECT switch (SW 405) is in AUTO position.
b. Throw AC INPUT breaker (CB 401) to ON position.
c. Throw DC OUTPUT breaker (CB 402) to ON position.

SHUT DOWN PROCEDURE


a. Throw AC INPUT breaker (CB 401) to OFF position.
b. Throw DC OUTPUT breaker (CB 402) to OFF position.

9 of 14
CHARGER THEORY

The Float cum Boost Charger is designed to charge the Non VRLA Batteries. Voltage and
current regulation is achieved by employing a digitally controlled circuit. A single PCB does the
function of voltage regulation, current regulation, output current limiting and takes care of
overload, over voltage and short circuit at the output of the charger. All the indications are brought
on the Front panel while two separate potentiometers are provided behind the front panel for Float
/ Boost voltage adjustments. Two meters mounted on the front panel to indicate Charger & Battery
output voltages and Currents and AC input voltage and current through selector switches.

The Three-phase input AC supply is connected through Circuit Breaker (CB 401) to the Double
Wound Charger Input Transformer (T 401). The secondary of the Transformer (T 401) is
connected to a full wave full controlled Bridge (SCR R,Y,B) through Fuses FU 401-402. The
secondary of the Transformer (T 402) is connected to the charger control circuit Board (PC 401).
This control card PC 401 fires charger SCRs slowly initially for DC soft start and controls the
phase angle depending upon the output voltage of the charger. Inductor L 401 is utilized to smooth
output from the ripple from the raw DC appearing across the Bridge output. The DC Capacitors
Bank C 402 is provided in the system to filter out all higher harmonics produced in the system.
Blocking Diode (D 401) prevents the reverse current flow into the charger. Shunt SH 401 provides
charger current feedback to PC 401 for current regulation; DC Voltmeter (M1) measures the DC
output and Battery voltages through selector switch (SW3) and DC Ammeter (M2) measures
Battery current. AC Volt meter M402 measures AC i/p Voltage through selector switch. AC
Ammeter M401 measures AC i/p current through selector switch SW 401.

Auto / Float / Boost mode of operation can be selected through front panel mode selector switch
SW 405. Float to Boost or vice versa takes place in Auto Mode, when the Battery charging current
exceeds / decreases 10%-6% of the Battery AH capacity. The Batteries can be charged in manual
mode by selecting the mode selector switch to Float or Boost position.

For battery under voltage protection Auto Trip cut off mechanism was incorporated with voltage
limit as 44VDC. This can be achieved by continuous monitoring of battery voltage using control
PCB (PC6). When the voltage of battery reaches the set point, contactor (CON.2) will get turn off
(contacts changes from Close to Open) through control PCB named as voltage detector board
(PC6-relay contacts pin nos 10,2) that in turn isolates the battery from load to avoid deep
discharging condition.

DROPPER DIODE CIRCUIT


The output voltage regulator circuit includes dropper diodes (D 1 -16) and contactor (CON 1)
associated with voltage sensing relay PCB (PC 10). The Charger output voltage will be sensed by
the voltage sense circuit boards (PC 11), which are set at different voltage levels. Whenever the
charger output voltage is higher than the set voltage point then that particular sense circuit will in
turn ON, closes the relay of the relay board which in turn opens the contactor associated with that
PCB and the related dropper diodes will drop the excess voltage so that the output voltage is
maintained at constant level. If the output voltage is less than the set point the contactor will be
closed and the current is allowed to pass through the contactor. The CON 1 is connected with relay
board PC 11 respectively.

The charger is provided with different indications with alarm. All these indications are provided
on the front panel.

10 of 14
MAINTENANCE AND TROUBLE SHOOTING

MAINTENANCE

Battery charger units ordinarily require very little routine maintenance. Occasionally the
customer may give the unit a visual inspection every six months or so to locate the components
which May be over heating.

Components located for use in chargers are of very high quality and are conservatively applied,
so they should last a very long time. There is no need for periodic replacement of any
component, since the problem associated with infant mortality failures are likely to be greater
than the failure of components due to aging.

The following general checks may be carried out once in three months for smooth running of the
system

====================================================================
Sl.No Parameter Check
====================================================================
1. Float Voltage
(52.8VDC) Check for the rated voltage. If there is any deviation,
adjust the respective potentiometers (R 401) slowly to
get the rated voltage.
2. Boost Voltage Check for the rated voltage. If there is any deviation,
(66.0V DC) adjust the respective potentiometers (R 402) slowly to
get the rated voltage.

3. DC Capacitor BankThere is a Red/Black/White tab on the top surface (next


C 402 Physical to the terminal post) of each capacitor. This should
Condition not be popped out. If any tab is popped out then the
respective capacitor should be replaced.
====================================================================

Normal operating conditions of all the switches and breakers are shown below:

SWITCH / BREAKER POSITION

1. AC INPUT (CB 401) ON

2. DC OUTPUT (CB 402) ON

3. DC VOLT SELECT (SW 3) CHARGER

3. AC VOLT- AMPS SELECT (SW 401) AS REQUIRED

4. MODE SELECT (SW 405) AUTO


Also during normal operation only the following Lamps/LED’s should glow:
1. Mains ON (Pilot lamps)
2. Float ON (LED)
3. Charger ON

11 of 14
TROUBLE SHOOTING
Before going for trouble-shooting make sure that proper AC input voltage is present at AC input
terminals.
CAUTION
DANGEROUS VOLTAGES CAPABLE OF CAUSING DEATH ARE PRESENT IN THE
SYSTEM. USE EXTREME CAUTION WHEN HANDLING, TESTING AND
ADJUSTING. ONLY QUALIFIED PERSONNEL SHOULD SERVICE.

NOTE
ALWAYS REPLACE THE BLOWN FUSES WITH EXACTLY SAME TYPE. DETAILS
OF FUSES USED IN THIS ARE AVAILABLE IN BILL OF MATERIAL

The trouble shooting procedure for various conditions is as follows:

Sl.No Problem Probable Case Recommended Action


This indication will glow Check AC input voltage across R, Y & B at
1 AC Supply Fail when the AC I/P mains TB 401 and bring it back to nominal if there
fail is a problem
1. Check AC I/P voltage R, Y & B
This indication glows 2. Check bridge fuse and SCR’s
when the DC load bus is 3. Check any over load at load side
Equipment Under
2 lower then the specified 4. Check whether the battery bank is
Voltage
preset value. supplying load current, if that is the
(48V DC) case battery bank is reaching its end cell
Voltage. Disconnect the load.
1. Check the charger output voltage
This indication glows
2. If it is higher than the set value adjust
Equipment Over when the DC load bus is
3 the potentiometer (Float/Boost)
Voltage higher than the set value
depending upon the condition of the
(54 DC)
Charger.
This indication will come Replace the rectifier fuse with the same
4 Rectifier Fuse Fail
when rectifier fuse fails. rating as given in BOM.

ALIGNMENT AND ADJUSTMENT

WARNING
HAZARDOUS VOLTAGES ARE PRESENT IN THE CHARGER CABINET. EXCERISE
EXTREME CARE WHILE WORKING IN THE CABINET WITH THE AC POWER APPLIED.

CAUTION
THE CHARGER IS FACTORY ADJUSTED FOR OPERATION. UNDER NORMAL
CONDITION INSTALLATION AND OPERATION, IT IS NOT NECESSARY TO PERFORM ANY
CIRCUIT ADJUSTMENT.

12 of 14
Following components replacement, control circuit board replacement. System changes or other
situations that might affect circuit alignment, it may become necessary to check and then readjust
those circuits affected by the change.

It is suggested that output voltage adjustments be made with output current between 10% and
20% of current rating.
Procedure for all adjustments and checks are provided in the following paragraphs:
A. FLOAT VOLTAGE (52.8V DC) [R 401]
Step-1: Energize the charger in Float mode and allow it to stabilize.
Step-2: Monitor the DC voltage at DC Capacitor (C402) filter bank.
Step-3: Set Float (R401) Potentiometer for desired output voltage (52.8V DC).

B. BOOST VOLTAGE (66.0V DC) [R 402]


Step-1: Energise the charger in Boost mode, and allow it to stabilize.
Step-2: Monitor the DC voltage across DC Capacitor (C402) bank and set the R402 (Boost)
Potentiometer to desired level (66.0V DC).
C. FCBC CURRENT LIMIT
Step-1: Energize the respective charger.
Step-2: Increase charger current to 105% of the rated current by adjusting resistive load.
Step-3: Turn the trimmer potentiometer VR23 (in PC 401Mother Board) in clock wise
Direction so that the output voltage just starts to fall.

D. CHARGER STABILITY
When the output voltage is not stable, though it is within the limit, to get the stable voltage
adjust the potentiometer VR38 (PC 401) in either directions up to the voltage to be
stabilized.

E. OVER VOLTAGE CUT BACK


Step-1: Disconnect the battery from charger and connect a resistance load across the battery
terminals/load terminals at output (the load should be at least 10% of the rated current)

pl.refer the below given table for different set points:


Sl no Test Parameter Set limit System/PCB Potentiometer Pot
description Designation & designation orientation
description
1 Equipment under voltage 48VDC PC12-PCB-Master VR3 Anti Clock-
UV/OV board increase

2 Equipment Over voltage 54VDC PC12-PCB-Master VR4 Clock-increase


UV/OV board
3 DC Over voltage cut back 68.4VDC PC401B-PCB-REG VR22 Anti Clock-
CTRL-6P-48V DC increase
4 Battery current limit 60A DC In system R1 Anti Clock-
Minimize
5 Battery under voltage 44VDC PC6-PCB-VOLT R9 44V DC Come
DETECT-48VDC-TB PCB Will off
6 Battery Over voltage 67.5VDC PC3-PCB-VOLT R9 67.5V DC Come
DETECT-48VDC-TB PCB Will ON

13 of 14
CAUTION
DO NOT CONNECT ANY VOLTAGE SENSITIVE LOADS WHILE MAKING THIS ADJUSTMENT.
Step-2: Monitor DC voltage at FCBC DC capacitor filter bank using a multimeter.
Step-3: Energize the FCBC and allow it to stabilize
Step-4: Set VR22 clock wise direction to out of voltage cut back.
Step-5: Misadjust the output volt adjustment pot to obtain the desired over voltage at FCBC
Output.
Step-6: Slowly rotate VR22 to Anti clock wise, stopping at the point where the FCBC output
Voltage oscillates.
Step-7: Stop rotating VR22 when voltage falls and, return the potentiometer to its rated output
Voltage setting.

F. FLOAT TO BOOST

Step-1: Put 'MODE SELECT' switch to 'AUTO' position.


Step-2: Disconnect Battery from the charger.
Step-3: Connect the load at battery side which is equal to required current for battery charging
Mode changeover from Float to Boost as per manufacturer's recommendation.
Step-4: Switch ON the charger and set the DC output voltage at 52.8V DC using float
Potentiometer in float Charger
Step-5: Set trim pot VR4 in Master Auto current detect board (PC-1) through Relay Board (i.e.
Float cum Boost charger switch in Boost mode).

G. BOOST TO FLOAT

Step-1: Reduce the load, which is equal to battery charging mode changeover from boost to
Float mode as per manufacturer's recommendation.

Step-2: Set trim pot 'VR 3' in the master current detector board (PC-1) through Relay
Board (i.e. system switches back to float mode).

Step-3: Switch OFF the charger and reconnect the Battery to the system.

14 of 14
POWER SYSTEMS Pvt. Ltd. Bill Of Material Report Doc Ref No : ENG-SFS-08/REV 0
Sale Order No PKOLS/000020/10-11 Line No 1 Configuration No 1 Customer Name Unitek Projects And Systems Rev No 5.00
Item Code FCBC-048-100-A Variant Code D763 Description 48V/100A FCBC:3Ph-4W-FWFC Jobno 10-0758 Qty 16 UOM NOS
Sl.No Rev Circuit Designation Input Item Code Description Variant Variant Description Qty / System UOM Sub Remarks
1 0 AL 42500000069V Buzzer-12V-20mm-CE-27-01 M064 Metronix 1.000 NOS
2 0 C 401 40730400200V capacitor-polyster-2mfd-400V-axial E013 2µF/±20%400VDC/KT12 1.000 NOS
3 0 C 402(10) 40711010000V Capacitor-electrolytic-10000mfd-100VDC S047 Sarada-50x105sq.mm 10.000 NOS
4 2 CABINET 49009310011 CAB-110V/60A DUAL FCBC with DCDB M075 MPPL1 1.000 NOS
5 2 CB 401 40071309630 MCB-63A-3P-AC-10KA L021 Legrand-D63-604979 1.000 NOS
6 0 CB 402 48622100012 MCCB-125A-2P-10KA-DC S049 NKS160R125DC2P 1.000 NOS
7 0 CB 402 AUX 48695100016 Aux.Sw-1C/O-NKS-100R/160R/200R/NKF100D S049 Sch-AX1CT1R (RHS) 1.000 NOS
8 0 CON 401-402 47920238010 Cont-10A-415VAC Coil- 2 NO + 2NC L001 MN0 22E-SS94662D000 2.000 NOS
9 0 CON1 47910294125V Contactor-1P-125A-48VDC coil-1C/O P041 Pow-SCR125AD048VWSOS 1.000 NOS
10 4 CON2 47910224050 Contactor-50A-1P-48VDC coil P041 Pownix-SCR50AD048 1.000 NOS
11 0 D 46081101150 Dropper Diode-forward-150A-100V-stud H004 HIRECT-S1HNS150 8.000 NOS
1/3/5/7/9/11/13/15
12 4 D 17/37 40462108002V Diode-GP-3A-1000V-DO-27-1N5408 M036 MIC 2.000 NOS
13 0 D 18-36 40462101003V Diode-GP-1A-1000V-SOD-81-1N4007 K003 KHEL 19.000 NOS
14 0 D 46081201150 Dropper Diode-reverse-150A-100V-stud H004 HIRECT-S1HRS150 8.000 NOS
2/4/6/8/10/12/14/16
15 0 D 401 46011104200 Diode-Forward-200A-400V-stud H004 S4BN201 1.000 NOS
16 0 DL 401 42500002104 BULB-CFL-5W-230VAC P007 Philips 1.000 NOS
17 0 DL 401(HOLDER) 42500000236V BULB HOLDER A008 Anchor 1.000 NOS
18 0 FU 1-4 47503035125 HRC fuse-slow-125A-500VAC-size 00-din ty B017 Bussmann-125NH00G 4.000 NOS
19 0 FU 401/402 47501123200 Semiconductor fuse-fast-200A-240V/300VAC B017 Bussman-200LMT 2.000 NOS
20 0 FU 410 47504200600 Glass Fuse-fast-6A-250VAC-20mm P011 Protec-PSF6A 1.000 NOS yes
21 0 FU 411 47503014063 HRC fuse-slow-63A-415V/690VAC-offset tag B017 Bussmann-63K07 1.000 NOS
22 0 FU 5/403-409 47504200100V Glass Fuse-fast-1A-250VAC-20MM P011 PROTECTRON 8.000 NOS

BOM Status Authorized DHANANJAYA NAIDU.V BALAKRISHNA REDDY.R BALAKRISHNA REDDY.R


Report Run Date & Time 22/04/2011 11:56:21 Prepared By Checked By Approved By Page No 1 Of 4
Proprietary Material of M/s AMARA RAJA POWER SYSTEMS (P) LTD., Tirupati. All rights reserved. No copying permitted. Unauthorised use prohibited,
POWER SYSTEMS Pvt. Ltd. Bill Of Material Report Doc Ref No : ENG-SFS-08/REV 0
Sale Order No PKOLS/000020/10-11 Line No 1 Configuration No 1 Customer Name Unitek Projects And Systems Rev No 5.00
Item Code FCBC-048-100-A Variant Code D763 Description 48V/100A FCBC:3Ph-4W-FWFC Jobno 10-0758 Qty 16 UOM NOS
Sl.No Rev Circuit Designation Input Item Code Description Variant Variant Description Qty / System UOM Sub Remarks
23 0 FUB 1-4 47512000029V Fuse base-160A-500/690V AC-size-0 B017 Bussmann-SB00-PB 4.000 NOS
24 0 FUB 411 47512000013V Fuse base-63A-415/500 VAC B017 Bussman-KA63 1.000 NOS
25 0 FUB 5/403-410 47512000063 Fuse base-1A-6.3A-600V W/O fuse C059 Connectwell-CSFL4U 9.000 NOS
26 0 FUT (PC403/407) 47599990000V Fuse Trip indicator G001 GEC-TI300 4.000 NOS
27 0 H 401 42500000011V SPACE HEATER -100W-240VAC P013 PYRO 1.000 NOS
28 0 HS (SCR 44802000150V Heat sink-130HD-150mm A003 AFCOCET 7.000 NOS
401-406/D401)
29 0 HS(D 1-16) 44802000200 Heat sink-130HD-200mm A003 AFCOCET 8.000 NOS
30 0 L 401 43200005115 Charger DC Choke-0.85mH A010 ARP-AT-5115 1.000 NOS yes
31 0 LA 401 47712105221 Clustered LED-assly-240VAC-22.5mm-red T001 TECKNIC 1.000 NOS
32 0 LA 402 47712105222 Clustered LED-assly-240VAC-22.5mm-yellow T001 TECKNIC 1.000 NOS
33 0 LA 403 47712105224 Clustered LED-assly-240VAC-22.5mm-Blue T001 TECKNIC 1.000 NOS
34 0 LED 1/3-15/17 40477112001V LED-RED-ROUND-5mm K013 KL53SBLRL6L-M 15.000 NOS
35 0 LED 2/16 40477112003V LED-GREEN-ROUND-5mm K013 KL53LBYGD1N-N 2.000 NOS
36 0 LED Holders (LED 42500002804 LED Holder-5mm round-press fit-white L016 Lalwani Elect-LHO-5 17.000 NOS
1-17)
37 0 M1 47610933007 DC voltmeter-0-75V-1.5%-96-A90D B011 BEEMET-SM96 1.000 NOS
38 0 M2 47611433012 DC ammeter-125-0-125A/75mV-1.5%-90D-(96) B011 Beemet-SM96 1.000 NOS
39 0 M 401 47610233002 AC ammeter-0-25A/5A-1.5-90D-(96) B011 BEEMET-SIF96 1.000 NOS
40 0 M 402 47610833050 AC voltmeter-0-500V-1.5-90D-(96) B011 Beemet-SIF96 1.000 NOS
41 0 MOV 401-406 40413061400V MOV-60V-14mm E036 Epcos-S14K60 6.000 NOS
42 0 PB 1/2 47310000104V PB-microswitch-1C/O-black R001 R.G.KESWANI-MR3/FPBB 2.000 NOS
43 0 PB 401 47311000200V PB-door lamp-NC-(Refrig switch) STD STD Vendor 1.000 NOS
44 0 PC 1 ARE02018202 PCB-MST-ACDB-48VDC A041 AREPL-P02018202 1.000 NOS Yes

BOM Status Authorized DHANANJAYA NAIDU.V BALAKRISHNA REDDY.R BALAKRISHNA REDDY.R


Report Run Date & Time 22/04/2011 11:56:21 Prepared By Checked By Approved By Page No 2 Of 4
Proprietary Material of M/s AMARA RAJA POWER SYSTEMS (P) LTD., Tirupati. All rights reserved. No copying permitted. Unauthorised use prohibited,
POWER SYSTEMS Pvt. Ltd. Bill Of Material Report Doc Ref No : ENG-SFS-08/REV 0
Sale Order No PKOLS/000020/10-11 Line No 1 Configuration No 1 Customer Name Unitek Projects And Systems Rev No 5.00
Item Code FCBC-048-100-A Variant Code D763 Description 48V/100A FCBC:3Ph-4W-FWFC Jobno 10-0758 Qty 16 UOM NOS
Sl.No Rev Circuit Designation Input Item Code Description Variant Variant Description Qty / System UOM Sub Remarks
45 0 PC 10 ARE02018201 PCB-MST-DDB-48VDC A041 AREPL-P02018201 1.000 NOS Yes
46 0 PC 12 ARE02018232 PCB-MASTER-UV/OV - 48V DC A041 AREPL-P02018232 1.000 NOS Yes
47 0 PC 2/11/404-405 ARE02002014 PCB-PLA-RL-48V DC-2C/O CONT A041 AREPL-P02002014 4.000 NOS Yes
48 0 PC 3/6/13/14 ARE02008204 PCB-VOLT DETECT-48VDC-TB A041 AREPL-P02008204 4.000 NOS Yes
49 0 PC 4 ARE02008401 PCB-BATT.CURRENT LIMIT-48VDC A041 AREPL-P02008401 1.000 NOS Yes
50 0 PC 401 ARE02009000 PCB-CHGR-6P-MOTHER BD A041 AREPL-P02009000 1.000 NOS Yes
51 0 PC 401A ARE02009011 PCB-POWER SUPPLY BD-6P A041 AREPL-P02009011 1.000 NOS Yes
52 0 PC 401B ARE02009021 PCB-REG CTRL-6P-48V DC A041 AREPL-P02009021 1.000 NOS Yes
53 0 PC 401C-D ARE02009031 PCB-GATE PULSE DRIVE-6P A041 AREPL-P02009031 2.000 NOS Yes
54 0 PC 402 ARE02001102 PCB-FILTER-2MFD-400V-TB A041 AREPL-P02001102 1.000 NOS Yes
55 0 PC 403/407 ARE02008301 PCB-FUSE FAIL-DUAL DPSS A041 AREPL-P02008301 2.000 NOS Yes
56 0 PC 406 ARE02018400 PCB-RELAY-SPP-OEN A041 AREPL-P02018400 1.000 NOS Yes
57 0 PC 5/9 ARE02008209 PCB-CUR DETECT-48VDC-TB A041 AREPL-P02008209 2.000 NOS Yes
58 0 PC 7 ARE02002000 PCB-PLA-RELAY-12VDC-3C/O CONT. A041 AREPL-P02002000 1.000 NOS Yes
59 0 PC 8 ARE02017017 PCB-ALARM-48VDC-TB A041 AREPL-P02017017 1.000 NOS Yes
60 0 R1 40486323104V POT-panel mount-100K-1W-10T B004 BOURNS 1.000 NOS
61 0 R 2-19 40483321002V Resistor-1K-2W-5%-Wire wound D023 DIAGRAM 18.000 NOS
62 0 R 401/402 40486341203V POT-panel mount-20K-3W-1T P009 POTEL 2.000 NOS
63 0 R 403 40483320221V Resistor-220R-2W-5%-wire wound D023 DEL 1.000 NOS
64 0 R 404(5) 40483352502V Resistor-2.5K-5W-5%-wire wound D023 DIAGRAM 5.000 NOS
65 0 R 405-407 40483381203V Resistor-12K-25W-5%-wire wound D023 Diagram-DRP25 3.000 NOS
66 0 SC 401 42500000245V SOCKET-3PIN-5A A008 Anchor 1.000 NOS
67 0 SCR 401-406 46021206170 SCR-slow-170A-600V-stud R006 RIR-111RK60 6.000 NOS
68 0 SH 401/1 47602110125 Shunt-125A/75mV B011 Beemet 2.000 NOS
BOM Status Authorized DHANANJAYA NAIDU.V BALAKRISHNA REDDY.R BALAKRISHNA REDDY.R
Report Run Date & Time 22/04/2011 11:56:21 Prepared By Checked By Approved By Page No 3 Of 4
Proprietary Material of M/s AMARA RAJA POWER SYSTEMS (P) LTD., Tirupati. All rights reserved. No copying permitted. Unauthorised use prohibited,
POWER SYSTEMS Pvt. Ltd. Bill Of Material Report Doc Ref No : ENG-SFS-08/REV 0
Sale Order No PKOLS/000020/10-11 Line No 1 Configuration No 1 Customer Name Unitek Projects And Systems Rev No 5.00
Item Code FCBC-048-100-A Variant Code D763 Description 48V/100A FCBC:3Ph-4W-FWFC Jobno 10-0758 Qty 16 UOM NOS
Sl.No Rev Circuit Designation Input Item Code Description Variant Variant Description Qty / System UOM Sub Remarks
69 3 SW 1/2 40070221112 Rotary switch-200A-2P-ON/OFF-ACDC S003 Sal-61192SNB03TDYR 2.000 NOS
70 3 SW 3 40070213201 Rotary switch-6A-1P-3W-ACDC S003 SAL-61049SAB13TDYR 1.000 NOS
71 0 SW 4 40070222201 Rotary switch-6A-2P-2W-ACDC S003 Sal-61038SAB13TDYR 1.000 NOS
72 0 SW 401 40070740002 Rot Sw-10A-AC volt amp select S003 Sal-72375SBB13TDYR 1.000 NOS
73 0 SW 402-404 40072110110V Toggle switch-pm-SPST-ON/OFF-10A R001 R.G.KESWANI 3.000 NOS
74 0 SW 405 40070223201 Rotary switch-6A-2P-3W-ACDC S003 SAL-61069SAB13TDYR 1.000 NOS
75 0 T 401 43200005572 Charger I/P Xformer-415V/35.43V,8.7KVA A010 ARP-AT-5572 1.000 NOS yes
76 0 T 402 43200003696 Control Xformer-415V/2 x 23.5V-0.16KVA A010 ARP-AT-3696 1.000 NOS yes
77 0 T 403-405 47622100025 CT-25/5A-Ring Type-ID-30mm-2.5VA-CL5 K006 Kappa-KTM1R25PD 3.000 NOS
78 0 TB 1/2/3 41004001170V Terminal block-power-170A-single E015 ELEMEX-cbt170 6.000 NOS
79 0 TB 4 41004001010V Terminal block-power-10A-single E015 ELMEX-CST2.5 15.000 NOS
80 0 TB 401 41004001110V Terminal block-power-110A-single E015 ELMEX-CBT110 4.000 NOS
81 1 TS401 42500000067V THERMAL SW-SET AT65`C-NC U007 UTILITY APPLIACES 1.000 NOS

BOM Status Authorized DHANANJAYA NAIDU.V BALAKRISHNA REDDY.R BALAKRISHNA REDDY.R


Report Run Date & Time 22/04/2011 11:56:21 Prepared By Checked By Approved By Page No 4 Of 4
Proprietary Material of M/s AMARA RAJA POWER SYSTEMS (P) LTD., Tirupati. All rights reserved. No copying permitted. Unauthorised use prohibited,
1 2 3 4 5 6 7 8
ENG-SFS-06/Rev.0

A498B
A472D V1
A2
VM M402
M401 AM SW401 V2
A1 A499B
A441D N
A463D
A470B

A470B
A1 R Y B L1 L2 L3
H1

FU407 A436B
D LA401 D

A441D

A432D

A433D

A434D
T402 A464D
INTERNAL A406D
CABLE DETAILS 6 LA402
H2
DESIG- CABLE SIZE

A437B
FU403 LA403

A453B
NATION IN Sq.mm A405D A466D A465D CB401 TB401
5
A453E A453E
A467D

A453B
B 1.0 A403D A463E T403 A453E
3

CON.401
R

FU408
A441D
D 2.5

415VAC ±10%, 50HZ ± 5%,


A470B
FU404 Z1 Y2 Y3 X2 H1
4.0

A438B
E X3

MOV402

MOV401

A454B

A454B A454B
MOV406 T401
16.0

3 PHASE , 4 WIRE
H
17D A454E A454E

MOV404

MOV405
J 35.0 X0 A454E

AC INPUT
A447B
A464E T404

FU409

CON.402
MOV403 H2 Y
A401D H3
1 Z2 X1
(SHEET 2 OF 3)

Z3 Y1

A455B

A455B
408D A402D FU405
A468D
TO PC4

8 2 A455E A455E A455E

A445J
A465E T405

A470B
410D A404D FU406 B

A453B
10 A469D
4
5 4 3

A446J

A444J
PC402 N
A445J 445B A470B A470D A470D
1
Proprietary material of M/s. AMARA RAJA POWER SYSTEMS LTD., Thirupathi . All rights reserved no copying permitted unauthorised use prohibited.

C A445B 6 C
1

A454D
A453D
2

A455D
A11B FU410
FU402

SC401 TS401
H401
CHARGER BOARD

A470B A456B
( FU. TRIP BD )

446B

444B

471D R405
R406
PC401 A,B,C,D

R407
GND

A457B
A461B
PC403

17D
2
A446J SW404

L
A11B

471D

471D
A446B

470D
3 A16B A11B
A444J SW403
FU401

DL401
A470B A459B +
A460B
4 PC406
-
SW402
A461J

A460J

A444J

A11B A12B
PB401
22 B422B
21 R421B SCR406 L401 CB402
TO PC 8 414J 415J
444J 415J 19J
( SHEET 3 OF 3 )
SCR403

415H
B420B 17D
20

415B

415B
R419B
478B

479B

19 SCR405
461J
6B

B C401 R403 B
B418B SCR402
18 415B
R417B

TO SHEET 2 OF 3
C 11 17 SCR404
460J 15 15

C402

R404
PC404

RL.BD.
R426B SCR401 PC404 PC405
NO 10 26 415B

145H
B425B
25 2 2
R428B
(FUSE TRIP BD)

SW405 28 145B
439B

B427B TO SW3
1
PC407

27

FU411
491B B1 A
R424B (SHEET 2 OF 3)
6 24
478B B2 2 B423B
8 F 481B

481B

481B
23
479B B3 B F415B 2
PC2

481B
15
481H
450J

490B A A1 SH401 D401


11 481J
440B 1 481J 40J
9 F A2 16 443J
462B 416B
10 B A3
13 413B
413D TO SW4
462B

440B

( Sheet 2 of 3 )
412B 412D
12
BOOST

FLOAT

NOTE :- ALL DOORS PROVIDED WITH ELECTRICAL COMPONENTS TO BE EARTHED PROPERLY


R402

A A
R401

: M/s. Oil India Limited / Guwahati


PROJECT

450B
ALL EARTH POINTS SHOULD BE INTERCONNECTED
A M A R A R AJ A
POWER SYSTEMS LTD
CUST
P.O.NO.
:
:
M/s. Unitek Project & Systems / Guwahati.
UPS/20/10-11/271 Dated : 26/07/2010
17D Registered Office & Works, DWG.NO : SCH - 0758 - 10 ( PKOLS/000020/10-11 )
450B G
karakambadi - 517520
CHASIS 1 0171 INSPECTION COMMENTS 07/01/11 Ph(0877) 2285561 to 2285565. TITLE : SCHEMATIC DRAWING 0F
GROUND 48V/100A FLOAT CUM BOOST CHARGER
REV ECO REMARKS DATE APPD DRAWN CHKD RECHKD APPD.
FILE NAME E:\Dhan\2010-11\0758-FCBC\A1-100A FCBC.sch V.Dhananjay DATE : 14/08/2010 SHEET 1 OF 3 REV. 0
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
ENG-SFS-06/Rev.0

TB2
SW2 312J FU3
800J 311J
24 th Cell

D BATTERY D
BANK - 2

1 35J 314J FU4 313J


D37
1 st Cell
PC6 CON.2
801D 35D
10 2
C NO

40D
40J
SW1 302J FU1
40J 40J 40J 301J
800J 24 th Cell

40D

40D
40D

40D

40D

40D
R1

40B

40B
(RL. BD.3C/O)
40B

8 8 8 2 3 1
FROM FCBC O/P

2
PC13 PC2

MASTER BD.
PC9 PC5

21D
28D
7 13 10 8 8
SW3 15
PC1
7 9
40J

9 7 BATTERY

17D
A3 12 PC3 PC6
29D 11 9 2

( SHEET 2 OF 3 )
M1 10 8 BANK - 1

35D

FROM PC401
19D
17D
42B

35D
1

19D
A2 5 410D 7 7
TO FCBC

8 12
48B 19D
481B PC14 PC4
VM A1 408D

19D

35D
892D
19B

11 R3

35B

35B
7 35D
Proprietary material of M/s. AMARA RAJA POWER SYSTEMS LTD., Thirupathi . All rights reserved no copying permitted unauthorised use prohibited.

C C

19D
6
19D

19J 35J 304J FU2 303J


19J
1 st Cell
19J 19J 35J 35J
SH1

19D

35D
TB1

TO SW4
42B
19J

40J

D2 D3 D8

42B
D1 D4 D5 D6 D7
40J TB3
40J
42J
40B
40B

FU5 42B

B
B
D9 D10 D11 D12 D13 D14 D15 D16
2

42B
3 7

Max. 52.8V DC + 1%
40J

PC407
19J

PC11

DC OUTPUT
4 6
10 R2
15
B 707B

ALARM BOARD
B PC12 B

FUSE FAIL
40J 42J
8B

10
13

46B

LED17
11
PC10 D17

TO PC8
11 PC11

19B
40D
6 8

19B
19B

76D

19B
C NC
19D

CON.1
19J 19J 19J
19J

19D 413D
TO SH 401
TO SH 1
413D

412D
19D

( SHEET 1 OF 3 )
( SHEET 2 OF 3 )
35D
B2 B1 A2 A1

2 1
A A
SW4 PROJECT
: M/s. Oil India Limited / Guwahati
169D

A M A R A R AJ A
179D

CUST : M/s. Unitek Project & Systems / Guwahati.


AM POWER SYSTEMS LTD P.O.NO. : UPS/20/10-11/271 Dated : 26/07/2010
Registered Office & Works, DWG.NO : SCH - 0758 - 10 ( PKOLS/000020/10-11 )
karakambadi - 517520
M2 1 0171 INSPECTION COMMENTS 07/01/11 Ph(0877) 2285561 to 2285565. TITLE : SCHEMATIC DRAWING 0F

REV ECO REMARKS DATE APPD DRAWN CHKD RECHKD APPD. 48V/100A FLOAT CUM BOOST CHARGER

FILE NAME E:\Dhan\2010-11\0758-FCBC\A2-int.sch V.Dhananjay DATE : 14/08/2010 SHEET 2 OF 3 REV. 0


1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
ENG-SFS-06/Rev.0

6B

6B

6B

6B

6B
6B

6B
6B
6B
CON.401
6B

6B
D D
7B

7B

7B

7B

7B

7B

7B

7B

7B

7B

7B

7B
7B
7B

6B
7B

6B
CON.401-402

49B

7B
R4

CB.402(Aux.)
10 C
DX 6 C 6 C 6 C C 6 C FROM SW405

R10
6

R11

R12

R13

R14

R15

R16

R17

R18

R19
R5

CON.402

R9
R6
10 7 PC407 ( Sheet 2 of 3 )

R7

R8
PC403 PC406 PC13&14 PC6 PC3 PC9 PC12 PC12 PC5
50B

9 6 9 NO

LED12

LED13

LED14

LED15
LED10

LED11
DO 5 1 5 5 4 1 5

LED7
NO NC NO NO NC NO NO

LED8
LED6

LED9
6B
7B

AC SUPPLY FAIL

55B
C
LED1

LED2

UNDER VOLTAGE

UNDER VOLTAGE
54B

OVER VOLTAGE

OVER VOLTAGE
PC404

DISCHARGING
CHARGER ON

BOOST ON
NO

DC CB TRIP

FLOAT ON

LED16
NC

EQUIPMENT

EQUIPMENT
DC EARTH

D28 OVER LOAD


7 8
CHARGER FAIL

LEAKAGE

BATTERY

BATTERY

BATTERY
LED3

478B
LED4

LED5

PHASE FAIL

479B
BATTERY
56B

57B

58B

59B

60B

61B

62B

63B

64B
52B

FUSE FAIL
RECTIFIER

FUSE FAIL
53B

FILTER

D20
D19

D22

D24

D26

D30

D32

D34

D35
D21

D23

D25

D27

D29

D31

D33

D36
D18
51B

124B

124B

125B

125B

126B

126B

127B

127B
80B

80B

80B

80B

80B

80B

80B

80B

80B

80B
80B

17 20 1RA 2RA 3RA 4RA 5RA 7 7 7 7 7 7 7 7 7 7


+12V 7 6RA 6RA 8RA 8RA 9RA 9RA 10RA 10RA
-VE
7 17 11 17 20 17 +12 -13 -15 +16 PC8 ( AL.BD )
Proprietary material of M/s. AMARA RAJA POWER SYSTEMS LTD., Thirupathi . All rights reserved no copying permitted unauthorised use prohibited.

C C

82B

83B
81B
80B

6B

6B
6B

7B

46B
19B
PC7
3 5
C NO 2 15
86B PC7 TO BATT. I/P
PB1 PB2
LAMP AL
TEST SILENCE AL

640B
CON.401-402

11
CON 401 - 402
PC406 PC5 PC6 PC7
PC405
B 12 11 10 B
631B BX BO 9 4 4 11
601B

602B

603B

604B

605B

606B
NC

607B

608B

609B

610B

611B

612B
NO
NC

NO

NO
NC
C
C

TB4

AC MAINS PHASE FAIL CHARGER FAIL BATTERY BATTERY CHARGER TROUBLE /


FAIL DISCHARGING UNDER VOLTAGE GROUP ALARM

POTENTIAL FREE CONTACTS

A A
: M/s. Oil India Limited / Guwahati
PROJECT
A M A R A R AJ A
POWER SYSTEMS LTD
CUST
P.O.NO.
:
:
M/s. Unitek Project & Systems / Guwahati.
UPS/20/10-11/271 Dated : 26/07/2010
Registered Office & Works, DWG.NO : SCH - 0758 - 10 ( PKOLS/000020/10-11 )
karakambadi - 517520
1 0171 INSPECTION COMMENTS 07/01/11 Ph(0877) 2285561 to 2285565. TITLE : SCHEMATIC DRAWING 0F

REV ECO REMARKS DATE APPD DRAWN CHKD RECHKD APPD. 48V/100A FLOAT CUM BOOST CHARGER

FILE NAME E:\Dhan\2010-11\0758-FCBC\A3-Al.bd.sch V.Dhananjay DATE : 14/08/2010 SHEET 3 OF 3 REV. 0


1 2 3 4 5 6 7 8

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