295102895-Battery-Charger-DCDB.pdf

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D:\Hema\2008-2009\conv\pcoos-000008-08-09\Write up-coo-08.doc

DRAWINGS

FOR

APPROVAL

RATING : 125V / 50A Dual Float cum Boost Charger & 125V DCDB

NAME OF PROJECT : EEPC- Accelerated Electricity Access Expantion

CUSTOMER : NCC LTD

JOB NO. : 2264-08

S.O.NO : PCOOS/000008/08-09

MANUFACTURER : AMARARAJA POWER SYSTEMS (P) LTD, TIRUPATI.

AMARA RAJA POWER SYSTEMS (P) LTD.

RENIGUNTA–CUDDAPAH ROAD, KARAKAMBADI–517 520

TIRUPATI (A.P.)

Tel : (0877) 2285561 – 2285565

Fax : (0877) 2285599 & 2285600

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G E N E R A L D E S C R I P T I O N

The system basically consists of Two Float Cum Boost Chargers. Each Float cum Boost charger is capable to supply the load and Battery Charging requirements. In normal mode of operation, the battery assembly is float charged by both the chargers while feeding the DC load thus operating in parallel and sharing the total load. When FCBC - 1 fails, the other charger FCBC - 2 comes into operation and supplies the load and battery bank.

Both Chargers basically consists of input transformer, Rectifier Bridge, Filter circuit and Charger Control Board. The Functional Block Diagram of redundant the system is enclosed in this package for reference. The Input Transformer steps down the AC input voltage to required AC level. The rectifier is built with SCRs, which are connected in full wave, Full controlled configuration. The Rectifier Bridge converts the stepped down AC into regulated DC. The Filter Circuit eliminates AC ripple in the DC output. The charger control board provides the gate pulses to SCRs. Voltage and current feedback circuits provide error signals to the charger control board to achieve voltage regulation and current limit.

A charger output voltmeter, a charger output Ammeter, AC input Ammeter and AC input voltmeter are provided to measure respective parameters continuously in each charger. Blocking diode is provided at the output of each charger to prevent reverse flow of current into the charger, which may damage the filter circuit in the charger when the battery is supplying the load.

A Battery Charge / Discharge Ammeter, Battery Earth Leakage Ammeter and DC Voltmeter with selector switch are provided to measure respective parameters continuously in Battery Charger System.

The chargers, FCBC-1 & FCBC-2 are housed in a single cabinet of Folded sheet steel construction. All Meters, Indicators and important Controls are brought on to the front door.

* * * *

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TECHNICAL SPECIFICATION OF CHARGER

TYPE : DUAL FLOAT CUM BOOST CHARGER

MODEL : FULL WAVE FULL CONTROLLED

RATINGS : 125V DC, 50Amp DFCBC suitable for VRLA-56cells-300AH battery

AC INPUT

Voltage : 380VAC ± 10% Frequency : 50Hz ± 5% Phase : 3 Phase, 4Wire DC OUTPUT

Float voltage : 126.0V DC adjustable by +2%, -5%

Boost voltage : 128.8V DC adjustable by +2%, -5%

Regulation : Better than ± 1% at full voltage

Ripple : Less than 1% RMS

Current : 50A

System output voltage : MAX.126V DC + 1% (at load terminalsterminals after dropper diode ckt)

Efficiency : Better than 80% at Full load

METERS : Following analogue type 72 X 72 mm meters shall be provided in

the system for monitoring the respective parameter.

a. AC voltmeter with selector switch to measure voltage across line to line and line to neutral

b. AC ammeter with selector switch

c. DC voltmeter with selector switch(FCBC-1/FCBC-2/BATT/LOAD)

d.DC ammeter for both FCBC - 1 & 2

e. DC ammeter to measure battery charge/discharge current

f. Load ammeter

INDICATIONS : Pilot Lamps shall be provided for following conditions.

a. AC Mains ON .

FACIA Display shall be provided for the following

conditions with audio alarm for abnormal conditions on each charger a. AC mains fail

b. AC I/P MCB Trip(FCBC-1&2) c. DC O/P MCB Trip(FCBC-1&2) d. Charger Fail(FCBC-1&2) e. Charger ON(FCBC-1&2) f. Battery I/P fuse fail

APL-2264-08 1 26.05.09 4 9

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g. Battery Earth Fault h. Float ON

i. Boost ON

j. Battery under voltage k. DC under voltage l. DC over voltage

5. PROTECTIONS : Following protections will be provided in the system:

a. AC Input Circuit Breakers for both FCBC-1 & 2. b. Fast acting semiconductor fuses for Rectifier bridges

for both FCBC-1 & 2.

c. DC Output Circuit Breakers for both FCBC-1 & 2. d. Over Voltage cutback protection for both FCBC-1 & 2. e. Charger Over Load protection for both FCBC-1 & 2. f. Battery Input Fuses

g. Battery Path Charging Current Limit h. Blocking Diodes for both FCBC-1 &2. i. Charger Current Limit

6. CONTROLS & SWITCHES :

a. AC Input Circuit Breakers for both FCBC-1 & 2. b. DC Output Circuit Breakers for both FCBC-1 & 2. c. Auto / Float / Boost Mode Selector Switch for both

FCBC-1 & 2.

d. Float & Boost Voltage Variable Potentiometers for both FCBC-1 & 2.

e. Test, Accept & Reset Push Buttons

f. AC Volts & Amps Selector Switch for both FCBC-1 & 2.

g. Heater, Door Lamp and Socket Power Supply ON/ OFF Toggle Switches with Fuses.

h. DC Voltmeter Selector Switch

7. SPECIAL FEATURES : The following features will be provided: a. Soft start on DC side.

b. Class-F insulation with Class-F Temperature Limits for all the Magnetics.

c. Automatic voltage regulation using digital control logic d. Built in auto phase reversal of operation

e. Charger Current Limit f. Battery Path Current Limit g. Filter Circuit to limit Ripple.

8. GENERAL

a. Cabinet : Freestanding Cabinet, Floor Mounting Type, Sheet Steel

Construction, Easy Access for Installation, Commissioning & Maintenance and Cable Entry at Bottom of the Cabinet. Proper louvers will be provided for better ventilation. Hinged doors will be provided at the front and back. All live parts will be properly shrouded.

[[

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b. Sheet Thickness : 1.6mm for Non-load bearing sections.

2.0mm for Load bearing sections.

c. i) Paint : EXT. : Light Grey 631 of IS 5

INT. : Glossy White

ii) Painting process : Powdered coating

d. Cooling : Natural air cooling

e. Protection class : IP – 42 as per IS 2147

f. Temperature range : 0°C to 50°C

of operation

g. Relative humidity : 0% to 95% non-condensing.

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TECHNICAL SPECIFICATION FOR DCDB

Incomer : 63A-2P-DC-MCB -1No.

Outgoing feeders : 32A-2P-DC-MCB -3Nos.

16A-2P-DC-MCB -7Nos.

METERS : Following Analog Type Measuring Meters of 72 x 72 Sq. mm with 240° deflection will be provided in the DCDB for measuring the respective parameters: a. DC Ammeter for DCDB

b. DC Voltmeter

8. GENERAL

a. Cabinet : Freestanding Cabinet, Floor Mounting Type, Sheet Steel

Construction, Easy Access for Installation, Commissioning & Maintenance and Cable Entry at Bottom of the Cabinet. Proper louvers will be provided for better ventilation. Hinged doors will be provided at the front and back. All live parts will be properly shrouded.

b. Sheet Thickness : 1.6mm for Non-load bearing sections.

2.0mm for Load bearing sections.

c. i) Paint : EXT. : Light Grey 631 of IS 5

INT. : Glossy White

ii) Painting process : Powdered coating

d. Cooling : Natural air cooling

e. Protection class : IP – 42 as per IS 2147

f. Temperature range : 0°C to 50°C

of operation

g. Relative humidity : 0% to 95% non-condensing.

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DEVIATION / JUSTIFICATION

S.No.

CLAUSE

DEVIATION / JUSTIFICATION

S.No Clause Deviations & Justifications

01 13.6&13.7 As battery charger designed suitable for VRLA battery, these batteries are

delivered to the site with full charge condition. Hence Initial charge at site is not required. So, We are not provide initial charge mode, equalizing charge setting timer and over ride selector switch in the offered charger.

02 13.6& 13.7 As Battery charger designed suitable for VRLA battery, Float and Boost

Voltage settings will be designed as per VRLA battery manufacturer Recommended voltage levels Float=2.25V/cell and Boost=2.3V/Cell. Offered charger is designed as its out put voltage shall vary with in the regulation limits, hence pulse limiter zener type is not required.

03 13.9 As the requirement is thyristor based battery charger, it can deliver

rated DC voltage within specified regulation for specified AC

supply and DC load variation. Hence, taps on transformer are not

required

04 13.11 Battery impedance monitoring facility is not available in the offered

charger. Hence we can provide battery fuse fail alarm indication and PFC for customer remote monitoring purpose. Earth fault indication is derived through amararaja make PCB cards.

05 13.12 All indications, alarms and protections are derived through Amara

Raja make PCB cards, which shall be built with PLA/OEN make Aux.relays and hence, no separate static relays being considered to derive protections and charger fail indication and PFC was provided in charger only not in DCDB.

06 13.14 For Emergency DC lighting control system Automatic and OFF selector Switch is provided ,manual position can not be provided.

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SYSTEM THEORY OF OPERATION

The system consists of two identical Float cum Boost Chargers, with necessary Interconnection Circuit and a Battery Bank. Both chargers are identical in nature & works on the same principle. These chargers are rated to meet the requirement of Load and Battery charging current as specified. For clear understanding of system description, refer the schematic drawing enclosed. The Float cum Boost chargers - 1 & 2 are connected to the AC input power through (CB 401/501). The Input transformer (T401/501) steps down the input AC Voltage to the required level and is connected to the rectifier bridge (SCR 401-406/501-506) through Fast acting Semiconductor Fuses (FU 401-402/501-502). PC402/502 are capacitive filter Boards that protect the system from surges and transients at AC Input. The charger control board PC 401/501 provides gate signals to these SCRs at appropriate timing depending on the output voltage/current feed back. The Rectifier DC is connected to DC filter (L 401 / 501 and C 402 / 502) which in turn filters out all harmonics and provide DC voltage with low ripple content as specified. The Blocking diodes (D401/501) prevent reverse current flow into the charger. The output voltage of Float cum Boost Charger is adjusted using the potentiometer R 401-402/501-502 respectively.

The shunt SH 401/501 provides current feedback to charger control board (PC 401/501), which causes the unit to go into current limit, when the load current (charging current) is more than set value.

The Rectifier DC is connected to DC filter (L 401 & C 402/L 501 & C 502) which in turn filters out all harmonics and provide DC voltage with low ripple content as specified.

The meter M 401/501 with shunt, SH 401/501 provides the current feedback to the charger control Board PC 401/501, which causes the unit to go into current limit beyond the set value. This Characteristics cause the output voltage to go down when the battery is run down, to maintain a constant level of charging current.

During normal operation, Charger - 1 & 2 supplying load current and float charge the battery. The current limit interface board (PC 3) connected across Battery shunt terminal, provides Battery Charging current limit protection, when both chargers are operating in Float mode.

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ANNEXURE - A

APPROVED SUB-VENDOR LIST

1. Contactors/Overload relays ABB/ L&T/ANDREW YULE

2. Thyristors / Diodes HIRECT/ RIR/ Semicran

3. Heavy duty switches SALZER (L&T) / KAYCEE

4. Control Switches SALZER (L&T)

5. MCBs MDS /INDO ASIAN/ Siemens/Schneider

6. MCCB C&S / SCHNIDER/siemens

7. Toggle Switches R.G.K/RECOM

7. Fuses (HRC & HBC)/ Fuse Bases GEC/Bussman(formerly S&S)/INDO ASIAN/

ELCOM/ ESSEN

8. Fuses (GLASS) PROTECTRON

9. Meters BEEMET / RISHAB

10. Push Button / Indicating lamps L&T/TEKNIC/R.G.K/JYOTHI ELECTRONICS

11. Auxiliary relays (PCB Type) PLA/OEN

12. LED's SANKEN/KWALITY

13. Wire Wound Resistor PEC/VEPL

14. Potentiometers POTEL / BOURNS / PANKAJ

15. Electrolytic Capacitors SARADA

16. Populated PCB’s ARPSL

17. Shunts BEEMET/MECO/ RISHAB

18. Heat Sinks AFCOSET / BM’s

19. Thermal Switches UTILITY APPLICATIONS

20. Heaters PYRO

21. Terminal Blocks ELMAX/ ESSEN

22. MOV’S ELPRO

23. Cable Glands NOVOFLEX/HMI/COMET/JAINSON

24. Cables CAPI

25. Fuse Switches GEC/C&S/HPC/HAVELLS/CGL

26. Facia window ACCYS ELECTRONICS/SUN INDUSTRIES.

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Bill Of Material Report

Doc Ref No : ENG-SFS-08/REV 0

POWER SYSTEMS Pvt. Ltd.

National Contracting Co. Ltd.,Saudi Arab

Line No

PCOOS/000008/08-09 1 Configuration No Customer Name Rev No 0.00

Sale Order No 1

Description 125V/50A DFCBC:3PH-4W-FWFC

Item Code DFCB125050A Variant Code E612 Jobno 08-2264 Qty 1 UOM NOS

Qty / System

Sl.No Rev Circuit Designation Input Item Code Description Variant Variant Description UOM Sub Remarks

M064

1 0 AL 42500000069V Buzzer-12V-20mm-CE-27-01 Metronix 1.000 NOS

E013

2 0 C 401/501 40730400200V capacitor-polyster-2mfd-400V-axial 2µF/±20%400VDC/KT12 2.000 NOS

S047

3 0 C 402/502 (3+3) 40712007700V Cap-Elec-7700mfd-200V DC- SARADA 6.000 NOS

L021

4 0 CB 401/501 40071310040 MCB-40A-3P-AC-10KA-DCurve Legrand-D 6049 77 2.000 NOS

L021

5 0 CB 401/501(AUX) 40071900009 Auxiliary C/O Switch-6A-250V AC Legrand-007350 2.000 NOS

S049

6 0 CB 402/502 40071299003 MCB-63A-2P-10KA-DC-AUX 1NO+1NC Sch-MGN22332+26924 2.000 NOS

A009

7 0 CON 1 47930245032 Contactor-32A-3P-110VDC coil-2NO+2NC PAK-20US-110VDC 1.000 NOS

L001

8 0 CON 401-402 47920238010 Cont-10A-415VAC Coil- 2 NO + 2NC MN0 22E-SS94662D000 2.000 NOS

L001

9 0 CON 401/402(AUX) 47960022001V Con aux block-2NO+2NC For MN9-MN25 Ser L&T-SS94085 2.000 NOS

H004

10 0 D 1/3 46081101150 Dropper Diode-forward-150A-100V-stud HIRECT-S1HNS150 2.000 NOS

H004

11 0 D 2/4 46081201150 Dropper Diode-reverse-150A-100V-stud HIRECT-S1HRS150 2.000 NOS

H004

12 0 D 401/501 46011106100 Diode-Forward-100A-600V-stud Hirect-S6BN100 2.000 NOS

M035

13 0 D 5 40462108002V Diode-GP-3A-1000V-DO-27-1N5408 M035 1.000 NOS

A010 yes

14 0 DCDB DCDB1250000 125V DC DISTRIBUTION BOARD ARPSL 1.000 NOS

P007

15 0 DL 401 42500000231V DOORLAMP-15W-230V AC Philips 1.000 NOS

A008

16 0 DL 401 (Holder) 42500000236V BULB HOLDER Anchor 1.000 NOS

S099

17 0 FD 1 42500000757 Facia display-16point-90-270V AC/DC Sun Indus-SMA16WUS 1.000 NOS

B017

18 0 FU 1-2 47503014063 HRC fuse-slow-63A-415V/550VAC-offset tag Bussmann-63K07 2.000 NOS

P011

19 0 FU

3/403-406/408-410/ 503-506

47504320100V Glass Fuse-fast-1A-250VAC-32MM PROTECTRON 12.000 NOS

B017

20 0 FU

401-402/501-502

47501122100 Semiconductor fuse-fast-100A-240V/250VAC Buss-100LET-T type 4.000 NOS

B017

21 0 FU 407 47504094010 HRC fuse-slow-10A-415/550V AC-clip on BUSSMAN-NSD10 1.000 NOS

BOM Status Prepare HEMALATHA.K

Report Run Date & Time 26/05/2009 16:05:40 Prepared By Checked By Approved By Page No 1 Of 4

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Bill Of Material Report

Line No

Sale Order No 1

Qty / System

B017

22 0 FUB 1/2 47512000013V Fuse base-63A-415/500 VAC Bussman-KA63 2.000 NOS

E014

23 0 FUB

3/403-406/503-506/ 408-410

47512000025V Fuse holder-glass-10A-32mm ELCOM-MF-20 6.000 NOS

B017

24 0 FUB 407 47512000016V Fuse base-32A-415/500V AC Bussmann-FA32 1.000 NOS

G001

25 0 FUSE SWITCH

BOX(FUSW 1)

40022301063 Fuse switch-63A-3P-ON/OFF-bolted type GEC-SP63EIT-BS 1.000 NOS

G001

26 0 FUSW FUSES(63A

FUSES)

47503134063 HRC fuse-slow-63A-415VAC-offset tag-eit GEC-EIT63 2.000 NOS

G001

27 0 FUT (PC 8) 47599990000V Fuse Trip indicator GEC-TI300 2.000 NOS

P013

28 0 H 401 42500000011V SPACE HEATER -100W-240VAC PYRO 1.000 NOS

A003

29 0 HS [D 1-4/401/501] 44802000250 Heat sink-130HD-250mm AFCOCET 4.000 NOS

A003

30 0 HS[ SCR

401-406/501-506]

44801000200 Heat sink-PI-20-200mm AFCOCET 6.000 NOS

A010 yes

31 0 L 401/501 43200003611 Charger D.C.Choke-3.25mH ARP-AT-3611 2.000 NOS

T001

32 0 LA 401 47711105221 Indicator assembly-240VAC-22.5mm-red TECKNIC-2LHBR230 1.000 NOS

T001

33 0 LA 402 47711105222 Indicator assembly-240VAC-22.5mm-yellow TECKNIC 1.000 NOS

T001

34 0 LA 403 47711105224 Indicator assembly-240VAC-22.5mm-blue TECKNIC 1.000 NOS

R007

35 0 M 1 47610932015 DC voltmeter-0-150V-1.5%-240D-72x72 Rsihab-PL72 1.000 NOS

R007

36 0 M 2 47611432007 DC ammeter-75-0-75A/75mV-1.5%-240D-72x72 Rishab-PL72 1.000 NOS

R007

37 0 M 401/501/3 47610532007 DC amm-0-75A/75mV-1.5%-240D-72x72 Rishabh-PL72 3.000 NOS

R007

38 0 M 402 47610832050 AC voltmeter-0-500V-1.5%-240D-72X72mm Rishab-VL72 1.000 NOS

R007

39 0 M 403 47610232005 AC ammeter-0-50A/5A-1.5%-240D-72x72 RISHAB-VL72 1.000 NOS

E006

40 0 MOV

401-406/501-506

40413061400V MOV-60V-14mm ELPRO-RDN 60/14 12.000 NOS

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Bill Of Material Report

Line No

Sale Order No 1

Qty / System

R001

41 0 PB 1/2/3 47310000104V PB-microswitch-1C/O-black R.G.KESWANI-MR3/FPBB 3.000 NOS

A008

42 0 PB 401 47311000200V PB-door lamp-NC-(Refrig switch) Anchor 1.000 NOS

A041

43 0 PC 1 ARE02018202 PCB-MST-ACDB-48VDC AREPL-P02018202 1.000 NOS

A041

44 0 PC 10 ARE02002000 PCB-PLA-RELAY-12VDC-3C/O CONT. AREPL-P02002000 1.000 NOS

A041

45 0 PC 12 ARE02018206 PCB-MST-DDB-110V DC AREPL-P02018206 1.000 NOS

A041

46 0 PC 2/406 ARE02002023 PCB-RELAY BD-130VDC-3C/O AREPL-P02002023 2.000 NOS

A041

47 0 PC 3 ARE02008404 PCB-CUR LIMIT-INT.FACE-130VDC AREPL-P02008404 1.000 NOS

A041

48 0 PC 4-7/13 ARE02008201 PCB-VOLT DETECT-130VDC-TB-OEN AREPL-P02008201 5.000 NOS

A041

49 0 PC 401/501 ARE02009000 PCB-CHGR-6P-MOTHER BD AREPL-P02009000 2.000 NOS

A041

50 0 PC 401A/501A ARE02009011 PCB-POWER SUPPLY BD-6P AREPL-P02009011 2.000 NOS

A041

51 0 PC 401B/501B ARE02009024 PCB-REG CTRL-110VDC- 6P AREPL-P02009024 2.000 NOS

A041

52 0 PC 401C-D/501C-D ARE02009031 PCB-GATE PULSE DRIVE-6P AREPL-P02009031 4.000 NOS

A041

53 0 PC 402/502 ARE02001102 PCB-FILTER-2MFD-400V-TB AREPL-P02001102 2.000 NOS

A041

54 0 PC 8 ARE02008302 PCB-FUSE TRIP-DPDS AREPL-P02008302 1.000 NOS

A041

55 0 PC

9/11/403-405/407/5 03-506

ARE02002012 PCB-PLA-RL-130V DC-2C/O CONT AREPL-P02002012 10.000 NOS

D023

56 0 R 1/2 40486470252V Resistor-variable-2.5K-25W-Wire wound Diagram 2.000 NOS

D023

57 0 R 3-5 40483321002V Resistor-1K-2W-5%-Wire wound DIAGRAM 3.000 NOS

P009

58 0 R 401/402/501/502 40486341203V POT-panel mount-20K-3W-1T POTEL 4.000 NOS

D023

59 0 R

403(1)/404(2)/503(1 )/504(2)

40483371003V Resistor-10K-10W-5%-wire wound Diagram 6.000 NOS

A008

60 0 SC 401 42500000245V SOCKET-3PIN-5A Anchor 1.000 NOS

R006

61 0 SCR 46040206090 Dual SCR block-slow-90/95A-600V RIR-IRKT-91/06 6.000 NOS

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Bill Of Material Report

Line No

Sale Order No 1

Qty / System

B011

62 0 SH 1/401/501/2 47602110075 Shunt-75A/75mV- ±0.5% Beemet 4.000 NOS

S003

63 0 SW 1 40070214201 Rotary switch-6A-1P-4W-ACDC Sal-SG91C-B13-61050 1.000 NOS

S003

64 0 SW 401 40070253201 Rotary switch-6A-5P-3W-ACDC 61124 SAB13TDYR 1.000 NOS

R001

65 0 SW 402-404 40072110110V Toggle switch-pm-SPST-ON/OFF-10A R.G.KESWANI 3.000 NOS

S003

66 0 SW 405 40070740002 Rot Sw-10A-AC volt amp select Sal-72375S10B13TDYR 1.000 NOS

A010 yes

67 0 T 401/501 43200004674 Charger I/P Xfr-380V/65.3V,10KVA ARP-AT-4674 2.000 NOS

K006

68 0 T 402-404 47622100050 Current Transformer-50/5A Kappa-Ring type 3.000 NOS

E015

69 0 TB

1/2/401/4/5(FUSW BOX)

41004001110V Terminal block-power-110A-single ELMEX-CBT110 12.000 NOS

E015

70 0 TB 3/INT 41004001010V Terminal block-power-10A-single ELMEX-CST2.5 42.000 NOS

L001

71 0 TM 401 42500002848 Timer-0.15-3 hrs-240VAC,NOVOLT PROTECT L&T-EM1000-BF42B2 1.000 NOS

U007

72 0 TS 401 42500000067V THERMAL SW-SET AT65`C-NC UTILITY APPLIACES 1.000 NOS

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Bill Of Material Report

Doc Ref No: ENG-SFS-08/REV 0

Item Code DCDB1250000 Variant A010 Description 125V DC DISTRIBUTION BOARD-ARPSL Qty 1 UOM NOS Rev 0

S.No Rev Circuit Designation Item Code Description Variant Var Description Qty / System UOM SUB Remarks

1 0 CB 1 40071609630 MCB-63A-2P-DC S049 Schn-MGN22332-10KA 1.000 NOS

2 0 CB 2-8 40071609160 MCB-16A-2P-DC-10KA S049 Schn-MGN22326 7.000 NOS

3 0 CB 9-11 40071609320 MCB-32A-2P-DC S049 Schn-MGN22329-10KA 3.000 NOS

4 0 CON 1 47930245016 Contactor-16A-110VDC coil-3P-2NO+2NC A009 AY-PAK-18U01-110VDC 1.000 NOS

5 0 LED 1/2 40477112001V LED-RED-ROUND-5mm K013 KL53SBLRL6L-M 2.000 NOS

6 0 LED1/2(HOLDERS) 42500002804 LED Holder-5mm round-press fit-white L016 Lalwani Elect-LHO-5 2.000 NOS

7 0 M 1 47610932015 DC voltmeter-0-150V-1.5%-240D-72x72 R007 Rsihab-PL72 1.000 NOS

8 0 M 2 47610532007 DC amm-0-75A/75mV-1.5%-240D-72x72 R007 Rishabh-PL72 1.000 NOS

9 0 PC 1-3 ARE02008201 PCB-VOLT DETECT-130VDC-TB-OEN A041 AREPL-P02008201 3.000 NOS

10 0 R 1/2 40483321003V Resistor-10K-2W-5%-wire wound D023 Diagram 2.000 NOS

11 0 SH 1 47602110075 Shunt-75A/75mV- ±0.5% B011 Beemet 1.000 NOS

12 0 SW 1 40070221103 Rotary switch-16A-2P-ON/OFF-ACDC S003 Sal-61192S16B03TDYR 1.000 NOS

13 0 SW 2 40070212201 Rotary switch-6A-1P-2W-ACDC S003 Sal-61037S6B13TDYR 1.000 NOS

14 0 TB 1 41004001110V Terminal block-power-110A-single E015 ELMEX-CBT110 2.000 NOS

15 0 TB 13/INT 41004001010V Terminal block-power-10A-single E015 ELMEX-CST2.5 6.000 NOS

16 0 TB 2-12 41004001044 Terminal block-power-44A-single E015 ELMEX-CST6 22.000 NOS

BOM Status : Prepare HEMALATHA.K

Approved By

Checked By BOM Ref Doc No

Report Run Date & Time 26/05/2009 16:06:23 Prepared By

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1 2 3 4 5 6 7 8 A B C D 8 7 6 5 4 3 2 1 D C B A PROJECT CUST P.O. NO. DWG. NO. TITLE

DATE SHEET OF REV :

A

MA R A R A J

A

POWER SYSTEMS LTD

Registered Office & Works karakambadi - 517520

Ph(0877) 2285561 to 2285565.

DRAWN CHKD. RECHKD. APPD.

REMARKS

REV. ECO DATE APPD.

: : :

A3 FILE NAME D:\Hema\2008-2009\conv\pcoos-000008-08-09\sch-coo-08-2264-08\4-BLD1.sch

Pro p ri eta ry m ateri al o f M/ s. AMARA RAJ A POWER S Y S TEMS LTD. , Ti ru p ath i. Al l ri gh ts reserv ed . No co p yi n g p erm it ted u n au th ori sed u se pr ohibite d . E N G -SFS-06/R ev.0

FUNCTIONAL BLOCK DIAGRAM OF DUAL FCBC

AC INPUT R CB Y B N 380V AC ±10%, 50HZ ± 5% 3 PHASE, 4 W IRE. D CB FU FU 56 th CELL 1 st HEMA FIG.1 1 1 0 CELL + -TB TB TO DCDB FCBC - 2 BANK ( 125V/300 AH ) VRLA BATTERY CB CB _D FCBC - 1

SCHEMATIC DRAWING OF 125V/50A DUAL FLOATCUM BOOST CHARGER

02/04/2009

SCH - 2264 - 08 ( PCOOS/000008/08-09 ) NCC LTD

NCC/EEPCO/LOT 1/PO/008 Dated : 14/03/2009 EEPC- Accelerated Electricity Access Expantion

DROPPER DIODE CKT

D D

CON.

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1 2 3 4 5 6 7 8 A B C D 8 7 6 5 4 3 2 1 D C B A PROJECT CUST P.O.NO. DWG.NO TITLE DATE SHEET OF ECO

A

DRAWN CHKD RECHKD : REV APPD. REV. : : : Registered Office & Works,

J R POWER SYSTEMS LTD karakambadi - 517520 R

A

A APPD M A DATE REMARKS Ph(0877) 2285561 to 2285565. A : : P rop riet ary m at erial of M /s . AM ARA RAJA P O W E R S Y STEM S LTD. , Th iru pa th i . All righ ts res erved n o cop yin g p erm it te d u na ut ho ri se d u se p roh ib it ed . E NG -S F S-06/Rev. 0

FILE NAME D:\Hema\2008-2009\conv\pcoos-000008-08-09\sch-coo-08-2264-08\1-FCBC 1.sch

412B 413B 40H 443H D401 19H AM M401 450H 13 12 L401 CHARGER BOARD PC401 A, B, C, D 450B 481H R403 C401 SH401 + TO SHEET 3 OF 4 CABLE DETAILS DESIG -NATION CABLE SIZE IN Sq.mm D B E 2.5 1.0 4.0 17D 443B TO SW1 ( SHEET 3 OF 4 ) CHASIS G GROUND 17B 413D 412D 415B HEMA CB402 15 2 PC403 443B 19B INTERNAL

SCHEMATIC DRAWING OF 125V/50A FLOAT CUM BOOST CHARGER - 1

1 4 0 ( SHEET 2 OF 4 ) TO FCBC-2 AC I/P. 455F 453F 454F 415H 450H F 6.0

ALL DOORS PROVIDED WITH ELECTRICAL COMPONENTS TO BE EARTHED PROPERLY NOTE

:-ALL EARTH POINTS SHOULD BE INTERCONNECTED

C402 _R404

415F

481F

10.0

EEPC- Accelerated Electricity Access Expantion 481H 02/04/2009 SCH - 2264 - 08 ( PCOOS/000008/08-09 ) NCC LTD AC INPUT 380VAC ± 10% , 50HZ ± 5% , TB401 R S T N 3 PHASE , 4 WI RE . 8 10 TO P C 3 (SHEET 3 OF 4) 408D 410D A453F A454F A455F A444H A460H A461H A453F A454F A455F A494F A495F 470E SW402 PB401 DL401 A11B A459B A470B FU407 A12B LN GND SC401 SW403 A11B A16B 17D A470B A 455B A470B H401 SW404 A11B A456B TS401 A470B A457B 414H B422B R421B B420B R419B B418B R417B 21 22 20 19 18 17 SCR401 SCR402 SCR403 444H 461H 460H SCR404 SCR405 SCR406 25 26 27 28 23 24 B423B R424B B425B R426B R428B B427B 15 415B 5 6 1 2 3 4 PC402 A445 H T401 X2 X3 X0 X1 H1 H2 H3 A445 H A447B A444 H A446 H A444 H A444B A446B A445B A446 H FU405 A406D A405D A401D A466D 1 5 6 FU403 FU404 3 FU406 A403D A402D A404D A468D A469D 2 4 A467D 17D Y1 Y3 Y2 Z1 Z2 Z3 MOV 401 MOV406 MOV403 MOV 405 MOV 404 MOV 402 FU401 FU402 A493F (S URG E BD) CB401 19H A470B CO N. 40 1 CO N. 40 2 A 453D A 454D A 454D A 455D 416B R402 R401 462B B OOS T FLO AT 440B 102B 8 7 TM401 6 462B 440B 2 15 PC404 C B 401 672B 2 15 PC405 C B 402 673B FRO M BATT I/P 11 9 10 PC2 6 7 8 1 A1 A2 A3 A F B 462B 440B 490B 16 2 B1 B2 A F B B3 TO FD 1 (S H E E T 3 OF 4) 6B 56B 55B 7 PC403 6 NO C 7 PC503 6 NO C 3 C1 C2 A F B C3 F R O M AC I N PUT 2B A470B A455B TM TM401 16 15 1 2 56B 55B 612B 57B 301B 303B

NCC/EEPCO/LOT 1/PO/008 Dated : 14/03/2009

A470B T404 T403 T402 A2 R Y B V1 V2 A2 A1 VM _AM

A476D A486D A472D A479D

M402 A482D A488D A472D A472D A487D LA401 LA403 L1 L2 L3 FU410 F U 409 F U 408 A 454B A 455B A 437B A 477B A 436B LA402 N A470B _SW405 M403 A453B SW 401 PC406 11 10 C NC NO 60B 2 15 PC406 688B 303B TM501 9 10 301B FRO M BATT I/P 15 2 PC407 32B 9 1 2 3 4 1 --- APPROVAL COMMENTS 20/05/09

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A

FILE NAME D:\Hema\2008-2009\conv\pcoos-000008-08-09\sch-coo-08-2264-08\2-FCBC 2.sch 550B 512B 513B 40H D501 515H AM M501 550H 13 12 L501 CHARGER BOARD PC501 A, B, C, D 581H R503 C501 SH501 + F R OM AC INPUT ( SHEET 1 OF 4 ) 543B TO SW1 ( SHEET 3 OF 4 ) 513D 512D 17D CB501 CB502 R S T 581H 515H CHASIS G GROUND 17D 19H 19H 543H 15 2 PC503 543B 19B 550H

C502 _R504 515F 581F 16 R501 516B R502 562B 540B FLOAT BOOS T 9 PC2 10 11 562B 540B 4 590B D1 D2 D3 A F B SW401 550B C NC NO 2 4 0 TO SHEET 3 OF 4 8 10 TO P C 3 ( SHEET 3 O F 4) 508D 510D

SCHEMATIC DRAWING OF 125V/50A FLOAT CUM BOOST CHARGER - 2

A453F A454F A455F A453F A454F A455F A593F A594F A544H A560H A561H HEMA B522B R521B B520B R519B B518B R517B 21 22 20 19 18 17 SCR501 SCR502 SCR503 A544H A561H A560H SCR504 SCR505 SCR506 25 26 27 28 23 24 B523B R524B B525B R526B R528B B527B 15 515B 5 6 1 2 3 4 PC502 A545 H T501 X2 X3 X0 X1 H1 H2 H3 A545 H A547B A544 H A546 H A544 H A544B A546B A545B A546 H FU505 A506D A505D A501D A566D 1 5 6 FU503 FU504 3 FU506 A503D A502D A504D A568D A569D 2 4 A567D 17D Y1 Y3 Y2 Z1 Z2 Z3 MOV 501 MOV506 MOV503 MOV 505 MOV 504 MOV 502 FU501 FU502 A595F (S URG E BD) 514H 515B 103B 7 6 PC 406 8 562B 2 15 PC504 C B 501 674B 2 15 PC505 C B 502 675B TO BATT I/P 301B 303B 02/04/2009 SCH -2264 - 08 ( PCOOS/000008/08-09 ) NCC LTD

15

2 PC506

19B

EEPC- Accelerated Electricity Access Expantion

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A

FILE NAME D:\Hema\2008-2009\conv\pcoos-000008-08-09\sch-coo-08-2264-08\3-INT.sch

10 11 12 PC1 19D 35D 301H 303H 56 th BATTERY BANK DC OUTPUT 40H 40H 72D 2 15 PC2 45D 40D TB1 35H 35H 13 R1 40D 9 19D 19H 19H 40H SH1 3 4 0 240H 119H TB2 Cell 1 st Cell 303H 301H FU1 FU2 PC3 10 8 34D 13 14 508D 510D TO PC501 (SHEET 2 OF 4) ( CL.BD ) 2 5 35D 19D 40D 6 19D 11 12 408D 410D TO PC401 (SHEET 1 OF 4) 19H FU3 TO FD 1 301B 46B 303B 40H 40H 19H 19H BO O S T CHARG ER - 2 F L O AT CUM (S H E E T 2 OF 3) 40H 40H BO O S T CHARG ER - 1 F L O AT CUM (S H E E T 1 OF 3) 19H 40H 19H 8 7 PC4 40B 19B

SCHEMATIC DRAWING OF 125V/50A DUAL FCBC WITH SWITCHING CUBICLE VM 19B 48B M1 A4 A3 1 40B 443B SW1 A2 A1 543B TO FCBC-2 TO FCBC-1 240B 8 7 PC5 40B 19B HEMA 19D 35D AM M2 C O N 401-402

FD1 (16 WINDOW ) (SUN Industrial Automation & Solutions)

F1 F C BC-1 DC O/P M CB T R IP PB1 PB2 PB3 181B 6B 183B 6B 185B 6B

TEST ACCEPT RESET

AC SUPPLY FAIL 6B 6B T C A C R C 201B 202B F3

FROM BATT. I/P.

3B 46B + -17D E F7 B A TT EA R T H FA U L T 5 6 PC6&7 NO C 212B F13 6B 6B _6B 6B C 203B F4 F5 F6 CON 401-402 F CBC - 2 AC I /P 7 6 PC504 NC C 204B F8 F CBC-2 DC O /P M CB T R IP 6B 208B F9 B A TT I/P FUSE BLO W N 209B F10 DC UNDER VO L T A G E 1 6 PC4 NC C 210B F11 DC O VER VO LTAG E 211B F12 FLO A T O N 213B F14 F15 M CB T R IP 231B F CBC - 1 FA IL 6B AL 227B 228B + R3 222B - + ALARM HTR2 55B F2 F CBC-1 AC I/P MCB T R IP 5 6 PC5 NO C 2 4 PC8 1 3 8 7 PC6 40D 7 8 PC7 35D 17D 17D 7 6 PC404 NO C 8 PC403 6 7 C NO NC 7 6 PC405 NO C 205B _FCBC - 1 ON 206B F CBC - 2 FA IL 8 PC503 6 7 C NO NC 207B _FCBC - 2 ON 7 6 PC505 NC C 6 7 9 10 PC8 NO C 2 15 PC9 F R OM S W 401 6B BOOS T ON 56B F R OM S W 401 6B 2 15 PC10 228B 227B TO SHEET 1 & 2 301B 303B CON.1 D1 D2 8 6 PC11 40D 40H 19D 54D C NC D3 D4 D5 11 10 13 40B PC12 2 15 PC11 40B 55B 19B 56B 12 40B R2 240B TO LOAD TO LOAD 8 7 PC13 BAT T UNDER VO L T A G E 1 6 PC13 NC C 214B F16 02/04/2009 SCH -2264 - 08 ( PCOOS/000008/08-09 ) NCC LTD

NCC/EEPCO/LOT 1/PO/008 Dated : 14/03/2009 EEPC- Accelerated Electricity Access Expantion SH2 19B 119B AM M3 R4 R5 701D 702D (TO DCDB) 5 6 7 8 (126V + 1% ) 1 --- APPROVAL COMMENTS 20/05/09

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A

FILE NAME D:\Hema\2008-2009\conv\pcoos-000008-08-09\sch-coo-08-2264-08\A5-PFC.sch

:-ALL EARTH POINTS SHOULD BE INTERCONNECTED.

0 4 4 HEMA MCB TRIP FCBC - 1 DC O/P FCBC - 1 ON FCBC-1 FAIL FCBC-1 AC I/P MCB TRIP 10 11 9 PC404 TB3 CON.401-402 FAIL AC MAINS PC 6&7 12 4 11 BATTERY EARTH FAULT PC 10 7 8 6 CHARGER TROUBLE

POTENTIAL FREE CONTACTS

TB3 101B 102B 103B 104B 105B 123B 124B 125B 126B 127B 128B C C C C NC NC NC NC NO NO NO 12 4 11 PC4 PC5 12 4 11 119B 120B 121B 122B 123B 124B DC UV DC OV C C NC NO NC NO

SCHEMATIC DRAWING OF 125V/50A DUAL FCBC 10 11 9 PC405 106B NC 107B C 108B NO C O N .401-402 111B 9 11 10 PC407 NO C NC C NO 109B 110B 112B NC 9 10 11 PC506 C NO NC NO NC 113B 114B FCBC - 2 FCBC-2 ON FAIL MCB TRIP FCBC - 2 DC O/P FCBC-2 AC I/P MCB TRIP 10 11 9 PC504 115B NC 116B C 117B NO 10 11 9 PC505 118B NC 119B C 120B NO 15 14 12 11 PC8 FUSE FAIL BATT I/P 121B C 122B NO TB(INT) CON.401-402 137B C NC 138B EMERGENCY LIGHTING 12 4 11 PC13 119B NC 120B C 121B NO BATT UV 02/04/2009 SCH -2264 - 08 ( PCOOS/000008/08-09 ) NCC LTD

(TO DCDB) PC8 1 A F B E1 E2 E3 11 10 134B 133B 129B 7 6 PC407 C NO 133B 132B C 133B NO SW502 9 130B 131B C NO 5 PC 406 3 5 C NO 4 NC 135B 133B 130B 7 6 PC506 C NO 130B FLOAT ON BOOST ON

EEPC- Accelerated Electricity Access Expantion

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

39 40 41 42 43 44 45 46 47 48

49 50

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1 2 3 4 5 6 7 8 A B C D 8 7 6 5 4 3 2 1 D C B A PROJECT CUST P.O. NO. DWG. NO. TITLE

DATE SHEET OF REV :

A

MA R A R A J

A

POWER SYSTEMS LTD

Registered Office & Works karakambadi - 517520 Ph(0877) 2285561 to 2285565.

DRAWN CHKD. RECHKD. APPD.

REMARKS

REV. ECO DATE APPD.

: : :

A3 FILE NAME D:\Hema\2008-2009\conv\pcoos-000008-08-09\sch-coo-08-2264-08\A7-BATT ISO-1.sch

Pro p ri eta ry m ateri al o f M/ s. AMARA RAJ A POWER S Y S TEMS LTD. , Ti ru p ath i. Al l ri gh ts reserv ed . No co p yi n g p erm it ted u n au th ori sed u se pr ohibite d . E N G -SFS-06/R ev.0 HEMA 1 1 0 : SCHEMATIC DRAWING OF

BATTERY FUSE BOX FOR 125V DC

FROM CHARGE R OUTP UT 303H 301H TO BATTE RY BANK TB5 TB4

BATTERY FUSE BOX

240H

119H

CABLE DETAILS

DESIG-NATION CABLE SIZEIN Sq.mm

H 16.0 INTERNAL FUSW 1 02/04/2009 SCH - 2264 - 08 ( PCOOS/000008/08-09 ) NCC LTD

1

2

3

4

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A

FILE NAME D:\Hema\2008-2009\conv\pcoos-000008-08-09\sch-coo-08-2264-08\A1-Dcdb.sch Hemalatha.k

R ed E Bl ack E CB3 DC DISTRIBUTION BOARD 240H 119H CB1 ( 63A ) TB1 16A-2P-DC CB OUTGOING EMERGENCY LIGHTING CHASIS G GROUND 17D ALL DOORS PROVIDED WITH ELECTRICAL COMPONENTS TO BE EARTHED PROPERLY

NOTE

2H R ed E Bl ack E CB4 R ed E Bl ack E CB5 R ed E Bl ack E CB6 TB3 TB4 TB5 TB6

603E 604E 605E 606E 607E 608E 609E 610E

1H CABLE DETAILS DESIG -NATION CABLE SIZE IN Sq.mm F 6.0 E 4.0 INTERNAL H 16.0 F R OM CHARGER DC OUT P UT FEEDERS - 7 NOS SCHEMATIC DRAWING OF 1 1 0 615E 616E (16A) SW 1 TB 9 Red E Bl ack E 8 7 PC1 119D (U V V DB BD.) 240D 8 7 PC2 8 7 PC3 V DB. BD. V DB. BD. 2D 1D 17D 17D PC1 4 11 TB13 250D 251D PC2&3 4 12 252D 253D C NO C NO DC UV DC EARTH FAULT

POTENTIAL FREE CONTACTS

SH1 22B 2B 119H 1H 2H VM M1 22H AM M2 CON. 1 2B 617E 618E 8B TB( INT) R ed E Bl ack E CB7 TB7 611E 612E R ed E _Black E CB8 TB8 613E 614E R ed E Bl ack E CB2 TB2 601E 602E R ed F Bl ack F CB9 TB10 619F 620F R ed F Bl ack F CB10 TB11 621F 622F R ed F Bl ack F CB11 TB12 623F 624F

32A-DC-O/P FEEDERS- 3NOS

LE D1 3 PC 1 10 C NC R 1 LE D2 2 PC 2&3 10 C NO R 2 DC UV BATT EARTH F AULT 240B 119B FROM TB1 TRF.CONTL PANEL (132KV/66KV SIDE) TRF.CONTL PANEL (33KV/15KV SIDE) SPARE 33KV COMMON CONTROL CUBICLE

REMOTE TAP CHANGER

CONTROL PANEL 132 OR 66KV ISOLAUX.SUPPLY 33 OR 15KV ISOLAUX.SUPPLY SPARE SPARE SPARE

02/04/2009

SCH -2264 - 08 ( PCOOS/000008/08-09 ) NCC LTD

24B SW2 1 A1 A2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 (126V + 1% ) 1 --- APPROVAL COMMENTS 20/05/09

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295102895-Battery-Charger-DCDB.pdf

DRAWINGS

FOR

APPROVAL

AMARA RAJA POWER SYSTEMS (P) LTD.

RENIGUNTA–CUDDAPAH ROAD, KARAKAMBADI–517 520

TIRUPATI (A.P.)

TABLE OF CONTENTS

G E N E R A L D E S C R I P T I O N

TECHNICAL SPECIFICATION OF CHARGER

TECHNICAL SPECIFICATION FOR DCDB

S.No.

CLAUSE

DEVIATION / JUSTIFICATION

SYSTEM THEORY OF OPERATION

Bill Of Material Report

Bill Of Material Report

Bill Of Material Report

Bill Of Material Report

Bill Of Material Report

A

A

A

A

A

A

A

A

A

A

A

A

A

A