raychem instruction manual

8/13/2019 Raychem Instruction Manual

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( I n d u s t r i a l El e c t r o n i c s D i v i s i o n )

R-508, TTC Industrial Area, MIDC, Rabale, Navi Mumbai 400708Tel.: (022) 6516 6318, 6516 6319, 6516 6504 Fax ; (022) 2764 2444

E-mail: [email protected] Website: www.raychemrpg.com

OPERATION & MAINTENANCE MANUAL

FOR

THYRISTOR CONTROLLED BATTERY CHARGER

Rating: 110V DC / 40A(Max. DC 110V, max. Current 40Amps)

CLIENTS NAME :- M/s FURNACE FABRICA (INDIA) LTD.

CLIENTS P. O. NO. :- 2009/200815/545 DT. 22.05.2009File Reference IE0068

SR. NO. :- 09G43

MODEL :- 3BCH110V 40A (THY.CONTROLLED)

Raychem RPG Ltd.

R-508, TTC Industrial Area,MIDC, Rabale-400708Navi Mumbai

T e l: 3 0 9 1 6 5 0 1


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INDEX

1. Brief Specification.

2. General Descr ipt ion.

3. Technical Description .

4. Protections & Indications.

5. Installation & Commissioning.

6. Maintenance.

7. Faultfinding & rectification.

8. Drawings.

General arrangement drawing (External) IE0068-01 (sheet 1 of 1)

Wiring circui t Diagram IE0068-04 (sheet 1 of 2)

Wiring circui t Diagram (Controller) IE0068-04 (sheet 2 of 2)


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I. BRIEF SPECIFICATION

TYPE: THYRISTOR CONTROLLED BATTERY CHARGER.

CAPACITY: 5.6 KW

INPUT: 415 Volts 3 Phase.50Hz. AC (Nom)

OUTPUT: 110 Volts DC

40 Amps DC Max.DETAILS:

a) TRANSFORMER-RECTIFIER UNIT: Air cooled

b) Solid state controller

c) Constant current settable from 0% to 100%

d) Voltage limi t maximum 140Volts DC

e) Meters provided on main unit.

f) MCB Provided on Main unit.

g) DC Over vol tage, DC under voltage & Battery low protections as per

Circuit di agram.

h) Ripple less than 2% at full volt age and full load.

WORKING CONDITIONS: Maximum Ambient temperature 45 C


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II. GENERAL DESCRIPTION

The battery charger is designed to provide constant voltage variable

current supply of 110-140 Volt at 40 Amps max.

The charger is a thyristor-controlled equipment, having high capacity,

thyristors connected on the secondary side of the transformer, in 3-phase full

wave Bridge configuration.

The unit is fully automatic; the output voltage & current can be adjusted

over the range of 105-140V & 0-40A with potentiometer on the front panel for

manual working. The output DC current in the manual mode can be adjusted

from 0-4Amps by selecting a low current range selection switch inside the

cubicle.

Separate sets of potentiometers are provided inside the charger for setting

Voltage and current in float mode & boost mode independently. The setting made

in the float mode and in boost mode applies directly in the auto mode wherein the

charger selects the working mode (Float/Boost) depending upon the state of

battery voltage.


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III. TECHNICAL DESCRIPTION

The battery charger set has been designed to give you satisfactory working in all the

working conditions and following circuitry has been incorporated for the same.

Kindly refer to the following circuit diagrams:IE0068-04 (sheet 1 of 2 & 2 of 2)

a) Main Transformer

The main Transformer has been designed with copper conductors & class F

insulation. The temperature rise is maintained below Class F permissible limits. It

is mounted towards rear, left hand side and is accessible on opening the rear

door. The secondary connections are taken directly to the Three - phase

Thyrister Bridge.

b) Rectifier assembly

The rectifier assembly is having 6 thyristors connected in three-phase Bridge

configuration. The Thyristors have been selected with over 2 times average

rating, mounted on aluminium heat sinks. The assembly is designed for natural

cooling, however fans are provided for additional cooling. The assembly is

streamlined by using fiberglass angles and partitions. The RC is provided for

each thyristor, and gate cathode terminals are provided for each thyristor

separately, with facility to disconnect gate terminal while carrying out the check.

Actual connections to the thyristor blocks are done by flexible copper wire to

avoid any tension on the elements.


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c) Filter Choke

To reduce the peak currents during process, a choke is provided, mounted by the

side of the transformer. It is wound with copper, and is having suitable cable

connections. The winding has been done with class F insulation with class F

temperature rise. The choke has been designed to reduce the ripple content in

the output to be less than 2% at full voltage and current condition along-with

suitable Filter capacitors.

d) Protections And Indications

An MCB rated for 32Amps on the incoming side

An MCB rated for 40Amps on the outgoing side

Battery low indication.

Under voltage indication.

Over voltage indication.

Over load indication.

Under voltage change over from float to boost.

Over voltage change over from boost to float.

Indications for float ON

Indications for Boost ON

Indications for charger ON

Indications for Mains ON

Indications for thyrister fuse fail.

Indications for Output MCB trip.


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e) Controller

The power for the control has been derived from mains by using an

isolation control transformer. The controller provides pulses to the phase

controlled thyristor assembly. It is having following different functions.

Provides pulses, which are synchronized in line with the input phase.

Pulses are shifted automatically to adjust the desired output current.

Feedback signals are compared with the reference signals for output

parameters adjustments.

The main controller provides control for the pulses as follows:


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CONTROL CARD - Type 105DJ1

This card generates the line-synchronized pulses required to trigger main

SCRs connected on the secondary side of the main transformer TR1. There are

three firing circuits in the unit. All the three circuits are identical. The Pulse

generator receives the control signal from the buffer output stage (explained

below). The pulses produced by the firing card are synchronized to Mains AC

cycle by using synchronizing circuits. The pulses from each firing circuit in the

card are synchronised to relevant phases. The Pulse generator card receives line

synchronising signals from secondary windings of the control transformers

TR2.The control transformer TR2 provides the synchronization of R Phase

signal for controlling the R Phase SCRs, Y Phase signal for controlling the Y

Phase SCRs & B Phase signal for controlling the B Phase SCRs. The control

voltage governs the position of the synchronized pulses with respect to the start

of each line half cycle. Thus, by changing this control voltage, the firing angle of

the main SCRs can be changed, which in turn gives rise to control of the rectified

output voltage, thereby controlling the DC output voltage of the unit.

The card also senses the AC supply voltage and the sequence of the

same from the supply received thru the secondary of control Transformers TR2.If the sequence of AC signal is reversed or if the level of input voltage falls (under

voltage) below the preset limit, all the three pulses on this card are automatically

shut down to make the DC output from the unit to zero. This feature prevents

mismatch firing of thyristers thereby ensuring proper control. Three Red LEDs

have been provided on this card to indicate normal functioning of the card.

These LEDs (normally dimly lit) indicate the presence of pulses corresponding to

the three phases generated by the card. All the three pulse-generating sections

in the firing card are completely independent of each other.


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The card controls the DC output voltage and current of the unit. The error

amplifier in this card receives a reference voltage from potentiometer (P1) for

setting the output voltage maximum limit, this potentiometer is provided inside

the controller unit. This card receives voltage feedback through the potential

divider card consisting of resistances connected across DC output. The amplifier

stage 1 on this card compares both the signals. Similarly, reference voltage from

potentiometer (P2) for setting the output current is provided on the front panel.

This card also receives current feedback from the shunt connected in series on

the DC output.

The millivolt signal from the shunt is amplified tot the desired level

(1000times) and is compared with the reference voltage of potentiometer (P2).The amplifier stage 2 on this card compares both the signals. The amplified

voltage from stage1 (CV) & stage 2 (CC) is again compared for constant voltage

or constant current control. Depending upon the load conditions and the settings

of the above potentiometers (P1 & P2) the controller automatically controls either

the voltage or current output. The DC output voltage can be set anywhere from

0V to the full rated value by varying the control voltage fed by potentiometer. The

current signal after processing is fed to the control logic on this card through

current setting potentiometer. Whenever the DC voltage exceeds the limit set by

the CV potentiometer, any further increase in current signal tends to retard the

firing pulses thereby reducing the DC output voltage to maintain the current at

this limiting value of voltage. Thus the unit operates in voltage limiting and holds

the voltage constant at the set limit. The voltage control logic overrides the

current control signal and maintains the output voltage at the limit value

irrespective of the setting of CC potentiometer. This feature is useful in protecting

the rectifier unit from delivering higher voltage. The control card gets AC supply

through secondary winding of auxiliary transformer TR2. Two LEDs are provided

on this card to indicate normal functioning of the card. The green LED indicates

that the card is energised while the red LED indicates the presence of control

signal from this the card.


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Pulse Driver card Type 118B (Dual) This card amplifies the pulses produced by the firing card (105DJ1) to a

level required for reliable and steady firing of the SCRs. This card also provides

isolation between the pulses produced by the firing card and the gates of the

main SCRs.

Two separate pulse transformer mounted on a PCB along-with LEDs

have been provided on this card to indicate pulse output from this card to

individual SCRs. Such 3 pulse driver cards are provided for relevant phases.


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DC over voltage & over current Type 19C

This card consists of a DC voltage & DC current sensing logic, on card

auxiliary Transformer & two on card Relays. This card has two independent

comparators for voltage & current. This card receives voltage signal from the unit

output and DC current signal from the shunt.

The voltage comparator stage on this card continuously compares the DC

O/P voltage signal to the reference level set by the voltage preset on this card.

Whenever the DC O/P voltage increases beyond the value set by the voltage

preset, a relay on this card is energised to provide a change over contact for

over-voltage condition. A delay of about 4/5 seconds is introduced after the over-

voltage condition is sensed. The over-voltage indication level can be set

anywhere from 10V to 30V by means of the voltage preset marked as V/S.

Similarly, The current comparator stage on this card continuously

compares the DC O/p current signal to the reference level set by the current

preset on this card. Whenever the DC O/P current increases beyond the value

set by the current preset, a relay on this card is energised to provide a change

over contact for over-current condition. A delay of about 4/5 seconds isintroduced after the over-current condition is sensed. The over-current indication

level can be set anywhere from 10mV to 75mV by means of the current preset

marked as C/S.

Two red LEDs have been provided on this card to indicate operation of

the voltage & current comparators. The respective LEDs glow when the

individual comparators are energised due to over-voltage or over-current

condition.

An alarm is provided for the above fault and an acknowledge push button

is provided for the same to acknowledge the same. The indications will continue

as long as the fault is not been rectified. Reset push button is clubbed along-with

the off push button by the OFF push button.


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f) Function of Auto-change over

In event of the batteries getting charged beyond 130V DC during Boost

working, the charger switches over to float mode. This is affected by sensing

over voltage of the Battery by an over voltage card. The over voltage card

senses 130Volts across the battery and effects the above operation. This results

in charger running in float mode as long as the battery voltage drop down below

115.0V, Moment the battery voltage drop below 115.0V the charger goes in

boost mode and charge the battery in constant current mode. This is affected by

sensing under voltage of the Battery by an under voltage card. The under voltage

card senses 115Volts across the battery and effects the above operation. Thisresults in charger running in boost mode and vice-versa.


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a) INSTALLATION & COMMISSIONING

a) Install the unit, sufficiently away from any wall. Proper ventilation must be

ensured in the room, where the unit is installed.

b) The unit must be installed away from chemical fumes and dust particles.

c) Keep the Constant current potentiometers in zero position.

d) Connect 415 Volt AC 3 Phase. 50 Hz supply to the input terminals.

e) Switch ON the MCB. The mains on indication lamp will light. Switch on the

control supply by ON push button.

f) Slowly the output voltage will rise to 118 Volts.

g) Switch off the supply and connect some dummy load.

h) With the constant current potentiometer (on front panel) at minimum,

switch ON the unit and adjust the DC output current with the

Potentiometer.

i) Switch off the supply and connect the actual load.


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b) MAINTENANCE

The equipment should be installed in a place, which is having free ventilation

from all the side. It should be installed sufficiently away from a wall, such that the

natural flow of air may not get obstructed.

The equipment has been designed for maintenance free service, however for

trouble free service, timely check up and maintenance will increase the life of the

equipment considerably as follows.

Wipe the dust from contactor, MCB and potentiometers once every month with a

smooth cloth.

Remove the dust from the PCBs, Thyristor and Heat Sinks by using vacuum

cleaner.

Check the connections tightness once every month.

Check the wires for snapped connections from time to time.

For the faults of malfunctioning, you will have to refer to the circuit diagram and

the description thereby.


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c) FAULT FINDING AND RECTIFICATION

FAULT POSSIBLE CAUSES METHODS OF RACING FAULT

RECTIFICATION

Rectifier not getting AC supply.

Check input fuses, control boxsupply and actual input to therectifier.

Self-explanatory.NO OUTPUTVOLTAGE

Control not getting ON a) Check the polarity andphase failure LED.

b) Check the wiring

1) Correct the same if LEDglows.

2) Correct the same.

Control Transformer

not setting fully

a) Check the

control fusesb) Check the

wiring

Restore the same.RECTIFIER NOT

DELIVERINGVOLTAGE ORCURRENT

Thyristors not gettingpulses

Check the wires connected tothe gate of each thyristors

Restore if found snapped

Shorting in the load Check the load. Self explanatoryDC OVERLOADTRIPPING.

Settings of overload

must have beenchanged.

Set the over load setting to max

and slowly increase the current.

Make new settings.

RECTIFIER I/P MCCBIS TRIPPING

Short-circuit somewhere in the unit.a) Transformer has

shorted.

b) One of the

thyristors hasshorted.

a) Isolate Transformer primaryand secondary and checkindividual coils with aDimmerstat.

b) After the above steps check

each thyristors with multi-meter and isolate the faultyone.

a) If faulty, replace transformercoils.

Replace the faulty one. While

replacing the thyristors properpolarity of the new thyristorsmust be ensured before fitting.They must match with the oldpolarity.


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