Battery Charger Manual - Hybrid-TF Series 9

TECHFILL Rectifier / Charger User Manual V5 [English]
Hybrid Analogue
TECHFILL Rectifier / Charger DC system

Technical & Engineering Manual
Charger Type: TF D380 G48-60

INPUT: AC 3Ph 3W 380V, 50Hz
OUTPUT: DC 48V, 60Amp
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5th Edition Rev. 2 PCB V9 TECHFILL ENGINEERING CO LTD
We reserve all right in this document and in the information contained therein. Reproduction, use or disclosure to third parties
without express authority is strictly forbidden © TECFILL ENGINEERING CO LTD
Hybrid Analogue
CONTENTS
Page
Chapter 1 SAFETY REGULATION AND ADVICES 4
1 Technical Safety Information For The User 4

1.1 Safety Instructions / Precautions 4
2 Warning Advices 5
3 General Safety Information 5

3.1 HAZARDOUS VOLTAGE (Low voltage > 42.4 Vpeck / 60 VDC) 5
3.2 Fire Outbreak 6
3.3 General Servicing Recommendations 6
Chapter 2 SYSTEM DESCRIPTION 7
1 Principle Of Work 7
1.1 Preface 7
1.2 System Operation 7
1.3 Charging Characteristic 9
2 Front Panel Description 9

2.1 Description Of Panel Indications 10
2.2 Reset / LED Test / Mute 12
2.3 Option LED / Warning / Functions 12
2.4 Metering / Instruments 12
3 Description Of Input / Output Connections 12
4 Description Of PCB Control Board 13

4.1 Charging Mode Selection 14
5 User Adjustment / Alignment 14

5.1 Timer Setting 14
5.2 Potentiometer Adjustment 15
Chapter 3 INSTALLATION, COMMISSIONING, START-UP & SHUT-DOWN 16
1. General 16
2. Room For The DC-System 16

2.1 IP Protection / Ventilation Grids 16
2.2 Placing 17
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2.3 Cable Inlet 17
3 Ventilation 17
Page
4. Installation, Wiring and Fuses 18

4.1 Grounding Of Enclosure 18
4.2 Mains Connection 18
4.3 Battery Connection 19
4.4 Grounding Of The Battery (for system with battery) 19
4.5 Connection Of The Load 19
4.6 External Fusing 19
4.7 Circuit Breaker 19
5 Commissioning 20
5.1 Connection Checks 20
5.2 Commissioning Procedures 22
6 Start-Up 23
7 Shut-Down 23
Chapter 4 MAINTENANCE 24
1. Maintenance Of The Rectifier 24

1.1 Monthly Checks 24
1.2 Semi-Annual Checks 24
Chapter 5 TROUBLESHOOTING 25
Chapter 6 SPECIFICATIONS, RELATED DRAWINGS AND TEST REPORT 27
Technical Specifications
Charger Layout & Outlook Drawing
Meter & LED Display Drawing
Single Line Diagram
Input / Output Connection Diagram
Schematic Diagram
System PCB Boards Description
Equipment BOM 1
Equipment BOM 2
Test Report
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Chapter 1 – SAFETY REGULATION AND ADVICES
It is assumed that only qualified personnel are engaged in assembly and installation of the components
provided.
Qualified personnel are persons who, on the strength of their training, experience and instruction, together
with their knowledge of the relevant standards, provisions, accident prevention regulations and operating
conditions, have been authorized by those responsible for the safety of the components / installation, to
carry out the relevant necessary work, with the ability to recognize and avoid possible hazards. Amongst
other things, knowledge of First Aid and of local rescue equipment are also necessary.
1 TECHNICAL SAFETY INFORMATION FOR THE USER
This description contains the necessary information for the correct application of the product described
below. It is intended for use by technically qualified personnel.
Qualified personnel are persons who, because of their training, experience and position as well as their
knowledge of appropriate standards, regulations, health and safety requirements and working
conditions, are authorized to be responsible for the safety of the equipment, at all times whilst carrying
out their normal duties and are therefore aware of, and can report, possible hazards (Definition of
qualified employees according to IEC 364).
1.1 SAFETY INSTRUCTIONS / PRECAUTIONS
The following instructions are provided for the personal safety of operators and also for the protection
of the described product and connected equipment.
Hazardous voltage
Failure to observe can kill, cause serious injury or material damage.
 Isolate from mains and battery before installation or dismantling work, as well as for fuse changes
or post installation modifications.
 Observe the prescribed accident prevention and safety rules for the specific application.
 Before putting into operation check if the rated voltage for the unit conforms with the local supply
voltage.
 Emergency stop devices must be provided for all applications. Operation of the emergency stop
must inhibit any further uncontrolled operation.
 The electric connections must be covered!
 Earth connection must be checked for safe function after assembly!
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2 WARNING ADVICES
The following ideograms in the manual and in the device (if available) signify:
Used for Possible consequences:
Immediate threatening danger can kill or cause grievous bodily harm
Possible dangerous situation can kill or cause grievous bodily harm
Possible dangerous situation insignificant physical injury. Also

possible as warning against material damage
Possible dangerous situation

Possible damage of the product or something in its environment
Tips for use and helpful information’s

Not information which warms against dangerous of harmful situations!
3 GENERAL SAFETY REGULATIONS
When working inside the device or when isolating parts in the DC system, the general safety
recommendation and the local electrical regulations have to be observed!
For compliance with the carious safety regulations the following points which constitute a hazard are
mentioned:
3.1 HAZARDOUS VOLTAGE (Low voltage > 42.4 Vpeak / 60 VDC)
As with other low-voltage installations DC system contain hazardous AC and DC voltages.
As soon as the door is opened the danger exists of coming into contact with the hazardous voltages.
Any operations inside the system must only be carried out by competent / authorized electrical
personnel. Extreme caution should be exercised at all times.
Certain parts of the current circuit are live, even if the system is shut down. Before any part is touched
the circuit diagram must be studied and measurements must be taken with the measuring instrument.
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3.2 FIRE OUTBREAK
If a fire should break out inside the system, fire extinguishers with CO2 must be used. Do not inhale
vapors.
3.3 GENERAL SERVICING RECOMMENDATIONS
The normal hazards are present, and we recommend that the following has to be observed:
ASSIGNMENT OF PERSONNEL:
When working with hazardous voltage do not allow personnel to work alone. A second person should
assist so that in the case of emergency help can be called for.
When working on the battery (measuring, topping up electrolyte) protective glasses, rubber gloves,
rubber apron and rubber boots should be worn. Tools for working on the battery should be insulated.
Refer to chapter on <<Battery servicing>>.
If safety covers are installed, i.e. they are according to VDE and are
building the command for the contact protection. They should prevent
contact with parts carrying hazardous voltages. However, in the case of
incorrect operation in the system the danger of electrical shocks inside
cannot be excluded, although correct protection covers are mounted.
Special caution is required at all times.
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Chapter 2 – SYSTEM DESCRIPTION
1. PRINCIPLE OF WORKS
1.1 PREFACE
This power supply system rectify the 60/50Hz AC current into 110V DC current system, connecting in
parallel with a battery system, providing continue and uninterrupted power supply and protection for
consumer load even during a mains power failure or abnormal AC power.
Such units are used in:
 Control and monitoring systems in power stations and chemical plants

 Direct-current emergency power units in power stations and chemical plants
 Tripping, closing and emergency lighting for substation
 Central monitoring systems
 Signaling systems
 Remote systems
 Remote control system
 Telecommunication systems
 Transmitter stations
1.2 SYSTEM OPERATION
After AC mains being adjusted and reduce by a separate transformer, it will go through a full wave
phase control which is conducted by the modular full bridge SCR set, using the principle of phase angle
tangent achieving the purpose of fixed voltage limit current.
Slow-start circuit raises the output voltage gradually from zero to its pre-set level at start-up. This
minimizes the inrush current surge exerting on the mains supply, and it also protects the rectifier from
excessive current surge if the output is short-circuited during start-up. Surge suppressors are
incorporated to protect the rectifier against transient mains voltage. Any transient across the output is
also suppressed
L-C filter is used to rectify and to smooth waveform in order to achieve the purpose of low wave.
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Upon request (optional feature), for the purpose of load protection e.g. in boost charging where the
charging voltage is increased, a serial of dropping diode is connected at the output to maintain the load
voltage within the requested range. When the output voltage is higher than the maximum allowed load
voltage, the diode dropper will be automatically connected and maintains a suitable output voltage.
When the DC voltage is below the set value (e.g. in battery discharging), the magnetic contactor will
bypass the diodes, in order to maintain the load voltage within the requested range.
For the purpose prolonging battery life, in addition to a timer controlled boost/float automatic switch
charging, manual boost/float charging voltage control is provided for specific operating mode.
For the protection of battery being over-charged, extra current limit for battery charging current is
provided in order to achieve the optimum battery life. This battery charging current limit is strongly
recommended for lead acid battery to prolong its service life, especially VRLA battery.
In normal supply state, the rectifier will be getting power from the utility. The output of the rectifier will
maintain the battery in fully charged as well as supply DC current to the load via voltage stabilized
diode (optional feature).
When Utility is interrupted or with poor quality, the DC load will be supplied by the battery system and
warning alarm will be sent. After AC utility restores, system returns to the normal supply state and
charger may switch automatically to boost charge with timer activated. Once the set charging time is
reached, it will switch back to float charge again and the system would be on standby mode until the
next emergency.
1.3 CHARGING CHARACTERISTIC
The IU-characteristic of this charger is in accordance with DIN 41773.
Assuming the IU-characteristic is adopted, the current and voltage can be adjusted. The charging
voltage is maintained within ±1% and the current limit stabilized at ±2%.
Floating voltage is generally set at 2.23V/cell for lead acid battery and 1.40V/cell for nickel cadmium,
however they can be adjustable to meet other special requirements. When the charging current of
battery is reducing, the battery is considerably fully charged.
To reduce charging time, boost charge is required which is generally set at 2.33V/cell for lead acid
battery and 1.55V/cell for nickel cadmium battery (adjustable). Boost charge can be initiated
automatically or manually.
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2. FRONT PANEL DESCRIPTION
LED Ver. 1b LED Ver. 2
2.1 DESCRIPTION OF PANEL INDICATIONS
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No INDICATION DESCRIPTION
System receives power with normal input of the unity indicator.

POWER ON
1 LED ON: System receives power
(Green)
LED OFF: System is not powered up / No Power
Mains input fails, indicates that the AC mains input is lower or higher
than its tolerance.
AC FAULT LED ON: AC / Mains Fail

2
(Red) LED FLASHING: Abnormity happened but rectified, press once the
Reset button on the front panel to clear the flashing LED
LED OFF: Normal
System currently in float charge mode.

FLOAT CHARGE
3 LED ON: System running on float charge mode
(Green)
LED OFF: System running on other mode
System currently in boost charge mode.

BOOST CHARGE
4 LED ON: System running on boost charge mode
(Amber)
Charger currently running in manual / equalize / initial charge mode.

Load must be disconnected in this mode.
MANUAL
5 CHARGE
LED ON: System running on manual / equalize / initial charge mode
(Amber)
Option Indicator
6 RESERVE
Indicates that the entire charger current reached the maximum rating.
Current limit for battery will not be displayed here.
CURRENT LIMIT
7
(Amber) LED ON: System running on full load
LED OFF: System running under full load
Option Indicator
8 RESERVE
Indicates that the output voltage is higher than the preset DC high
voltage value. If the DC HV alarm persist after the time delay of 2
seconds, rectifier will shut down to prevent any damage to the load
or battery.
DC HIGH
9 VOLTAGE
LED ON: DC High Voltage Alarm
(Red)
LED FLASHING: Abnormity happened but rectified, press the Reset
button for 3 seconds to clear the flashing LED and restart the system.
LED OFF: Normal
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No INDICATION DESCRIPTION
Indicates that the output voltage is lower than the preset DC low
voltage value, system continues to operate.
DC LOW
LED ON: DC Low Voltage Alarm
10 VOLTAGE LED FLASHING: Abnormity happened but rectified, press once the
(Red) Reset button on the front panel to clear the flashing LED
LED OFF: Normal
It is activated when AC input is normal but the output voltage goes

down to certain preset level or when the High DC voltage alarm
appears.
Charger failure will not be activated when the voltage goes down
CHARGER during current limit.
11 FAILURE
(Red) LED ON: Charger Fails
LED FLASHING: Abnormity happened but rectified, press once the
LED OFF: Normal
Indicates that there is a leakage from the positive side of the DC

output to the ground.
EARTH FAULT + LED ON: Positive Earth Fault

12
LED OFF: Normal
Indicates that there is a leakage from the negative side of the DC

output to the ground.
EARTH FAULT – LED ON: Negative Earth Fault

13
LED OFF: Normal
14 RESERVE Option Indicator

15 RESERVE Option Indicator
16 Battery Reversal Battery Polarity reversal warning
2.2 RESET/LED TEST/MUTE
Press the button will silence the acoustic buzzer in case of fault. Press and hold the button for more
than 8 seconds for LED test.
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If the LED indicator appears consistently, the indicated fault is not yet cleared. If the indicator is
flashing, it’s indicating the condition of abnormality is resolved. Press this button to clear the flashing
indicator.
2.3 OPTION LED / WARNING / FUNCTION
 Changer temperature higher than 45°C

 Charger high voltage shutdown
 Low electrolyte level for vented cells, use with sensor probe
 Low electrolyte ( too low) tripping breaker
 Battery discharged too low tripping breaker
 Charger fan failure
 Others on request
2.4 METERING / INSTRUMENTS
 Standard DC Volt and DC Amps

 Option AC Volt meter
 Option AC Amps meter
 Option AC selector Switch for each phase
 Option Selector switch for battery and Load current
 Option Digital Meter
 96 x 96 mm for analogue meter with class 1.5 accuracy
 96 x 48mm for Digital meter
 Others on request
Analogue meter example Digital meter example
3. DESCRIPTION OF INPUT \ OUTPUT CONNECTIONS
1. AC INPUT (AC input MCCB)

 AC input power for starting of charging and operation of the charger
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2. DC OUTPUT (DC output MCCB)

 DC output power for application by load
3. BATTERY INPUT (Battery input MCCB)

 Engagement of battery set
4. Additional Distribution as option
4. DESCRIPTION OF PCB CONTROL BOARD
PCB MAIN BOARD TMB VER 3.1
+/- 12V +12V,0V,-12V To TR4, TH, To TST PCB DC AC Main Option 2nd
to TEM from TPS PCB TLC, +12,0V (XTR) -CT -CT CPU CPU
To TST RSTP Interal

and 0V Comms. to
TR4,THD
From TPS Parallel

PCB Connection
Comms
AC 15V Power
Supply Board Power
LED
To TPS PCB System

(IR,IS,IT,IN) Condition LED
(RGB)
To TEM , SCR
Analogue
Adjustment
Board
To TPS PCB
( SCR,BAT,LO To Ver.1b
D,GRD) front LED
panel
From
SCR+,BT+,LD System shunt Battery Reversal To Earth MCB,MCCB To Ver.2 front
+,and - and Meter Detection fault PCB AUX detection LED panel
To TPS PCB
Battery shunt
(SCR,BAT,LCD,014)
and Meter
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4.1 CHARGING MODE SELECTION
Techfill introduce the new Analogue adjustment board (TMA ) with LED indicator, Press the
“SELECT” button and the first LED “FLC” will Light Up, using the Central Potentiometer ( Tool
Free), turning the knob to select the desire setting, LED will Light up to indicate which setting is
on ( See Setting List) , thereafter press “select” to confirmed the selection and the LED will be
blinking, if nothing is been adjust, it will return back to stable light after 10 seconds, adjust the
Central potentiometer while it is blinking and set the desire setting.( as long as the Central
Potentiometer is been adjust, it will stay blinking unless adjust stop for 10 second )
For Timer setting a Number indicator is provided to confirm the time setting.
Manual Push Button

Float Charge
Boost Charge
Manual Charge
Battery Discharge Test
Adjustment Select
Adjustment LED
Central Potentiometer meter
Number Indicator for EQU and BST

adjustment
Selection of charging mode can be done manually by pressing:
A. Float button: Change to FLOAT CHARGE mode

B. Boost button: Change to BOOST CHARGE mode
C. Equalize button: Change to MANUAL CHARGE mode
Equalize charge mode is only used for battery initial charge.

During this charge mode, please keep the load NFB off.
D. Discharged button: Option service and adjustment
5. USER ADJUSTMENT / ALIGNMENT
Factory default settings are configured to the specification of the

order, if alignment setting is need to be made on site, please proceed
with careful meter minoring.
5.1 Timer Setting
5.1.1 Manual / Equalize / Initial / Commissioning Charge
The Factory default setting is 12Hrs for Initial and commissioning. Max Timer setting 250hrs
5.1.2 Auto-Boost Charge Timer set (EQUSW)
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The Factory default setting is 8Hrs for Initial and commissioning. Max Timer setting 250hrs
NOTE: Timer will start when current limit have been disengage.
5.2 Potentiometer Adjustment List
There are 20 potentiometers for adjusting 20 most essential monitoring controls.

Adjusting clockwise to increase setting value, anti-clockwise to decrease setting value.
Actuation value
Nos Potentiometer Adjustment Function Max Min

1 FLC Float charge voltage setting 120% 80%
2 BOC Boost charge voltage setting 120% 80%
3 EQC Manual Charge voltage setting 120% 80%
4 CHF Charger Fault Voltage setting 120% 80%
5 SCL System current limit 100% 20%
6 BCL Battery current limit 100% 50%
7 DCH DC High voltage setting 120% 80%
8 DCL DC Low voltage setting 120% 80%
9 ACH AC High voltage setting 120% 80%
10 ACL AC Low voltage setting 120% 80%
11 S1H Adjusting SID ( 1 Step ) voltage high limit 120% 80%
12 S1L Adjusting SID ( 1 Step ) voltage low limit 120% 80%
21 SP1 Option spare 1 120% 80%
22 SP2 Option spare 2 120% 80%
23 EQU Equalize / Initial / manual charge Timer 250hrs 1hr
24 BST Boost charge Timer 250hrs 1hr
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Chapter 3 – INSTALLATION, COMMISSIONING, START-UP & SHUT-DOWN
1. GENERAL
The following has to be considered in connection with the installation of DC systems:
 System room
 Cable connection/cable interconnection
 Losses, ambient temperature, ventilation
 Installation, wiring and fuses
 Grounding of the cubicle
 Mains connection
 Connection of load / distribution
In the following sections the general requirement for the installation of DC systems is explained.
2. ROOM FOR THE DC SYSTEM
2.1 IP PROTECTION / VENTILATION GRIDS
Fit the ventilation grids on the top and the bottom of the device socket to the snap action on both
sides.
A. AIR FILTERS / GLAND PLATES
Dependent on the degree of protection with which the system was ordered, the system can optionally
be equipped with gland plates. These can be pushed in form the front on the rails designated for that
(See Fig 1).
If gland plates are to be mounted, it is absolutely necessary to displace

the system to its definite place of erection before attaching the
ventilation grids to the front, since a transport of the system with
mounted air filters and gland plates by means of a fork-lift or a pallet-truck
is than no longer possible.
Mounting of gland plate

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B. MOUNTING OF THE RAIN ROOF
The rain roof (optional) has to be fastened in accordance with the «Dimensional drawing», if it was not
already mounted in the factory.
When mounting the rain roof special attention must be paid to the
fact that no parts fall into the system. Besides, the rain roofs are not
appropriate for a load form above and the system may also not be
raised at the rain roof.
2.2 PLACING
The grids have in any case to be fixed on the side of the system before
it will be placed to the wall or back to back.
The DC system is built in a cubicle with a stable frame. On this frame

heavy component such as transformers, chokes, etc. are mounted. The
frame can be placed direct on a leveled concrete floor.
The DC system can be placed with the backside to the wall or back to back (but a space of at least
100mm must be ensured). If possible, preferably a distance of 500mm from the backside of the system
to the wall or between the systems (if these are placed back to back) should be provided.
Above the top of the system a clearance of 500mm has to be provided to ensure sufficient space for
the air outlet.
2.3 CABLE INLET
As a standard the cable inlet is from below, but optionally can also be performed from above, if this is
stated in the order. At the installation the bending radius of the cables must be in accordance with the
Standards.
3 VENTILATION
Attention must be paid to the heat that is to be removed which is generated by the power losses of the
system. The inlet and outlet of air must be ensured, otherwise the system can produce an alarm due to
overheating, or even shut down. Therefore the ambient temperature stated in the “Technical
Specifications” is to be observed. Alarm indication is given if the temperature of the power components
exceeds the permitted level.
Objects which obstruct ventilation or which are easily combustible should under no circumstances be
placed on, under or very near the system.
If the DC system is placed with the backside to the wall or back to back, a space of at least 100 mm
has to be guaranteed.
The necessary quantity of air cooling per hour depends on the one side on the total developed power
dissipation, i.e. from the size and number of installed rectifiers, and on the other side on the possible
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resp. permitted warming of the cooling air. The permitted warming of the cooling air is the difference
between the admissible room temperature (e.g.30°C) and the incoming temperature of the cooling air
into the room (e.g. 25°C).
4 INSTALLATION, WIRING AND FUSES
Ensure all of the breaker is “OFF” before attempting to work.

[R]: RED LINE, [S]: WHITE LINE, [T]: BLUE LINE, [G]: GREEN LINE
4.1 GROUNDING OF THE ENCLOSURE
The system enclosure must be earthed, for which purpose terminals are provided inside the system
enclosure.
4.2 MAINS CONNECTION
The incoming feeders must comply with the general recommendation of IEC or the general Standards
of VDE (D), SEV/HV (CH), or possibly with the additional standard corresponding to the local electrical
regulations.
The person carrying out the work must be an authorized installation electrician.
The fuse protection and the wire cross section of the mails connection can be seen in the Technical
document, however, only if these meet also to the local electrical regulations.
The rectifier mains input must be protected by external fuse or MCCB.
For 3 Phase Input: Please ensure that the R.S.T phase is correctly
connected, when the system detect that the phase‘s is wrongly
connected, it will not start up.
4.3 BATTERY CONNECTION
The battery feeders must comply with the general recommendation of IEC or the general Standards of
VDE(D), SEV/HV(CH), or possibly with the additional standard corresponding to the local electrical
regulations. The battery must be protected by external fuse or MCCB.
The fuse or MCCB protection can be seen in the Technical Data.
4.4 GROUNDING OF THE BATTERY (for systems with battery)
It is not necessary to earth the battery. However, if it is desired only the minus pole (-) if the battery
may be earthed, but only if there is an isolating transformer at the input of the rectifier.
It is not permitted to earth the plus pole (+) of the battery because it
could affect the functioning of the system.
Note: Only on special request by the customer a system can be
built, the plus pole (+) of which may be earthed.
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4.5 CONNECTION OF THE LOAD
The load cables are to be installed and connected according to the maximum allowable load. It has to
be assured that the connected load does not exceed the maximum rated capacity of the DC system!
4.6 EXTERNAL FUSING
To ensure selectivity between the internal MCCB and the distribution MCCB, the maximum fuse nominal
current (rated circuit breaker current) at the load output is limited.
In addition, the conditions for the rectifier incoming feeder MCCB (mains) can be seen in the Technical
data.
4.7 CIRCUIT BREAKER
We recommend when inserting circuit breakers between the busbar and the consumer, to choose such
a type that is rated current not exceeds 15% of the nominal current of the system (voltage drop over
the line between DC system and consumer max. 3%).
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5 COMMISSIONING
Phase should be correct and connector should be tightly fitted.

We QC our system before delivery but sometime due to
transportation, connectors will get loosen, it is good to check the
connector before commissioning the system.
5.1 CONNECTION CHECKS
5.1.1 SCR Firing Connector – TST PCB Board (1); Confirm SCR connection: Check if XTR, XTS, XTT is
connected properly.
5.1.2 AC Filter Connector (2); Check that the NTSR (TMB PCB Board), XAC FILTER is connected
properly.
(V1)R (V2)S (V3)T
AC FILTER
(PW) Connect to TSP PCB (GND RSTD)
(XTR) Connect to TMB PCB
5.1.3 Earth Fault PCB Check
Connect to TPS PCB
Connect to TPS PCB
Potentiometer adjustment from 0 to 10mA
Connect to TMB PCB (EARTH)
+ & - Earth LED
* Note: Earth fault board are mounted on the TPS board

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5.1.4 Power Board TPS PCB Check
Connect to TR4 PCB

DC System Voltage /
battery voltage / load
Voltage / negative voltage
DC Voltage meter
0 to 15V detection from

PCB transformer
5.1.5 Power Board TPS PCB startup LED check
A. Check if the R-LED, S-LED, T-LED are illuminated, if not, perhaps the XAV is not connected
properly or fuse blown.
R phase
S phase
T phase
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B. Check if the LED SCR, BAT, Load are illuminated, if not, perhaps the XDV is not connected
or fuse blown.
Load
Battery
SCR
C. Check if the LED D19, D18 are illuminated, if not, perhaps the TPS PCB is damage or XAC
are not connected properly.
5.2 COMMISSIONING PROCEDURES
Ensure all of the breaker is “OFF” before attempting to work. [R]: RED
LINE, [S]: WHITE LINE, [T]: BLUE LINE, [G]: GREEN LINE
(1) Ensure that the AC input N.F.B (Q1). is “OFF” and the AC input voltage is within the range as
per technical specifications and the phase is connected correctly.
(2) Ensure that the Battery input N.F.B. (Q3) is “OFF” and the battery voltage is normal and “+ / -
“ polarity is connected correctly.
(3) Ensure that the DC output N.F.B. (Q4) is “OFF” and the output “+ / -“ polarity is connected
correctly.
(4) Switch the AC input N.F.B. to “ON” position.

The charger will be activated and in “Soft-Start Stage after 10 ~ 15 seconds”.
Check the battery voltage, it shall slowly increase from 0Vdc to the preset value. At the same
time, the green indicating lamp of Power On lamp will light up. The indication lamp for DC low
will also be blinking – clear the blinking by pressing the test/reset button.
(5) Now, the charger is in “float charge mode”.

If needed, press the “Boost” button to go to boost charge mode. The Boost Charge Timer is
preset at 8 hours. That means, after 8 hours of boost charge, charger will go to float charge
mode and float charge indicating lamp will light up.
(6) Confirm the DC voltage meter is normal, then switch the Battery input N.F.B. to “ON” position.
The charger shall deliver current to charge the battery.
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(7) Switch the DC output N.F.B. to “ON” position. Now the charger will have supplied the load as
well.
Under normal operation when DC voltmeter selector switch is provided, please keep the switch
at “charger side”. When the DC ammeter selector switch is provided, please keep the switch at
“battery side”.
6 START-UP
(1) AC Input N.F.B. switch to “ON”. Wait about 15 seconds and ensure the output voltage has
reached the preset value.
(2) Battery Side N.F.B. switch to “ON”.
(3) DC Output N.F.B. switch to “ON”
a. Easy LED Check for all the connection
Start up the system, the Firing LED and CPU LED should light up and follow by the system condition
Indicating (SCI) LED ( RGB) with green light ( indicating float), thereafter soft stat will commence. Once
the soft start have finish and the voltage have stop at the prestart voltage and the rely indication LED
should be blinking. That mean you have connected most of the wiring correctly.
After starting up the system if the SCI LED is flashing red that means the AC INPUT R.S.T phase is
connected wrongly.
Firing LED
CPU LED
System condition (SCI)

LED
Reply indication LED
7 SHUT-DOWN
(1) DC Output N.F.B. switch to “OFF”.

(2) Battery Side N.F.B. switch to “OFF”.
(3) AC Input N.F.B. switch to “OFF”.
IF THE CHARGE VOLTAGE MUST BE ADJUSTED, THE BATTERY

SIDE N.F.B. HAS TO BE TURNED “OFF” FIRST.
____________________________________________________ 23
Hybrid Analogue
Chapter 4 – MAINTENANCE
The system is designed for continuous operation and is virtually maintenance-free. In the system
predominantly semiconductor components are used which are not subject to maintenance. Due to the
critical intended purpose and to assure optimum operation, however, inspection and preventive maintenance
should be performed.
Please according Safety regulations through thoroughly before

Performing any manipulations on the installation and maintenance.
1. MAINTENANCE OF THE DC SYSTEM
In consideration of expediency, the maintenance of the complete system is made by the furnisher
guided by a maintenance contract. This can include e.g. the following:
1.1 MONTHLY CHECKS
The following checks should be made monthly:
(1) Check DC output voltage by means of a measuring instrument.

(2) Check DC output current by means of a measuring instrument.
(3) Persisting alarm indications or incorrect operating statuses must be recorded.
(4) Press “LAMP TEST” button for more than 8 seconds. All operating status and alarm indications
must illuminate for Lamp Test.
1.2 SEMI-ANNUAL CHECKS
(1) Monthly checks as above.

(2) Check all instrument switches and instruments for proper functioning.
(3) Check tightness of all connections. Check all screws and nuts in the device (in volt-free
condition-system isolated).
(4) In case of heavy contamination clean system of dust (Caution: Switch off entire system). Don’t
use any liquid for cleaning – only vacuum cleaner.
(5) Only for systems with filter mats: Check whether the filter mats are dirty. With high
contamination the filter mats have to be replaced. (A high contamination results in a reduction
of velocity of are, necessary for the ventilation, and thus sufficient cooling is no longer
guaranteed).
(6) Functional check of the entire system.
____________________________________________________ 24
Hybrid Analogue
Chapter 5 – TROUBLESHOOTING
RESET/TEST fault alarm mute ON/OFF – Once fault occurs, acoustic alarm will sound, if necessary, it can be
mute by pressing the RESET/TEST button. It will also runs a lamp test if it is pressed >8 seconds.
(a) If fault indication LED continues to appear, that means fault are not
corrected.
(b) If indication LED is blinking, that means fault is corrected, you just
need to press the RESET/TEST button and the blinking will stop.
No FAULT LED ACTION IF YES IF NO
1 AC Power abnormal Check to see if the 1. Push Reset Button if 1. Correct the AC input
indication LED input power is within it's flashing, otherwise voltage.
the range and the Check if the FR, FS,
phase is correct. FT, FN fuse is burnt.
2. If the fuse is not burnt,
please contact
manufacturer or agent
to repair the system.
2 DC Voltage high Check if the DC 1. Push Reset Button to 1. Verify the adjustment
indication LED output voltage is restart the system. If of high voltage alarm
high. the problem still setting.
persists, please
2. If the adjustment has
contact manufacturer
been set properly but
or authorized agent.
the problem still
persists, please
3 DC Voltage low Check if the DC 1. Ensure the AC input 1. Check the fuses on
indication LED output voltage is low. voltage is within the main control board.
range and restart the
2. If the fuses are good,
system. If the problem
verify the adjustment
still persists, please
of low voltage alarm
setting.
3. If the fuses are good
and the adjustment
has been set properly
but the problem still
persists, please
4 Charger fault Check if the DC 1. If output voltage is too 1. Check the fuses on
____________________________________________________ 25
Hybrid Analogue
No FAULT LED ACTION IF YES IF NO
indication LED output voltage is low, please contact main control board.
within the range. manufacturer or
2. If the fuses are good,
authorized agent.
verify the adjustment
2. If output voltage is too of charger failure low
high, please refer to voltage setting and
item 2 (DC Voltage high voltage alarm
High indication). setting.
3. If the fuses are good
and the adjustments
have been set
properly but the
problem still persists,
please contact
manufacturer or
authorized agent.
5 DC earth fault Check if positive 1. Disconnect the load Contact manufacturer or

indication (positive) output voltage is and/or battery, check agent to repair the
grounded if the DC positive system.
earth indication light is
off. If it goes off,
resolve the load
and/or battery from
earth fault.
2. If the load and/or
battery have been
disconnected but the
please contact
manufacturer or
authorized agent.
6 DC earth fault Check if negative 1. Disconnect the load Contact manufacturer or

indication (negative) output voltage is and/or battery, check agent to repair the
grounded. if the DC negative system.
earth indication light is
off. If it goes off,
resolve the load
and/or battery from
earth fault.
2. If the load and/or
battery have been
disconnected but the
please contact
manufacturer or
authorized agent.
____________________________________________________ 26

Battery Charger Manual - Hybrid-TF Series 9

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Battery Charger Manual - Hybrid-TF Series 9

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TECHFILL Rectifier / Charger User Manual V5 [English]

TECHFILL Rectifier / Charger DC system

Charger Type: TF D380 G48-60

Chapter 1 SAFETY REGULATION AND ADVICES 4

1 Technical Safety Information For The User 4

3 General Safety Information 5

Chapter 2 SYSTEM DESCRIPTION 7

2 Front Panel Description 9

3 Description Of Input / Output Connections 12

4 Description Of PCB Control Board 13

5 User Adjustment / Alignment 14

Chapter 3 INSTALLATION, COMMISSIONING, START-UP & SHUT-DOWN 16

2. Room For The DC-System 16

4. Installation, Wiring and Fuses 18

1. Maintenance Of The Rectifier 24

Chapter 6 SPECIFICATIONS, RELATED DRAWINGS AND TEST REPORT 27

Chapter 1 – SAFETY REGULATION AND ADVICES

1 TECHNICAL SAFETY INFORMATION FOR THE USER

1.1 SAFETY INSTRUCTIONS / PRECAUTIONS

Used for Possible consequences:

Immediate threatening danger can kill or cause grievous bodily harm

Possible dangerous situation can kill or cause grievous bodily harm

Possible dangerous situation insignificant physical injury. Also

Possible dangerous situation

Tips for use and helpful information’s

3 GENERAL SAFETY REGULATIONS

3.1 HAZARDOUS VOLTAGE (Low voltage > 42.4 Vpeak / 60 VDC)

As with other low-voltage installations DC system contain hazardous AC and DC voltages.

3.2 FIRE OUTBREAK

3.3 GENERAL SERVICING RECOMMENDATIONS

Chapter 2 – SYSTEM DESCRIPTION

Such units are used in:

 Control and monitoring systems in power stations and chemical plants

1.2 SYSTEM OPERATION

1.3 CHARGING CHARACTERISTIC

The IU-characteristic of this charger is in accordance with DIN 41773.

2. FRONT PANEL DESCRIPTION

LED Ver. 1b LED Ver. 2

2.1 DESCRIPTION OF PANEL INDICATIONS

System receives power with normal input of the unity indicator.

AC FAULT LED ON: AC / Mains Fail

System currently in float charge mode.

System currently in boost charge mode.

Charger currently running in manual / equalize / initial charge mode.

It is activated when AC input is normal but the output voltage goes

Indicates that there is a leakage from the positive side of the DC

EARTH FAULT + LED ON: Positive Earth Fault

Indicates that there is a leakage from the negative side of the DC

EARTH FAULT – LED ON: Negative Earth Fault

14 RESERVE Option Indicator

16 Battery Reversal Battery Polarity reversal warning

2.2 RESET/LED TEST/MUTE

2.3 OPTION LED / WARNING / FUNCTION

 Changer temperature higher than 45°C

2.4 METERING / INSTRUMENTS

 Standard DC Volt and DC Amps

Analogue meter example Digital meter example

3. DESCRIPTION OF INPUT \ OUTPUT CONNECTIONS

1. AC INPUT (AC input MCCB)

2. DC OUTPUT (DC output MCCB)

3. BATTERY INPUT (Battery input MCCB)

4. Additional Distribution as option

4. DESCRIPTION OF PCB CONTROL BOARD