The Basic Design. Advantages. Extensive Range. High Reliability. Versatility. Minimal Maintenance. User Friendly. System Solutions

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2 The Basic esign HBL Battery Charger uses Thyristor switching principle for achieving the desired C output. It basically consists of a transformer, a semi conductor bridge rectifier, a filter circuit and a control circuit. The AC mains voltage is transformed to a suitable level and fed to the rectifier bridge which rectifies the AC input and feeds controlled C output to the battery and load, after being smoothened by the filter circuit. The power output requirement is adjusted by using phase control technique which is provided by the control circuit. The feedback signals from the output to the control circuit are used for maintaining voltage regulation and current limit. Advantages HBL Battery Chargers offer numerous advantages, some of which are listed below Extensive Range Available in a wide range of standard and customised models, HBL Battery chargers can be supplied in voltage outputs upto 500V C and current outputs upto 2000 Amps. High Reliability Conservative design and high quality standards ensure absolute reliability of the equipment and failsafe operation. Versatility HBL chargers and C systems find usage in variety of applications such as Process Control, telecommunications, Emergency Lighting, Switch Gear protection, Engine starting and Power Station Control, to mention a few. Minimal Maintenance esigned for low maintenance and remote operation, HBL Battery Charger can work for many years, without any special attention. User Friendly Cautiously conceived alarms and annunciations, easily accessible component layout, meticulously designed Operation Manual and easy availability of spare parts enable the users to quickly attend to the equipment, in the unlikely event of a fault arising in the HBL Battery Charger. System Solutions HBL designs and manufactures under one roof, the complete C System consisting of Nickel Cadmium Batteries, VRLA, Battery Chargers and istribution Panels. This facilitates the company to offer integrated systems solution to meet individual customer needs.

3 s of Chargers F C B C F C B C Float charger (FC) rectifies the input AC to C and does the dual function of float or trickle charging the battery and supplying C power to the load. Boost Charger (BC) is required for quick recharge of a discharged battery. Float Cum Boost Charger (FCBC) as the name indicates, is a twoinone functional combination of a float charger and a Boost charger. Under normal condition FCBC works as a float Charger. When the mains fail, battery takes over supply to the load. On resumption of power, FCBC switches to the Boost Mode, Boost charges the discharged battery and return s to the Float Mode, after the battery is restored to full charge. All along, it supplies uninterrupted C power to the load. Load Voltage Limiters (VR) In order to protect the load against the voltage variation during the Boost Mode operation, a load voltage limiter in the form of iode Voltage regulater (VR) is required L O A End Cell Switching which uses a divided battery, tap cell diodes and change over contactor is yet another method of protecting the load from high boost voltage. Redundant Systems The increasing criticality of C power requirement has led to the evolution of systems with redundant configuration, using more than one rectifier and one or more battery banks, operating either in parallel or independently. HBL offers a variety of such redundant systems with various combinations of interlocks and features. Each of these systems differ from the other, depending on the level of redundancy and functional features required by the user. Some typical examples are given on the next page. F C B C F C B C VR L O A

4 FC 1 BC 1 FC 2 BC 2 Hot Standby Redundant System T It consists of a single battery bank and two charger systems, one designated as 'Main' and other as 'Standby'. Each of these charger systems consists of one float charger and one boost charger. Interlocks are provided in such a way as to enable the standby float charger or standby boost charger to take over respectively, in the event of failure of the main float charger or main boost charger Tap cell connection provides uninterrupted C Power to the load, should the mains fail during boost charging. L O A Parallel Redundant System using two nos. FCBC + one VR + one Battery Under normal condition, two FCBCs function in parallel and share the total ( load current + battery current). When Mains fail, battery supplies to the load. On Mains return, battery gets charged 'online'. Load is protected from the higher boost voltage through the VR. When one FCBC fails, the other FCBC takes over the function. This system can also be designed for 'offline' charging, without VR, providing tap cell connection. FCBC 1 FCBC 2 VR L O A FCBC 1 FCBC 2 Parallel Redundant System using two nos. FCBC + two Batteries L O A Under normal conditions, total current is shared by the two chargers. Each charger float charges the respective battery. When Mains fail, both batteries share the load. On Mains return, batteries get charged 'offline' one after the other. The charger and the battery on boost get isolated from C bus while the other charger meets the full load current. When one FCBC fails, the other FCBC takes over. One battery provides redundancy for the other.

5 Features and Specifications HBL Battery Charger / Series Standard Optional Charger Characteristics Applicable Standards Input Voltage Input Frequency Output Current Constant voltage with current limit IEC 230 V +/ 10% 415 V +/ 10% 50 Hz +/ 5% Refer page 8 and 9 Any other voltage Any other voltage Any other Frequency Output Voltage Nominal Float V adjustment Boost V adjustment 24/48/110/220 VC 80% to 115% of Nominal 80% to 135% of Nominal Any other voltage Ripple Voltage Voltage stability (with variation in load & input V) 5% rms (without Bty connected) 3% rms (without Bty connected) +/ 1V of set value for > 48 VC +/ 1V of set value for < 48 VC 100mV with Battery connected or As required by user Rectifier Bridge Magnetics Full wave, half controlled Full wave, full controlled Insulation class Temp. rise above ambient High voltage insulation Class F 90 eg C 2.5 KV for 1 minute with maximum leakage current of 5mA Class B,Class H 70 eg C, 110 eg C Instrument Output voltmeter & ammeter 72 X 72 Sq. mm. analog type Accuracy 2.5 % igital Meters / LC isplay 1% Accuracy Output voltmeter & ammeter Input voltmeter with selector switch eflection 90 eg 96 X 96 Sq. mm analog type Accuracy 1.5 % eflection 90 deg 96 X 96 Sq. mm analog type Accuracy 1.5 % igital Meters / LC isplay 1% Accuracy eflection 240 eg igital Meters / LC isplay 1% Accuracy eflection 90 eg. eflection 240 eg Note "Apart from the above specifications, any other specific requirements of the customers (not listed above) can be provided as per requirement on a case to case basis".

6 / Series Standard Optional Indications & Alarms Lamps Input ON, Output On LE Charger on Float Charger on Boost Alarms Input supply fail Ground fault alarm for (LE+Buzzer) C under voltage unearthed systems C over voltage Rectifier fuse fail Charger fail output fuse fail Capacitor fuse fail As required by the user Protection Input MCB Switch and Fuse Switch & Fuse MCB/MCCB/Thermal OL relay/ Contactor Output MCB Switch and Fuse Switch & Fuse MCB / MCCB Rectifier bridge HRC Fuse High speed semi Filter capacitor HRC Fuse Conductor Fuse Safety Features Short circuit protection Battery Current limit Reverse polarity protection Soft Start Mechanical Surge protection Enclosure protection IP 20 Upto IP 54 Paint finish Epoxy based matt / finish As required by the user Paint colour External/Internal Light Gray As required by the user Construction Folded sheet / MS construction As required by the user Panel access Front & rear Only Front Panel mounting Floor mounting Wall mounting for smaller panels Note "Apart from the above specifications, any other specific requirements of the customers (not listed above) can be provided as per requirement on a case to case basis".

7 / Series Standard Optional Ventilation Natural convection Upto 400 A Natural convection Forced Cooling Above 400 A / Forced air cooling Cable entry Bottom entry Top entry Noise Level Typically 65 dba for panels with natural convection & 75 dba for panels witth forced air cooling Environment Operating ambient 0 to +50 eg C temperature (surrounding the panel) Storage Temperature 30 to +70 eg C Up to MSL Humidity 0 to 95% RH Non condensing Altitude Upto 1000 MSL Routine Tests Routine tests conducted at HBL works generally conforming to IEC 146/IS 4540 Visual & imensional check Insulation Resistance test High Voltage test Measurement of voltage regulation Burn in test on PCB's, Heat run test (8hrs) Efficiency and Power Factor measurement. Annunciation checks ynamic response Measurement of ripple measurement Charger functional Checks (overshoot / undershoot). Note "Apart from the above specifications, any other specific requirements of the customers (not listed above) can be provided as per requirement on a case to case basis".

8 Other Features Soft Start Specially designed 'walk in feature' ensures gradual development of C output after the charger is switched ON, protecting the charger from heavy inrush currents. Automatic charging control HBL chargers are provided with an Auto function option; enabling automatic recharging of the battery. When the mains supply return while the charger is in Auto function, the control circuit of the charger senses state of charge of battery and switches to Boost mode if required. The charger will automatically return to Float mode after fully charging the battery. Special options Some of the special options offered for HBL chargers are LC isplay for panel Metering & Alarms 2. Input Harmonics limitations as per IEEE RS 232 / RS 485 Inter face with MOBUS Protocol 4. High temperature alarm for forced air cooled panels. Contacts for remote alarm indications. 5. Radio interference / Harmonic filters. 6. Thermostat controlled space heater for anti condensation 7. Temperature compensation. Tests In addition to the routine tests, HBL chargers have undergone special tests listed below > Surge withstand capability test > Short circuit tests on transformers for dynamic ability. > Heat run test at 50 eg. C > Radio Frequency Interference test. > Environmental & Soak tests on PCB. > Vibration tests of PCB rack / panels. > egree of protection tests upto IP5X & IPX2. > Siesmic Qualification tests Standard Models, and imensions for Single Phase Charger Nomenclature (example) Amps output Single Phase 48 V C Nominal 24 V C 48 V C 110 V C 220 V C Output Rating 10 A A A A A A A 80 A 225 Panel imension for Single and Three Phase Charger imensions In mm imensions In mm H W H W x x 1 1 FR 18/80/ x FR 18/80/ x x FR 22/80/ x FR 22/80/

9 H Height W Width epth Standard Models for Three Phase Charger Nomenclature (example) Amps output Three Phase 48 V C Nominal 24 V C 48 V C 110 V C 220 V C Output Rating 10A A A A FR10/60/ A A A A FR 18/80/ FR 18/80/ A A 280 FR 18/80/ A x A x A x A xFr 18/80/ x A 2xFR 18/80/ xFR 18/80/ xFR 18/80/ A 2xFR 18/80/80 2xFR 18/80/80 2x x A 750 2xFr 20/80/ A xFR 22/80/ A 850 2x A A 2xFr 22/80/ A A 2xFR 22/80/ A 3xFR 22/80/100 In accordance with its policy of continuous improvement the company reserves right to change specifications and designs without notice. All illustrations, descriptions, dimensions and weight in this catalogue are for guidelines only and cannot be held binding on the company. Consult HBL

10 Information to be provided by the customer for sizing a battery charger system. A. Charger Application of the equipment C Nominal Voltage Load voltage Tolerance + %, % Load Cycle format given below Sequence No. Equipment drawing C power Total current ( A ) uration ( Sec/min ) Maximum Continuous Load on the charger A ( Excluding Battery charging current ) Whether Redundancy required YES / NO (If yes, provide details) B. etails of battery to be charged of battery No. of Cells Capacity of Battery No. of Batteries per system of charging Time available for recharge of battery (Hrs) NICA / VRLA / Vented Lead Acid/others Off line / On line C. C istribution Board ( If required ) of Construction A) Inside the charger / Separate cubicle B ) Compartmentalised / Non Compartmentalised Mounting Floor / Wall Mounted Feeder Qty. Rating Incomers Outgoings Special options required in Charger CB

11 ISO 9001 Certified Other Electronic Products C C Converters Integrated Power Supplies (IPS) ata Loggers Special Power Supplies for efence Applications Inverters Battery Monitoring Systems Earth leakage Monitors

12 Corp.comm\5. nov HBL Power Systems Limited 82601, Road No.10, Banjara Hills, Hyderabad ,TG, INIA website