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INSTRUCTION AND OPERATION MANUAL

FOR
24V, 180 AH
FLOAT CUM BOOST
BATTERY CHARGER

Manufactured By :
ELECTRONIC SYSTEMS.
991 / 3- C GIDC INDUSTRIAL ESTATE,
MAKARPURA,
VADODARA
Tel Nos. : +91-265-2635723
Fax No. : +91-265-2632820

Client : BHARAT HEAVY ELECTRICALS LIMITED

P. O. No. : --
Project : KOSTI, Thermal Power Station 4 x 125 MW
Panel Sr. No : 111499-501
Drawing No. : ES-499

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INDEX

SR. NO. TITLE PAGE

1 Introduction 3
2 Technical Specifications 4
3 Enclosure 5
4 Storage and Unpacking 6
5 Installation 7
6 Pre-Commissioning Checks 8
7 General Features of Equipment 9
8 Operational Feature 11
9 Start / Stop Logic 14
10 Control Cards 15
11 Documents list 22

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CAUTION

THIS EQUIPMENT CONSISTS OF SENSITIVE SOLID STATE ELECTRONIC DEVICES. IT SHOULD NOT

BE SUBJECTED TO MEGGER OR HV TEST WITHOUT ISOLATING THESE DEVICES. IF NOT DONE SO

IT MAY PERMANENTLY DAMAGE THE EQUIPMENT.

INTRODUCTION

The purpose of this document is to provide Battery charger users, Consulting

engineers, Project engineers and Maintenance engineers with required technical background
enough insight into the construction operation and trouble shooting of the Battery Charger.

Battery Chargers have wide range of application in the field of Railways, Electricity Boards,
P&T Switchyards, Automobile Industry, EPABX manufacturers, Continuous Process industries
like Cement, Steel, Glass, Petrochemicals etc. Battery Charger s caters to the DC load
requirements of the above applications. Battery Charger is a SECURED UNINTERRUPTED
DC POWER SUPPLY. Battery chargers are also used as a backup power source.

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TECHNICAL SPECIFICATIONS

Nominal AC Input

Mains AC Supply : 1-Ph , 230 VAC, 50 Hz

Battery Details

No. Of Cells : 19 Nos.

AH Capacity : 180 AH (19 KPH 180P)
Each Cell : 1.2 VDC
Make : AMCO SAFT

Battery Charger Details

Type : Float Cum Boost Charger

DC Output : 21V - 32.3V, 20 A DC Max.

Float Charger : 21V - 26.6V, 20 A DC max.

Boost Charger : 21V - 32.3V, 20 A DC Max.

Cubicle
Dimension : 1400 x 700 x 525 mm (H X L X W)
Paint : Siemens Gray RAL 7032 Powder Coating
Construction : Floor Mounting
Cable Entry : Bottom Only

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ENCLOSURE

The Charger is fabricated from cold rolled mild steel sheet not less than 16 SWG. Care
has been taken at all stages of fabrication, all bends, joints, profiles etc are critically examined
during each stage to produce robust charger cubicle. Each charger undergoes seven tank
Phosphating process; it also undergoes Lapi, Red oxide and surface preparation before final
painting.

The base of the charger is fabricated from special channel or 10 SWG sheet structure.
It is exclusively used for heavy fitment like Transformers, Ballast choke, Autotransformer, DC
Chokes.

Adequate louvers (filters) are provided for proper cooling and heat transformer. Wire
mesh with such arrangement enable easy cleaning at altars date. Earthling Bus bar is provided
for solid earthling of cubicle with system earthing pits. Adequate capacity lifting hooks are
provided for ease of lifting and transportation of Charger.

All components are mounted on mounting sheets of minimum 1mm thickness.

Mounting sheets are mounted on angle structure for rigid fitment. PVC coated copper wires
housed in PVC channels do all wiring. Plug socket and panel illuminating lamp is provided with
ON/OFF switch.

Gland Plate of adequate size is provided for bottom entry of cables.

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STORAGE AND UNPACKING

STORAGE

During the period between unpacking and installation the equipment should not be exposed to
extreme atmospheric conditions. The storage area should be clean (relatively dust free) The
area should be exposed to reasonable sunlight, it should also be protected against
unauthorized tampering of controls which can severely affect the commissioning. In case of
excessive humidity (above 80%) it is advised that the panel be suitable heated before operation
(panel internal heater is provided for the same) panel temperature should be raised 1degree
above ambient. During normal operation heat dissipated from the components maintain the
temperature difference.

UNPACKING

The packing case should be handled only with right side up (see markings on the packing
case). Remove packing slips carefully form the wooden case it is pasted on the front of the
charger.
Unpack carefully by removing the sides of the packing case. Inspect visually for any transit
damages. Check the material as per packing slip. Immediately inform our office for damages
and shortfall items. Check that heavy fitment like transformers; choke, etc are firmly fixed to
their positions. Battery charger houses various components like switches, bridges, meters,
MCBs etc which require special care during unpacking and storage. All screws and
terminations should be checked and tightened. Any soldered wire found should be resold red
after checking the circuit diagram carefully. Special care should be taken for conductors
carrying large current; they should be clean and tight.

It is recommended that above-mentioned initial checks for transit damages be carried out even
though the equipment is not required for immediate installation. For any transit damages claim
should be immediately registered with the transport authority under intimation to our office.

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INSTALLATION

This equipment is designed to operate under normal indoor conditions with ambient
temperature not exceeding 50 degrees centi. While mounting care must be taken to see that
the panel is not unduly close to abnormal heat source e.g. engine exhaust radiation etc,
Similarly close proximity to desert cooler and other source or moisture laden air should be
avoided. As this is static equipment no special foundation is required. Foundation details and
layout drawings are provided; these should be studied before installation.

Input, output and earth terminals should be identified clearly with reference to drawing and
panel marking. Cables of proper rating should be used.

Ensure that the incoming and outgoing leads are free from EARTH FAULT before connecting it
to the equipment. CHECK THE TAPINGS ON TRANSFORMER MATCH THE SYSTEM
VOLTAGES.
For floor mounting chargers a clear space of 1Meter should be left on all sides.

Batteries should be installed in proper insulated stand in a well-ventilated room (see battery
manufacturers instruction manual). FOLLOW THE BATTERY INSTALLATION PROCEDURE
REGARDING FIRST FILLING, FILLING SPECIFIC GRAVITY AND INITIAL CHARGING. These
can have detrimental effect on the life of the battery.

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PRE–COMMISSIONING CHECKS

Study the detailed operating instruction and drawings carefully and check the following points.

1 Check and tighten all terminals

2 Check and tighten all mounting nuts and bolts.
3 Check all bus bar joints and tighten.
4 Check all fuses are healthy and in place.
5 Check capacitors no spilling of electrolyte should be seen.
6 Check visually RC surge suppressor connection.
7 Check lamps and lamp holders.
8 Check potentiometers for various manual mode settings.
9 Check all control switches/ MCBs are in OFF position.
10 Check input connections for their phase sequence.
11 Check Output/ Battery connections for polarity.
12 Check the transformer tapping is correctly connected according to the available
source.

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GENERAL FEATURE OF EQUIPMENT

Following are the general features of the Battery Charger. These are provided in the battery
charger to make it sturdy and reliable DC source with necessary protections for ease of
operation and maintenance. For exact details refer charger drawing and bill of material.

1. The charger is protected on the AC and DC side by Switch & MCB properly rated for
safe operation.
2. RC Surge suppressors protect diode and SCRs against line surges, also power
devices are protected by semiconductor fuse of suitable rating.
3. DC current limit is provided to protect charger against DC Overload.
4. Heavy filters are provided after rectifications to provide almost ripple free DC at the
output
5. In case of Boost charging constant current charging of batteries can be carried out.

INDICATIONS:

1 LED indicating lamps are provided for indicating AC mains presence.

2 DC voltmeter is provided for DC output voltages.
3 Suitable DC Ammeters are provided on DC side for monitoring DC Load current and
battery charging current.
4 LED indicating lamp L6 is provided for battery fully charged indication.
5 Other LED indicating lamps are provided for DC O/V, DC U/V, AC Main Fail, Rectifier
Fuse Fail, Filter Fuse Fail, DC Fail, Surge Circuit Fail, Cooling Fan Fail, Charger O/L
Trip, earth leakage indications.

METERS:

1. AC Voltmeter for AC input voltage indication (G1).

2. DC Voltmeter for charger DC output voltage indication (G2).
3. DC Ammeter for charger output current indication (G3).

SWITCHES AND PUSH BUTTONS:

Designation Description
A1 For AC isolation
A2 MCB for DC isolation
B1 For Float / Boost auto c/o mode selection.
B2 For Rectifier/Bus/Battery voltage selection.
B3 Push button for Lamp Reset/Test

CONNECT BATTERY POSITIVE TO T3 (19th CELL +VE TERMINAL OF CHARGER)

CONNECT BATTERY NEGATIVE TO T4 (1st CELL -VE TERMINAL OF CHARGER)
CONNECT BATTERY NEGATIVE TO T5 (15th CELL +VE TERMINAL OF CHARGER)

INCORRECT POLARITY IN CONNECTION CAN SEROUSLY DAMAGE THE BATTERIES

AND THE CHARGER.

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ALWAYS START INITIAL CHARGING OF BATTERIES WITH MINIMUM SETTING TO

PREVENT HIGH CURRENT FLOW. ADJUST VOLTAGE/CURRENT TO THE REQUIRED
VALUE AS PRESRIBED BY THE BATTERY MANUFACTURER, AFTER THE BATTERIS ARE
CHARGED TO SOME EXTENT.

Use only HRC fuses of correct rating; use of other fuses will cease our guarantee clause.

Keep the charger clean and free from dust collection. Collection of dust in contactor, MCBs,
Switches etc can create high resistance contact and hamper smooth operation.
Use blower to clean the charger once a week/ fortnight as per prevailing site conditions. Care
should be taken during cleaning, not to damage the control cards.
Initial charging should be done with boost charger after checking current requirement and
Boost charger capacity. It is advised to consult manufacturer/ manual before initial charging.

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OPERATIONAL FEATURE

The rectified output is obtained from Single-phase Silicon Rectifier Bridge consisting of
two SCRs and two Diodes plus Freewheeling diode with individual RC network across each
device. Separate surge suppressor is provided before each bridge to protect the rectifier
against voltage surges.
Phase angle control led rectification is the working principle of the Charger. SCR is a
three terminal device, namely Anode, Cathode and Gate. Phase angle control pulses are
applied between Cathode and Gate. Depending on the position of pulse the SCR conducts and
thereby the magnitude of DC voltage is controlled. A minimum current equal to latching current
should flow through SCR to retain it in conduction so the latching resistor is provided. The SCR
will not conduct till the gate pulse is applied.

BOOST CHARGER.

When the battery feeds to load it gets discharged and that charge has to be
replenished periodically this process is known as Boost charging.

FCB charger features two modes namely.

1 Boost Auto mode.

2 Float mode.

1. The boost circuit consists of single-phase half controlled thyristorized bridge.

2. Rectifier is fed from a single-phase step down transformer.

3. Initial charging should be done with constant attention, damage to Thyristor, fuses and
transformer is not ruled out due to high current. High current surge may result if proper
care is not taken. CONSULT MANUFACTURER BEFORE INITIAL CHARGING.

4. IN CASE OF ANY DISORDER FUSES IN SERIES OF SEMICONDUCTOR DEVICES

WILL BLOW. IT IS IMPORTANT THAT FUSES REPLACE THE FUSES WITH
CORRECT TYPE NUMBER AND RATING. THESE FUSES ARE MATCHED WITH
DIODE AND SCR CHARACTERISTICS FOR PROPER DEVICE PROTECTION.

5. If charging is not taking place as per the characteristics check each cell and cell
connectors to ensure proper connection, acid filling and polarity in the Battery bank.

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COMMISSIONING OF CHARGER:

BOOST CHARGER:

Before commencing charging with charger check battery bank connections. The battery bank
should be firmly connected with proper IRIT connections.

1. Check AC input supply voltage and phase sequence at the terminals.

T1 T2
Phase Neutral

2. Primary tap of the transformer should be selected properly depending on the available
AC voltage at the site.
3. Ensure correct polarity of the battery connection.

T3 T4 T5
+ve -ve +Ve
Pole Pole Pole
19th cell First cell 15th Tap cell

4. Remove battery terminals, put B1 switch on 2 for boost charging, turn A1 on turn A2 on
and monitor voltage rise in DC voltmeter.
5. Connect Battery to the terminals and perform step 3 & 4.
6. As charging [proceeds further battery voltage will increase and current will fall, under
no condition should the current be allowed to fall below the finishing rate specified by
the battery manufacturer. Keep adjusting the battery current till charging voltage
reaches about 2.35 V /Cell is reached after which initial charging can be terminated as
per specifications of the battery manufacturer.(Refer battery manufacturer datasheet
for more detail)

FLOAT CHARGER

1. The Float charger normally supplies to the station load.

2. Similar to Boost charger, Float charger consists of a single phase full
wave half-controlled SCR rectifier bridge. The bridge supplies a
stabilized DC output at the rated voltage and current under normal
variation in the input power supply and DC load condition.
3 The Float circuit DC output variation is limited to + 1% of rated voltage.
4 Suitable L-C filter is provided in the output circuit of rectifier to limit ripple content in the
output by +3%.

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COMMISSIONING OF FLOAT CHARGER:

Before any of the feeder are connected to the load proper checking of the voltage build up must
be carried.

1 Check AC input supply voltage and phase sequence at the terminals.

T1 T2
Phase Neutral

2 Primary tap of the transformer should be selected properly depending on the available
AC voltage at the site.

3 Remove battery terminals, put B1 switch on 1 Float Charger, turn A1 and A2 ON and
monitor voltage rise in DC voltmeter.
4 If build up process is smooth, than load can be connected to the load.
5 In all conditions batteries should be connected to its terminal so that on failure of float
charger load can be supplied by the battery

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START/STOP LOGIC

In order to achieve the best performance from the charger for a longer period following steps
should be followed which will enhance the life.

Here battery charger must be supplied from single phase line.

Following steps must be carried out :

1. Ensure that all the power and control switches are in OFF position.
2. Switch ON AC input isolation A1 and observe that AC Mains lamp will glow.
3. Switch ON the DC isolation Switch (A2).
4. Select the mode of operation of the battery charger using switch B1 i.e. Float / Boost/
Auto mode.
5. Once the batteries are fully charged, the charger protection module will sense battery
voltage i.e. 32.3 VDC it will automatically changeover on Float mode. Now the
batteries will be trickle charged by the float charger.

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CONTROL CARDS

AUTOMATIC VOLTAGE REGULATOR (AVR) : (ES-FWHCAVR-1106)

¾ Check the card for loose connections, dry solders and burnt components.
¾ Check Transformer Primary: 240 V, Secondary: 16-0-16 V power supply and 16 V
synchronizing voltages at input terminals. Also check availability of reference voltage at
terminals.
¾ Check terminal voltages as per the table given below.

Sr No. Terminal Description Voltage

1. 1 Not used -
2. 2 16 V AC Power supply wrt Gnd. 16 V AC
3. 3 16 V AC Power supply wrt Gnd. 16 V AC
4. 4 Gnd. / Power supply transformer center. 0.0 V
5. 5-8 Not used -
6. 9 R Phase SCR Cathode pulses. Pulse
7. 10 R Phase SCR Gate pulses. Pulse
8. 11 R Phase synchronizing signal. 16 V AC
9 12 Neutral SCR Cathode pulse. Pulse
10 13 Neutral SCR Gate pulse. Pulse
11 14 Neutral synchronizing signal. 16 V AC
12 15 N.A. N.A.
13 16 N.A. N.A.
14 17 N.A. N.A.
15 18,19 Not used -
16 20 Voltage feedback signal 24 V DC
17 21 Not used -
18 22 Not used -
19 23 Reference voltage outgoing (Pot upper end) 5.1 V DC
20 24 Reference voltage input (Pot variable) 0- 5.1 VDC
21 25 Reference voltage outgoing ( Pot lower end) Gnd
22 26 Voltage controller error signal 0-5.1V DC
23 27 Current limit reference 0-5.1V DC
24 28 Not used -
25 29 Current feedback Shunt (Gnd) Gnd
26 30 Current feedback signal. 0-75 mV

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¾ Check testpoint voltages as per the details given below

Testpoint Description Voltage

TP1 Not used -
TP2 12 V DC +VE Power supply wrt Gnd. +12 V DC
TP3 12 V DC -VE Power supply wrt Gnd. -12 V DC
TP4 Pulse inhibit signal. +10.0V DC
TP5 Voltage Reference signal output. +5.1 V DC
TP6 Current feedback signal (Amplified) +0.125 to 2.5 V DC
TP7 Not used -
TP8 60 degrees shifted phase synch sine wave 8.5 V AC sine
TP9 60 degrees shifted Neutral synch sine wave 8.5 V AC sine
TP11 Phase final formed pulse. 21.0 V DC pulse
TP12 Phase final synchronized square wave 11.0 V Square wave
TP13 Phase 555 timer output monostable Pulse width
TP14 Phase control voltage for 555 timer. 1.4 V to 9.5 V DC
TP15 Neutral final formed pulse. 21.0 V DC pulse
TP16 Neutral final synchronized square wave 11.0 V Square wave
TP17 Neutral 555 timer output monostable Pulse width
TP18 Neutral control voltage for 555 timer. 1.4 V to 9.5 V DC

1. To start with check availability of 12 V DC positive and negative power supplies. If not
available check the availability of 16 V AC at their respective terminals, then check 32.0
V DC at the diode rectifier bridge and the input of regulator ICs. If both the inputs are
OK and Outputs are not available the replace respective ICs as they are defective.
2. Check availability of R & N synchronizing waves, check their respective transformers on
the Transformer PCB.
3. Check Synchronizing voltages at TP12 and TP16 which ever is absent check it
respective sync wave and U1 (LM 324) IC output.
4. Check reference voltage 5.1 V DC at terminals and observe variation in reference
voltage as per the potentiometer settings.
5. Check current reference signal Terminal no 27, if the DC voltage is not available then it
should be of the order of 3.0 Volts.
6. Check output of 555 timer ICs TP13 & TP17 . Check pulse waveform for transistors
T101 & T201 at TP11 & TP15 if not present check transistor and pulse transformer.

PROTECTION : (ES-PROT6C-2106)

¾ Check the card for loose connections, dry solders and burnt components.
¾ Check Transformer Primary: 240 V, Secondary: 16-0-16 V power supply and 16 V
synchronizing voltages at input terminals. Also check availability of reference voltage at
terminals.
¾ Check terminal voltages as per the table given below.

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Sr No. Terminal Description Voltage

1. 1 16 V AC Power supply wrt Gnd. 16 V AC
2. 2 16 V AC Power supply wrt Gnd. 16 V AC
3. 3 Gnd. / Power supply transformer center. 0.0 V
4. 4 + 12 V DC output of the card power supply +12.0 V DC
5. 5 - 12 V DC output of the card power supply -12.0 V DC
6. 6 Bus Over voltage sensing signal. 28.0 V DC
7. 7 Bus Under voltage sensing signal. 22.0 V DC
8. 8 AC Under voltage sensing signal. N.A.
9 9 AC Under voltage sensing signal. N.A.
10 10 Rectifier DC Fail sensing signal. 18.0V DC
11 11 Battery Fully Charged sensing signal. 32.3V DC
12 12 Battery Under voltage sensing signal. N.A.
13 13-16 Bus Over relay changeover. Relay O/P
14 17- 20 Bus Under relay changeover. Relay O/P
15 21- 24 AC Under relay changeover. Relay O/P
16 25- 28 Rectifier DC Fail relay changeover. Relay O/P
17 29- 32 Battery Over voltage relay changeover. Relay O/P
18 33- 36 Battery Under voltage relay changeover. Relay O/P
19 37 Lamp Test signal System volt
20 38 Alarm Buzzer System volt

¾ Check testpoint voltages as per the details given below

Testpoint Description Voltage

TP1 12 V DC -VE Power supply wrt Gnd. -12 V DC
TP2 GND/ center tap of power supply transformer 0.0 V
TP3 12 V DC +VE Power supply wrt Gnd. +12 V DC
TP101 Error Output of comparator IC. +10.0V DC

1. To start with check availability of 12 V DC positive and negative power supplies. If not
available check the availability of 16 V AC at their respective terminals, then check 32.0
V DC at the diode rectifier bridge and the input of regulator ICs. If both the inputs are
OK and Outputs are not available the replace respective ICs as they are defective.
2. Check availability of positive feedback signals at their respective terminals.
3. Check whether refrence signal (positive volts as per the setting of reference pot) is
present at resistor R108.
4. Compare magnitudes of feedback and reference voltages at resistor R106,
R107.
5. Depending on whether reference or feedback voltage is higher output of comparator
should switch between +10.0 to –10.0 V DC. This in turn will switch ON/OFF the relay. If
this does not occur check IC and replace.
6. If the relay does not change state check Diode D104 and Zenner Z101. And finally
check transistor of last stage Q101.
7. If the collector of transistor changes stated from +12.0 to-12.0 volts then check Relay
and replace if faulty.

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FUSE FAILURE DETECTION CARD: (ES-PROTFFD-4106)

Function of the Fuse failure detection card is to detect the failure of fuse across its input
terminals.

FUSE-FD: It is a single card module with external unregulated power supply transformer.
Functionally the card can be divided into three functional groups namely.

1. POWER SUPPLY
2. FUSE DETECTION

1. POWER SUPPLY: Power supply to the card is supplied from step down
transformer. Ratio Prim: 240V or sec: 16 – 0 – 16 V AC supply. Supplied from the
transformer is rectified by a regulated +12 V & -12 V.
OR
Power supply to the card is supplied directly from charger output.

a. TP101: +12 V DC

2. Fuse Fail Detection: This Section does basic function of the detection.
The detection is done by the opto-isolator. Sensing is done across the fuse terminals,
when the fuse is in healthy condition no potential is develop across the opto-isolator,
however when the fuse fails it develops potential across opto-isolator this is detected in
the output side of the IC. The output of the IC is amplified so as the drive the relay.

¾ Check terminal voltages on card E4 as per the table given below.

Sr No. Terminal Description Voltage

P1 1,2 Fuse – 3 detection System
P2 3,4 Fuse – 4 detection System
P3 5,6 NA System
P4 7,8 Fuse – 5 detection System
P5 9,10 Dc supply +12 V DC
11-13 Relay-1 set of change over contacts C/O
14-18 Annunciation relay contacts C/O
19-21 Relay-2 set of change over contacts C/O

¾ Check terminal voltages on card E5 as per the table given below.

¾
Sr No. Terminal Description Voltage
P1 1,2 Fuse – 11 detection System
P2 3,4 NA System
P3 5,6 NA System
P4 7,8 NA System
P5 9,10 Dc supply +12 V DC
11-13 Relay-1 set of change over contacts C/O
14-18 Annunciation relay contacts C/O
19-21 Relay-2 set of change over contacts C/O

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EARTH LEAKAGE DETECTION : (ES-PROTEL-6106)

¾ Check the card for loose connections, dry solders and burnt components.
¾ Check terminal voltages as per the table given below.

Sr No. Terminal Description Voltage

1. 1
2. 2
3. 3 - 0.0 V
4. 4 + ve Supply of System under supervision 24 V DC
5. 5 - ve Supply of System under supervision 16 V AC
6. 6 Earth potential/ Centre point of Resistor network. 0.0 V
7. 7 + 24 V DC relay supply +12.0 V DC
8. 8 Lamp Test signal 24.0 V DC
9. 9 +ve Leakage Lamp signal 24.0 V DC
10. 10 Alarm Buzzer 24.0 V DC
11. 11 -ve Leakage Lamp signal 24.0 V DC
12. 12 Fault ( Reset line) 24.0 V DC
13. 13 + ve Leakage Relay N/O -
14. 14 + ve Leakage Relay Common -
15. 15 + ve Leakage Relay N/C -
16. 16 - ve Leakage Relay N/O -
17. 17 - ve Leakage Relay Common -
18. 18 - ve Leakage Relay N/C -

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EARTH LEAKAGE DETECTION : (ES-PROTEL-6106)

¾ Check testpoint voltages as per the details given below

Testpoint Description Voltage

TP1 12 V DC -VE Power supply wrt Gnd. -12 V DC
TP2 Refrence for +ve leakage 0.6- 2.0 V DC
TP3 12 V DC +VE Power supply wrt Gnd. +12 V DC
TP4 Error Output of comparator IC U1. +7.0V DC to - 7.0 V DC
TP5 Leakage Sensing potential for IC U1 0.6- 2.0 V DC
TP6 Leakage Sensing potential for IC U2 0.6- 2.0 V DC
TP7 Error Output of comparator IC U2. +7.0V DC to - 7.0 V DC
TP8 12 V DC -VE Power supply wrt Gnd. -12 V DC
TP9,10,11 Transistor Base drives for – ve circuit --
TP12,13,15 Transistor Base drives for + ve circuit --
TP16 GND.

5. To start with check availability of 8.2 V DC positive and negative power supplies. If not
available check the availability of system voltage DC at their respective terminals, then
check zenners D1 and D2 if not replace defective.

6. Check availability of earth leakage feedback signals at their respective terminals.

7. Check whether reference signal (positive volts as per the setting of reference pot)

8. Compare magnitudes of feedback and reference voltages at input of ICs.

9. Depending on whether reference or feedback voltage is higher output of comparator

should switch between +7.0 to –7.0 V DC. This in turn will switch ON/OFF the relay. If
this does not occur check IC and replace.

10. If the relay does not change state check driver circuit and replace intermediate
transistors if required.

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DOCUMENTS LIST

24 V , 180 AH FLOAT CUM BOOST BATTERY CHARGER.

SR No. Description Page no.

1 GA drawing 01 of 08
2. Schematic & control scheme 02 to 06 of 08
3. Bill of Material 07 to 08 of 08

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