O&M - MANUAL - 220V - 187 AH PLANTE BATTERY.pdf

8/10/2019 O&M - MANUAL - 220V - 187 AH PLANTE BATTERY.pdf

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CHLORIDE POWER SYSTEMS & SOLUTIONS LIMITED(A wholly owned subsidiary of EXIDE Industries Limited)


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CONTENTS

ANNEXURE - I - TECHNICAL SPECIFICATION

ANNEXURE - II - SYSTEM DESCRIPTION

ANNEXURE - III - SYSTEM DESCRIPTION OF THE AVR UNIT

ANNEXURE IIIA - SYSTEM DESCRIPTION OF THE ACR UNIT

ANNEXURE IV - PROTECTION & ANNUNCIATION CIRCUITANNEXURE V - PRE-COMMISSIONING CHECKS & COMMISSIONING

PROCEDURE

ANNEXURE VI - TROUBLE SHOOTING PROCEDURES

ANNEXURE VII - WITNESSED TEST REPORT

ANNEXURE VIII - DRAWINGS & BILL OF MATERIALS

DRAWING & BOM NOS.

BATTERYCHARGER

POWER CIRCUIT BC-11-288

GENERAL ARRANGEMENT BC-11-289

RELAY MODULE WIRING DETAILS RL -11-289

BILL OF MATERIALS BOM-BC-11-288-289


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ANNEXURE - I

TECHNICAL SPECIFICATION OF AUTOMATIC FLOAT & BOOSTBATTERY CHARGING EQUIPMENT

SUITABLE FOR 220VOLTS 187AHPLANTEBATTERY

FLOAT CHARGER - SCR CONTROL:

1.00 Input Power Supply - 415 Volts + or - 10%, 3-Phase, 3Wire,

50 Hz. 5%.

2.00 Output Voltage :2.01 Auto - 243 Volts (2.23V/cell)

2.02 Manual - 218V 243 Volts

3.00 Output Current - 40 Amps DC continuous including 70mA tricklecharging current.

4.00 Output Ripple - Around 1%r.m.s. at full load and 243V DC.

5.00 Output Regulation - Around + or -1% for + or -10% supply

voltage fluctuation and 10% to 100% load

variation.

6.00 Mode of Operation - Automatic / Manual

7.00 Control Configuration - 3-Phase full wave fully controlled thyristorised

bridge fed thru' 3-phase transformer and

controlled by constant potential controller

unit with load limiting feature (AVR).

8.00 DC Voltage setting adjustment - 10% of nominal voltage

BOOST CHARGER - SCR CONTROL:

1.00 Input Power Supply - 415 Volts + or - 10%, 3-Phase, 3 Wire,

50 Hz. 5%

2.00 Output Voltage : Up to 2.4V/cell

3.00 Output Current - 40 Amps (max.)

3.01 Boost Charging

a) Normal charging - 18.2 Amps (max.) up to 2.4 V/cell

b) Initial charging - 18.2 Amps (max.) up to 2.65 V/cell

4.00 Mode of Operation - Automatic / Manual

5.00 Termination of Charging - Automatic / Manual

6.00 Control Configuration - 3-Phase full wave fully controlled thyristorisedbridge fed thru' 3-phase transformer andcontrolled by constant current controller


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9.00 DC current adjustment for Boost - 30% - 100% of Boost charging current.

Charging

10.00 Power factor at a)100% Load - 0.8 (displacement p.f.) (Displacement power factoras per IS-4540)

b) 50% Load - 0.78 (displacement p.f.) (Displacement power factor

as per IS-4540)

11.00 Current stabilisation for constant

current regulator for boost charger - 2%

and time.

12.00 Efficiency () at a) 100% load - 85%

b) 50% load - 80%

13.00 Boost Charging time - Within 10Hrs.


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ANNEXURE II

SYSTEM DESCRIPTION

FLOAT CHARGER (SCR CONTROL)

The float charger is meant for supplying the continuous DC load and at the same time tricklecharging the battery to keep it in fully charged condition.

The float charger may either be operated in Auto or Manual mode. In the Automatic mode, theoutput voltage is held constant at a preset value whereas in manual position the output voltagemay be varied within the specified limit by an external potentiometer. The incoming AC supply tothe charger will be fed to a 3-phase double wound step down transformer thru' suitably ratedswitch & fuse unit. The secondary of transformer will be fed to a 3-phase full wave full controlthyristorised bridge thru' line surge suppressor and high-speed semi conductor protection fuses.The bridge circuit consists of 6 nos. of thyristors which are adequately protected by snubbercircuit against voltage transients. The triggering of the thyristors are controlled by the A.V.R unitwhich senses feedback from the output voltage and current. These feedback signals are suitably

processed and compared with the reference generated in the A.V.R circuits, then the error isamplified and phase compensated by high gain operational amplifier. The incorporation offeedback ensures automatic correction of any deviation of the set voltage, which may arise dueto line or load fluctuations. The output of the final amplifier will be fed to triggering circuits,which control the output voltage of the charger by adjusting the firing angle of the thyristors.With the help of the A.V.R unit the regulation of the output voltage of the float charger may bekept constant around 1% of the rated voltage against line or load fluctuations. Due toincorporation of inner current loop, by which the output voltage drops as the rated load isincreased thereby automatically transferring the load to the battery in order to avoid the

overloading of the charger. Suitably designed L-C filter circuit is provided in this system to bringdown the ripple within the specified limit.

BOOST CHARGER (SCR CONTROL)

The Boost Charger is basically meant for quick charging the battery after a heavy discharge, soas to restore the capacity of the battery within minimum time.

In this system the boost charger is an automatic constant current charger, consisting of asuitably rated 3-phase double wound step down transformer fed thru' a suitably rated switch &fuse unit. The secondary of the transformer is fed to a 3-phase full wave full control thyristorisedbridge thru' line surge suppressors and high-speed semi conductor protection fuses.

The bridge circuit consists of 6 nos. of thyristors, which are adequately protected by snubbernetwork as protection against voltage transients. The triggering of the thyristors are controlledb an ACR Unit hich senses feedback f om both the batte oltage and cha ging c ent


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FUNCTIONAL DESCRIPTION OF CHARGER:

This system consists of a Float charger and a Boost charger. In this system the battery willnormally float across the float charger so that in case of power failure the battery can maintainthe load without interruption.However, after heavy discharge of battery, the battery is placed on boost mode operation. Atthat time load is taken care by float charger and boost charging is done by Boost charger.Now if supply fails, the battery will be connected to the load bus through the DC contactor andshare the load.When supply is present and battery is in boost charging condition and Float charger fails then

boost charging of Battery will be continued and the load is taken care by the battery through tapcell diode & when Boost charging will be completed then DC contactor will be closed & Batterywill take care the load thru DC contactor.However, if power supply fails, while boost-charging operation is in progress, the battery shouldbe connected to the load immediately to avoid any interruption.

During normal operation the tap cell diode will be reverse biased. In the event of power failureduring boost charging with battery isolated, the output voltage will start dropping. As soon as itdrops slightly lower than the cell voltage the diode will conduct thereby maintaining the voltage

at the load bus, though lower in magnitude, to avoid complete interruption of load supply.However, after this brief interval, the DC contactor will energize thereby connecting the batteryto the load bus and restricting the original load voltage. Thus, this arrangement provides anuninterrupted DC supply to the load.

In this system as described above a suitably AC voltmeter or Ammeter with Selector Switch isprovided for monitoring input supply voltage or current. DC Voltmeters are provided formonitoring the output voltage of float chargers and boost charger. DC Ammeters are provided

for monitoring the output current of float chargers and boost charger. DC Ammeter is providedfor monitoring the battery path current. Necessary indications are provided for different statusand fault monitoring.

TABLE SHOWING THE SEQUENCE OF THE CHARGERS :

SL.NO.

FLOATCHARGER

BOOSTCHARGER

BATTERY LOAD

1 Float mode standby Trickle charging by floatcharger

Fed by the floatcharger

2 Float mode Boost mode Boost charging by boostcharger

Fed by floatcharger


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ANNEXURE III

SYSTEM DESCRIPTION OF AVR UNIT

FOR 3-PHASE FULL CONTROLLED SCR BRIDGE

The electronic controller (A.V.R) is the heart of the system, which maintains stable output D.Cvoltage

of the charger in spite of supply voltage fluctuations and load variations. The electronic controllerbasically consists of the following sections: -

1.0 POWER SUPPLY:

The power supply consists of a transformer which gives a dual step down voltage of 20 Volts A.Cfrom the line voltage which is rectified by two bridge rectifiers and further filtered by suitably

rated capacitors. The filtered output is then fed to 2 Nos. 3 terminal regulators which gives astable output of + or - 15 Volts D.C. Red and green LEDs are provided for visual indication of ahealthy supply voltage. From -15 V another voltage of 6.8 V is derived with the help of aprecision zener, which gives the reference signal for setting the output voltage. An unregulatedsupply of + 24 Volts is also tapped to drive circuit.

2.0 REGULATOR CARD:

The regulator consists of the following sections:

a)

RAMP GENERATOR:

The ramp generator is provided to give a soft start feature which ensures gradual rise of outputvoltage even if the reference is set at full value. It consists of an integrator, which determinesthe slope i.e. the time for gradual rise of voltage.

b)

VOLTAGE REGULATOR WITH CURRENT LIMIT FEATURE:

The output of the ramp generator is fed to the voltage regulator, which consists of a suitablycompensated OPAMP. The reference signal is compared with the voltage feedback signalobtained from the output. Then the error is phase compensated and amplified. The output is


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c) CURRENT REGULATOR:

The current regulator controls the load current/ charging current by comparing the current

feedback signal with an internal reference signal and subsequent amplifications and phasecompensation thru the amplifier. The reference signal is proportional to the 10% extra of loadcurrent / charging the battery up to 2.30 v/cell of battery. Whenever an error is encountered atthe input of the amplifier, the error will immediately be amplified and phase compensated by ahigh gain operational amplifier. The incorporation of feedback ensures automatic correction ofany deviation of the set current, which may arise due to line or load fluctuation. The output ofthe final amplifier is fed to the triggering circuit, which controls the output current by adjustingthe firing angle of the thyristor.

d) FIRING CIRCUIT:

The output of the current regulator is fed to the firing circuit for modulating the position of thepulse, fed to the thyristor for achieving the closed loop control action. The firing circuit consistsof 3 nos. identical "UJT" controlled osicillator circuits for triggering thyristors. Each section isproperly synchronised with the line voltage so as to trigger the thyristors in right sequence. Thefrequency of the oscillator circuit is varied by the control signal from current regulator, therebyachieving pulse position modulation. The output pulse obtained from the base terminals of UJT'sare utilised for triggering thyristors. Potentiometers are provided on each firing channel forbalancing the conduction angle of individual phases at operating conditions to ensure balanceloading on input supply lines.

3.0

AUXILIARY CARD:

The auxiliary card consists of 3 nos. additional pulse generator circuits, synchronized with the

negative half cycle of the input line voltage. The main card and auxiliary thus generate 6independent triggering pulses necessary for sequential firing of 6 nos. thyristors of the 3-phasefull control Thyristorised Bridge.

4.0

GATE FIRING LOGIC CARD:

The pulse logic module is used for feeding the trigger pulses to the gate-cathode of thethyristors, after necessary cross coupling between primary pulses thru' double secondary pulse

transformer.


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ANNEXURE IIIA

SYSTEM DESCRIPTION OF ACR UNIT

FOR 3-PHASE FULL CONTROLLED SCR BRIDGE

The electronic controller (A.C.R) is the heart of the system, which maintains stable output D.C.voltage of the charger in spite of supply voltage fluctuations and load variations. The electroniccontroller basically consists of the following sections: -

1.0 POWER SUPPLY :

The power supply consists of a transformer, which gives a dual step down voltage of 20 VoltsA.C from the line voltage, which is rectified by two bridge rectifiers and further filtered bysuitably rated capacitors. The filtered output is then fed to 2 Nos. 3 terminal regulators whichgives a stable output of + or - 12 Volts D.C within a regulation of + or - 1%. Red and greenLEDs are provided for visual indication of a healthy supply volatage. From -12 V another voltageof 5.6 V is derived with the help of a precision zener, which gives the reference signal for setting

the output voltage. An unregulated supply of + 24 Volts is also tapped for drive circuit.

2.0

REGULATOR CARD :

The regulator consists of the following sections:

a)

RAMP GENERATOR:

The ramp generator is provided to give a soft start feature from which ensures gradual rise ofoutput voltage /current even if the reference is set at full value. It consists of an integrator,which determines the slope i.e. the time for gradual rise of voltage/current.

b) CURRENT REGULATOR:

During constant current mode, Shunt amplifier is incorporated to amplify the current feedbacksignal obtained from the output shunt. The amplifier has provisions for variable gain underdifferent operating conditions of the battery charger.

The current regulator controls the charging current by comparing the current feedback signalwith an internal reference signal and subsequent amplifications and phase compensation thruthe amplifier. The reference signal is proportional to the starting rate of charging, after which thereference is automatically reduced to the finishing value of current.Whenever an error is encountered at the input of the amplifier, the error will immediately be

lifi d d h d b hi h i i l lifi Th i i f


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c)

FIRING CIRCUIT:

The output of the current regulator is fed to the firing circuit for modulating the position of thepulse, fed to the thyristor for achieving the closed loop control action. The firing circuit consistsof 3 nos. identical pulse generator oscillator circuits for triggring thyristors. Each section isproperly synchronised with the line voltage so as to trigger the thyristors in right sequence. Theoutput pulse obtained from the base terminals of UJT are that is utilised for triggering thyristors.The frequency of the oscillator circuit is varied by the control signal from current regulator,thereby achieving pulse position modulation. Potentiometers are provided on each firing channelfor balancing the conduction angle of individual phases at operating conditions to ensure balanceloading on input supply lines.

3.0 AUXILIARY CARD:

The auxiliary card consists of 3 nos. additional pulse generator circuits, synchronized with thenegative half cycle of the input line voltage. The main card and auxiliary thus generate 6independent triggering pulses necessary for sequential firing of 6 nos. thyristors of the 3-phasefull control Thyristorised Bridge.

4.0

GATE FIRING LOGIC CARD:

The pulse logic module is used for feeding the trigger pulses to the gate-cathode of thethyristors, after necessary cross coupling between primary pulses thru' double secondary pulsetransformer.


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ANNEXURE IV

ANNUNCIATION AND PROTECTION SCHEME

ALARM AND PROTECTION SCHEME

The basic controls circuits are protected with suitably rated SWITCHE/MCB/MCCB & fuses toprotect the controller section, relay module power supplies, aux. AC supply and annunciation.

The fault sensing circuits are AC supplies trouble, charger over current, DC output under &over voltage etc.The Alarm Module is an electronic circuitry with LED lamps and alarms, with separate TEST,ACCEPT & RESET push buttons. On occurrence of a fault that particular lamp will glow withhuge sound of HOOTER and when ACCEPT button is pressed, it only stop the sound ofHOOTER but the respective lamp still will be in glow mode. The lamp remains glowing untilRESET push button is pressed. If the fault is already cleared, the lamp goes off but glowsagain if the fault persists.

A set of potential free NO contact common to all faults of Relay is provided for remoteannunciation of BATTERY CHARGER TROUBLE for customers use.

AC SUPPLY TROUBLE (ACSTR)

These consist of sensing circuits, which sense the input, supply voltage and OPAMPcomparator circuits at the input of which the input supply voltage, after being suitably scaled

down or up, are compared with a preset stable reference voltage. When the AC input supplyvoltage becomes lower or higher than the preset minimum or maximum level the comparatoroutput switches thus energizing the relay or when phase failure occurs the comparatoroutput switches thus de-energising the relay. The relay activates the audio/visualannunciation circuit for fault monitoring.

Unbalance voltagebetween any two

phasesUnder Voltage Over Voltage

Cut off at 40V 6VSite selectable between80%-95% of Aux.supply

Site selectable between105% - 120% of Aux.supply

Trip time3 5 Sec 1 5 sec Less than 2 sec Less than 2 sec


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CHARGER OVER CURRENT RELAY

The charger is provided with DC over current relay driver circuit which trips charger AC

contactor when the load current exceeds the preset value. In this control circuit high gain op-amp comparator circuits are provided for over load protection of the chargers. The loadcurrent is compared with the input of the comparator and a stable preset maximum level ofcurrent. The output of the comparator drives the over current relays thru timer circuits tointroduce time delay for relay actuation to prevent tripping due to momentary over load.Separate push buttons are provided for re-setting the relay once the fault is acknowledged.Relay contacts are also interlocked with the audio/visual annunciation circuit for faultmonitoring. This circuit will only operate if the current limiting circuit in the main controllerfails to operate.

CHARGER UNDER CURRENT RELAY

The charger is provided with DC under current relay driver circuit which trips charger ACcontactor when the load current goes below the preset value. In this control circuit high gainop-amp comparator circuits are provided for under load protection of the chargers. The loadcurrent is compared with the input of the comparator and a stable preset minimum level of

current. The output of the comparator drives the under current relays thru timer circuits tointroduce time delay for relay actuation to prevent tripping due to momentary under load.Separate push buttons are provided for re-setting the relay once the fault is acknowledged.Relay contacts are also interlocked with the audio/visual annunciation circuit for faultmonitoring. This circuit will only operate if the current limiting circuit in the main controllerfails to operate.

INTEGRATED DC SENSING RELAY MODULE

DC UNDER/OVER VOLTAGE RELAY

These consist of sensing circuit which sense the output DC voltage at the load terminal, afterbeing suitably scaled down and is compared with the stable preset reference. When thisvoltage goes lower or higher than the stable preset level, the under or over voltage relay

actuates. Relay contacts are interlocked with the audio-visual annunciation circuit for faultmonitoring.DC under voltage can occur in case of power failure and charger failure below set voltage.DC over voltage will occur only if the controller circuit becomes faulty or if the filter capacitorfuse fails imposing a high ripple voltage above set voltage at the output.


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BATTERY ON LOAD RELAY

This electronic circuit ensures the battery discharge condition. This incorporates a time delayfeature to prevent wronged signal of the relays during short current discharge as often

happens during float charging operations due to the closing or tripping operation of circuitbreakers. The relay circuits drive its DC supply from the battery bank and the battery signalis compared with a suitable reference at the input of the high gain comparator. When thebattery signal reaches in stable condition during discharge, the relay actuate with a timedelay thru' switching of the comparator. The relay contacts are also interlocked with theannunciation circuit for fault monitoring.

AUTO EQUALISING RELAY:

Auto equalizing charging facilities are provided in this system. The purpose of equalizingcharge is to bring the cells in a battery bank in step, since they tend to fall out of step duringprolonged float charging operation.

Auto equalizing relay card is meant for automatic equalizing charging of the batterybank (recommended half rate of charging current), when the battery draws a currentmore than a specified value continuously during floating operation. The electronic

control card basically consists of a shunt amplifier, which constantly monitors thebattery trickle charging current by amplifying the signal derived from the ammetershunt in series with the battery. The amplified signal is compared with a stablereference at the input of a high gain comparator and when it exceeds the presetreference for more than 30 Sec. the output switches, thereby actuating the autoequalizing relay which is suitably interlocked to switch the float cum boost charger inequalizing mode of Charging, as per selection of the switch. The battery voltage isalso compared with a stable reference at the input of another comparator. When the

battery voltage on charge reaches around set value, it switches off the relay after apre-adjusted time delay and the battery is again transferred to the float-chargingmode and trickle charging continues in the usual manner.


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ANNEXURE V

COMMISSIONING INSTRUCTIONS

VISUAL CHECK:

After unpacking the panel, inspect the panel externally for any damage of components duringtransits (lamps, switches, meters, etc). If anything is found damaged, replace it at the earliest.

Open the panel and check all connections and the mounting conditions of relays and printedcircuit boards.

Check the insulation of the input lines (marked R, Y, B) the bottom of the back of the panelwith a 500 Volts megger. If megger is not available, the same should be checked using agood avometer in the higher resistance scale. The insulation resistance should be more than5 M-ohms.

Check the input supply voltage. This should be within 415 Volts 10%. If found O. K. thenconnect the line at the input terminals (R, Y, B) after checking the phase sequence. The

panel should be properly earthed thru the earthing terminals provided at the back of thepanel. Connect a resistive load at the output terminal (F+ & F-) after making sure that thereis no shorting in the load circuit.

FLOAT CHARGER CHECK:

Keep the Auto / Manual selector switch, provided inside the panel to "manual" position.Switch on float input and output MCCB. Indicating lamps should glow and output voltage

and load current should be shown in the voltmeter and ammeter. If any adjustment in theoutput voltage is required, the setting of the potentiometer, provided on the front door ofthe panel, should be adjusted to set the voltage at the required value. Do not tamper thesetting of any other potentiometer, which may otherwise lead to serious malfunctioning ofthe float charger. If the above tests are O.K switch off the input isolator.

BOOST CHARGER CHECK:

Connect a dummy load same as in the float charger to the terminals marked B+ and B-.Keep the Auto / Manual selector switch, provided inside panel, to manual position Changethe voltmeter selector switch to boost position. Switch on boost charger input and outputMCCB. DC voltmeter will show some voltage and ammeter will show some current. Theinput and output indicating lamps should glow.

If any adjustment in the charging current is required the setting of the potentiometer,


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LOAD TEST

FLOAT CHARGER:

After performing the above tests connect the actual load across the float charger outputterminals after making sure that there is no shorting in the load circuit.

Now, keeping the auto / manual selector switch to auto position. Switch on float inputisolator. The output voltage and load current will be shown in the voltmeter and ammeter.If the load/current exceeds the rated value, the output voltage will start dropping due to

load limiting action. If the above tests are O.K. switch off input isolator.

BOOST CHARGER:

Connect the battery +ve and -ve terminals carefully to the boost charger output terminalsmarked B+ and B- and also connect the battery tap cell point to the terminals marked TC.Keep the auto/ manual selector switch to auto position. Switch on boost charger inputisolator. Now check the boost charging current in the Ammeter. Once the battery voltagereaches up to 2.75 v/cell, the battery will automatically be transferred to float charging thru'the float/boost changeover relay circuit and float charging continues as usual manner.

SPECIAL NOTE:

From the tap cell of the battery, a diode bank is connected to the output of the floatcharger for supplying uninterrupted load during the change over interval due to the finite

time constant of the DC contactor coil. However, during commissioning special careshould be taken regarding its connection to avoid damage to the tap cell diode andassociated circuit if by mistake the float charger is switched on during the initial chargingoperation with the load connected to the system, in that case a continuous current willflow thru the tap cell circuit and it may get damaged due to overheating and also resultsin uneven charging of the battery cells. It is preferable to disconnect the tap cell diodefrom the circuit during commissioning and connection should only be restored withbattery fully charged and kept in floating condition with float charger energised to keepthe tap cell diode in reverse biased condition.

NOTES : FOR INITIAL CHARGING OF THE BATTERY, STRICTLY FOLLOW


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UIN 1007018 CPSSL. Page 16 of 16

A N N E X U R E VI

TROUBLE SHOOTING PROCEDUREPOWER CIRCUITS

OBSERVATION: No Voltage is obtained at the output of Charger

Disconnect the output load circuits and Switch ON input isolatorInput Indicating Lamps are glowing?

No Yes| |

Is AC Supply voltage available? Is AC voltage available at the input of the rectifier bridge ?| |

No Yes No Yes

a) Check for input supply failure a) Check the lamp ballast resistance a) Check AC Contactors a) Check Thyristors by measuringand lamps, rectify the fault. the Anond Cathode resistance

b) Check the input fuses. Replace b) If even after energising the b) Check the electronic controlit after rectifying any possible Contactor no output results circuit provided for automatic

fault which could be an earth then check the transformer operations.fault or short circuit in the secondary voltage.Charger

c) If secondary voltage is O.K. thenCheck the High-speed fuse/MCB.

NOTE: It is very much desirable to have a ready stock of critical spares such as Thyristors, Diodes, HRC Fuses, Filter Capacitors,Electronic Control Card etc. so as to replace the damaged components with minimum delay.

O&M - MANUAL - 220V - 187 AH PLANTE BATTERY.pdf

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