OPERATION AND

MAINTENANCE MANUAL
FOR

IGBT BASED STATIC BATTERY

CHARGE/DISCHARGE CIRCUIT
PANEL (310V/220A),TYPE-IV

MODEL NO: CDIG-310220

AS PER RDSO SPECIFICATION NO.
RDSO/PE/SPEC/AC/0008(REV-2)
DOC. NO. CDIG/310-220/11/00
ISSUE NO: CDIG/310-220/01
ISSUE DT: 23.06.2011
ISSUED BY:

SIGNOTRON (INDIA) PVT. LTD.

PLOT NO.J1-6, BLOCK-EP, SECTOR-V
SALT LAKE ELECTRONIC COMPLEX
CALCUTTA – 700 091
PHONE : 91-33-2357-3481
FAX : 91-33-2357-7877
Email: signomail@vsnl.net/sigpl@cal3.vsnl.net.in
Web Site: www.signotron.com
SL.NO. CONTENTS PAGE

01. Introduction 1

02. Brief Specification 1-3

03. Description & operation 3-5

04. Wor king princ iple of car ds 6

05. Fault Alarm Scheme 6-7

06. I ns ta ll ati on, c ommiss i oni ng & testi ng 7-8

07. Maintenance & Fault rectification 9-10

08. Bill of mate rial 11-13

09. Main Circuit Diagram 1-4

10. M ec ha ni ca l Dr a wi ng 1

11. Safety requirement 1

12. Preservation of product 1

01: INTRODUCTION:

Battery charge/discharge system is the IGBT based DSP controlled

battery charger for sealed maintenance free batteries/conventional batteries
of 1100/120AH capacity. This instruction manual is designed keeping in view
the user’s suitability. This manual is divided into the following basic parts.

Technical Specification.
Operation & Working principle.
Installation & commissioning.
Faults & rectification.
Bill of material.
Drawings.

Technical specification contains the electrical parameters of the Battery

charger/discharger as per specificaton no. RDSO/PE/SPEC/AC/0008(REV-2).

Operation and working principle describe the mode of operations of the Battery
charger and then the operation of DSP board.

Installation and commissioning describe the vital instructions to be followed after

receipt of the equipment at site. Faults and rectification provide useful tips to the
maintenance personnel to ensure smooth and trouble-free operation of the
charger.

02: BRIEF SPECIFICATION:

The IGBT based battery charge/discharge system has been designed for the
following rating and other particulars.

i)Type: Constant voltage/constant current with current limiting.

ii)Input Voltage:

Nominal voltage = 415V AC, 50HZ, 3 phase, 4 wire.

Operating line to line Voltage = 350V AC to 480V AC.

iii) Rectification Mode:

The front end converter is IGBT based DSP controlled PWM voltage source
converter and second converter is a PWM DC-DC isolated converter controlled
by DSP.

1
iv) Output voltage & output current:

For CV mode: 60V to 257.6V(2V to 2.3 V per cell) & 220A for VRLA battery.
Recommended voltage of charging in float mode: 2.25V/cell. It may be adjusted
by key pad.
Recommended voltage of charging in boost mode : 2.30V/cell. It may be adjusted
by key pad.

For CC mode: 302.4V( 2.70V per cell) & 110A(10% of the rated 10 hrs. capacity
of battery) for LEAD ACID battery.

Output current may vary from 22A to 220A by key pad under constant current
mode.

v) Output voltage regulation:

Under constant voltage mode, the output voltage will be maintained within ±1%
over the entire range of the input AC supply variation and the output load
variation from 10% to 100% of rated capacity.

vi) Output current regulation:

Under constant current mode, the output current will be maintained constant
within  1% of the set value at 35% to 100% load over entire range of the input
AC supply.

vii) Efficiency:

Efficiency of the unit is better than 85% at half load & 93% at full load for the
entire input voltage range & 90% for discharge mode.

viii) Ripple content:

Voltage/current ripple  2% rms at full load when measured across a resistive

load.

ix)) Protections:
Input under/over voltage, Input phase sequence, Output over voltage, Current
limit, Overload etc.

x) Insulation Resistance: 10MΩ or more while measured with the help of 500 Volt
megger between shorting terminal and body of the enclosure.

xi) High Voltage Test : Dielectric test shall be carried out by applying the following
voltage.
a. 2000Vrms sine wave, 50 Hz for 1 minute for 415V ac
circuits.
b. 1500Vrms sine wave, 50 Hz for 1 minute for 110V dc
circuits.

2
xii) Power factor : Better than 0.98 at full load for both charging & discharging
mode.

xiii) Current harmonic distortion: Less than 8% at full load both charging &
discharging mode.

03: DESCRIPTION & OPERATION:

Wiring diagram & single line diagram of IGBT based charge/discharge system is
enclosed in the manual. This diagram shows the overall schematic of the
charge/discharge system . The front end converter is a IGBT based DSP controlled
voltage source converter to obtain almost unity power factor and input current THD less
than 8% for both charging & discharging mode. The DC link is a stiff DC voltage
maintained by a bank of electrolytic capacitors. The second stage is a pulse width
modulated DC-DC isolated converter to provide the desired output power. 3rd stage is a
diode rectifier for charging mode & behaves like a PWM converter for discharging mode.
This unit is suitable to work from 350 Volt AC to 480 Volt AC (line to line voltage)3
phase, 4 wire 50 Hz. supply and to deliver 257.6 Volt, 220 Amps. for VRLA battery and
302.4 Volt , 110 Amps. for LMLA batteries (Low maintenance lead acid batteries). Input
supply is fed to input side of the line choke via Input MCCB ,Input fuses F1, F2, F3, and
power contacts of input contactor (designated as Input CON).This contactor is used for
ON / OFF operation of the unit, & pre-charging resistances are connected across the
power contacts.

This line choke is a three phase inductor. Outputs of this line choke are fed to the input
of the 3 phase full bridge IGBT module. Output voltage of the bridge module is fed to the
input of the isolated DC-DC converter which is shown in the wiring diagram. High
frequency transformer is used in output stage for isolation. Output of the high frequency
transformer is fed to the single phase full bridge IGBT module. This module behaves like
a rectifier in charging mode & behaves like a switching device in discharging mode. The
output voltage of the charger is controlled by the PWM controller of DSP board. To
achieve voltage regulation, a sample of output voltage is taken by voltage transducer
and compared with a fixed reference. The difference of these two signals is called “Error
Signal”. The error signal is processed in the control module and required PWM pulses
are sent to gate- emitter of the IGBTs.
Thus by controlling PWM pulse of the IGBTs, automatic regulation is achieved. One hall
sensor is used for current feedback signal to the controller for current limiting. Ripple
content at the output side of the converter is very high. So, L-C filter is used at the
output side of the converter to reduce the ripple content.

SOFT START OPERATION:

When the charger has been started, output voltage will be gradually increased
through soft start within 6 seconds.

3
Operation of all switches placed on the front side of the panel:

SW1(ON/OFF): This toggle switch is provided for ON/OFF operation of the unit.

SW2(CHARGE/OFF/DISCHARGE): When this mode selector switch is kept at

‘OFF’ position, then the starting of the unit is not possible. For getting started the
unit in charging mode, keeping ‘SW1’ in ‘ON’ position and then SW2 put at
charge position. Under this condition, unit can charge the battery bank either in
constant voltage mode or constant current mode selected by the key pad.

Output Voltage in CV mode(either float or boost) can be adjusted by key pad &
output current can be adjusted in constant current (CC) mode selected by key
pad. Follow operating instruction of charge/discharge circuit panel described in
later.

For discharge mode of operation of the battery into AC mains, select ‘SW2’ at
discharge position & then made on the switch SW1. Discharge current may be
adjusted by key pad. Please note that Parameters such as output voltage in float,
boost or auto mode, current in CC mode or current in discharge mode are not
adjusted by user during ‘Unit ON’ condition. User can select the parameter during
‘Unit OFF’ condition only.

RESET PUSH-SWITCH: This switch is provided for resetting the system.

4
 OPERATING INSTRUCTION OF CHARGE/DISCHARGE CIRCUIT PANEL

Before making the input AC connection &output DC connection, put both

‘ON/OFF’ & ‘CHARGE/OFF/DISCHARGE’ switches in ‘OFF’ position. Keep the
input MCCB & output MCCB in ‘OFF’ position. Proceed the following steps for
input/output connections.

DC CONNECTION:

i) Connect the positive of the battery bank to the positive terminal designated as
‘+’ & negative to the negative terminal designated as ‘-‘ of the panel.
CAUTION: Make sure the connection of the battery bank in correct polarity.
Otherwise, unit may be damaged.
ii. Put ‘ON’ the output MCCB.

AC CONNECTION:

i) Connect 3 phase, 4 wire suitable cable to the input terminal designated as

R,Y,B,N. Make proper Earth connection of the panel.
ii) Put on the input MCCB.

Proceed the following steps for normal operation of charger in charge mode.

HOW TO CHARGE THE BATTERY BANK :

i) Switch ‘OFF’ the unit by ‘ON/OFF’ toggle switch.
ii) Put ‘CHARGE/OFF/DISCHARGE’ switch at charge position.
iii)Press the ‘MENU’ key. Go-to ‘set parameter’ option by using ‘UP & DOWN’
keys. Press the ‘ENTER’ key. After this operation, select one of the modes such
as float mode, boost mode, Auto mode or C CUR mode by ‘UP & DOWN’ keys as
per user’s requirement. Then press ‘NEXT’ key. Then set the required voltage or
current(depending on mode selection) by using UP & DOWN keys. Then press
‘ENTER’ key. ‘Set parameter stored’ message will appear on the LCD display.
Then run the unit by placing the ‘ON/OFF’ selector switch at ON position.

HOW TO DISCHARGE THE BATTERY BANK INTO THE GRID :

i. Switch ‘OFF’ the unit by ‘ON/OFF’ toggle switch.

ii. Put ‘CHARGE/OFF/DISCHARGE’ switch in Discharge position.
iii. Press the ‘MENU’ key. Go-to ‘set parameter’ option by using ‘UP & DOWN’
keys. Press the ‘ENTER’ key. After this operation, set the required discharge
current by ‘UP & DOWN’ keys. Then press ‘NEXT’ key. Then select the No. of
cells by using UP & DOWN keys for battery under voltage indication. Then press
‘ENTER’ key. ‘Set parameter stored’ message will appear on the LCD display.
Then run the unit by placing the ‘ON/OFF’ selector switch at ON position.

5
04: WORKING PRINCIPLE OF CARDS:

There are three main cards, which are described below.

A)Power supply card:

This card generates the 15V & 5V. 15 volts & 5V are required for DSP card .
Driver card is energized by +15V.

B) DSP & driver cards:

This card generates all PWM switching pulses for front end converter, second
rd
stage & 3 stage converter. This card senses output voltage of front end
converter, input AC voltage, input AC current, output dc voltage & output dc
current through suitable sensors. These signals are processed in this card &
generate the gate pulses of IGBTs for all stages. These signals are fed to the
input of the driver card & output of the driver cards are connected to the gates of
the IGBTs. The objectives of DSP based controller for front end converter are as
follows:
i) Control the DC link voltage to pre-determined voltage 700V DC.
ii) Control the input ac phase current to have a nearly sinusoidal shape in phase
with the ac phase voltage.

This card also senses output voltage & output current through suitable sensors.
After processing these signals, required PWM pulses having switching frequency
8KHz are generated by controller. These signals are fed to the input of the driver
card & output of the driver cards are connected to the gates of the IGBTs of
second stage DC-DC converter. In charge mode, gate pulses of front end
converter & 2nd stage converter are released from the dsp board & in discharge
mode gate pulses of front end converter & 3rd stage converter are released from
the dsp board. All fault detections are generated by this card.

05: FAULT ALARM SCHEME:

Visual indications (LEDs) are provided on the front side of the panel. The audible
alarm is common for all faults, which are given below. It will be actuated for any
one of the following faults.
a)Phase failure.
b)Input AC under voltage.
c)Input AC over voltage.
d)DC under voltage.
e)DC over voltage.
f)Overload.
g)Fuse failure.
h)Earth fault.

6
Indications:

i) Phase fail.
ii) Input AC under voltage.
iii) Input AC over voltage.
iv) DC under voltage.
v) DC over voltage.
vi) Over load.
vii) Fuse failure.
viii) Earth fault.
ix) Float charging on.
x) Boost charging on.
xi) Auto charging on.
xii) Discharging on.

06: INSTALLATION, COMMISSIONING & TESTING:

Visual check:

Whether any damage has been caused during transit. If there is no sign of
damage then the panel can be taken for installation.

Input Supply voltage check:

Input 3 phase, 4 wire supply voltage should be between 350V AC to 480VAC. If

found O.K., then connect the lines at the input terminals designated by R, Y, B &
N. The panel should be properly earthed through earthing terminals.

Battery bank voltage check:

Check the voltage of the battery bank. If the bank voltage will remain from 60V
DC to 310V DC, then +Ve & -Ve terminals of the charger can be connected with
positive & negative terminals of the battery bank respectively.

Note: Make sure the connection of the battery polarity before starting of the
charger.

Performance check:

First of all, ‘ON/OFF’ and ‘CHARGE/OFF/DISCHARGE’ switches kept at off

position. After connecting the input mains at the inputs of the charger, put
MCCB2 & MCCB1 at ‘ON’ position and observe the battery bank voltage in LCD
display placed at front side of the panel. Follow the operating instruction for
proper operation of the unit.

7
FOLLOWING SAFETY PRECAUTIONS TO BE FOLLOWED BY USER TO
AVOID INJURY & PREVENT DAMAGE TO THIS PRODUCT:

TO AVOID FIRE OR PERSONAL INJURY:

1. Use only the suitable cable for input connection for this Product.

2. This Product is grounded through the groundings conductor. To avoid

Electrical Shock, the grounding conductors must be connected to earth
ground. Before making input/output connection of the product, ensure that the
Product is properly grounded.

3. To avoid Fire or Shock hazard , observe all ratings of component which are
mentioned in BOM.

4. Do not operate the unit without covers.

5. Do not touch exposed connection & components when power is present.

6. Following Minimum outside clearance of the unit for indoor installation to be

maintained.
Rear side: 900mm, Front side: 1.2mtr, Left or right side: 600mm

Maintenance of the charge/discharge unit

To do the following under de-energized condition of the unit

1) Keep the hinged covers of the unit always tightly closed.

2) Use only HRC fuse links of correct rating.
3) Periodically clean the tightness of all connection.
4) Periodically clean the heat sinks.
5) Periodically cheek the tightness of fixing nuts & bolts of the unit.

8
07: MAINTENANCE & FAULT RECTIFICATION:

1) Fault: Indication of the AC under voltage is glowing in spite of healthy

input voltage.
Probable cause: a) Due to failure of input fuse.
b) Due to loose connection of sensing voltage.

Remedy: a) Replace the input fuse with same rating.

b) Tight the connection of sync. transformer.

2) Fault: Input fuse failure LED glows & unit does not get started.

Probable cause: a) Due to failure of input fuse & trip indicator fuse.

Remedy: a) Replace the input fuse & trip indicator fuse with same rating.

3) Fault: Output fuse failure LED glows & unit does not get started.

Probable cause: a) Output fuse may be burnt.

Remedy: a) Replace the output fuse & trip indicator fuse with same rating.

4) Fault: Unit does not get started in spite of "no fault indication"
Probable cause: a) Either power supply or on/off switch or driver may be faulty.

Remedy: a) Replace the either power supply card or on/off switch or driver.

5) Fault: Unit does get started but no output voltage of the unit

Probable cause: a) DSP card may be faulty.

b) Driver card may be faulty.
c) IGBT may be damaged.
d) Output MCCB may be damaged.

Remedy: a) Replace the DSP card.

b) Replace the driver card.
c) Replace the IGBT.
d) Replace the Output MCCB.

9
6) Fault: In CC mode, unit has been tripped due to over-voltage.

Probable cause: a)Battery bank may be disconnected from the output of the
panel.
b) Output fuse may be burnt.
c) Cell of the battery bank is open.

Remedy: a) Clean the battery terminal & connect the battery bank.
b) Replace the output fuse having same rating.
c) Replace the faulty cell.

7) Fault: Overload indication is coming after getting started of the unit.

Probable cause: a) IGBT may be shorted.

b) Driver card may be faulty.

Remedy: a) Replace the IGBT having same part no.

b) Replace the Driver card.

10
10
 BOM OF IGBT BASED
CHARGE/DISCHARGE CIRCUIT PANEL REV NO. 0

PREPARED BY : S. DE ROY
REV DATE: Nil
CHECKED BY : R. M
MODEL : CDIG-310-220

APPROVED BY : S. DAS DOCUMENT NO. ISSUE DT. PAGE : 1 of 3

RDSO/CDIG/3122/PPLS/01 23.06.2011

Sl. No Component Description Designation Make Qty Remarks

1. Input 3 phase line choke 0.65mH L1 Indusree 01 -
2. Input AC Capacitor, 25µF/500 C13, C14, C15 EPCOS 03 -
VAC.
3. Input potential transformer, SYNC Indusree 02 -
Primary : 510VAC,
Secondary : 6VAC (max),
100mA.
4. Pre-charging resistance, PCH1, PCH2, PCH3 Laxmi 03 -
2.5Ω/200W,
Wire Wound.
5. IGBT module, FF450R12KT4 T1B1, T2B2, T3B3 Semikron/Infi 03 Infineon
neon used
6. Heat sink, 215LT - CEL/Afcoset 03 CEL used
7. Polypropylène Capacitor, C16,C17,C18, ALCON 05 -
3µF/1250 VDC, C19, C20
8. IGBT driver, - Semikron/infi 07 Semikron
SKYPER32PRO(R), neon used
9. Electrolytic DC bus capacitor C1, C2, C3, C4, C5, ALCON 10 -
10000µF/450VDC C6, C7, C8, C9, C10
10. Teflon wire,0.5mm2 - - 1 coil -
11. Wire wound SN1-SN6 Laxmi 06 -
resistance,150Ω/500W
12. I/P MCCB, I/P MCCB ABB/GE 01 ABB used
T1C160FFC3PTMDR160,
13. Output contactor, A145-30-11, O/P CONT ABB/GE 01 ABB used
coil voltage=220-230VAC
14. Earth fault relay - Protech 01 -
15. CBCT - Protech 01 -
16. PCB assembly SMC6004J SIG 01 -
17. PCB assembly SIG-4007A - 01 -
18. Thermal switch - Honeywell 03 -

11
 BOM OF IGBT BASED
CHARGE/DISCHARGE CIRCUIT PANEL REV NO. 0

PREPARED BY : S. DE ROY
REV DATE: Nil
CHECKED BY : R. M
MODEL : CDIG-310-220

APPROVED BY : S. DAS DOCUMENT NO. ISSUE DT. PAGE : 2 of 3

RDSO/CDIG/3122/PPLS/01 23.06.2011

Sl No Component Description Designation Make Qty. Remarks

19. O/P MCCB, O/P MCCB ABB/GE 01 ABB used

T3N250FF3PTMDR250,
20. HRC fuse, 160A, 415V, F1, F2, F3 GE 03 -
TSFP160.
21. HRC fuse, 250A, TSK250. F4, F5 GE 02 -
22. Trip indicator fuse with clamp - GE 05 -
23. Micro switch, 2A. - Kaycee 05 -
24. Input contactor, A110-30-11- I/P CONT. ABB/GE 01 ABB used
230-240,
25. Diode, 1N4007. - 04 -
26. Wire wound resistance.68KΩ / R1, R2, R3, R4, R5, Hi-tech 10 -
11W R6, R7, R8, R9, R10.
27. Gate resistance, 10KΩ, MFR, - THERMAX 14 -
1/4W.
28. Auxiliary Transformer AUX.TX Indusree 01 -

29. Power Supply, PS1, PS2,PS3 Meanwell 03 -

Model: PT45C
30. PCB assembly SGD-4077A SIG 01 -
31. PCB assembly SGN4030 SIG 03 -
32. PCB assembly S-4087A SIG 02 -
33. PCB assembly DSP SIG 02 -
34. IGBT module, FF450R12KT4 T4B4, T6B6 Semikron 02 Infineon
/Infinieon used
35. IGBT module, FF450R12KT4 M1, M2, Semikron 02 Infineon
/Infinieon used
36. PCB assembly SGD4103A SIG 01 -
37. IGBT module,FF150R12RT4 M3,M4,M5 Semikron 03 Infineon
(used as a diode) /Infinieon used
38. PCB assembly SGN4029A SIG 02 -
39. PCB assembly S4077 SIG 01 -

12
 BOM OF IGBT BASED
CHARGE/DISCHARGE CIRCUIT PANEL REV NO. 0

PREPARED BY : S. DE ROY
REV DATE: Nil
CHECKED BY : R. M
MODEL : CDIG-310-220

APPROVED BY : S. DAS DOCUMENT NO. ISSUE DT. PAGE : 3 of 3

RDSO/CDIG/3122/PPLS/01 23.06.2011

Sl No Component Description Designation Make Qty. Remarks

40. Electrolytic capacitor, C11, C12 ALCON 02 -
6800µF/400V,
41. Buzzer, Buzzer Keltron 01 -
24VDC.
42. PCB assembly S4078 SIG 01 -
43. Relay, 4 C/O, 24VDC coil, RL1 OEN 01 -
Type: 37D-4-24-SL
44. Toggle switch, Single pole, SW1 Kaycee 01 -
ON/OFF, 415VAC, 10A
45. Rotary switch, 2 pole 2 way with SW2 Kaycee 01 -
centre off, 440VAC, 6A,
46. Push button switch, DECTTL, PB Gilard 01 -
Red
47. Main high freq.Transformer, Tx Indusree 02 -
Class of Insulation: H ,
48. DC choke,70µH Class of L2,L3 Indusree 02 -
Insulation: H,
49. E-beam cable 50mm2. - Radient 35mtr -
50. E-beam cable 35mm2. - Radient 35mtr -
51. Enclosure as per drawing RDSO/CDIG/3122/ Balaji 01 -
APPV/MECH/01
52. Operating Instruction of - RAJU 01 -
charge/discharge panel
53. Anodized single line diagram - RAJU 01 -
54. Wire wound BLD Laxmi 01 -
resistance,620Ω/500W
55. PCB assembly SGD6027 SIG 01 -
56. PCB assembly SGD6074 SIG 02 -
57. Fan, 2GDS35 133x190L(Z18-18) Fan1,fan2,fan3 Ecofit 03 -

13
 COMPLIANCE TO SAFETY
REQUIREMENTS REV. NO. 00

PREPARED BY: S. DE ROY PRODUCT: IGBT BASED CHARGE

DISCHARGE CIRCUIT PANEL REV.DATE: NIL
MODEL: CDIG-310220
APPROVED BY: S. DAS DOCUMENT NO: ISSUE DATE: PAGE: 1/1
RDSO/CDIG/3122/SFRQ/01 23-06-2011

1. PCB design as per requirements of creepage distances.

2. Wherein assembly carried out as per industrial standard with sufficient distances
provided:-
a) Between conductors.
b) Between terminals.
c) Between any conducting components to metal cabinet/chassis.

3. Circuit design to provide for the following protections:-

a) Input over voltage
b) Input under voltage
c) Short circuit
d) Output over voltage

4. To avoid fire or personal injury:-

a) Use only the suitable cable for input connection for this product.
b) To avoid fire or shock hazard, observe all ratings of component which are
mentioned in BOM.
c) Do not operate the unit without cover.
d) Do not touch exposed connections & components when power is present.
e) This product is grounded through the groundings conductor. To avoid
electrical shock, the grounding conductor must be connected to earth ground.
Before making input/output connection of the product, ensure that the product
is properly grounded.
 COMPLIANCE TO PRODUCT
PRESERVATION REV. NO. 00

PREPARED BY: S. DE ROY PRODUCT: IGBT BASED CHARGE

DISCHARGE CIRCUIT PANEL REV.DATE: NIL
MODEL: CDIG-310220
APPROVED BY: S. DAS DOCUMENT NO: ISSUE DATE: PAGE: 1/1
RDSO/CDIG/3122/PRES/01 23-06-2011

To preserve the product, followings are maintained.

1. Storage ambient temperature not more than 55ºC & avoid from direct sunlight.
2. Clean the product periodically in duration of 3 months.
3. Use wooden package for transportation to avoid mechanical shock, vibration,
etc.