TECHNICAL MANUAL – FLOAT CUM BOOST BATTERY CHARGER

Doc. No. STSPL/IBC/S1A02/TM Date 05.02.18

Revision No. 00 Page No. Page 1 of 8

TECHNICAL MANUAL FOR

FLOAT CUM BOOST
BATTERY CHARGER
(S1A02)

This document is prepared by:

M/s. Sanjay Technical Services Pvt. Ltd.
Name Department Sign Date
Prepared by Deepak
Checked by Vijay
Approved by Sanjay
 TECHNICAL MANUAL – FLOAT CUM BOOST BATTERY CHARGER
Doc. No. STSPL/IBC/S1A02/TM Date 05.02.18
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INDEX

A. General Description ......................................................................................................................... 3

B. Principle of Operation .................................................................................................................... 4

C. Logic Table ...................................................................................................................................... 5

D. Technical Specifications .................................................................................................................. 6

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A. GENERAL DESCRIPTION

This specification covers the ‘Float cum Boost Battery Charger’ with a rectifier unit which works on 1-
phase AC input power supply and gives required DC voltage as output, delivering certain amount of
power as demanded by the application. The rectifier is controlled using a control circuit realized using
a micro- controller. The control section uses advanced micro-controller for this application, which
provides accuracy of operations. Block diagram of a typical battery charger is as given under

The charger is fed with AC voltage source. The primary of the main transformer is energized
through the input switchgear. The transformer steps the voltage down at the secondary as required
for the specific DC output voltage and provides isolation between input and output.

The secondary of the transformer is connected to a bridge rectifier assembly. The bridge is the heart
of the power circuit. The rectifier assembly will be a full wave silicon bridge. Initially SCRs are
fired gradually for DC soft start. The voltage control is achieved by the application of positive pulse
to the gate terminals of SCR at desired time.

The filter circuit is employed to filter-out ripples in output DC supply. The filter circuit is typically
LC type; with Choke (L) for filtering out current ripples & Capacitor (C) for filtering out voltage
ripples.
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The control card is the heart of control circuit. The control card is used to atomize the entire battery
charger in controlling the output voltage and thereby output current by triggering SCRs. The control
card also accomplishes the DC side protection circuit. The control card derive feedbacks from the
system to perform its functions.

The charger mode of operation can be selected through selector switch. The charger will work in
AUTO, FLOAT & BOOST modes. In any mode, monitoring & controlling happens through micro-
controller based control circuit. Charger feedback signals are fed to the board to compare with
reference parameters. The control card have LED indicators for different operating conditions like
DC over voltage, DC under voltage, output over current & manual boost mode over charging.
Based on the faulty condition appropriate LED glows and actuates audio alarm. It also have
potential free contacts for alarm conditions. The audio alarm can be silenced by accept push button.
However, indicating LED will be glowing continuously until the fault is rectified.

The firing circuitry on the control card receives voltage and current reference from the micro-
controller and generates firing signals based on reference and feedback signals.

B. PRINCIPLE OF OPERATION

During normal operation, Float cum Boost charger works as a float charger and takes care of load
and battery float charging requirements.

Float cum Boost charger has three modes of operation: AUTO, FLOAT & BOOST

In AUTO mode, Float cum Boost Charger can act as either a Float charger or a Boost charger
depending on battery current requirement. Manual intervention is not required when Float cum
Boost charger is selected to AUTO mode.

Float cum Boost charger is provided with provision of MANUAL FLOAT and MANUAL BOOST
modes in which battery can be charged in either FLOAT or BOOST by manual selection.

On failure of AC mains supply to Float cum Boost charger; battery starts supplying the load.
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Once the AC mains supply restores, FCBC switches over to Float or Boost mode based on battery
charging requirements if the charger is kept in AUTO mode of operation.

Whereas in manual mode; the charger does not switches from Float to Boost and remains in the
mode it is selected. As a safety feature in MANUAL BOOST mode; when the battery is sufficiently
charged; an overcharging alarm is initiated by control card to instruct user to change its mode.
Normally MANUAL mode is not resorted to but only if AUTO mode fails.

Even in Boost mode; the charger applies boost mode voltage to the load and battery. This type of
charger is only used where the boost mode voltage is not critical to the load.

C. LOGIC TABLE

SYSTEM CHARGER
FCBC BATTERY LOAD
CONDITION MODE
AC ON & FCBC WILL SUPPLY LOAD &
ON
BATTERY AUTO ON FLOAT VOLTAGE ACROSS
FLOAT
HEALTHY APPEARS ACROSS LOAD
AC ON & FCBC WILL SUPPLY LOAD &
BATTERY AUTO ON ON BOOST BOOST VOLTAGE ACROSS
DISCHARGED APPEARS ACROSS LOAD
FCBC WILL SUPPLY LOAD &
ON
AC ON FLOAT ON FLOAT VOLTAGE ACROSS
FLOAT
APPEARS ACROSS LOAD
FCBC WILL SUPPLY LOAD &
ON
AC ON BOOST ON BOOST VOLTAGE ACROSS
BOOST
APPEARS ACROSS LOAD
BATTERY SUPPLIES
AC OFF -- OFF DISCHARGE
LOAD
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D. TECHNICAL SPECIFICATIONS

Scheme : Float cum Boost Battery Charger

Model : S1A02
Type : Full wave, half controlled
Type of battery : Suitable for VRLA / Ni-Cd / Plante / Tubular

INPUT:
a) Single phase input : 230V AC ± 10% / ± 15% (Single phase, 2-wire)
b) Frequency : 50Hz ± 5%

OUTPUT:
a) Nominal voltages : 12V DC/24V DC/30V DC/36V DC/48V DC/110V DC
b) Output currents : 10A / 15A / 20A / 25A / 30A (based on voltage)
c) Ripple : < 1% / 2% / 3% RMS (without battery connected)
d) Efficiency : > 70% at full load

VOLTAGE REGULATION:
Charger output shall be ±1% of the set value in the following conditions in all the modes.

Load variation : 10 – 100 %

Line variation : ± 10 % / ± 15 %
Frequency variation : ±5%
Temperature variation : 0 – 45 ℃

INDICATIONS:

AC ON : ‘Red’ Pilot lamp

DC ON : ‘Red’ Pilot lamp
FLOAT ON : ‘Green’ Pilot lamp
BOOST ON : ‘Blue’ Pilot lamp
DC OVER VOLTAGE : ‘Amber’ Pilot lamp
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DC OVER CURRENT : ‘Amber’ Pilot lamp

BATTERY OVERCHARGE : ‘Amber’ Pilot lamp
FUSE FAIL : ‘Amber’ Pilot lamp

METERS:
The following parameters will be indicated by meters mounted on the charger
a) DC output voltage
b) Charger current
c) Battery current

ALARMS WITH BUZZER:

a) DC Over voltage
b) DC Over current
c) Battery over charge
d) DC Fuse fail

PROTECTIONS:
The following protections are provided.
a) AC input circuit breaker
b) Fast acting semiconductor fuses for bridge rectifier & capacitors
c) DC over voltage cutback & firing inhibition
d) DC over current cutback & firing inhibition
e) DC output circuit breaker
f) DC circuit breaker with no line-load bias for battery
g) Battery circuit current limiting

SPECIAL FEATURES:
a) DC side Soft start
b) Class-F insulation for all magnetics
c) Automatic voltage regulation
d) Filter circuit to limit ripple
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e) Battery circuit current limiting

f) Automatic float to Boost changeover based on battery current
g) Automatic Boost to float changeover based on current or voltage
h) Anti-condensation heaters with thermostat control.

GENERAL:
Cabinet : Freestanding cabinet, Floor mounting type, Sheet steel
construction; Components accessible from front and rear;
Cable bottom entry
Ingress Protection : IP 42 (Indoor) / IP 55 (Outdoor)
Paint shade : RAL 7032
Nature of Cooling : Natural Air-cooling
Dimensions in mm : As per drawing