07.09.

2009 1
 BRIEF NOTE ON COMPANY

¾ Started as partnership firm by two design engineers in 1987 , it was

converted to limited company in 1995.
¾ Company was started to design & manufacture STATic CONverter
and hence the name Statcon.
¾ Initially the company focused on manufacturing of 48V Thyristor
Controlled Battery Chargers and till 1993 manufactured such
chargers upto 48V/400Amps capacity.

¾ Almost over 8000 Battery chargers are working with various users
across the length & breadth of the country for applications in
Telecom, Power sector, Railways, Army & Airforce.

Contd…

07.09.2009 2
 BRIEF NOTE ON COMPANY

¾ In addition to above, we have exported chargers to countries like

Algeria, Ethiopia, Bangladesh, Vietnam, Sri-Lanka, Nepal for the last
many years.
¾ Started ISO-9000:1994 certified systems in year 1998 and now having
ISO-9001:2000 certification.

¾ Having approval and enlistment with RDSO, PGCIL, NHPC, AREVA,

ALSTOM, L&T, SIEMENS, ABB, BHEL (T&D), BHEL (PEM), MECON,
EPI, DGAQA, JAIPRAKASH, VA-Tech, Ansaldo (US&S), Ge-Transport,
Mazgon Docks, HAL and large nos. of consultants and EPC
contractors.

¾ Part-I supplier with Indian Railways for supply of Integrated Power

Supply equipment for use with Railway Signalling networks.

Contd…

07.09.2009 3
 BRIEF NOTE ON COMPANY

¾ Successfully developed Ground Power Unit (GPU) for Aircraft

starting for wide range of Aircrafts for Indian Air Force . Exported
GPU to ISRAEL through HAL, currently in use with Uganda Air Force.
¾ Present factory building at A-34, Sector-59, NOIDA was built in 1997
having 14500 Sq. Ft. plot area.
¾ Present work force consists of around 150 personnels in various
disciplines.

¾ Number of key personnels in major departments :

a) Marketing - 10 Nos.
b) Design & Development - 6 Nos.
c) Engineering - 4 Nos.
d) Testing / Servicing - 20 Nos.
e) Quality Control - 4 Nos.
f) Production - 10 Nos.

07.09.2009 4
 OUR VISION & MISSION

OUR VISION
“ To get globally recognized for
product value and employee care.”

OUR MISSION
¾ To set standards for manufacturing power electronic products
which competitors can only follow.
¾ To offer customized products & services and increased customer's
comfort level.
¾ To ensure consistent profitability, satisfactory returns to the
investors and good environment for its employee’s holistic
development through efficient operational and organizational
strength.

07.09.2009 5
 QUALITY POLICY OF STATCON

“Statcon shall always strive to serve its customers with

better technology at reasonable price.”

QUALITY OBJECTIVE MEASUREMENTS

To enhance technical & Number of new products

managerial skills of developed in a year.
employees.

Economizing the product 10% reduction in rework

through better efficiency of and failures every year.
employees.

07.09.2009 6
ISO 9001:2000 CERTIFICATE

07.09.2009 7
D & B CERTIFICATE

07.09.2009 8
 COMPANY’S SALES TURNOVER

471.7

346.0
Rs. In Millions

221.2

35% Growth
168.1

32% Growth
31.5% Growth
122.7

37.7% Growth
114.0
7% Growth
23.9% Growth

92.0

2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09

Years

07.09.2009 9
 ABOUT STATCON

PRODUCTION FLOORS

PRODUCTION (CHARGER) FLOOR VIEW PRODUCTION (IPS) FLOOR VIEW

Contd…
07.09.2009 10
ABOUT STATCON

MARKETING

Contd…
07.09.2009 11
ABOUT STATCON

DESIGN & DEVELOPMENT

Design Facility :-

• Software for:
• Transformer Sizing Calculation.

• Filter Choke and Capacitor calculation.

• Thyristor Rating Calculation.
• P.F. Correction Capacitor Calculation.
• 3-D designing of panel.
• PCB Designing through software.
• Embedded System design/programming

07.09.2009 12
 PRODUCT RANGE
POWER SECTOR

300KW BATTERY CHARGER

THYRISTOR CONTROLED BATTERY CHARGERS
FOR GENERATION, TRANSMISSION & DISTRIBUTION

24V/30A Battery Charger with

TUBULAR BATTERY

SMPS BASED
CHARGER 220V/75A+150A Battery Charger
Ni-Cd Battery Bank
with TUBULAR Battery Type
OPzS

BATTERY DISCHARGER Contd…

07.09.2009 13
 PRODUCT RANGE
RAILWAY APPLICATIONS
INTEGRATED POWER SUPPLY SYSTEM
FOR RAILWAY SIGNALLING INSTALLATION SMPS based Battery Charger Available in
24V / 48V / 110V / 220V FOR VARIOUS APPLICATIONS

110V
DC-DC
CONVERTER

24V / 48V

220V

48V/25A DC
POWER PLANT

CELL MONITORING 110V Battery Charger with

TUBULAR BATTERY Contd…
07.09.2009 14
 PRODUCT RANGE
INDIAN AIRFORCE

GPU FOR AN-32 AIRCRAFT

28V DC GPU FOR AIRCRAFT

FREQUENCY CONVERTER
(60/200/400Hz.)

CELL MONITORING
BATTERY CAPACITY TESTER

24V BATTERY
CHARGER

POWER SUPPLY FOR SU-30

AIR CRAFT FOR INDIAN AIR FORCE

40 KVA GPU FOR GROUND TESTING LOAD BANK Contd…

/ STARTING OF AIRCRAFT
07.09.2009 15
 PRODUCT RANGE
AC/DC LOAD BANK UPTO 500kW INDIAN NAVY

THYRISTOR CONTROLLED BATTERY CHARGERS/CONVERTERS

CELL MONITOR
1000A POWER DC SUPPLY
ROTARY FREQUENCY CONVERTER
(60/200/400Hz.) FOR DEFENCE Contd…
07.09.2009 16
 VENDOR APPROVALS WITH POWER SECTOR
FEW APPROVALS/CUSTOMERS

RRVUNL PSEB BBMB HVPNL BHEL

MECON HPSEB DESEIN PGCIL NHPC

NTPC MSETCL GETCO DMRC ABB

ALSTOM JAIPRAKASH VOITH AREVA SIEMENS

PUNJLLOYD LANCO L&T NDPL KPTCL

KPCL APGENCO NEVYELLI TNEB

AVANTE-GRADE WBSEB VATECH DVC

07.09.2009 17
 PRODUCTS FOR POWER SECTOR

STATCON offers complete DC Package including

(1)Battery Charger
(2)All types of Batteries
(3)DC Distribution Board
(4)Battery Monitoring System
(5)Feeder Earth Monitoring System
(6)AC-DC Converter
(7)DC-DC Converter
(8)High Power Industrial Inverter upto 60 KVA

07.09.2009 18
 BREIF NOTE ON BATTERIES
Battery Is Considered To Be The “HEART” Of The Power Plant

ƒ Battery provides the ultimate and final DC back-up for operating emergency
equipments which power the turbo generators (viz. emergency oil pumps
etc.)
ƒ DC power for operation of all switchgear, protection relays, indicating lamps
and facia
ƒ Power for emergency lighting within the generating station building
ƒ Uninterrupted power for controlling C & I equipment and associated UPS
systems
ƒ Power for vital communication equipment (PLCC), essential for
resynchronising the unit with the grid or for reviving the grid in the case of a
major grid failure

07.09.2009 19
 BREIF NOTE ON BATTERIES

The Most Important DC Power Requirements For Power

Sector Applications Are:

¾Reliability
¾Predictability of Service Life
¾Ease of Maintenance
¾Energy Efficiency
¾Size

07.09.2009 20
 BREIF NOTE ON BATTERIES
What If The Battery Fails In An Emergency
Unit Battery
ƒ Generation Revenue Loss.
ƒ Transformer damage.
ƒ Failure of Instrumentation and Controls
ƒ Total darkness in the powerhouse
ƒ Damage of Turbine’s bearings
Substation
ƒ Extensive damage to transformers and power lines
PLCC
ƒ Extremely difficult to resynchronize the unit with the grid
ƒ Major setback in the process of reviving the grid in the event of a regional grid
failure.
ƒ If the battery fails while the unit is in operation, it may become essential to
shutdown

07.09.2009 21
 BREIF NOTE ON BATTERIES

WHAT IS A BATTERY?

Batteries are electrochemical energy storage devices. The chemical energy

contained within the battery can be converted to dc electrical energy.

A Battery is an interconnected array of similar/identical

objects i.e electrical storage cells.

Contd…

07.09.2009 22
 BREIF NOTE ON BATTERIES

WHAT IS AN ELECTRICAL STORAGE CELL

Consists of two dissimilar electrodes immersed in electrolyte.

Stores electrical energy in the form of chemical energy.
When the circuit is made between its positive & negative
electrodes, there is a chemical reaction inside the cell & it
delivers electricity- Direct Current (D.C.) through the circuit.

TYPES OF ELECTRICAL STORAGE CELLS

1. Primary cell or dry cell
2. Secondary cell

What is the difference between the two ??

Contd…

07.09.2009 23
 BREIF NOTE ON BATTERIES

DIFFERENCE BETWEEN PRIMARY AND SECONDARY CELL

07.09.2009 24
 BREIF NOTE ON BATTERIES
LEAD ACID BATTERIES

CHARGED DISCHARGED
+ve -ve Electrolyte +ve -ve
PbO2 + Pb + 2H2SO4 PbSO4 + PbSO4 + H2O
Lead Spongy Dilute Lead Lead Water
Peroxide Lead Sulphuric Sulphate Sulphate
Acid

NI-CD BATTERIES
NI-CD

+ve -ve +ve -ve

Discharged
2 NiOOH + 2H2O + Cd 2 Ni(OH)2 + Cd(OH)2
Charged

Nickel Hydroxide Cadmium Divalent Nickel Cadmium

Hydroxide Hydroxide

07.09.2009 25
 BATTERIES FOR STANDBY APPLICATION

Basically a Battery is formed by putting together nos. of 2V ( for Lead

Acid) or 1.2V (for Ni – Cd.) cells in series. Hence all further discussions
would refer to per cell voltages only.

BATTERY

Ni - cd Lead Acid

Sintered Pocket Plate

FLAT PLATE FLOODED VRLA

Tubular Plante GEL

AGM
OPzS Normal Discharge High Discharge

07.09.2009 26
 NI-CD BATTERIES

ADVANTAGES

• Sintered cells are compact, with high Power density used mostly for
Defense Application.
• Pocket Plate cells are used in Electric locomotives and are also popular in
Power Sector segments.
• Low Discharge, Medium Discharge and High Discharge performance types.
• Compact and easy to handle.
• Uses Alkaline medium and needs topping-up at regular intervals.
• Longer Battery life even if used for frequent deep discharge application.

Contd…

07.09.2009 27
 NI-CD BATTERIES

DISADVANTAGES

• Very Expensive
• Have memory effect if used under Float condition continuously.
• High Float charging Power requirement and needs frequent equalize charging.
• Problem of sedimentation.
• Nickel mesh gets corroded.
• No method to know state of charge of cell.
• Practical life is not more than 10-15 years in standby application.
• Have low AH and WH efficiency (around 50-60%).

Contd…

07.09.2009 28
 NI-CD BATTERIES
DISADVANTAGES

Environmental Constraints
ƒ Ministry of Environment & Forest declared that the allowable concentration limit is
as
¾ Nickel – 50 mg/kg
¾ Lead – 5000 mg/kg
ƒ Cadmium can cause flu-like illness, irritation in lungs and cancer.
ƒ During recycling of Ni-Cd, it yields cadmium containing sludge. It requires special
disposal of cadmium.
ƒ European Parliament and The Council of European Union has given directions to
protect & make an overall strategy to restrict the use of Cadmium. Resolution
stresses than use of Cadmium to be limited to cases where safer alternatives do
not exist.

07.09.2009 29
 LEAD ACID BATTERIES
ADVANTAGES

™ Lead Acid Battery is the most versatile type of secondary

storage battery, which has been in commercial use for over a
century.
™ Plante batteries are preferred for critical applications like
Nuclear Power, hydro Power and other UMPPs
™ OPzS Batteries have advantage of Both Plante and Tubular
™ Can supply very high or very low currents on instant demand.
™ Have high AH (> 90%) and WH (> 75%) efficiency
™ Can operate over a wide range of temperature
™ Low self discharge rate
™ Ease of maintenance through monitoring of Specific Gravity
(Unlike Nickel Cadmium)

Contd…

07.09.2009 30
 LEAD ACID BATTERIES
ADVANTAGES

• For stationary applications, Tubular or Plante Batteries are used.

• Difference lies in their basic construction.
• Tubular Batteries are governed by IS1651 while Plante are governed by
IS1652.
• Tubular cells are Normal Discharge and High Discharge type both while
Plante are High Discharge performance types only.
• Uses Acidic medium and needs topping-up.
• Generally Tubular Batteries have 8-10 years life span, while OPzS has
10-12 years.
• Plante cells are known for its very long life and they work from 15-20
years.
• VRLA (AGM) cells are compact, stackable, low maintenance cells but
have poor reliability and are unpredictable. Hence popular in Telecom &
commercial segment.

07.09.2009 31
 LEAD ACID BATTERIES
Courtesy EXIDE

TYPES OF BATTERY

TUBULAR PLANTE OPzS VRLA

CELLS CELLS CELLS CELLS

07.09.2009 32
 LEAD ACID BATTERIES
Courtesy EXIDE
CAPACITY OF BATTERY

Capacity is the quantum of electricity that can be delivered from a

battery over a fixed period of time, such as 10 hours, down to a set terminal
voltage per cell.
Expressed in Ampere-hour(AH).

Contd…

07.09.2009 33
SELECTION CRITERIA OF A BATTERY
• Primary Factors
¾ Load Current
¾ Backup time
¾ Minimum & Maximum voltage requirements of the system
¾ The lowest excepted operating temperature

• Secondary Factors
¾ Expected frequency of discharge
¾ Depth of discharge
¾ Ambient temperature
¾ Limitation on space
¾ Maintenance limitation
¾ Floor loading

07.09.2009 34
FOR SINGLE RATE OF DISCHARGE

Continuous DC Load = 100 Amp. (1)

Max DC voltage at Load = 121 V (2)
Min DC voltage at Load = 99 V (3)
Nominal DC voltage at Load = 110 V (4)
Back up time required = 3 Hrs. (5)
Min & max ambient temp. = 20C and 400C (6)
Battery Capacity, C is calculated as
Ampere x k factor x Temperature correction factor x Design Margin factor x Ageing
Margin (7)
Type of Battery as per application is say, Tubular Lead Acid (NDP)
Nos. of cell needed = Max DC Voltage/Float Voltage of cell = 121/2.2 = 55 Cells (8)
End cell Voltage = Min. DC Voltage/Nos. of cells= 99/55 = 1.8V/cell (9)

Contd…

07.09.2009 35
 Courtesy EXIDE
K-FACTOR GRAPH (LEAD ACID TUBULAR – NDP)

Contd…

07.09.2009 36
FOR SINGLE RATE OF DISCHARGE
From the discharge curve of Battery manufacturer select the K-factor of
Lead Acid Tubular (NDP) cell where end cell voltage is 1.8 V/cell
at the end of 3 hr discharge.
The value of k factor = 4.2 (10)
Temperature correction factor is calculated as
= 1 + 0.0043 (27-t) for Tubular battery
= 1 + 0.0090 (27-t) for Plante battery,
where t is minimum temperature.
In this case, temperature correction factor = 1 + 0.0043 (27-2) = 1.1075
Design Margin is normally taken as 10 %.
As per IEEE,
Ageing Margin = 1.25 for all Batteries except Plante Battery.
In case of Plante Battery, the ageing Margin is 1.0

From (7), C = 100 x 4.7634 x 1.1075 x 1.1 x 1.25 = 726 AH

Next Highest available Battery Bank = 750AH (TH750H)

Note: In case of Ni-Cd Battery, float charge correction factor (1.35) shall also be
taken into account.
07.09.2009 37
FOR SINGLE RATE OF DISCHARGE
For same load cycle, the capacity of Battery Bank required shall be as

Lead Acid Tubular (HDP-II)

From (7), C = 100 x 4.1483 x 1.1075 x 1.1 x 1.25 = 632 AH
Next Highest available Battery Bank = 700 AH (TH700H HDP-II)

Lead Acid Tubular - OPzS

From (7), C = 100 x 4.7634 x 1.1075 x 1.1 x 1.25 = 726 AH
Next Highest available Battery Bank = 800 AH (OPzS 800P)

Lead Acid Plante

From (7), C = 100 x 3.7475 x 1.225 x 1.1 x 1.0 = 505 AH
Next Highest available Battery Bank = 535AH (YHP 11)

Ni-Cd (Medium Discharge Type)

From (7), C = 100 x 3.2 x 1.1236 x 1.1 x 1.25 x 1.35 (float charger correction factor)
= 670 AH
Next Highest available Battery Bank = 680 AH (KPM 680P)

07.09.2009 38
FOR DIFFERENT RATES OF DISCHARGE

819A

Current

417A
Enter load & time durations
In the following table:
Period Load Time (min)
A0 0 0 110A
A1 819 1
minute 60 120
A2 417 60 0
A3 110 60 Time

Contd…

07.09.2009 39
FOR DIFFERENT RATES OF DISCHARGE
Section-1
period Load change in load duration of period time to end of section K-factor reqd size
Section 1 : first period only – if A2 is greater than A1 go to section 2

1 819 819 1 1 1.04 651.76

Section-2
period Load change in load duration of period time to end of section K-factor reqd size
Section 2 : first 2 periods only – if A3 is greater than A2 go to section 3

1 819 819 1 61 2 153.8

2 417 -402 60 60 2 -804

Section-3
period Load change in load duration of period time to end of section K-factor reqd size
Section 3 : first 3 periods only – if A4 is greater than A3 go to section 4

1 819 819 1 121 2.8 2293.2

2 417 -402 60 120 2.8 -1125.6
3 110 -307 60 60 2 -614

Contd…

07.09.2009 40
FOR DIFFERENT RATES OF DISCHARGE

Section-4
period Load change in load duration of period time to end of section K-factor reqd size
Section 3 : first 3 periods only – if A4 is greater than A3 go to section 4

1 819 819 1 121 2.8 2293.2

2 417 -402 60 120 2.8 -1125.6
3 110 -307 60 60 2 -614
4 0 -110 0 0 0 0

MAXIMUM SECTION SIZE IS - 851.76

AGING MARGING - 1.25
DESIGN MARGIN - 1.1
TEMP. CORRECTION FACT. - 1.0946
ESTIMATED CELL SIZE - 1281.962682

REQUIRED CELL : - TH1300HDPII(1300AH)

Contd…

07.09.2009 41
 COMPARISON
COMPARISON

NOMINAL VOLTAGE:
Tubular 2V
VRLA 2V
Plante 2V
Ni-Cd 1.2V, 183 cells of Ni-Cd are required for a 220V system where
110/108 cells of Lead Acid are used.

SENSITIVITY TO OVERCHARGE & UNDERCHARGE:

Tubular Moderately Sensitive
VRLA Extremely Sensitive
Plante Moderately Sensitive
Ni-Cd Moderately Sensitive

Contd…

07.09.2009 42
 COMPARISON

DISCHARGE PERFORMANCE:
Tubular Standard
VRLA Best
Plante Much superior to HDP Tubular but slightly inferior to VRLA
Ni-Cd Superior to Plante for very short duration (3 sec & below) but
inferior to Plante for longer duration.

RECHARGE:
Tubular Capable of quick recharge by boost charging upto 2.7 vpc and
C/10 Amps recharge current
VRLA Quick recharge limited to fast charging upto 2.3 VPC and C/10 Amps
recharge current
Planté Very fast recharge by boost charging upto 2.7 VPC
and C/10 Amps recharge current
Ni-Cd Capable of very fast recharge, however charge
retention is relatively poor
Contd…

07.09.2009 43
 COMPARISON
SUSCEPTIBILITY TO HIGH TEMPERATURE:
NDP Tubular Satisfactory operations upto 48/500C electrolytic
temperature
VRLA Prolonged operation at high ambient temperature curtails battery life
severely. For every 10oC increase in temp., the capacity reduces to
Half.
Planté Satisfactory operations upto 48/500C electrolytic
temperature
Ni-Cd Satisfactory operations upto 48/500C electrolytic
temperature
DISCHARGE AT FLOAT OPERATIONS:
Tubular Satisfactory
VRLA Best
Planté Satisfactory
Ni-Cd Ni-Cd does not give full capacity when discharged after remaining
on float for a long time. In order to obtain the desired capacity,
float charge retention factor is to be added.
Contd…

07.09.2009 44
 COMPARISON

MONITORING STATE OF CHARGE:

Tubular Can be done by measuring electrolyte specific gravity
VRLA Cannot be determined externally, acts as a black box
Planté Other than measuring electrolytic specific gravity, battery condition
can be monitored visually through the transparent containers
NI-CD Cannot be determined externally, acts as a black box

TOPPING UP REQUIREMENT:
Tubular Topping up upto 3-4 times in a year
VRLA No topping up required
Planté Topping up once in 12-18 months
Ni-Cd Topping up once a year. Existing electrolyte needs to be
changed every 7-8 years.

Contd…

07.09.2009 45
 COMPARISON
AGEING:
Tubular Degrades gradually during service life. 25% capacity has to be
increased to compensate for ageing.
VRLA Degrades gradually during service life & falls to about 80% in 10-15
years. 25% capacity has to be increased to compensate for ageing.
Planté Planté capacity does not drop rather increases in service life
Ni-Cd Degrades gradually during service life & falls to about 80% in 8-10
years. 25% capacity has to be increased to compensate for ageing.
RELIABILITY:
Tubular Quite reliable
VRLA Less reliable however prone to unexpected
malfunctioning
Planté Most reliable in float operations
Ni-Cd Reliable during routine duty cycles however reduction of available
capacity during long term float operation

Contd…

07.09.2009 46
 COMPARISON

LIFE EXPECTANCY:
Tubular 10-12 years
20
VRLA 10-15 years
15
Plante 15-20 years

Life Expectancy
HDP Tubular 10-12 years 10

Ni-Cd 15-20 years

Tubul VRL Plan Ni-

Tubular VRLA Plante Ni-Cd

INTERNAL RESISTANCE:
NDP Tubular Highest
VRLA Lowest Internal Resistance
Planté 30-40% lower than
equivalent HDP
Tubular Cells
Ni-Cd Average
Tubular VRLA Plante Ni-Cd Contd…

07.09.2009 47
 COMPARISON
COMPARISON BETWEEN OPzS, Ni-Cd AND PLANTE BATTERY BANK

Sr. Feature OPzS Ni-cd Plante

No.
1 Container Transparent Opaque/ Transparent
Transparent
2 Monitoring Easily Monitored Not possible Easily Monitored
3 AH & WH More than 90% & Much lower around More than 90% &
efficiency 75% 50/60% 75%
4 Effect of prolonged Retain its fully Reduction in Retain its fully
float charger charged state even capacity during long charged state even
operation after prolonged float term float operation after prolonged float
charger charger
5 Nos. of cells for 110 Nos. 171-185 Nos. 108 Nos.
220V Battery Bank
6 Expected life 10-12 years 15-20 years 15-20 years
7 Retention of Very Good Very Poor Very Good
Charger
07.09.2009 48
 COMPARISON
COMPARISON BETWEEN OPzS, Ni-Cd AND PLANTE BATTERY BANK

Sr. Feature OPzS Ni-cd Plante

No.
8 Maintenance Topping up once in Topping-Up Topping-Up once in
a year once/twice in a year 12-18 Months
9 Memory Effect Do not suffer from Suffer from Memory Do not suffer from
Memory Effect Effect Memory Effect
10 Hazardous Basic Material is Basic Material is Basic Material is
Substances Lead which is less Cadmium which is Lead which is less
Hazardous. one of the most Hazardous.
Hazardous Materials.
11 Range Available upto Limited range Available upto
3000 AH available upto 2250 AH
990 AH
12 Ageing Degrades gradually. Degrades gradually. Capacity does not
25% capacity has to 25% capacity has to drop
be increased be increased

07.09.2009 49
THUS, THERE IS NO SINGLE TYPE
OF BATTERY
WHICH SUITS
ALL APPLICATIONS.

07.09.2009 50
 CHARGING REQUIREMENTS OF BATTERY
To elaborate the charging needs and various terminologies used to describe it,
see the fig. shown below :

Input Battery DC Load

Supply Charger
Battery
BATTERY
Bank

Tubular Batt. VRLA Plante Ni-Cd

Float Voltage (Volt/cell) 2.15 - 2.2V 2.2 – 2.25V 2.23 – 2.25V 1.4 – 1.45V

Boost Voltage (Volt/cell) 2.65 – 2.7V 2.25 – 2.30V 2.7 – 2.75V 1.65 – 1.7V

Normal Boost Current C/10 Amp. C/10 Amp. C/10 Amp. C/5 Amp.

Contd…
07.09.2009 51
 CHARGING REQUIREMENT OF BATTERY
¾ Every time Power is drawn from a Battery, it needs to be charged so
that the Power drawn is fed back to Battery.

¾ Battery should not be discharged below the recommended cell’s

voltages.

¾ Discharge current drawn from a Battery, the duration of discharge

and cut off voltages are all inter-related.

¾ Battery capacity is always defined as Ah at 27oC and as temp. falls

below 27oC, the capacity also reduces.

¾ Battery charging Power fed be 1.13 to 1.15 times more than the
power drawn.

¾ Battery charging needs to be done at higher voltages.

¾ Battery charging is done at constant current rate by applying higher

voltage across the cells, Called Boost charging voltage.
Contd…
07.09.2009 52
 CHARGING REQUIREMENT OF BATTERY
¾ As the charging current continues with time (i.e. accumulating the
products amp. hour) the cell voltage also rises.

¾ Once Battery has attained full state of charge, this charging needs to
be terminated.

¾ An open ckt. Cell will keep loosing its power due to very slow rate of
internal discharge taking place within the Battery itself.

¾ To over come above, each cells needs to be kept at a higher

potential than the normally open ckt. voltage of each cell. This is
called Float voltage.

¾ Each cell draws small amount of current with Float voltage across it
to meet the losses due to internal current. This trickling of current
into each cell is called Trickle or Float current and cell is called in
FLOAT MODE.

¾ Initial Charging, Float Charging, Boost Charging and extended

charging voltages for various cells is given below.
Contd…
07.09.2009 53
 CHARGING REQUIREMENT OF BATTERY

Type Of Battery

Tubular
Ni-cd Plante VRLA
Load Acid
Open ckt. Voltage (V) 1.22 2.0 2.0 2.07

Nos. of cell for 220V 172 110 108 108

Boost Charging current 20% of Ah 10-13% of Ah 10-15% of Ah 10-12% of Ah

Boost Charging Voltage 1.55V/cell 2.45V/cell 2.45V/cell 2.35V/cell

Float Voltage 1.42V/cell 2.15-2.2V/cell 2.23-2.25V/cell 2.25V/cell

Initial / Equalise Charge 1.7V/cell 2.7V/cell 2.7V/cell 2.35V/cell

Voltage

07.09.2009 54
 CHARGING REQUIREMENTS OF BATTERY
Battery charging curve for VRLA Battery :

TRICKLE Charger Battery Boost Charging

MODE Off
2.30V/Cell (CC) (cv) Trickle
Mode
i = C/10
Contant current

2.25V/Cell
Float Voltage
Float Voltage

2.0V/Cell
Batt. Voltage

V Trickle Current

t
0

Red indicates Voltage

Green indicated current Contd…
* Not to Scale
07.09.2009 55
 CHARGING REQUIREMENTS OF BATTERY
Battery charging curve for Lead Acid Tubular :
(Equalise charging)

TRICKLE Charger
Battery Boost Charging Extended Charging
2.7V/Cell MODE Off
Trickle
(CC) Mode
2.45V/Cell (cv)

i = C/10
Contant current

2.15V/Cell
Float Voltage
i = C/20 Float Voltage

2.0V/Cell
Batt. Voltage

V Trickle Current

t
0

Red indicates Voltage

Green indicated current Contd…
* Not to Scale
07.09.2009 56
 BATTERY CHARGER TECHNOLOGIES

L L

+ +
Transformer Transformer
D1 D2 D1 D2

AC Supply sw
AC Supply

D3 D4

_ D3 D4

D1-D4 : Rectifier AC/DC Rectifier SW- Voltage selector switch

K : DC Filter Capacitor
L : Filter Choke
- Step control type Rectifier
Vac
Elementary AC/DC Rectifier with no - Still used as Boost charger on the
control over output voltage. pretext of being very rugged and
reliable t
- Very harmful for VRLA Battery. May Vdc
damage any Battery.
t

Contd…
07.09.2009 57
 BATTERY CHARGER TECHNOLOGIES

Boost Tx. L
Main +
Transformer
D1 D2
AC Supply Variac
(Auto Tx)

D3 D4

- Variac controlled Buck – Boost type Battery charger.

- Gives smooth control of DC output.
- Can be used with motor to give automatic function.
- Was a popular design before solid state devices (SCR etc.) became
commercial (that is around end 70’s). Vac

- Has poor transient response due to mechanical movements.

- Has poor reliability due to wear and tear of variac. t

Vdc

Contd…
07.09.2009 58
 BATTERY CHARGER TECHNOLOGIES
THYRISTOR CONTROLLED CHARGER
Vdc
t

Th1 D1
Vdc
AC MAINS R1 t
K1

Th2 D2 t P-P ripple

Vdc
t

Advantages:
• Fully Solid State
• Stepless Control of output DC
• Good response
• Accuracy in voltage & current
• Stable output against I/P or output fluctuation

Disadvantages:
• Bulky in size
• Disturbs AC mains
• Poor input Power factor
Contd…
07.09.2009 59
 BATTERY CHARGER TECHNOLOGIES
SMPS BASED BATTERY CHARGER

230V AC EMI MOV K

RFI

AC CONTROLLER

DC
OUPUT

Advantages:
• Compact & light weight, stepless control
• Very Good response and accuracy, expandable design
and can be used in N+1 configuration.
• Very good input PF and low current harmonic input.

Disadvantages:
• Needs clean and dust free atmosphere.
• Prone to lightning & surges. 48V/110V

220V

Contd…
07.09.2009 60
 IGBT BASED BATTERY CHARGER

415V AC DC OUTPUT
3 PHASE

Advantages:
• Compact & light weight, stepless control
• Very Good response and accuracy, expandable design and can be used in N+1
configuration.
• Very good input PF and low current harmonic input.
• Modules of bigger rating available, sturdy design,
• Less prone to failure against AC line surge.

Disadvantages:
• Relatively new technology and needs to be proven in
Indian environmental condition.

07.09.2009 61
 TECHNICAL PARAMETERS OF BATTERY CHARGER

b) Stability of output voltages & current i.e. regulation:

• Regulation is defined as the ratio of charger in O/p voltage or current
w.r.t. the I/p line or output load conditions. It is shown in percentage.
• Regulation against I/p supply variation is measured by setting the O/p
voltage at rated current and by varying its I/p supply.

• Regulation against output load is checked by maintaining the input

supply and changing the output load from min to max (100%) values.

Regulation

100% 110%
I

Contd…
07.09.2009 62
 TECHNICAL PARAMETERS OF BATTERY CHARGER

c) Output Ripple:
• Output ripple is the AC content in DC output.
• It is measured as the AC content output w.r.t. the max DC voltage. It is
represented in %.
• In telecom, in order to check the AC content in audio frequency range, the
ripple is expressed in psophometric noise which is weighted noise at 800hz.
• Ripple is normally expressed in rms or PP as the case may be.

P-P ripple

Vdc DC voltage

Contd…
07.09.2009 63
 TECHNICAL PARAMETERS OF BATTERY CHARGER

d) Output Efficiency:
• It is the conversion efficiency to change the AC into DC O/p.
• It is defined as ratio of output DC Power Vs input AC power.
• It takes into account all loses i.e. resistance loss, Tx. Loss, switching loss etc.
• Efficiency is always represented in percentage.

e) Input Power Factor:

• It is defined as ratio of output DC Power Vs input AC VA.

• Due to non-sinusoidal nature of input current in as SCR controlled charger,
The equation of power i.e. P = VI CosØ does not hold good.
Hence PF is always measured in PF meter as calculated values may have error.

Contd…
07.09.2009 64
 TECHNICAL PARAMETERS OF BATTERY CHARGER

f).Overload, voltage droop and short ckt. at O/p.

• The output of the charger needs to be protected against overload.

• This is achieved using “Voltage droop” characteristic of controlled rectifier.

• If the current drawn from the rectifier exceeds the set value, the voltage is
reduced in the same proportion as the excess current so that the effect of
change in Load (resistance) is nullified.

Regulation
I = V/R
Example
V If R= IE, V= 100V, Then I=100A
If R~ 0.5E, V= 100V, I= 200A
So if V is reduced to 50 V
100% 110%
I I = 50 / 0.5 = 100 A

• This gives solid state overload protection and gives constant current.

07.09.2009 65
 PROTECTIONS & INDICATIONS

a). Measuring Parameters of a charger

• It is AC to DC conversion equipment .
• Hence we need to measure output DC voltage total current, Battery charging
current and Load current only.
• AC voltage measurement, if necessary can be specified.

b). Protections And Indications

• Protections and Indications relate to safety and its information.
• Some of the necessary protections are :
¾ Input phase fail or phase sequence fail.
This is applicable to 3Ph charger only and it must protect the charger by
tripping the incoming 3Ph supply.
¾ Rectifier Fuse Fail :
For high capacity chargers, separate fuses are used at rectifier input and its
failure is sensed and charger be tripped.
( Now with advent of a reliable electronics and by sensing ripple, this may not
be necessary. )
Contd…
07.09.2009 66
 PROTECTIONS & INDICATIONS

¾ Output Fuse Fail :

Senses the output fuse and trips the charger.

¾ DC over voltage :
Senses the output DC voltage and if it is more than 10% of the rated value, the
charger needs to be tripped.

¾ DC under voltage :
This is basically protection for the Battery but provided in the Battery charger. It
protects battery under deep discharge.

¾ Battery earth fault protection :

For ungrounded DC system, it senses the earth resistance to ground in both the
outputs and will give an alarm if the current to earth exceeds some fixed value.

¾ Charger Fail :
In case the AC main is available, but there is no DC output, this is extended as
“Charger Fail”.

Contd…
07.09.2009 67
 PROTECTIONS & INDICATIONS

The Indications can be divided into Visual & Audio-Visual both.

Visual Audio / Visual

Mains On 9 X
Charger On 9 X
Phase Fail 9 9
Rectifier Fuse Fail 9 9
Filter Capacitor Fail 9 9
DC Over Voltage 9 9
Battery Under Voltage 9 9
Battery Earth Fault 9 9

However in small capacity charger all above are not needed and they be specified
very judiciously.

07.09.2009 68
 PROTECTIONS & INDICATIONS

Other Common Tests

Degree of Protection - As per IS 2148

High Voltage Test - As per IS 4540 / IEC146
Megger Insulation Test - As per IS 4540 / IEC146
Test on Transformer - As per IS 4540 / IEC146

Contd…
07.09.2009 69
 EMI / EMC COMPATIBILITY

Th1 D1

AC MAINS R1 0
K1

Th2 D2

Changes are provided with protection against

(a) Conducted interference
(b) Radiated interference
Capability Tests are carried out at ERTL, Sameer
centre etc. and thereafter same designs are
followed.

07.09.2009 70
 PROTECTION AGAINST LIGHTNING & SURGE
Courtesy OBO

Disturbance variables/
Number of
appliances with
electronics

Vacuum Transistors
tubes
Immunity to
Integrated circuits interference

Personal computers

Time

1950 1960 1970 1980 1990 2000

07.09.2009 71
 DESIGN & COMPONENT SELECTION OF
THYRISTOR CONTROLLED CHARGER
L Blocking
Diode
Io

SW F C1 IL
I1 Th1 D1
~ Vo
Iav
IB
V2 Irms
K1
V3 RB RL
Input V4
I2
Supply
F
N
shunt
AC voltage
protection

Th2 D2 shunt

Firing
Pulses
I sense
CONTROL CIRCUIT I batt.

V1

V Ref. I Ref.

V2

V3

V4

Contd…
07.09.2009 72
 DESIGN & COMPONENT SELECTION OF
THYRISTOR CONTROLLED CHARGER
Component Section:
Input voltage V1 : 230V +10%, -15%, 50Hz., Single phase
Max output DC : Vo
Max Load current : IL
Battery Boost Current : IB
Net O/P limit of charger Io : IL+IB
DC output power : Vo x Io
V2 = 1.18 (Vo+2.4+1.5+2) 1.15 x 1.05
I2 = Io
TX VA = V2 x I2
Input current I1 = V2 xI2
0.96 x V1
Average current through each Thyristor/Diode, Iav = 0.5 Io
RMS current through each Thyristor/Diode, Irms = 0.6Io
Using single section LC filter, Attenuation = ω2 LC
In a single phase thyristor bridge ripple frequency = 2 x mains freq.
In a three phase half controlled thyristor bridge ripple frequency = 3 x mains freq.
In a three phase full controlled thyristor bridge ripple frequency = 6 x mains freq.
One of the components out of L or C is selected and 2nd is calculated.
Contd…
07.09.2009 73
 DESIGN & COMPONENT SELECTION OF
THYRISTOR CONTROLLED CHARGER
L

3 Phase Fully Controlled Bridge

SW F C TX

DC OUTPUT
415V AC RB
K
-

3 Phase Half Controlled Bridge

SW F C TX

DC OUTPUT
415V AC RB
K
-

Contd…
07.09.2009 74
 DESIGN & COMPONENT SELECTION OF
THYRISTOR CONTROLLED CHARGER

Scheme # 1:- Float-Cum-Boost Charger with Single Battery Bank

ISOLATOR DROPPER DIODES

~
~
AC MAINS
=
FLOAT-CUM-
BOOST CHARGER

Selector
BATTERY Card
BANK DC Feeders

Popular Ratings : Upto 24V/100A, upto 48V/100A, upto 110V/50A

Applications/ Users : EPABX,PLCC, Sub-Stations, Industrial application normally

used by PSEB for PLCC, GAIL (Telecom).

Contd…
07.09.2009 75
 DESIGN & COMPONENT SELECTION OF
THYRISTOR CONTROLLED CHARGER

Schemes # 2:- Float & Float-Cum-Boost Charger with Single Battery Bank

~
Isolator =
Float Rectifier
~
AC Mains
C DC Feeders

~
Isolator = D
Float-Cum
Boost Charger

Battery
Bank Tap Cell

Popular Ratings : Possible in any voltage from 24V to 250V (or higher) and
currents from 20A to 2500 Amps.

Applications/Users : All types of Power sector requirements in Switchyard, Sub-

Station, PLCC, EPABX etc.
Normally all SEB’S, EIL, NHPC, NLC, APGENCO, RRVUNL
and misc users use this scheme.

Contd…
07.09.2009 76
 DESIGN & COMPONENT SELECTION OF
THYRISTOR CONTROLLED CHARGER

Schemes # 3:- Dual Float & Float-Cum-Boost Charger with Single Battery Bank

~
Isolator =
Float Rectifier
(Main)
DC Feeders
~
Isolator =
Float-Cum-Boost
~ Charger (Main)
AC Mains

~
Isolator = ‘C’
Float Rectifier
(Standby)

Battery
~ Bank
Isolator = TAP
Float-Cum-Boost CELL
Charger (Standby) DIODE

Popular Ratings : Possible in any voltage from 24V to 250V and currents from 20A to 2500
Amps.
Applications/Users : All types of Power Plants for main, Switchyard and C&I application like
KPTCL, APGENCO, HPSEB, some old Power station, RRVUNL etc.
Contd…
07.09.2009 77
 DESIGN & COMPONENT SELECTION OF
THYRISTOR CONTROLLED CHARGER

Schemes # 4:- Dual Float-Cum-Boost Charger with two Battery Banks

~ ~
AC Mains AC Mains

SW1 SW2

~ ~
= =
FCBC-I FCBC-Ii
INTERLOCK INTERLOCK
SW3 SW4

SW5 CB SW6
Battery Battery
Bank-1 Bank-2

DC Feeders DC Feeders

Popular Ratings : Possible in any voltage from 24V to 250V and currents from 20A to 2500 Amps.

Applications/ Users : Generally used in various types of Power Plants and HV Sub-Stations,
Recommended by NTPC, PGCIL & some Power Stations in some of the
contracts.

Contd…
07.09.2009 78
 DESIGN & COMPONENT SELECTION OF
THYRISTOR CONTROLLED CHARGER

Schemes # 5:- Dual Float-Cum-Boost Charger with Standby Charger

~ ~ ~
AC MAINS AC MAINS AC MAINS

SW1 SW7 SW2

~ FCBC-
~ ~
STANDBY
FCBC-I = = = FCBC-I

SW5 SW6
SW3 SW4
INTERLOCK

SW8 SW9

BATTERY BATTERY
BANK-1 BANK-2

DC Feeders DC Feeders

All others ratings applications and uses are same as in scheme # 4 above.

07.09.2009 79
 DESIGN & COMPONENT SELECTION OF
SMPS BASED BATTERY CHARGER
FLOAT CUM BOOST CHARGER WITH DROPPING DIODE
(GENERALLY RECOMMENDED FOR 48V)

SMR
~
- DCDB
SMR
415V ~
- + I2
3 PHASE

-
I1
IB
DC DB -1
SMR
Lightning
& Surge ~ BATTERY
Protection -
(N+1)

Contd…
07.09.2009 80
 DESIGN & COMPONENT SELECTION OF
SMPS BASED BATTERY CHARGER
TWO FLOAT CUM BOOST CHARGER WITH TWO BATTERY SETS
SMR
~ DC FEEDER
-
SMR
~
-

Lightning SMR
& Surge DC DB -1
~ BATTERY
Protection -
FCBC

COUPLER

SMR
~
-
SMR
~
-

DC DB-2
Lightning SMR
& Surge ~ BATTERY
Protection -
FCBC

07.09.2009 81
 SELECTION OF BATTERY CHARGER RATING

It varies with type of total configuration,

Output voltage Output current
Scheme # 1 - Max. Boost voltage IB + IL

Scheme # 2
Float Charger - Max. Float voltage Load current IL
Float-cum-Boost charger - Max, Boost voltage IB+IL or Higher of the two

Scheme # 3
Float Charger - Max. Float voltage - Load current IL
Float-cum-Boost charger - Max, Boost voltage - IB+IL or Higher of the two

Scheme # 4 - Max. Boost voltage - Higher of IL / IB

Scheme # 5 - Max. Boost voltage - IL +IB

In SMPS based charger using N+1 configuration

Max. output voltage : Max. Boost voltage
Max. output current : (Rating of each module) X N+1 or N+2

07.09.2009 82
 TYPE TESTS & ACCEPTANCE TEST

TYPE TESTS

(1) Temperature rise test at full load.

(2) Insulation resistance tests.
(3) High voltage (power frequency) test on power and control circuits except low
Voltage electronic circuits.
(4) Ripple content test
(5) Automatic voltage regulator operation test at specified A.C. supply variations
(6) Load limiter operation test
(7) Efficiency and power factor measurement.
(8) Degree of Protection
(9) Short circuit test.
(10) Overshoot/Undershoot in out put voltage of the charger as a result of sudden
Change in load from 100% to 20% and 20% to 100% shall be measured

Contd…
07.09.2009 83
 TYPE TESTS & ACCEPTANCE TEST

ROUTINE TESTS

(A) Complete physical examination

(B) Insulation resistance test.
(C) High voltage (power frequency ) test.
(D) Ripple content test at full load
(E) Automatic voltage regulator operation test at specified
A.C. supply variations.
(F) Load limiter operation test
(G) Checking of proper operation of annunciation system.
(H) Functional test.
(I) Power factor at full load.

07.09.2009 84
 NEW DEVELOPMENTS IN BATTERY CHARGER
& ASSOCIATED PRODUCTS

a) Microprocessor controlled Thyristorised charger.

b) SMPS based charger in N+1 configuration.
c) Battery Cell Monitoring.
d) Feeder Earth Fault detection.
e) Battery Discharger.

Contd…
07.09.2009 85
 NEW DEVELOPMENTS IN BATTERY CHARGER
& ASSOCIATED PRODUCTS
A) MICROPROCESSOR CONTROLLED THYRISTORISED CHARGER

¾ Embedded Technology for Control

circuitry, hence improved reliability.
¾ Local & remote parameter setting.
¾ Local & remote alarm annunciation.
¾ RS485 port / Internet connectivity for
status of charger.
¾ Battery status.
¾ Battery condition and predictive
information about Battery Bank.

Contd…
07.09.2009 86
 NEW DEVELOPMENTS IN BATTERY CHARGER
& ASSOCIATED PRODUCTS
B) SMPS BASED CHARGER IN N+1 CONFIGURATION

¾ Compact & Light weight.

¾ Higher efficiency, hence power saving
¾ N+1 configuration, hence total system cost
effective
¾ Low input current harmonics and good PF.
¾ Easy to maintain & higher output
availability.

Contd…
07.09.2009 87
 NEW DEVELOPMENTS IN BATTERY CHARGER
& ASSOCIATED PRODUCTS
C) BATTERY MONITORING UNIT
• Intellectual Battery patrolling device to
ensure reliable Battery operation.
• Cell data collected with precision.
• Monitors and simultaneously displays
total Battery voltage, Cell voltage,
Battery charging / discharging current,
typical cell temperature & ambient.
• Cell voltage alarm function w.r.t.
preset value.

• Facility to store upto 180 records even if power fails

• Large LCD screen with keypad operation.

• Remote communication function through R 485 / 232 series port.

• Ideal for use in communication, petroleum , chemical, Railway, Coal & Power Sector.
Contd…
07.09.2009 88
 NEW DEVELOPMENTS IN BATTERY CHARGER
& ASSOCIATED PRODUCTS
D) INTELLIGENT FEEDER EARTH MONITORING UNIT

• Monitors isolation of individual DC

feeder on-line to ensure secured
operaton.
• High sampling precision of isolation
resistance, reliable alarm with EMC
compatibility.

• No signal injection or DC system for DC sampling. Monitors both +Ve & -Ve
polarities.
• Displays feeder number, polarity, feeder earthing resistance and earthing
line.
• Large LCD screen, friendly interface with audio-visual alarm.
• Upto 180 records can be saved even if power is off.
• Remote communication function with RS 485 / 232 serial port.

Contd…
07.09.2009 89
 NEW DEVELOPMENTS IN BATTERY CHARGER
& ASSOCIATED PRODUCTS

E) BATTERY DISCHARGING UNIT

• Intelligent & settable constant current Battery

Discharger.
• Precision reliable, stable & stepless selection.
• Excellent structure with unique cooling.
• Friendly interface, 5 - 7”, chromatic LCD, easly
to operate.
• Both AUTO & MANUAL Discharge Mode
available.

• Discharging process stops when Voltage / Current / Time / Battery capacity

meets set condition.

• Upto 6 discharge records can be saved.

• Gives graph of Battery discharge current Vs time.

• Available for 30V, 48V, 110V & 220V Battery banks.

07.09.2009 90
 A-34, SECTOR-59, NOIDA- 201 301 (U.P. State, INDIA)
TELE: 0120-4640200 to 4640210, FAX: 0120-4640240
E-mail : info@stat-con.com, Website : www.stat-con.com
Customer Support: 0120-4640239, 09910383509
c-care@stat-on.com, servicing@stat-con.com

07.09.2009 91