Download - 1205099 1 USER MANUAL 550A
-
Ope
rational & M
aintenance
Manual for 2
20V 550A D
FCBC
d
ubas
1
du
ba
s
MX SERIES BATTERY CHARGER
80010
200010
80010
80010
80010
100 190010
FCBC - 1FCBC - 1
FCBC - 2FCBC - 2
80010
SWC
DU
AL
FL
OA
T C
UM
BO
OS
T C
HA
RG
ER
+ S
WIT
CH
ING
CU
BIC
LE
-
Ope
rational & M
aintenance
Manual for 2
20V 550A D
FCBC
d
ubas
2
CO
NG
RA
TU
LA
TIO
N
Congratulation
s for choosing dubas Product. Y
ou now belon
g to dubas family of
over many satisfied custom
er across the world. d
ubas is a 100%
dedicated company to
Power Electron
ics Industry
. With
absolute knowledge
of techn
ologies and
understan
ding the
importan
ce of Battery
Charger
in a critical
automated
environ
ment, we have built our products to provide reliability
to the industry
and
commerce. d
ubas is been
in pow
er electronics in
dustry over a decade an
d has done
various pioneerin
g works in
power electron
ics. dubas is an
ISO 9001 certified
company. dubas delivers un
comprom
ised quality products an
d services to accomplish
highest customer satisfaction
.
-
Ope
rational & M
aintenance
Manual for 2
20V 550A D
FCBC
d
ubas
3
Op
era
tion
& In
stru
ctio
n M
an
ual
Fo
r
MX
-SE
RIE
S B
AT
TE
RY
CH
AR
GE
R
DE
SC
RIP
TIO
N
: D
UA
L F
LO
AT
CU
M B
OO
ST
CH
AR
GE
R
+ S
WIT
CH
ING
CU
BIC
LE
RA
TIN
G
: 1
36
KW
INP
UT
: 3-4W, 415V, +
10% -1
0%, 5
0 Hz,
OU
TP
UT
: 220V
DC
Co
nfig
ura
tion
: T
he System consists of fo
llowing sub-systems.
a) C
harger 1
& 2
: 3, 415V AC input, O
/P 136KW, 220V DC
b) S
witching Cubicle
: 220VDC, 5
50A
This m
anual is a
ccompanying the above-referred
product, w
hich has been manufactured in accordance w
ith the
customer p
urchase o
rder, co
nforming to dubas quality system
s for manufacturing quality. T
he operating procedure,
maintenance, in
stallation, tro
uble sh
ooting in the even
t of fault occurren
ce has been given
in this m
anual. Electrica
l
hazards given
in this m
anual must be understo
od and strictly fo
llowed otherwise it co
uld prove fa
tal. P
lease refer
to warranty certifica
te for warranty co
ver details.
PLEASE READ THE M
ANUAL THOROUGHLY, B
EFORE OPERATING THE SYSTEM.
DU
BA
S E
NG
INE
ER
ING
PV
T. L
TD
.,
# 43 (P
), Electro
nics City Phase II,
Hosur M
ain Road, B
angalore, 5
60 100.
Phone: +
91-80-40336000 (3
0Lines) F
ax: 0
80-40336222,
E-m
ail d
[email protected], [email protected]
om visit u
s @
www.dubaspower.c
om
-
Ope
rational & M
aintenance
Manual for 2
20V 550A D
FCBC
d
ubas
4
Ta
ble
of C
on
ten
ts
1
.0
Syste
m D
es
crip
tion
----------
5
2.0
T
ec
hn
ica
l Sp
ec
ifica
tion
----------
6
3.0
In
sta
llatio
n &
Co
mm
iss
ion
ing
Im
po
rtan
t Sa
fety
Ins
truc
tion
s ----------
9
Ins
talla
tion
----------
10
Co
mm
issio
nin
g
----------
16
4.0
S
yste
m C
on
stru
ctio
n
----------
17
5.0
O
pe
ratin
g M
od
es
----------
22
6.0
In
dic
atio
ns
, Co
ntro
ls a
nd
Dis
pla
y ----------
2
5
7.0
Us
er In
terfa
ce
Dis
pla
y
----------
28
8.0
B
atte
ry C
ha
rgin
g M
eth
od
s
----------
30
9.0
R
ou
tine
Main
ten
an
ce
----------
3
2
10
.0
Re
pla
ce
me
nts
---------
33
11
.0
Tro
ub
le S
ho
otin
g F
or
Ba
ttery
Ch
arg
er
----------
37
12
.0 F
ailu
re R
ep
ort
----------
3
9
13
.0 Q
ua
lity P
olic
y
----------
4
1
14
.0 P
rod
uct V
arie
ties
----------
42
15
.0 M
ajo
r Bill o
f Qu
an
tity
---------
43
16
.0 A
S B
UIL
T D
RA
WIN
GS
---------
5
3-5
9
FU
NC
TIO
NA
L C
HA
RT
-
Ope
rational & M
aintenance
Manual for 2
20V 550A D
FCBC
d
ubas
5
1.0
SY
ST
EM
DE
SC
RIP
TIO
N
The availability
factor o
f a DC UPS SYSTEM is
paramount. W
hich is determ
ined by th
e quality
and perio
dicity of
preventive m
aintenance, o
perating conditio
ns (e
nviro
nmental, lo
ad determ
ined and operator d
eterm
ined), a
s well a
s
the dovetail o
f the actual application re
quire
ments and system design crite
ria.
The document is
intended to
facilita
te th
e operator to
optionally utiliz
e th
e 220V BC as DC UPS SYSTEM and we
sincerely believe th
at it a
chieves th
is goal effe
ctively.
Du
ba
s Batte
ry Chargers, ty
pe M
X: B
atte
ry Charger is
a ra
nge of IG
BT contro
lled re
ctifie
r units, fo
r charging `L
ead
Acid' or `N
ickel C
admium' B
atte
ries. T
his can also be used as a general power s
upply without a
batte
ry connected
in parallel. In
case batte
ry is always connected in parallel w
ith th
e charger a
nd lo
ad, th
is system constitu
tes a DC
UPS system.
The Charger is
of C
onstant V
oltage Curre
nt lim
ited type, w
ith th
ree levels of voltage fo
r charging th
e batte
ry. T
hese
levels are `A
uto Float C
harge', M
anual flo
at C
harge and `M
anual B
oost C
harge' le
vels; w
hich essentially designate
band voltage le
vels th
at c
an be set a
s per c
harging re
quire
ment o
f the batte
ry (w
hich is determ
ined by th
e ty
pe of
batte
ry). "M
anual B
oost C
harge" v
oltage is re
quire
d to
recharge a discharged batte
ry, a
nd "A
uto Float C
harge" is
require
d fo
r keeping th
e alre
ady charged batte
ry in
fully charged conditio
n. U
nder b
oth Float a
s w
ell a
s B
oost
charging conditio
n th
e Charger o
utput c
urre
nt c
an be lim
ited to
values ra
nging fro
m 10% to
100% of th
e charger
output capacity.
Output v
oltage re
gulation is
achieved by IG
BT contro
l. IGBT bridges w
hich are switched using PWM te
chnique
ensures bette
r input power factor under all working conditio
ns which is a plus point compared to a thyristor
contro
lled re
ctifie
r circuits. T
his w
ill also ensure a very lo
w percentage of in
put h
arm
onics curre
nt is
fed to
the
source and also th
e in
put P
ower fa
ctor is
maintained to
unity fro
m 10% to
100% of ra
ted lo
ad. T
he C
onverte
r
contro
l logic is fu
lly softw
are based & is perfo
rmed by W
orlds leading D
igita
l Sig
na
l Pro
ce
ss
or.
This batte
ry charger h
ere onwards re
ferre
d as equipment consists The DC system shall c
omprise of 2
no.s Float
cum Boost C
hargers (e
ach ra
ted fo
r 100% capacity) o
perating in parallel m
ode and equally sharin
g to
tal lo
ad
simultaneously a
nd 1 sets of B
atte
ries (ra
ted fo
r 100% Capacity). T
he details of th
e scheme are explained in th
e
furth
er c
hapter.
WARNING
1.
The Batte
ry Charger P
anel has to
be operated only by skille
d operators, w
ith necessary authorization.
2.
The Batte
ry Charger s
hall n
ot b
e accessible to
unauthorized personnel.
3.
The Batte
ry Charger p
anel shall b
e opened only in Power O
ff conditio
n.
4.
Only qualifie
d service te
chnicians shall h
ave th
e access to
open th
e door. In
side of B
atte
ry C
harger
panel has Very dangerous electric
al components, which can potentially electro
cute the careless
operator.
-
Ope
rational & M
aintenance
Manual for 2
20V 550A D
FCBC
d
ubas
6
2.0
TE
CH
NIC
AL
SP
EC
IFIC
AT
ION
(GU
AR
AN
TE
ED
TE
CH
NIC
AL
PA
RT
ICU
LA
RS
)
A) B
atte
ry C
ha
rge
r
1. Ite
m No. a
s per P
.O
----
2. T
ag No.
----
3.M
anufacturers Name
d
ub
as E
ng
ine
erin
g P
vt L
td.
4. T
ype
D
FC
BC
5. N
o. o
f Dual F
CQ Chargers
1
SE
T (2
NO
s)
6. In
put A
C Voltage
4
15
V +
/-1
0%
, 3
, 4 w
ire
7. Frequency
50
Hz +
/-3
%
8.In
put P
ower fa
ctor a
t rated voltage & load
>
0.9
5
8.1 Fault le
vel
50
KA
Fo
r 1S
ec
9. In
put A
C curre
nt : a
. Float m
ode
b. Q
uick m
ode
24
4A
10
4A
10.Rating in Float m
ode
a.) C
harger R
ating
13
6K
W
b.) O
utput V
oltage & %
varia
tion
2
47
V, +
/-1
%
c.) Output C
urre
nt &
% variation
5
50
A, +
/-1
%
11
. Rating in quick m
ode
a.) C
harger R
ating
58
KW
b.) O
utput V
oltage & %
varia
tion
2
64
V, +
/-1
%
c.) Output C
urre
nt &
% variation
2
20
A, +
/-1
%
12
. Nominal V
oltage
a.) F
loat C
harging
2
47
V
b.) Q
uick Charging
2
64
V
13.M
anual F
loat C
harging voltage ra
nge
2
20
2
47
V (S
etta
ble
)
14. M
anual B
oost C
harging voltage ra
nge
2
20
2
96
V (S
etta
ble
)
15.M
inimum effic
iency o
f the charger
a.) A
t 25% load
>8
0%
b.) A
t 40% load
>8
0%
c.) A
t 50% load
>8
0%
d.) A
t 75% load
>8
5%
e.) A
t 100% load
>8
5%
16
. Ma
x. e
fficien
cy a
t No
min
al in
pu
t & co
rresp
on
din
g o
utp
ut
>8
5%
@ R
ate
d lo
ad
17
. Ma
x. R
MS
ripp
le v
olta
ge
con
ten
t at ra
ted
loa
d
a). W
ith b
atte
ry co
nn
ecte
d
+/
-1%
b). W
itho
ut b
atte
ry co
nn
ecte
d
+/
-1%
-
Ope
rational & M
aintenance
Manual for 2
20V 550A D
FCBC
d
ubas
7
18
. Me
tho
d o
f vo
ltag
e co
ntro
l
a). In
floa
t mo
de
C
V
b). In
qu
ick m
od
e
VL
19
. Me
tho
d o
f curre
nt co
ntro
l
a). In
floa
t mo
de
C
L
b). In
qu
ick m
od
e
CC
20
. Sa
fety
Fa
ctor u
sed
for se
lectin
g co
mp
on
en
ts 1
.5 fo
r Ele
ctron
ic po
we
r de
vice
s & 1
.25
for
Ele
ctrical co
mp
on
en
t
21
. Ch
arg
er D
ime
nsio
ns
a). W
idth
(mm
)
80
0 m
m
b). D
ep
th (m
m)
70
0 m
m
c). He
igh
t (mm
) 2
00
0m
m
22
. Ma
x. H
ea
t loss in
wa
tts 4
77
96
Wa
tts
23
. De
gre
e o
f pro
tectio
n (IP
) IP
31
24
. Re
fere
nce
Sta
nd
ard
s IE
C-6
01
46
25
. Pa
int S
ha
de
a).In
side
R
AL
70
32
b).O
utsid
e
RA
L 7
03
2
26
. Dim
en
sion
s of sw
itchin
g cu
bicle
a).W
idth
(mm
) 8
00
mm
b). D
ep
th (m
m)
70
0 m
m
c). He
igh
t (mm
) 2
00
0m
m
27
.No
ise le
ve
l AQ CO Set)
OFF/FLT AF AF AF CW OFF OFF OFF ON ON 2
AQ changeover don't occur when Alternate FCBC is
OFF/Fault
6
FCBC 2 is MF Charging the BATT & FCBC1 is Feeding the load
AF AF MF MF CW ON OFF OFF OFF ON 2
7
FCBC 2 is MB Charging the BATT & FCBC1 is Feeding the load
AF AF MB MB CW ON OFF OFF OFF ON 2
8
FCBC 2 was MB charging the BATT & FCBC1 is Feeding the load
later boost charge timer is completed at FCBC2
AF AF AF MB CW ON OFF OFF OFF ON 2
To repeat the Manual Boost charge of BATT , position
MSS to AF and reposition MSS to MB by this timer will
reset to zero and manual boost charge shall commence
at FCBC2.
9
FCBC 2 was MF/MB charging the BATT & FCBC1 is Feeding the
load later FCBC2 fails
AF AF OFF/Fault MB CW ON ON OFF OFF OFF 2
DC2A / DC2B switches OFF when Alternate FCBC is
healthy & Alternate FCBC MSS is selected to MF/MB OR
Alternate FCBC is on AQ mode.
10
FCBC 2 was MB charging the BATT & FCBC1 is Feeding the load
later boost charge timer is completed at FCBC2 , BATT Amps >
AQ CO Set).
AF AF AF MB CW ON OFF OFF OFF ON 2
FCBC2 working in AF mode will not go AQ CO(Even if
BATT Amp > AQ CO set) unless MSS is positioned to
AF
11
FCBC 2 was MF/MB charging the BATT & FCBC1 is Feeding the
load later MSS at FCBC1 selected to MF/MB
AF MF/MB MF/MB MF/MB CW ON OFF OFF OFF ON 2
FCBC1 with not work in MF/MB/AQ when PSSw is
selected to FCBC2
12
FCBC 2 was MF/MB charging the BATT & FCBC1 is Fault/OFF
Load is Fed Through TCD
OFF/Fault AF MF/MB MF/MB CW OFF OFF OFF OFF ON 2
13
FCBC 2 was MF/MB charging the BATT & FCBC1 is Fault/OFF
Load is Fed Through TCD later FCBC 2 is OFF/Fault
OFF/Fault AF OFF/Fault MF/MB CW OFF OFF ON OFF OFF 2
14
FCBC 1 is AQ charging the BATT, FCBC2 is Feeding the load
(BATT Amps > AQ CO Set) AQ AF AF AF CW OFF ON OFF ON OFF 1
FCBC1 goes to AQ CO only if PSSw is selected to
FCBC1 & BATT1 Amps > AQ CO Set
15
FCBC 1 is MF/MB Charging the BATT & FCBC2 is Feeding the
load
MF/MB MF/MB AF AF CW OFF ON OFF ON OFF 1
LF
Ref
FCBC1 FCBC2
FCBC which is operating in AQ/MF/MB mode BATT
contactor is switched OFF i.e., DC1A /DC1B
-
Notes:-
--> Column PSSw if mentioned 2 it is to be understood that AQ/MF/MB Pre-Select switch is selected to FCBC2
---> In status column if AF is mentioned, it say the FCBC is ON in AF mode similarly for MF & MB
--> If any one node (controller ) i.e. Main Controller / Auxiliary Controller of FCBC1 / 2 is disconnected from the CAN BUS it will be displayed as CF (CAN Fail)
--> With PSSw selected to FCBC 1 above mentioned Logics (LC1-13) can be performed, (Replace FCBC1 to FCBC2 & FCBC 2 to FCBC1)
--> When FCBC1 & FCBC2 are working in parallel mode, If the Load current is less than 120A , entire load current shall be fed by the FCBC which is working as MASTER
--> When FCBC1 & FCBC2 are working in parallel mode, If the Load current is greater than 120A , entire load current shared between FCBC1 & 2
--> FCBC working as master is indicated with M at STATUS & OUTPUTPARAMETER at GT100 diplay
--> When FCBC operating as slave (Indicated as S at Status & Output Parameter) FCBC does not share any of the load current.
--> When FCBC operating as slave parallel (Indicated as S PAR at Status & Output Parameter) Both the FCBC's shares the total load current.
Abbreviations
MF : Manual Float MSS : Mode Select Switch
MB: Manual Boost PSSw : Pre-Select Switch
AQ : Auto Quick AQ CO : AutoQuick Change Over
BATT : Battery CF/CW : CAN bus Fail / Working