IndustrialPower Electronics

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/ Battery Charger Rect i f i e r /

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Advantages

HBL Battery Chargers offer numerous advantages, some of which are listed below :

Extensive Range

Available in a wide range of standard and customised models, HBL Battery chargers can be supplied in voltage outputs upto 500V DC and current outputs upto 2000 Amps.

High Reliability

Conservative design and high quality standards ensure absolute reliability of the equipment and failsafe operation.

Versatility

HBL chargers and DC systems find usage in variety of applications such as Process Control, telecommunications, Emergency Lighting, Switch Gear protection, Engine starting and Power Station Control, to mention a few.

Minimal Maintenance

Designed for low maintenance and remote operation, HBL Battery Charger can work for many years, without any special attention.

User Friendly

Cautiously conceived alarms and annunciations, easily accessible component layout, meticulously designed Operation Manual and easy availability of spare parts enable the users to quickly attend to the equipment, in the unlikely event of a fault arising in the HBL Battery Charger.

System Solutions

HBL designs and manufactures under one roof, the complete DC System consisting of Nickel Cadmium Batteries, VRLA, Battery Chargers and Distribution Panels. This facilitates the company to offer integrated systems solution to meet individual customer needs.

HBL Battery Charger uses Thyristor switching principle for achieving the desired DC output. It basically consists of a transformer, a semi conductor bridge rectifier, a filter circuit and a control circuit.

The AC mains voltage is transformed to a suitable level and fed to the rectifier bridge which rectifies the AC input and feeds controlled DC output to the battery and load, after being smoothened by the filter circuit. The power output requirement is adjusted by using phase control technique which is provided by the control circuit. The feedback signals from the output to the control circuit are used for maintaining voltage regulation and current limit. Th

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User friendly with prominently displayed instrumentation

Available in a wide range of standard and customised models

Reliable and fail-safe operation

Designed for low maintenance and remote operation

Features

Thyristor based charger

Thyristor ChargerDSP Controlled T

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The all new HBL Battery charger uses 16 Bit DSP Controller for switching

and control of Thyristor for achieving desired DC output. The charger

output voltage, output current and battery current, including battery

temperature compensation are controlled by the Digital Signal

Processor. The charger output parameters can be set or adjust through

keypad-display provided on the front panel. It has communication ports

for local monitoring using a PC and also remote monitoring of

measurements and events as well as event history.

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Features

Performance

Fully DSP Based SCR controlled charger

Output voltage Range : 24V to 500V DC

Output current Range : 20 to 2500A

Regulation: less than 1%

Efficiency: more than 80%

Dynamic response: less than 150mS.

Ripple at the output: less than 1%

Less wiring, Easy of testing, production and installation.

Display and Data Monitoring:

Measurements display over 128X64 Graphics LCD.

11 special function keys for user interface

Customization of display measurements and alarm conditions upto 28 Alarms.

User access for parameters setting like output voltage, output current limit, battery current limit etc.,

from front panel display and keypad, with password protection

Momentary Load Test facility with data logging for battery health check

Provision for storing 500 events /faults

Communication:

MODBUS over RS485,

Live data (Measurements and alarms) monitoring on Local PC through USB

Remote data monitoring through TCP/IP over Ethernet

Charger management Software for monitoring data locally as well remotely.

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Switch Mode Rectifiers for Industry

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SMPS MODULE | 3000WSMR 110SP20 | 230VacSwitch Mode power Supply modules of series SMR 110SP20 are

compact battery charging rectifiers with an optimized switching

principles and therefore with very high power density. The

rectifier can be used in all DC applications with or without

battery.

Due to modular concept and high scalability the user is able to

equip the power supply with additional modules according to his

actual power profile. The chargers are very user-friendly. The

devices get their operation parameters through communication-

bus between module and SCU. Therefore, the supply of the

connected loads and the charging of the batteries are

guaranteed without any interruption.

Key Features

Compact in size.

Single-Phase module with Sinusoidal input Current(PFC).

Input Voltage Protection

High Power Density

Front-to-Back airflow with temperature controlled fan cooling.

Wide range of input 150Vac ~ 275Vac at rated power.

Universal input: 90Vac~300Vac(Optional).

Electrical safety IEC 60950-1 UL 60950-1 CSA 22.2EMC WXMXD 345x286x136 EN 61000-6-4 (emission, industry) EN 61000-6-3 (emission, light industry) EN 61000-6-2 (immunity, industry) EN 61000-6-2 (immunity, light industry)

Harmonics EN 61000-3-2Environment ETSI EN 300 019-2 ETSI EN 300 132-2 RoHS compliant

The above module is manufactured in 24,48V, 220V Dc as well for other modulate Application

Applicable standards

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DC DC CONVERTERS

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A DC to DC Converter is a circuit which converts a source of direct current (DC)

from one voltage level to another. In many applications, there is a need to

convert one DC Voltage to another DC Voltage, either increasing or decreasing

it. This is the role of a DC/DC Converter.

Configurations

Single/Parallel Redundant or any customer specific configurations

Product Range:

110-24V/ 220-24V/ 48-24V DC

100W to 1500W.

Application

- I ndus t r i a l

Input VoltageVoltage Range

Input CurrentProtection

INPUT

48V / 110V / 220V+20% TO -10%

SOFT STARTMCB AT INPUT SIDE INPUT UNDER /OVER VOLTAGE

INPUT PEAK CURRENT 125% OF MAXIMUM INPUT CURRENT

OUPUT

Output VoltageOutput Power Output Current Current ShareStatic Voltage RegulationDynamic Voltage Regulation

Ripple & NoiseProtection

48V / 24V / 110V1200W / 800W / 500W / 250W50A AT 24V OUTPUTWITH IN +/- 5%+/-1% FROM 10% TO 100% LOAD+/-5% FOR 10% TO 100% OR 100% TO 10%1% RMS OR 100mV RMSOVER LOADSHORT CIRCUITOVER VOLTAGE SHUTDOWNMCB AT OUTPUT SIDE

Isolation Voltage 500VDC INPUT TO EARTH1000VDC INPUT TO OUTPUT500VDC OUTPUT EARTHBattery Low (LVD Disconnect)

Indications & Alarms INPUT ONOUTPUT ONOUTPUT FAIL / CONVERTER FAILUNDER VOLTAGE OVER VOLTAGE INPUT OUT OF RANGE

Efficiency > 80% AT RATED LOAD

0 TO 50Deg C

Storage Temperature -20 TO 85 Deg C

Type Of Cooling NATURAL COOLING

Enclosure Ingress Protection

IP 51

Dimensions 500(W) X 400(D) X 600(H) IN mm

Transducers(optional) 4-20mA SIGNAL FOR OUTPUT VOLTAGE AND CURRENT FOR SCADA

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Operating

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Advanced Battery MonitoringAdva

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Monitoring

Advanced Battery Monitoring is an

innovative battery monitoring system

where power and system availability

are critical to successful business

operations. It smartly operates by

preventing costly downtime due to

unexpected battery failures. ABM has

been designed to monitor individual

cells up to 15V & control the

charge/discharge operations on

battery systems ranging from 24V. It is

designed for varied requirements such

as stand-alone/networked models.

ABM has been designed to be portable,

accurate, reliable, and simple model

that is best suited for all types of Lead-

Acid and Ni-Cd battery systems

installed at UPS, Power stations,

Telecom & Industrial applications. It

can be left unattended at sites for data

collections (can later be exported for

further analysis), or, by its integrated

alarm feature which can assist the user

to initiate the charge/discharge cycles.

ABM can monitor & log various battery

parameters like voltage, current and

temperature at programmed intervals.

ABMs are configured to a single-point

access for thousands of units located in

remote sites anywhere in the world.

Features Fully Programmable scan interval/prioritized pre-alarm conditions with Voltage(pot) free outputs

suitable to connect SCADA (Supervisory Control & Data Acquisition) systems.

Logging of cell/battery parameters (voltage, current and temperature) and Alarm conditions with

date/time stamp.

RS232 port for connection to PC/Laptop provides real time access and to export logged data.

Option for remote control/monitoring through Ethernet. Connectivity with Internet iNetworks with

adjacent ABM’s over RS485

Graphical representation of various parameters to analyse the battery performance periodically.

Simulates time duration a battery can discharge safely.

Represents battery Ah during charge/discharge cycles

Notifies the system problems by considering the number of days since battery bank was fully

charged.

Out of limit alarms for battery low voltage & deep discharge.

Protected against accidental mis-wiring & over voltage on all channel inputs.

Automatically sends reminders of Alarm status / battery parameters through email / SMS (Optional) i

Efficiently manages the battery by calculating the state of charge of batteries. Graphically displays

the computed average voltage of the battery and compares individual cell voltages with the average.

iEase of installation & expand ability

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Benefits

24/7 alarm notification

Event Log of all activities affecting the battery bank

Automatic capture of data and report generation

Remote Access through Ethernet & Internet

Ease of installation and expand ability

Reduction of call-out charges through preventive maintenance

Analysis of data allows remedial action for individual cells to extend their life

Enables procurement of batteries through planned schedules, not emergency replacement

Reduce or eliminate revenue loss by knowing the reliability of stand-by batteries

Stand-alone modelNetwork Model

ABM ( Telecom Applications )

Network model

ABM (Industrial Applications) Instantaneous connection to multiple sites.

Real time & Historic information for Alarms &

battery parameters (battery health diagnostics).

Calculates Ah values based on recorded

battery trends at any point of time.

Displays min/max/avg cell voltages. Identifies

under voltage/over voltage cells by comparing

with average voltage & battery manufacturer

statistics for the past 15 years.

Configurable query utility to search for data by

providing various user defined filters.

Generates reports / Exports data into Excel for

further analysis and management.

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Integrated Power

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Supply SystemIn

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HBL introduced India's first Integrated Power Supply System

in 1999 to help provide reliable & continuous power at the

lowest cost considering both capital & maintenance.

With backup from a single battery, IPS ensures power

availability of all voltages, AC or DC, for all the S&T loads in

yard obviating the need for independent UPS for each yard

element.

HBL is now developing a State of the Art IPS that is designed

to operate at higher efficiency and enhanced reliability levels.

Product Range

Transformers 0.5 KVA – 5 KVA (for IPS)

0.5 KVA – 175 KVA (for others)

Charging cum Regenerative discharger : 12V – 10A to 300V – 200A

SMRS : Std module 110V – 20A expanded in multiples of 20A

Inverter : 0.5 KVA – 5 KVA

CVTS : 0.5 KVA – 5 KVA

DC DC Converters : 2V /0.5A – 110V/10A

2V/0.5A – 80V/1A

24V/10A – 6

2V-80V – 10 A

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Switch Mode Rectifiers

Inverters

DC-DC Converters

Transformers

AVRs

Charger cum Regenerative Discharger

IPS Modules

Integrated power supply systems comprises of

Point machine

Relays

Axle Counters

Telecommunications

Block Instruments

Signal Loads

Battery Charging

Regenerative Discharging

Applications

Feeding DC various loads in Railways stations like

Features

Simplified, centrally located, with remote alarm panel

Standardized, modularised

Low volume, Less weight

Design flexibility with n+1 redundancy and parallel operation

High efficient, high power and low THD

Compact installation and easy monitoring

Easy interchangeability of power supplies

Easy portability and occupies less space

Can increase capacity by adding modules and low MTTR (no interruption to load for maintenance)

Complete utilization of all loads within the restricted source, low running costs, existing 7.5KVA gen set adequate

Benefits

We manufacture DCDB Panels that are designed as per customer specifications.

Manufactured using quality raw material & panels are fabricated from wiring and

harnessing that minimizes onsite installation, our DCDB panel are is design for

both indoor and outdoor applications. Distributions boards are available for AC,

DC application in co depending upon the site requirements. These panels are

widely demanded in the industry as these are not only user-friendly but also

demand minimum maintenance.

Features

Fully designed, tested, wired and assembled with various electric switchgears

Single or multiple incomings & outgoings.

Installation of power elements along with Digital or analog meters and control elements.

Configurations:

Wall /Floor-Mounted

Compartmentalised / Non-Compartmentalised DCDB

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DISTRIBUTION Board

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Eart

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onitor

Earth Leakage Monitor is one important device used in DC power

systems like battery chargers AC-DC converter systems, DC-DC

converter systems and DCDBs. Where an independent DC power

source is used, the connections between transducers, control units and

DC power source are very important. Monitoring and signalling of earth

faults is essential in these situations. HBL ELM enables quick detection

of earth faults so prompt corrective action can be taken.

Features

Principle of Operation

HBL make ELM (Earth Leakage Monitor) works on the residual or differential magnetising current induced in a

current transformer.

The two current carrying conductors (positive and negative) are passed through a ring type current

transformer. Under normal conditions there is no residual current in the CT as the current flow in the two

conductors is in opposite direction.

In the event of earth-fault the current flowing through the conductors will be different and this difference

gives rise to a residual / magnetizing current in the CT. The CT forms a part of magnetic oscillator which would

oscillate symmetrically when there is no magnetizing current in core.

The magnetizing current which is proportional to the fault leakage current is sensed and used to drive an LED

and a relay through a comparator for local and remote (potential free contacts) annunciation.

The ELM is provided with a test button which can be used to check the correct functioning of the device during

operation.

Earth leakage current monitoring and protection of DC power supply systems and wiring with local and remote alarm / annunciation

Every outgoing feeder can be monitored individually

Reliable and rugged as any short circuit at load end will not affect the system configuration

Low power consumption

Compact

ApplicationsHBL’s Earth Leakage Monitors can be widely used in Petro-chemical industries, Process industries and

Substations.

Installation RequirementsSystems with floating power supply or centre of power supply grounded / earthed are compatible

with these ELMs. Systems with either positive and negative earthing are not compatible.

In accordance with its policy of continuous improvement the company reserves the right to change

specifications and designs without notice. Illustrations, data, dimensions and weights given in this

brochure are for guidance only and cannot be held binding on the company.

Earth Leakage Monitor

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SOLAR CHARGER CONTROLLER

The HBL Solar charge controller incorporates a dynamic Maximum Power Point Tracking (MPPT) algorithm designed to

maximize energy harvest from the PV array. The MPPT constantly adjusts the operating points of the array to ensure it

stays on the maximum power point.

While charging, it the XW SCC regulates battery voltage and output current based on the amount of energy available

from the PV array and state-of-charge of the battery.

The HBL Solar Charge Controller can be used with 48,96, and 110-volt DC battery systems.

Standard features of the Solar Charge Controller include:

Maximum Power Point Tracking (MPPT) delivers maximum available power from PV array

to battery bank

Ultra-reliable, convection-cooled design does not require a cooling fan.

Two-line, 16-character liquid crystal display (LCD).

Input over-voltage and under-voltage protection, output over-current protection, and

backfeed (reverse current) protection

Over-temperature protection and power derating when output power and ambient

temperature are high

Battery Temperature Sensor (BTS) included - automatically provides temperature

compensated battery charging

Specifications

DC input voltage 48V, DC 2-wire(96V, 1100) Optional

DC input voltage range

SPV nominal voltage 48V DC

SPV maximum voltage 72V DC

SPV open circuit voltage 90V DC (should be 150V)

DC O/P voltage settings

Nominal voltage 48V DC

Float 2.15-2.25 V/Cell

Boost 2.30-2.40 V/Cell

O/P Current limit 60A

Power conversion DC to DC by means of SERIES PASS

REGULATOR using MOSFET/IGBT

MPPT Process

Voltage regulation ±2% of set value for Input voltage

Variations, 10-100% load variation.

Efficiency 95% at full load

Standby power consumption Xxxx

Ripple voltage 2% RMS (without battery connected)

Switchgear and Protection

I/P side I/P ON/OFF switch

Protection Current limit protection, Soft start

feature and Surge suppressor

Meters (Digital type/LCD Display) DC Input Voltmeter,

DC Input Ammeter,

DC Output voltmeter and

DC Output Ammeter

Indications Input ON LEDs,

Charger ON Float and

Charger ON Boost

Alarms Input out of range,

Battery High,

Battery low and

Load out of range

Operating Ambient temperature 0°C to +50°C (need upto 60degC)

surrounding the Panel

Remote Monitoring System compatibility/controller Xxxx Optional

Data logging Xxxx Optional

PANEL Dimensions (Tentative) in mm 200(H) X 300(W) X 400(D)

Battery temperature compensation Xxxx Optional

Protection grade IP-31

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HBL Power Systems Limited# 8-2-601, Road No.10, Banjara Hills, Hyderabad - 500034,TG , INDIA

e-mail : contact@hbl.in website : www.hbl.in

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