dwgs&doc_for 24v-350a_05.04.10
TRANSCRIPT
Sr. No. Doc. No. Rev.
No.No. of Prints Remark
1 - 2 3 C
DOCUMENTS TRANSMITTAL SHEETFormat No. : QF/DD/06Rev.No. : 00W.E.F. : 01/04/2006
TO, Our Ref. No. : CE2417/0413/2010/PMPEMERSON PROCESS MANAGEMENT Date : April 05, 2010
Your P.O. No.: Date :
WINDSOR IT PARK, GROUND FLOOR, Your Ref. No.:
NOIDA - 201 301Date : TOWER A, A-1 SECTOR - 125,
PROJECT:- 6X135MW CPP ANGUL, ORRISA PROJECT [B] For Approval [C] For Final Approval
Kind Attn. : Mr. Rajeev Srivastava. Legends:[A] For Information Only
Refer Annexure-I enclosed.
We refer to the above subject. We are sending herewith Drawings & documets Listed below for your approval:
Description / Title Of Drawing & Documents
Kind Attn.: Mr. P.K. Jain (G.M.)
Kindly expedite the final approval of the same within one week and send us one set duly approved drawings & documents for our reference/record.
Thanking you & assuring you of our best & prompt attention all the times.
Yours Truly, CC :
Dear Sir,
(Manager – Design)D.J. Patil
For Chhabi Electricals Private Limited 1) Chhabi Electricals Pvt. Ltd., New Delhi
Regional Offices :Mumbai :
Delhi :
Bangalore :
Kolkata : ,
Bhubaneshwar :
20, Anupam Indl. Estate no. 3, L.B.S. Marg Mulund (W) Mumbai - 400 080 (Maharashtra) - INDIA. Phone No. : +91-22-2561 4435/5945, Fax No. : +91-22-2568 0513, Email : [email protected]
F-12, First Floor, Pankaj Grand Plaza, Mayur Vihar Phase-1, Delhi - 110 091. Phone No. : +91-11-4215 1213 - 14, Fax No. : +91-11-4215 1215 Email : [email protected]
120, First Floor, “Ajantha” 6th C Main Road, Remco Layout Vijayanagar 2nd Stage Bangalore - 560 040 (Karnataka) - INDIA. Phone No. : +91-80-2314 0031, Fax No. : +91-80-2314 0031 Email : [email protected]
16/1A Bose Pukur Road Kolkata . Phone No. : +91-33-24411375, Email : [email protected]
A/62, Nayapalli, NS-5, Bhubaneshwar - 751 003 (Orissa) - INDIA. Email : [email protected]
- 700 042 (West Bengal) INDIA
Regd. Office & Factory : E-66, MIDC, Jalgaon - 425 003 (Maharashtra) INDIA.Tel : 91-257-2210626/ 27/ 28, 2270174/75 Fax : 91-257-2213434
Email : , Web site : [email protected]
QUALITYASSUREDCOMPANY
ISO:9001-2000International Standards
CertificationsLic. No. QAC/R91/0100
SR. NO.
CODE NO. DESCRIPTION RATING
TERMINAL PLATES & LINKS
1 TB1415V 3 Phase 4 wire AC input Terminal for incoming power supply of charger. (R Y B) T1 -T3)
Suitable for 1 x 3½C x 25 Sq.mm. Cu. Cable
2 TB2 DC output Battery Terminals (T4-T6) (+ve, -ve)Suitable for 2x1Cx400 Sq.mm. Cu. Cable
3 TB3 DC output Load Terminals (T7-T8) (+ve, -ve)Suitable for 2x1Cx400 Sq.mm. Cu. Cable
4 TB4230V 1 Phase 2 wire AC input Terminal for Auxiliary power supply. (L N) (T9-T10)
Suitable for 1x2Cx2.5 Sq.mm. Cu. Cable
5 TB5 Terminal for charger trouble (T11-T12) Suitable for 1x2Cx2.5 Sq.mm. Cu. Cable
FUSES :
1 FS1-3 Glass cartridge Fuses with suitable fuse fitting for LED1-3 100mA
2 FS4-9 Semiconductor fuses for the MR1. GS450/400
3 FS10 HRC fuse with suitable fuse fittings for FC1. 125A
4 FS11-12 HRC fuse with suitable fuse fittings for DC Output. 400A
REV.25 FS13,13A HRC fuse with suitable fuse fitting for DC control supply. 4A
6 FS14 HRC fuse with suitable fuse fitting for AC control supply. 2A
7 FS15-16 HRC fuse with suitable fuse fitting for Fan1& Fan2. 2A
: C11848A, C11848B, C11848C.
: EMERSON PROCESS MANAGEMENT INDIA PVT. LTD., NOIDA
: FLOAT CUM BOOST A&B : CP-CC 24V / 250A-350A (100A+250A)
: 6 NOS. QTY
CLIENT
P.O.NO.
: 6 X 135MW CPP ANGUL, ORRISA PROJECT.PROJECT
:
TYPE
REF.DRG. NO.
BILL OF MATERIAL
: 02
: 04.04.2010
: BATTERY CHARGER FOR 24V BATTERY CHARGER
W.O.NO.
REV. NO.
: CE 2417
DATE
UNIT
CHHABI ELECTRICALS PVT. LTD., JALGAON - 425 003 SHEET NO. : LC3977 / 1 OF 5
SR. NO.
CODE NO. DESCRIPTION RATING
8 FS17 Glass cartridge Fuses with fitting for the VM1 100mA
9 FS18 HRC fuse with suitable fuse fitting for Contactor C1 2A
INDICATING LEDS
1 LED1-3 AC `ON' indicating LEDs. 230V
2 LED4 DC 'ON' indicating LED. 24V
TRANSFORMERS, CHOKES
1 TR1Double wound impregnated, naturally air cooled Three phase mains transformer.
21 KVA(456V/42V)
2 CH1 Filter choke for FCB charger 350A
3 TR2 Auxiliary transformer for mV amplifier & ACOR ckt.supply. 20VA (270V/18-0-18V)
RECTIFIERS & BLOCKER DIODES
1 MR13phase, Full controlled full wave rectifier bridge complete with RC surge suppression network and suitable heat sinks for Charger.
250A/1000PIVHS: 80AD/300MMSuitable RC Network
2 MR2 Charger silicon blocker diode with suitable heat sink. 400A/1000PIVHS: HS209/300MM
3 MR3 Charger silicon battery tap diode with suitable heat sink. 300A/1000PIVHS: HS209/200MM
4 D1-D10 Voltage dropping diode300A/1000PIVHS: Suitable Size
REV.25 D11-D14 Diode for Buscoupler Contactor supply18A/600PIVHS: HS208/150MM
RESISTANCES, POTENTIOMETERS & FILTER CONDENSER
1 RB1 Bleeder Resistance 50V/300W
2 RV1Wire wound potentiometer to adjust output voltage in float mode.
10K/3W
3 RV2Wire wound potentiometer to adjust the output current limit in boost mode.
10K/3W
4 RV3Wire wound potentiometer to adjust the DC output voltage in manual mode.
10K/3W
5 RF1-4 Voltage Dropping resistance for FFD 200E/50W
6 FC1 Filter condenser Test Selected
SWITCHES / MCCB
1 MCCB1 3 pole ON/OFF AC incoming MCCB 50A / 10KA
2 MCCB22 pole ON/OFF DC Output MCCB (4 Pole MCCB - 2 Pole connected in parallel)
250A / 10KA
CHHABI ELECTRICALS PVT. LTD., JALGAON - 425 003 SHEET NO. : LC3977 / 2 OF 5
SR. NO.
CODE NO. DESCRIPTION RATING
3 SW12 pole, 2 way ‘NO OFF’ cam type Auto/Manual mode selector switch for controller.
10A
4 SW2A/B2 pole Isolator for isolation of load (4 Pole isolator - 2Pole connected in parallel)
250A
5 SW3, 4 1 pole ON/OFF toggle switch for cubical lamp & heater. 10A
6 SW5, 6 1 pole ON/OFF switch for FAN 1-2 10A
REV.27 SW71pole, 2 way ‘NO OFF’ cam type Auto/Manual mode selector switch for CH.A/B
10A
REV.28 SW81pole, 2 way ‘NO OFF’ cam type Auto/Manual mode selector switch for Buscoupler
10A
1 VM1DC moving coil Voltmeter to read the charger output voltage
0-50V DC
2 AM1DC moving coil ammeter to suitable shunt to read the charger o/p current.
0-400A
3 AM2DC moving coil Ammeter with suitable shunt to read the discharge /charge of the battery.
400A-0-400A
4 SH1-3Shunt for the Charger output current, Load current & Batt. Voltage
0 - 400A / 75mV
PRINTED CKT.BOARD, ELECTRONIC RELAY, FFDS & CONTROL CARDS.
1 FFD1,2Fuse Fail Detector Circuit of solid state sensing type for FS4-9
24V
2 FFD3Fuse Fail Detector Circuit of solid state sensing type for FS10
24V
3 FFD4Fuse Fail Detector Circuit of solid state sensing type for FS11-12
24V
4HV & PF PSR CKT.
High Voltage & Phase fail/phase sequence reversal ckt. 25VA/415V
5 CPC13-phase SCR controller for constant voltage/current mode of operation.
24V
6
DISPLAY UNIT WITH ANNUNCIATOR
Charger Monitoring & Annunciation circuit for displaying voltage/current parameters on LCD as well as Window type Annunciation with RS485 communication.
24V
7 mV AmpMillivolt amplifier circuit for battery current limit in float mode
4A
REV.28 ACORAutomatic change-over relay for auto float/boost mode change-over.
24V
CONTACTOR'S & AUXILARY RELAY
1 CA1, CA2Auxiliary contactor for AC mains fails annunciation & interlocking purpose.
4A/415V AC Coil
2 CA3 Auxiliary contactors for Float / Boost selection. 4A/24V DC Coil
3 CA4 Auxiliary contactor for charger DC O/P failure annunciation. 4A/24V DC Coil
METERS & SHUNTS (ACCURACY CLASS- 1.0%) 96 sq.mm. 90 deg. Deflection
CHHABI ELECTRICALS PVT. LTD., JALGAON - 425 003 SHEET NO. : LC3977 / 3 OF 5
SR. NO.
CODE NO. DESCRIPTION RATING
4 C1 3 pole in parallel DC Contactor for interlocking purpose. 125A/24V DC Coil
REV.25 C2 3 pole in parallel DC Contactor for Buscoupler 125A/24V DC Coil
MISCELLANEOUS
1 L1 Cubicle Fluorescent lamp. 11W/240V AC
2 H1 Space strip heater. 100W/240V
3 TH1 Energy regulator for heater. 240V AC
4 S1 3 Pin socket with switch. 6A/240V AC
5 FAN1,2 Exhaust fans for air circulation. 240V
6 T1 Solid state timer. 24V DC COIL 0-10 Hrs.
7 TS1 Temperature sensor 65°C
8 PB1-2 Float / Boost mode of operation selector push buttons 4A / 415V AC
9 PB3-6 Accept, Test, Reset & Hold push buttons for Display Unit 4A / 415V AC
CHHABI ELECTRICALS PVT. LTD., JALGAON - 425 003 SHEET NO. : LC3977 / 4 OF 5
SR.NO. DESCRIPTION MAKE
1 DC POWER ISOLATORS & SFU C&S
2 CONTROL SWITCHES Kaycee
3 FUSE LINKS GE Power / C&S
4 DIODEs/SCRs Ruttonsha / Semikron
5 FILTER CONDENSER Alcon
6ELECTRONIC CONTROLLER, SOLID STATE SENSING TYPE CIRCUIT FFD, ANNUNCIATION, DISPLAY UNIT
Chhabi (Our Own Make)
7 FILTER CHOKE Chhabi (Our Own Make)
8 TRANSFORMER Chhabi (Our Own Make)
9 INDICATING LEDS Teknic
10 CONTROL TERMINALS Elmex
11 POTENTIOMETERS Pankaj
12 MCB Indo Asian
13 TIMER Selectron
14 CONTACTOR C&S
15 MCCB Schneider
16 Meters AE / IMP / Rishab
17 Fan Rexnold
18 Temp Sensor Radix
19 Heater, TH, Socket & CFL Lamp Reputed Make
REV. 2
PREPARED BY : P.M.P.
CHECKED BY : D.J.P.
APPROVED BY : R.S.K.
DATE : 05.04.10
W.O.NO. : CE-2417
MAKE OF COMPONENTS
CHHABI ELECTRICALS PVT. LTD. JALGAON - 425 003 SHEET NO. 5 OF 5
OPERATION WRITEUP The System comprises of 2x100% Float Cum Boost Chargers (Charger-A & Charger-B), 1x100% DC Distribution Board & 2x100% Battery.The float-cum-Boost Chargers A&B, DC Distribution Board and Battery are connected in parallel. The battery charger-A&B will float charge respective battery &Charger-A supply the load connected through DCDB.
When Both the AC source fails then buscoupler C2 will close automatically depending on the position of SW-8 ( Auto/ Maual Closing selection of Bus coupler )& both batterie will get discharge to certain extent depending upon the duration of power failuer & Load current.
When charger operateds in float mode DC contactor C1A/B remains closed. When the power resumes, the battery has to be recharged. Regharging of batteries is automatic as well as manual.Automatic boost charging selection will be through ACOR & Manual Boost charging operation will be through push buttons. During boost charging of batteries the load will be supplied through the dropping diodes.. Interlock is provided such that when both the chargers are healthy then only ( Charger -A& Charger-B) will operate in Boost Mode.
For detail operation of charger refer LOGICAL SIMULATION TABLE attached.
DISPLAY UNIT :
The Display unit consist of
a) 4 Line LCD display : The Upper 2 lines are utilised for Metering purpose & Lower 2 lines are utilised for Battery Cell Status display.The Metering Parameters will be displayed are as follows,i) Charger A DC Vii) Charger A DC Aiii) Charger B DC Viv) Charger B DC Av) Load DC Vvi) Load DC AThe Battery Cell status parameters will be dispalyed as follows,i) Cell No.ii) Cell Voltageiii) Cell status (High / Low / Normal)
PROTECTIONS PROVIDED:1 AC MCCB2 DC SWITCH+FUSES3 DC CURRENT LIMIT 4 BLOCKER DIODE FOR REVERSE VOLTAGE BLOCKING5 FUSES FOR RECTIFIER, CAPACITOR, CONTROL SUPPLY
When battery gets full charger the ACOR gets rest & Charger will revert back in float mode.If the ACOR fails to revert back the charger in float mode then the suporting Timer T1 will revert back the charger in float mode when the set time on the timer laps.Thus the batterise are prvented from geting over charge.
Each Float cum Boost charger has i) Constant Current & ii) Constant Voltage mode.
Normally, in float mode the charger will float the batteries at 1.4V per cell within a stabilization of ±1% of the floating voltage. The float charger-A will supply the trickle charging current required for the batteries and will also feed the DC continuous load as required. During this time, the float charger-A and the battery are across the DC load terminals.When Charger-A fails the bus coupler will close automaticaly( depend on position of Switch SW 8) & load will be supplied by battery charger -B as well as both batteries will be trickle charge by charger-B Or When Charger-B fails the bus coupler will close automaticaly( depend on position of Switch SW 8 , by selection of this switch one can close the bus coupler manualy also) & load will be supplied by battery charger -A as well as both batteries will be trickle charge by charger-A.
After resumption of AC power both chargers will operate inetially in float mode. The battery draws higher current, this Higher current will be senced by the ACOR ( Automatic Change Over Relay) which will operate the charger in boost mode automatically , when Switch SW-7A/B is at Auto Float -Boost position.One can operate the charger in boost mode Manualy by selecting the switch SW 7 at Manual float -boost mode through the push buttons. During boost charging of batteries DC Contactor C1 A/B gets open & the load will be supplied through the dropping diode by maintaing the load voltage within the range of 20V-31Volts
1 - 2
PARAMETERVALUE
CELL NO. / CELL VOLTAGESTATUS (HIGH / LOW / NORMAL)
b) Inputs / Outputsi) Analog Input - 7Nos. [ i) Charger A DC V, ii) Charger A DC A, iii) Charger B DC V, iv) Charger B DC A, v) Load DC V, vi) Load DC A, vii) Cell Voltage ]ii) Digital Inputs - 18Nos. [Annunciation Faults - 14Nos. + ATRH]iii) Digital Outputs - 15Nos.[Annunciation Faults - 14Nos. + Bz]iv) RS485 Modbus serial communication port
The Digital ouputs for Annunciation will be as followsa) CH.A AC MAINS FAILb) CH.A RECTIFIER FUSE BLOWNc) CH.A FILT. FUSE BLOWNd) CH.A DC FAILe) CH.A FLOAT MODE ONf) CH.A BOOST MODE ONg) CH.A DC FUSE BLOWNh) CH.B AC MAINS FAILi) CH.B RECTIFIER FUSE BLOWNj) CH.B FILT. FUSE BLOWNk) CH.B DC FAILl) CH.B FLOAT MODE ONm) CH.B BOOST MODE ONn) CH.B DC FUSE BLOWNo) LOAD DC UNDER VOLTAGEp) LOAD DC OVER VOLTAGE
c) Power Supply : 24V DC
The Digital inputs for Annunciation will be as followsa) CH.A AC MAINS FAILb) CH.A RECTIFIER FUSE BLOWNc) CH.A FILT. FUSE BLOWNd) CH.A DC FAILe) CH.A FLOAT MODE ONf) CH.A BOOST MODE ONg) CH.A DC FUSE BLOWNh) CH.B AC MAINS FAILi) CH.B RECTIFIER FUSE BLOWNj) CH.B FILT. FUSE BLOWNk) CH.B DC FAILl) CH.B FLOAT MODE ONm) CH.B BOOST MODE ONn) CH.B DC FUSE BLOWN
BHMS
The Battery Health Monitoring System comprises of the Battery data collector & transmits the same to the dispaly unit.The data collector will select the data of individual cell which will be transmitted to the LCD dispaly & the LCD dispaly will dispaly the same as above.
2 - 2
CHARGER-A CHARGER-B CONTACTOR C1A
CONTACTOR C1B
BUS COUPLER C2
LOAD BATTERY-A BATTERY-B REMARK
AC Mains/DC Fail AC Mains /DC Fail
CLOSE CLOSE CLOSE By Battery __ __ Load will be supplied by both the Battery Banks.
Float Mode AC Mains/DC Fail
CLOSE CLOSE CLOSE By Charger-A Trickled charged by Charger-A
Trickled charged by Charger-A
Charger-A will operate in float mode & will supply load as well as trickle charge both the Battery set.
AC Mains/DC Fail Float Mode CLOSE CLOSE CLOSE By Charger-B Trickled charged by Charger-B
Trickled charged by Charger-B
Charger-B will operate in float mode & will supply load as well as trickle charge both the Battery set.
Float Mode Float Mode CLOSE CLOSE OPEN By Charger-A Trickled charged by Charger-A
Trickled charged by Charger-B
Charger-A will operate in float mode & will supply load as well as trickle charge battery-A & Charger–B will trickle charger Battery B.
Boost Mode (Manually by
PB1A /Automatically through ACOR-
A)
Float Mode OPEN CLOSE OPEN By Charger-A Battery will be Boost charged by Charger-A
Trickled charged by Charger-B
Charger-A will boost charge the battery-A as well as supply load through the dropping diodes. Bus coupler will remains open. Charger-B will trickle charger battery-B. During this condition if the charger-B fails, Charger-A will revert back in float mode & will supply the total load & also trickle charge both the battery banks by closing C1A & Bus coupler and load will be supplied by Charger-A.
Float Mode Boost Mode (Manually by
PB1B /Automatically through ACOR-
B)
CLOSE OPEN OPEN By Charger-A Trickled charged by Charger-A
Battery will be Boost charged by Charger-B
Charger-B will boost charge the battery-B. Bus coupler will remains open. Charger-A will trickle charger battery-A. During this condition if the charger-A fails, Charger-B will revert back in float mode & will supply the total load & also trickle charge both the battery banks by closing C1B & Bus coupler and load will be supplied by Charger-B.
LOGICAL SIMULATION TABLE