INSTALLATION & OPERATION MANUAL

48V/80A FLOAT CUM BOOST BATTERY CHARGER

CUSTOMER : TANTRANSCO

PROJECT : P&C

P.O.NO : 1004 DT: 27.05.2020

JOB NO : ELE/20-21/002

1
 TABLE OF CONTENTS

S.NO DESCRIPTION

1 IMPORTANT SAFETY INSTRUCTIONS FOR INSTALLER AND

OPERATOR
2 TECHNICAL SPECIFICATION

3 PROTECTION & FEATURES

4 GENERAL SPECIFICATION

5 BATTERY CHARGER OPERATION & FUNCTIONAL

DESCRIPTION OF BOARDS

6 SYSTEM SET POINTS

7 AUTOMATIC MANUAL CHARGER CONTROL

8 INSTALLATION AND OPERATIONAL ROUTINES

9 INITIAL CHARGING OF BATTERY

10 TROUBLE SHOOTING

11 BILL OF MATERIAL

12 DRAWING

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1.1 IMPORTANT SAFETY INSTRUCTIONS FOR INSTALLER AND
OPERATOR
1. Save these instructions.

2. Do not expose charger to rain or snow.

3. Only trained and qualified personnel may install and service this unit.

4. Do not operate charger if it has received a sharp blow, been dropped, or otherwise
damaged in any way; shut off power at the branch circuit protectors and have the
unit serviced or replaced by qualified personnel.

5. To reduce risk of electric shock, disconnect the branch circuit feeding the charger
before attempting any maintenance or cleaning. Turning off controls will not reduce
this risk.

6. Working in the vicinity of a lead-acid or nickel-cadmium battery is dangerous.

Storage batteries generate explosive gases during normal battery operation. For this
reason, it is of utmost importance that each time before using your charger, you read
this manual and follow the instructions exactly.

7. To reduce the risk battery explosion, follow these instructions and those published
by the battery manufacturer and the manufacturer of any equipment you intend to
use in the vicinity of a battery. Review cautionary markings on these products and on
the engine.

1.2 PERSONAL PRECAUTIONS

A. Someone should be within range of your voice or close enough to come to your aid
when you work near a storage battery.

B. Have plenty of fresh water and soap nearby in case battery electrolyte contacts skin,
clothing, or eyes.

C. Wear complete eye protection and clothing protection. Avoid touching eyes while
working near a storage battery.

D. If battery electrolyte contacts skin or clothing, wash immediately with soap and
water. If electrolyte enters eye, immediately flood the eye with running cold water for
at least 10 minutes and get medical attention immediately.

E. NEVER smoke or allow a spark or flame in vicinity of battery or engine.

3
 F. Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark
or short circuit battery or other electrical part that may cause explosion. Using
insulated tools reduces this risk, but will not eliminate it.

G. Remove personal metal items such as rings, bracelets, necklaces, and watches when
working with a storage battery. A storage battery can produce a short circuit current
high enough to weld a ring or the like to metal, causing a severe burn.

H. Use this charger for charging LEAD-ACID or LIQUID ELECTROLYTE NICKEL-

CADMIUM batteries only. Do not use this battery charger for charging dry cells,
alkaline, lithium, nickel-metal-hydride, or sealed nickel-cadmium batteries that are
commonly used with home appliances. These batteries may burst and cause injuries
to persons and damage to property.

I. NEVER charge a frozen battery.

2. Technical specification
2.1.1. AC INPUT SUPPLY

Input Voltage : 415V AC +10%,-15%

Frequency : 50 Hz ±5%
Phase, Wire : 3 phase 4 Wire

2.1.2. CHARGER OUTPUT:

Description Battery voltage Load Voltage

Auto float mode 2.23 X 24=53.5V 53.5V

Auto Boost mode 2.4 X 24=58V DVR Position OFF – 43.4V
DVR Position 1 - 46.5V
DVR Position 2 - 50V
DVR Position 3 - 53.7V

Manual Boost 2.78 X 24=65V DVR Position OFF - 49.7V

mode DVR Position 1 - 53.62V
DVR Position 2 - 57.16V
DVR Position 3 - 60.81V

* Manual Float External Potentiometer DC Voltage range: 48V-54V at Load Terminal

* DVR Selector Switch Works in Boost Mode both Auto and Manual Condition.

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2.1.3. Meters & Switches Explanation: Following Digital Type meters 48 X96
90Deg 1% Accuracy provided in the charger for measuring respective parameters.

a) V1-AC Voltmeter (0-500V AC) with selector switch SW1 To measure AC

input voltage

b) V2-DC Voltmeter (0-100V DC) with selector switch SW2 To measure

Charger Voltage , Battery Terminal Voltage, Load Terminal Voltage

c) A1-DC Ammeter (100-0-100A DC) with selector switch SW3 To measure

both Load & battery charger/Discharger Current

d) A2-Trickle ammeter with Push button to measure Battery Trickle Current

DVR Selector switch:

This switch working only in Manual Boost and Auto Boost mode. It is used
to regulate the Load terminal Voltage 48V-54V under initial charging of Battery.

This switch used to select 25%, 50%, 75% of DVR diode based on Battery terminal
Voltage Setting.

2.1.4. Indications & Explanation:

AC Input Mains ON (R, Y, and B): (L1 TO L3)

It shows the 3 Phase Input available at Charger Input Terminal

Charger output ON: (GREEN -L4)

It shows DC Voltage is available at the bridge rectifier output

AUTO MANUAL & FLOAT BOOST ON: (Amber -L5TO L8)

It shows the which mode in charger working

Indications with alarms & Explanation:

DC UNDER VOLTAGE:

It alarms when the occurrence of the Charger DC Voltage Below the set Limit

(< 40V)

DC OVER VOLTAGE:

It alarms when the occurrence of the Charger DC Voltage above the set Limit

(> 54V) and also Tripping the charger

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Charger over Load:
It alarms when the occurrence of the Charger output current beyond the set limit
(>110% of 80A)

AC Over Voltage:

It alarms when the occurrence of the Charger input PH-PH Voltage beyond the set
limit (>456V)

AC Under Voltage/ AC supply failure:

It alarms when the occurrence of the Charger input PH-PH Voltage below the set limit
(< 365V)

AC input Fuse Fail:

It alarms when input fuse blown due to Overload of Main Transformer.

DC Fuse Fail:
It alarms when the output fuse blown due to overload of charger

Rectifier Fuse fails:

It alarms when the Rectifier series fuse blown due to thyristor short / DC output short

Filter/Capacitor Fuse Fail:

It alarms when the capacitor fuse blown due to internal fault of capacitor.

Note: Potential free contact provided for group alarm.

3.1. PROTECTIONS: Following Protections are provided in the Charger.

AC input MCB

DC output MCB

Input & output fuse

Blocking diode

Freewheeling diode

SCR Fuse

AC contactor
6

Surge protection board

Battery input MCB

DC Over Voltage Cutback

DC Over Current Cutback

3.2. FEATURES: The following features are provided in the charger.

 Soft –Start feature

 Automatic Voltage regulation

 Current limiting circuitry for Both Battery & Load side

 Smoothing filter Circuit to Limit ripple

 Built in auto phase reversal operation with single Phase preventing

 Automatic float/Boost Changeover, based on current drawn by the battery.

 On time delay timer

4. GENERAL SPECIFICATION

4.1. Panel:
Cabinet : Freestanding, Floor Mounting cabinet, sheet steel
Construction

Sheet thickness : CRCA & 1.6mm

Paint : RAL 7032
Protection : IP42
Ambient Temperature : 0-50Deg

4.2. Magnetics:
Standard feature:
Average winding temperature rise over ambient : 50º C
Minimum insulation class : Class F
Insulation voltage breakdown : 2000V/min.

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4.3. Wiring:

Insulation: 1100V grade, PVC insulation is used. The wire sizes are decided based on design
calculation for current in respective circuits.
Cabling details:

Wiring/Cabli
V Details
ng
1 Insulation PVC insulated
2 Voltage grade 1100V
2.5 Sq.mm for control circuits
Minimum
3 1.0 ,0.5sq.mm for annunciation
conductor size
circuits
Input -4 Sq. mm
FCBC
DC Output -25 Sq. mm

5.1. BATTERY CHARGER OPERATION

The battery charger is designed to supply a constant voltage for any load
within its rating. Beyond approximately 100% of the rated load, the output voltage will
drop rapidly, thereby protecting the charger and the system to which it is connected. With a
battery connected to the output, the charger will supply sufficient current to maintain the
battery at full charge regardless of variations in line or load within its rating. Silicon
controlled rectifiers (thyristors) are employed and operated by a solid state firing circuit to
maintain constant voltage.
Float cum Boost charger is a combination of a float charger and a boost charger
is a two-in-one functional combination of a float charger and a Boost charger. Under normal
condition FCBC works as a float charger, on failure of mains supply battery starts supplying
to the load. Once the main power restores FCBC switches to float or Boost mode based on
the battery charging Requirements. This configuration is most suitable where the load can
withstand the boost voltage of the battery bank

5.2. RECTIFIER CIRCUIT:

When the charger is connected to appropriate AC voltage source, voltage is
connected to the primary of the main transformer through the inputs switch or MCB. The
transformer steps the voltage down as required for the specific DC output voltage and
isolates the commercial AC line for the battery circuit. The transformers secondary is
connected to the full wave bridge rectifier assembly.

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 The bridge rectifier is the heart of the power circuit. This assembly is a standard
three phase full wave full control silicon bridge. The voltage control is accomplished by
applying a positive pulse to the gate terminals of the SCR at the desire time. Before the
“Pulse” is applied, the SCR is “open” and no current flows in the circuit. However, as soon as
the SCR is fired, it operates as a standard silicon rectifier until the forward current is
reduced to almost zero. Charger output control can therefore be accomplished by changing
the point in time, the SCRs are fired. The bridge rectifier provides a variable DC voltage at
its output.

The standard modules of series chargers have an inductance in the output circuit
to bring down the ripple voltage to 1% when the battery is connected to the charger.

5.3 CONTROL UNIT:

The electronic control system of the rectifiers is mounted in each rectifier in a
control rack assembly.

The control rack consists

• Primary control Board (B1)

• Secondary control Board (B2)

• Synchronizing Board (B3)

• Auto Manual/Float Boost Board (B4)

• Annunciation Board (B5)

• Surge Board (B6)

• Timer Board(B7)

• Phase failure Board(B8)

• DC power supply Unit (B9)

• Led Board (B10)

5.3.1. Primary control board B1 and Secondary control Board (B2):

The main function of the Control Board B1& B2 is to controls the firing
angle of the SCR. it senses the variations in input and output parameters and maintains
regulated output Voltage at the output through gate pulse triggering.

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5.3.2. Synchronizing Board (B3):
The main function of this board is to convert the PH-PH Voltage of AC input voltage
into 2 sets of 9-0-9V control signals and fed to Primary & Secondary boards.

5.3.4. Auto Manual Float Boost Board (B4):

The main function of this board is to change the modes of operation as per System
requirement

Dip Switch Details:

Internal Pot Control External Pot Control

1 2 3 4 5 6 7 1 2 3 4 5 6 7

2, 4, 5, 7: should be in ON condition 1, 3, 6 : should be in ON condition

For internal DIP switch

Manual Mode:
In this Mode of Operation User will select whether Float or Boost mode through
Float Boost selector switch.

Auto mode:
In this mode B4 board senses the battery current through Battery Shunt and the
battery current reaches above the set current the Charger will changeover automatically
from float to boost and Vice versa.

5.3.5. Annunciation Board (B5):

This Board is used to monitor the LED alarms provided on the charger, it senses any
alarms generated in the charger and gives out a signal for the corresponding alarm
indication, as well as to the audible alarm (buzzer). After the occurrence of an alarm, if the
alarm-reset push button is pressed, the audible alarm will go off but the indication will
persist. Before resetting the indication, the causal fault has to be cleared & then the reset
button has to be pressed for the second time.

5.3.6. Surge Board (B7):

This board protects the charger from Voltage Spikes.

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5.3.7. Timer Board (B7):
This board Provides On time delay to the charger. This board also incorporated
with Load Over voltage and over current Trip signal to de-energies the AC Input Contactor.

5.3.8. Phase failure Board (B8):

This Board senses the Failure of Phases and if any of phases is missing, sends
the signal to Timer board to De-energies the AC Contactor.

DC power supply Unit (B9):

This board provides 12V control supply to the DC contactor and Annunciation
Board.

6.0 SYSTEM SET POINTS:

6.1.1 OUTPUT VOLTAGE SETTING – MANUAL FLOAT MODE

STEP 1 : Disconnect the load and the battery from the charger

STEP 2 : Switch ON the charger

STEP 3 : Select the SW4 switch Position to Manual Mode

STEP 4 : Select the SW5 Position to Float Mode

STEP 5 : Adjust the following Trim pot (EXTERNAL POT –POT 1) for the
Corresponding voltage setting to get desired output.

*EXTERNALVOLTAGE ADJUST POT WORKS ONLY IN MANUAL

FLOAT MODE

6.1.2 OUTPUT VOLTAGE SETTING – MANUAL BOOST MODE

STEP 1 : Disconnect the load and the battery from the charger

STEP 2 : Switch ON the charger

STEP 3 : Select the SW4 switch Position to Manual Mode

STEP 4 : Select the SW5 Position to Boost Mode

STEP 5 : Adjust the following Trim pot (INTERNAL POT) for the
Corresponding voltage setting to get desired output.

• Boost voltage : PR12/FCBC in B1 Control Card

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6.1.3 OUTPUT VOLTAGE SETTING – AUTO FLOAT MODE

STEP 1 : Disconnect the load and the battery from the charger

STEP 2 : Switch ON the charger

STEP 3 : Select the SW4 switch Position to Auto mode and don’t care
About SW5 switch Position
STEP 4 : Adjust the following Trim pot (INTERNAL POT) for the
Corresponding voltage setting to get desired output.

• Float voltage :PR15/FCBC in B1 Board

6.1.4 OUTPUT VOLTAGE SETTING – AUTO BOOST MODE

STEP 1 : Disconnect the load and the battery from the charger

STEP 2 : Switch ON the charger

STEP 3 : Select the SW4 switch Position to Auto mode and don’t care
About SW5 switch Position
STEP 4 : Put the 5A Load to Battery Terminal using resistive load Bank

STEP 5 : wait until Charger Changeover from float to boost mode, if charger
Changed to boost mode, Adjust the following Trim pot (INTERNAL
POT) to achieve desired output.

• Boost voltage :PR14/FCBC in B1 Board

6.2. CURRENT LIMIT ADJUSTMENT:

6.2.1. BATTERY CURRENT LIMIT CONTROL

It provide max limit for the battery charging current delivered by the rectifier. The
current limits are independently adjusted by the potentiometer.

Current level adjustment procedure

To reduce the battery limit, load the charger at the battery path, with the desired
limit level and slowly turn the below mentioned potentiometer provided in the Main control
board B1, Stop as soon as the output voltage stops dropping.

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 Mode Pot Place of Pot Direction
Manual Float PR9 B1 Board Clock wise
Auto Float PR11 B1 Board Clock wise
Auto Boost PR10 B1 Board Clock wise
Manual Boost External Current Adjust POT

(Note: In Auto boost Mode Current Setting kindly follow the Point No: 6.1.4)

* EXTERNAL CURRENT POT WORKS ONLY MAUNAL BOOST MODE

6.2.2. CHARGER CURRENT LIMIT CONTROL

To reduce the Current limit, load the charger, with the desired limit level
and slowly turn the potentiometer PR6 provided in the Main control board B1, Stop as soon
as the output voltage stops dropping.

Potentiometer Details: PR6-B1 BOARD

7.0. AUTOMATIC CHARGE CONTROL:

By using this feature put the switch SW4 in Auto Mode, the automatic change over
done based on current drawn by battery

 If battery current reaches above the set limit (5A Load at Battery Path) charger
changeover from FLOAT to BOOST mode

 If battery current reaches below the set limit (5A Load at Battery Path) charger
changeover from BOOST to FLOAT mode

8.0. INITIAL CHARGING OF BATTERY: (in manual Boost Mode)

Step 1: Connect the battery to the battery terminal X2

Step 2: Select DVR SELECTOR SWITCH (SW7) must be in position 1 only.

Step 3: Select Switch SW4 in Manual mode

Step 4: Select Switch SW5 in Boost mode

Step 5: Switch ON charger (Both MCB 1 & SW3 in ON condition)

Step 6: Switch ON Battery MCB 3

Step 7: Adjusting the battery current by using External potentiometer (POT 2)

* DVR SELECTOR SWITCH WORKS ONLY IN MANUAL BOOST AND AUTO BOOST MODE
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8.1. PRINCIPLE OF OPERATION FOR BATTERY CHARGER ( IN AUTO MODE)
Step 1: Connect the battery to the battery terminal X2

Step 2: Select DVR SELECTOR SWITCH (SW7) must be in position 2 only.

Step 3: Select Switch SW4 in Auto Mode

Step 4: Do not care about SW5 (Float/Boost) position

Step 5: Switch ON charger (Both MCB 1 & SW3 in ON condition)

Step 6: Switch ON Battery MCB 3

9.0. INSTALLATION AND OPERATIONAL ROUTINES:

1) Do not install battery charger near heat generating equipment avoid location subjected
to corrosive fumes or extremes of dirt and moistures

2) The charger is cooled by natural convection. Hence sufficient clearances (Min 1mtr) to be
provided wherever the system is installed

3) Check the nominal output voltage of the charger shown on the name plate. It must
correspond to the battery voltage

4) To maintain proper voltage regulation at the battery, cables installed between charger
and battery must be sized to provide minimum voltage drop

5) Assembled battery according to battery layout drawing furnished by the battery

manufacturer. Check that all cells in the battery are installed properly with regards to
polarity. Cell terminals are connected positive to negative

6) Check the AC line for the input voltage, frequency to match the charger specification .The
AC cable must be sized to allow for maximum current capacity as indicated by the rating of
the input fuse

7) De- energizes the AC line and connects the cable to the power charger

8) Check only when the battery is in fully drained state put the charger in boost mode else use it in
float mode or manual mode

10.0 TROUBLESHOOTING

Primary Checks:

• Before going for trouble shooting makes sure that proper AC input voltage is present
with Phase sequence at AC input terminal.

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 • Ensure the load and battery terminal connection has been done properly.

• Ensure the Battery +VE and –VE terminal Connected Correctly.

• During normal operation only the following LED’s should glow

R-PHASE

Y-PHASE

B-PHASE

Failure of Fuses:

• In case of any fuse failure indication always replace blown fuses with exactly same
type with reference to the Bill of material.

• Use the Test /Reset button on annunciation window to check the LED’s Buzzer.

DC Voltage is not available in charger output:

This caused could be:

1. control Fuse failure (FTB)

2. Synchronizing Board (B3) fuse failure / Board Failure

3. SCR fuse failure -Replace the same.

Charger output fluctuation or UN even current of Each Phase:

a) Any one of the SCR fuse blown

b) Synchronizing Transformer Board (B3) may be faulty

c) Check the any of defective Battery Cell in Battery Bank.

c) Thyristor may have failed.

d) Control Card B1 may be fault - Replace the same

AC mains fuse blown when Power ON:

a) Switch of the Charger ,disconnect the Load and Battery

b) Then check the SCR or Diode with Multimeter

c) replace the same, if Shorted

15
 d) Again switch on the charger and check

e) Again fuse blown check the input & output cable would be shorted.

SCR Fuse Blown:

a) Check the SCR or Diode with multimeter ,if shorted replace same and replace the
failed fuse

DC output dropped when loaded:

a) Control card B1 may be fault –replace the same

b) Check the Total Charger Current exceeds beyond the limit.

11. BILL OF MATERIAL:

S.No Component Circuit Specification. Make. Qty UOM
Description. Reference
1 TRANSFORMER T1 7.5KVA I/P TAP :415 ±5% & VOLTECH 1 NOS
O/P : 60V

2 CHOKE CH 2 mH / 80A VOLTECH 1 NOS

3 SCR (Silicon Controlled SCR1 SKKT 92B/16E - 92A SEMIKRON 3 NOS

Rectifier) ,SCR2,SCR3

4 DIODE MODULE DVR SKKD 101/16 SEMIKRON NOS

5 DISCRETE DIODE (FREE D1 RUTTONSHA 1 NOS

WHEELING DIODE)

6 CAPACITOR CAP1 10000MFD/100V IKEN 1 NOS

7 BREEDER RESISTOR R1 250OHM/100Watts GALAXY 1 NOS

8 CONTROL T2,T3,T4 18VA I/P : 0-415V O/P: 18V- OHMEGA 3 NOS

TRANSFORMER 0-18V

9 AC INPUT MCB MCB1 MCB-3P-16A- 415V AC L&T 1 NOS

10 DC LOAD MCB MCB2 MCB-2P-63A-250V DC L&T 1 NOS

11 BATTERY MCB MCB3 MCB-2P-63A-250V DC L&T 1 NOS

12 AC CONTACTOR C1 MNX 22 -22A-415V AC L&T 1 NOS

13 DC CONTACTOR C2 100A SUZHOI 1 NOS

14 EMI FILTER EMI 16A-440V AC EMIS INDIA 1 NOS

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 SWITCHES

15 AC VOLTAGE SELECTOR SW1 6A -VSS L&T -SALZER 1 NOS

SWITCH

16 DC VOLTAGE SELECTOR SW2 6A -1POLE 3WAY WITH OFF L&T -SALZER 1 NOS
SWITCH

17 LOAD / BATTERY SW3 6A - 1 POLE 2WAY L&T -SALZER 1 NOS

CURRENT SELECTOR
SWITCH

18 AUTO / MANUAL SW4 6A -4POLE 4WAY L&T -SALZER 1 NOS

SELECTOR SWITCH

19 FLOAT / BOOST SW5 6A-3POLE 3 WAY L&T -SALZER 1 NOS

SELECTOR SWITCH

20 CHARGER ON/OFF SW6 6A - ON /OFF SWITCH L&T -SALZER 1 NOS

SWITCH

21 DVR SELECTOR SWITCH SW7 63A - 1 POLE 3WAY WITH L&T -SALZER 1 NOS
OFF

METERS

22 AC VOLTMETER V1 0-500V AC -AUX SUPPLY : NIPPEN 1 NOS

12V DC-48 X96

23 DC VOLTMETER V2 0-200V DC -AUX SUPPLY : NIPPEN 1 NOS

12V DC-48X96

24 LOAD / BATTERY A1 100-0-100A - AUX SUPPLY : NIPPEN 1 NOS

AMMETER 12V DC-48X96

25 TRICKLE AMMETER A2 100A- AUX SUPPLY :12V DC- NIPPEN 1 NOS

48X96

26 DC SHUNT SH1,SH2,SH3 100A /75mv AE 1 NOS

FUSE LINK

27 INPUT FUSE F1,F2,F3 FUSE BASE : HD -20H L&T 3 NOS

FUSE LINK : HG -F1- 16A L&T 3 NOS

28 OUTPUT FUSE F7,F8 FUSE LINK : HQ -A3- 100A L&T 2 NOS

29 SCR FUSE F4,F5,F6 FUSE LINK : HQ -A3- 80A C&S 3 NOS

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INDICATION LAMPS

30 AC INDICATION LAMP L1 -R-PHASE RED,YELLOW,BLUE : 220V L&T ESBEE 1 NOS

,L2-Y PHASE AC -22.5mm
,L3-B PHASE

31 DC INDICATION LAMP L4 GREEN-48V DC -22.5mm L&T ESBEE 1 NOS

32 AUTO INDICATION LAMP L5 AMBER-220V AC-22.5mm L&T ESBEE 1 NOS

33 MANUAL INDICATION L6 AMBER-220V AC-22.5mm L&T ESBEE 1 NOS

LAMP
34 FLOAT INDICATION L7 AMBER-220V AC-22.5mm L&T ESBEE 1 NOS
LAMP

35 BOOST INDICATION L8 AMBER-220V AC-22.5mm L&T ESBEE 1 NOS

LAMP

36 VOLTAGE ADJUST POT POT 1 200 Ohm PANKAJ 1 NOS

37 CURRENT ADJUST POT POT 2 470 K ohm ELCON 1 NOS

38 TRICKLE CURRENT PUSH PB1 TEKNIC 1 NOS

BUTTON

39 DOOR SWITCH DSW 1 NOS

40 PANEL LAMP 240V AC CROMPTON 1 NOS

41 CONTROL FUSE TB FTB ELMEX 3 NOS

42 CONTROL TERMINAL X4 2.5 SQMM ELMEX 3 NOS

PCB BOARDS

43 PRIMARY CONTROL B1 VOLTECH 1 NOS

BOARD

44 SECONDARY CONTROL B2 VOLTECH 1 NOS

BOARD

45 SYNCHRONISING B3 VOLTECH 1 NOS

TRANSFORMER BOARD

46 AUTO MANUAL / FLOAT B4 VOLTECH 1 NOS

BOOST BOARD

47 ANNUNCIATION BOARD B5 VOLTECH 1 NOS

48 SURGE BOARD B6 VOLTECH 1 NOS

18
49 TIMER BOARD B7 VOLTECH 1 NOS

50 PHASE FAILURE BOARD B8 VOLTECH 1 NOS

51 DC POWER SUPPLY UNIT B9 VOLTECH 1 NOS

52 ANNUNCIATION LED B10 VOLTECH 1 NOS

BOARD

19
 1 2 3 4 5 6 7 8

A A

VOLTECH MANUFACTURING COMPANY LIMITED

#132,133,134 SRI KUMARAN NAGAR, KUNDRATHUR MAIN ROAD,
KOVUR, CHENNAI-128.
B B

C C
CLIENT TANTRANSCO-ANNASALAI

EPC CONTRACTOR -------------

D
CONSULTANT ------------- D

PROJECT -------------

PO REFERENCE P.O.1004/D.01/20, dt.27.05.2020

E E

RATING 48V/80A BATTERY CHARGER.

JOB NO. ELE/20-21/002

F F
DWG NO. VMC/BC/02-20

QUANTITY / SCHEME ID 209 SETS

G
TOTAL PAGES 09 PAGES G

H H

USE OR CMMUNICATION OF THE CNTENTS THERE OF ARE FORBIDDEN WITHOUT EXPRESS AUTHORITY. OFFENDERS ARE LIABLE TO THE PAYMENTS OF DAMAGES. ALL RIGHTS ARE RESERVED THE EVENT OF THE GRANT OF A PATENT OR THE REGISTRATION OF A UTILITY MODEL OR DESIGN.

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

A A

B B

V V A A

C 8MM DOOR C
1200

1200
KNOB

EARTH BUS
D 25*3MM D
Cu.FLAT
75

500 750 500 750

E E

750

F F
500

550 GLAND PLATE

3MM THICKNESS
120

G G

CLIENT. NAME : TANTRANSCO ANNASALAI TITLE : OUTER GENERAL ARRANGEMENT DATE 22-06-20 PURPOSE : ASBUILT

------------------ 48V/80A BATTERY CHARGER. REVISION REVISION

EPC CONTRACTOR NAME : RATING : DRAWN R.V
DATE
CONSULTANT NAME : ------------------ MODEL : FCBC CHECKED M.S 1 06-08-20

PROJECT NAME : ------------------ JOB NO : ELE/20-21/002 APPROVED G.P.H 2 18-08-20

H VOLTECH MANUFACTURING COMPANY LTD, H
KOVUR,CHENNAI. CUST. PO.REF:NO : P.O.1004/D.01/20, DT.27.05.2020 DRAWING NO. : VMC/BC/02-20 SHEET NO: 01 of 09

USE OR CMMUNICATION OF THE CNTENTS THERE OF ARE FORBIDDEN WITHOUT EXPRESS AUTHORITY. OFFENDERS ARE LIABLE TO THE PAYMENTS OF DAMAGES. ALL RIGHTS ARE RESERVED THE EVENT OF THE GRANT OF A PATENT OR THE REGISTRATION OF A UTILITY MODEL OR DESIGN.

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

A A

B B
Specification;-
1. System Voltage : 3Ph, 4 Wire, 400V AC +/-10%,
50Hz
2. Construction
(a) Material : MS, CRCA
C (b) Thickness C

Shell/Partition/Door : 1.6mm
Mounting Plate : 2.0mm
Base Frame/Gland Plate : 2.0mm

(c) Type : Free Standing

D (d) Installation : Front D

(e) IP Category : IP-42

(f) Cable Entry : Bottom at Front
(g) Painting
External/Internal : RAL 7032
E Mounting Plate : RAL 7032 E

Base Frame : Black

3. Powder Coating thickness : 80 microns and above

4. Earth bar : 25*3mm Copper
5. Panel Size : 1200H x 750W x 500D(With Door)
F F
With Plinth 75mm.

6. Charger weight (Approx) : 200kgs

G G

CLIENT. NAME : TANTRANSCO ANNASALAI TITLE : PANEL SPECIFICATION DATE 22-06-20 PURPOSE : ASBUILT

------------------ 48V/80A BATTERY CHARGER. REVISION REVISION

EPC CONTRACTOR NAME : RATING : DRAWN R.V
DATE
CONSULTANT NAME : ------------------ MODEL : FCBC CHECKED M.S 1 06-08-20

PROJECT NAME : ------------------ JOB NO : ELE/20-21/002 APPROVED G.P.H 2 18-08-20

H VOLTECH MANUFACTURING COMPANY LTD, H
KOVUR,CHENNAI. CUST. PO.REF:NO : P.O.1004/D.01/20, DT.27.05.2020 DRAWING NO. : VMC/BC/02-20 SHEET NO: 02 of 09

USE OR CMMUNICATION OF THE CNTENTS THERE OF ARE FORBIDDEN WITHOUT EXPRESS AUTHORITY. OFFENDERS ARE LIABLE TO THE PAYMENTS OF DAMAGES. ALL RIGHTS ARE RESERVED THE EVENT OF THE GRANT OF A PATENT OR THE REGISTRATION OF A UTILITY MODEL OR DESIGN.

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

A A

LEGENDS :

B B

C C

1200
D D

10*50MM BOLT
and NUT
WASHER SET SMC
BOARD

EARTH BUS
25*3MM
Cu.FLAT

75
E E

750 750

F F

G G

CLIENT. NAME : TANTRANSCO ANNASALAI TITLE : INNER GENERAL ARRANGEMENT DATE 22-06-20 PURPOSE : ASBUILT

------------------ 48V/80A BATTERY CHARGER. REVISION REVISION

EPC CONTRACTOR NAME : RATING : DRAWN R.V
DATE
CONSULTANT NAME : ------------------ MODEL : FCBC CHECKED M.S 1 06-08-20

PROJECT NAME : ------------------ JOB NO : ELE/20-21/002 APPROVED G.P.H 2 18-08-20

H VOLTECH MANUFACTURING COMPANY LTD, H
KOVUR,CHENNAI. CUST. PO.REF:NO : P.O.1004/D.01/20, DT.27.05.2020 DRAWING NO. : VMC/BC/02-20 SHEET NO: 03 of 09

USE OR CMMUNICATION OF THE CNTENTS THERE OF ARE FORBIDDEN WITHOUT EXPRESS AUTHORITY. OFFENDERS ARE LIABLE TO THE PAYMENTS OF DAMAGES. ALL RIGHTS ARE RESERVED THE EVENT OF THE GRANT OF A PATENT OR THE REGISTRATION OF A UTILITY MODEL OR DESIGN.

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

A A

B B

C C

D D

E E

F F

G G

CLIENT. NAME : TANTRANSCO ANNASALAI TITLE : POWER WIRING DRAWING DATE 22-06-20 PURPOSE : ASBUILT

------------------ 48V/80A BATTERY CHARGER. REVISION REVISION

EPC CONTRACTOR NAME : RATING : DRAWN R.V
DATE
CONSULTANT NAME : ------------------ MODEL : FCBC CHECKED M.S 1 06-08-20

PROJECT NAME : ------------------ JOB NO : ELE/20-21/002 APPROVED G.P.H 2 18-08-20

H VOLTECH MANUFACTURING COMPANY LTD, H
KOVUR,CHENNAI. CUST. PO.REF:NO : P.O.1004/D.01/20, DT.27.05.2020 DRAWING NO. : VMC/BC/02-20 SHEET NO: 04 of 09

USE OR CMMUNICATION OF THE CNTENTS THERE OF ARE FORBIDDEN WITHOUT EXPRESS AUTHORITY. OFFENDERS ARE LIABLE TO THE PAYMENTS OF DAMAGES. ALL RIGHTS ARE RESERVED THE EVENT OF THE GRANT OF A PATENT OR THE REGISTRATION OF A UTILITY MODEL OR DESIGN.

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

A A

B B

C C

D D

E E

F F

G G

CLIENT. NAME : TANTRANSCO ANNASALAI TITLE : DVR MODULE DETAILS DATE 28-08-20 PURPOSE : FOR ASBUILT

------------------ 48V/80A BATTERY CHARGER. REVISION REVISION

EPC CONTRACTOR NAME : RATING : DRAWN R.V
DATE
CONSULTANT NAME : ------------------ MODEL : FCBC CHECKED M.S 1 06-08-20

PROJECT NAME : ------------------ JOB NO : ELE/20-21/002 APPROVED G.P.H 2 18-08-20

H VOLTECH MANUFACTURING COMPANY LTD, H
KOVUR,CHENNAI. CUST. PO.REF:NO : P.O.1004/D.01/20, DT.27.05.2020 DRAWING NO. : VMC/BC/02-20 SHEET NO: 04A of 09

USE OR CMMUNICATION OF THE CNTENTS THERE OF ARE FORBIDDEN WITHOUT EXPRESS AUTHORITY. OFFENDERS ARE LIABLE TO THE PAYMENTS OF DAMAGES. ALL RIGHTS ARE RESERVED THE EVENT OF THE GRANT OF A PATENT OR THE REGISTRATION OF A UTILITY MODEL OR DESIGN.

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

A A

B B

C C

D D

E E

F F

G G

CLIENT. NAME : TANTRANSCO ANNASALAI TITLE : CONTROL WIRING DRAWING DATE 22-06-20 PURPOSE : ASBUILT

------------------ 48V/80A BATTERY CHARGER. REVISION REVISION

EPC CONTRACTOR NAME : RATING : DRAWN R.V
DATE
CONSULTANT NAME : ------------------ MODEL : FCBC CHECKED M.S 1 06-08-20

PROJECT NAME : ------------------ JOB NO : ELE/20-21/002 APPROVED G.P.H 2 18-08-20

H VOLTECH MANUFACTURING COMPANY LTD, H
KOVUR,CHENNAI. CUST. PO.REF:NO : P.O.1004/D.01/20, DT.27.05.2020 DRAWING NO. : VMC/BC/02-20 SHEET NO: 05 of 09

USE OR CMMUNICATION OF THE CNTENTS THERE OF ARE FORBIDDEN WITHOUT EXPRESS AUTHORITY. OFFENDERS ARE LIABLE TO THE PAYMENTS OF DAMAGES. ALL RIGHTS ARE RESERVED THE EVENT OF THE GRANT OF A PATENT OR THE REGISTRATION OF A UTILITY MODEL OR DESIGN.

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

A A

B B

LED1

C LED2 C
LED3

LED4

LED5

LED6

LED7

LED8

LED9

LED10

LED11

D D

E E

F F

G G

CLIENT. NAME : TANTRANSCO ANNASALAI TITLE : ANNUNCIATION WIRING DRAWING DATE 22-06-20 PURPOSE : ASBUILT

------------------ 48V/80A BATTERY CHARGER. REVISION REVISION

EPC CONTRACTOR NAME : RATING : DRAWN R.V
DATE
CONSULTANT NAME : ------------------ MODEL : FCBC CHECKED M.S 1 06-08-20

PROJECT NAME : ------------------ JOB NO : ELE/20-21/002 APPROVED G.P.H 2 18-08-20

H VOLTECH MANUFACTURING COMPANY LTD, H
KOVUR,CHENNAI. CUST. PO.REF:NO : P.O.1004/D.01/20, DT.27.05.2020 DRAWING NO. : VMC/BC/02-20 SHEET NO: 06 of 09

USE OR CMMUNICATION OF THE CNTENTS THERE OF ARE FORBIDDEN WITHOUT EXPRESS AUTHORITY. OFFENDERS ARE LIABLE TO THE PAYMENTS OF DAMAGES. ALL RIGHTS ARE RESERVED THE EVENT OF THE GRANT OF A PATENT OR THE REGISTRATION OF A UTILITY MODEL OR DESIGN.

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

A A

B B

C C

D D

MS 10*50MM BOLT
WITH WASHER
SMC BOARD
AND NUT SET

E E

F F

G G

CLIENT. NAME : TANTRANSCO ANNASALAI TITLE : TERMINAL DETAILS DATE 22-06-20 PURPOSE : ASBUILT

------------------ 48V/80A BATTERY CHARGER. REVISION REVISION

EPC CONTRACTOR NAME : RATING : DRAWN R.V
DATE
CONSULTANT NAME : ------------------ MODEL : FCBC CHECKED M.S 1 06-08-20

PROJECT NAME : ------------------ JOB NO : ELE/20-21/002 APPROVED G.P.H 2 18-08-20

H VOLTECH MANUFACTURING COMPANY LTD, H
KOVUR,CHENNAI. CUST. PO.REF:NO : P.O.1004/D.01/20, DT.27.05.2020 DRAWING NO. : VMC/BC/02-20 SHEET NO: 07 of 09

USE OR CMMUNICATION OF THE CNTENTS THERE OF ARE FORBIDDEN WITHOUT EXPRESS AUTHORITY. OFFENDERS ARE LIABLE TO THE PAYMENTS OF DAMAGES. ALL RIGHTS ARE RESERVED THE EVENT OF THE GRANT OF A PATENT OR THE REGISTRATION OF A UTILITY MODEL OR DESIGN.

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

A A

B B

C C

D D

E E

F F

G G

CLIENT. NAME : TANTRANSCO ANNASALAI TITLE : PCB DETAILS DATE 28-08-20 PURPOSE : FOR APPROVAL

------------------ 48V/80A BATTERY CHARGER. REVISION REVISION

EPC CONTRACTOR NAME : RATING : DRAWN R.V
DATE
CONSULTANT NAME : ------------------ MODEL : FCBC CHECKED M.S 1 06-08-20

PROJECT NAME : ------------------ JOB NO : ELE/20-21/002 APPROVED G.P.H 2 18-08-20

H VOLTECH MANUFACTURING COMPANY LTD, H
KOVUR,CHENNAI. CUST. PO.REF:NO : P.O.1004/D.01/20, DT.27.05.2020 DRAWING NO. : VMC/BC/02-20 SHEET NO: 08 of 09

USE OR CMMUNICATION OF THE CNTENTS THERE OF ARE FORBIDDEN WITHOUT EXPRESS AUTHORITY. OFFENDERS ARE LIABLE TO THE PAYMENTS OF DAMAGES. ALL RIGHTS ARE RESERVED THE EVENT OF THE GRANT OF A PATENT OR THE REGISTRATION OF A UTILITY MODEL OR DESIGN.

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

A A

B B

C C

D D

E E

F F

G G

CLIENT. NAME : TANTRANSCO ANNASALAI TITLE : PCB DETAILS DATE 28-08-20 PURPOSE : FOR APPROVAL

------------------ 48V/80A BATTERY CHARGER. REVISION REVISION

EPC CONTRACTOR NAME : RATING : DRAWN R.V
DATE
CONSULTANT NAME : ------------------ MODEL : FCBC CHECKED M.S 1 06-08-20

PROJECT NAME : ------------------ JOB NO : ELE/20-21/002 APPROVED G.P.H 2 18-08-20

H VOLTECH MANUFACTURING COMPANY LTD, H
KOVUR,CHENNAI. CUST. PO.REF:NO : P.O.1004/D.01/20, DT.27.05.2020 DRAWING NO. : VMC/BC/02-20 SHEET NO: 09 of 09

USE OR CMMUNICATION OF THE CNTENTS THERE OF ARE FORBIDDEN WITHOUT EXPRESS AUTHORITY. OFFENDERS ARE LIABLE TO THE PAYMENTS OF DAMAGES. ALL RIGHTS ARE RESERVED THE EVENT OF THE GRANT OF A PATENT OR THE REGISTRATION OF A UTILITY MODEL OR DESIGN.

1 2 3 4 5 6 7 8