BATTERY CHARGERS

By : Rajinder Hans

UNINTERRUPTED
POWER SUPPLY

Introduction to Uninterrupted
power supply.

AC to DC conversion (Rectification)

Battery charger system

Batteries

UNINTERRUPTED
POWER SUPPLY

Uninterrupted power supply as the name

suggest is power supply available without any
interruption.

This is required for maintaining power supply to

critical system/equipment, failure of which may
result in process disturbance, equipment
damage or safety hazards.

Generally provided to DCS system, SDV supply,

emergency pumps, and control supply to PLC
and electrical switchboards.

UNINTERRUPTED POWER
SUPPLY
TYPES
1.

DC SUPPLY :
SOURCE : Battery chargers located at substations.
USED FOR : Electrical panels control supply, Fire alarm
system, Telecommunication, Solenoid valves (SDV),
Switches at field (e.g. flow, pressure), & Emergency lighting
supply.

2.

AC SUPPLY :
SOURCE : Provided by UPS system located at Control room
buildings.
USED FOR : DCS, Analysers, and Instrumention field control
panels, ECS stystem, PLC, VFD etc

BLOCK DIAGRAM OF CHARGER AND UPS

3 phase
AC
supply
BATTERY
CHARGER

L
O
A
D
Rectifier
Battery
L
O
A
D

3 phase
AC
supply

UPS
SYSTEM

Rectifier

Inverter
Battery

RECTIFIER

RECTIFIER

Rectification is the conversion of

current (AC) to Direct current (DC).

Alternating

This involves the use of a device called Rectifier

that only allows one-way flow of electrons.

Rectifiers can be classified as uncontrolled and

controlled rectifiers.

Uncontrolled rectifier circuits are built with

diodes.

Controlled rectifier circuits are built with SCRs.

RECTIFIER
A Diode is an electrical device
allowing current to move through
it in one direction.

+ve cycle Diode

2&3
- ve cycle Diode
1&4

 Current flows through one diode from the RIGHT group

and one from the LEFT
Diode with highest anode potential from the RIGHT and
diode with lowest cathode potential from the LEFT will
conduct

THREE PHASE UNCONTROLLED

RECTIFICATION WAVEFORM

SILICON CONTROLLED RECTIFIERS

(SCR)

The SCR is a semi-conductor device with 3 terminals

i.e. Anode, Cathode and Gate.
The main load current is carried by Anode and Cathode
while the control current flows through Gate and
Cathode.
When the gate to cathode voltage exceeds a certain
threshold, the device turns 'on' and conducts current

SILICON CONTROLLED
RECTIFIERS (SCR)

The characteristic of SCR is such that it blocks

the forward voltage until the Gate current
reaches the specified level.

Therefore the instant at which the SCR goes

into conduction can be controlled by changing
the instant at which the gate current or pulse
is applied.

Once the SCR is triggered it remains in

conduction till Anode current is reduced to
Zero or reverse voltage is applied to anode

Uncontrolled rectifier

Controlled rectifier

Period, range of q

SCR Pair in conduction

30o to 90o
90o to 150o
150o to 210o
210o to 270o
270o to 330o
330o to 360o and 0o to
30o

S1
S1
S2
S3
S4
S5

and
and
and
and
and
and

S6
S2
S3
S4
S5
S6

SCR1

SCR2

SCR3

Fully
Controlled

Bridge

Loa
d

SCR4
SCR1

SCR5

SCR6

SCR2 SCR3
Half
Controlled

R
Y

Loa
d

D1

D2

D3

Bridge

BRIDGE RECTIFIER DIAGRAM

SCR1
CAPACITOR

SCR2

SCR3

CHOKE

R
Y

Uo
DC

B
3 PHASE AC
INPUT

Us RMS AC
SCR4
LOAD

SCR5

SCR6

F/W DIODE

EQUATION FOR O/P VOLTAGE U o = 0.675*Us( 1+ CosA)

A= FIRING ANGLE OF SCR , Us= RMS AC VOTAGE INPUT

THREE PHASE CONTROLLED

RECTIFICATION WAVEFORM

DCFILTER
Ripple is the small AC voltage or current
occurring in a DC component as an
unavoidable byproduct of rectification.
Ripple filter is a combination of
inductance and capacitance used to
reduce the level of ripple.

BATTERY CHARGER
SYSTEM

Block Diagram of Battery Charger

Input
Transformer

Rectifier
Bridge

Filter
Circuit

Load

Battery
Control
And alarm
section

BATTERY CHARGER

BATTERY CHARGER is a Controlled Rectifier

which converts AC power to DC power.
It uses a Three phase Controlled SCR bridge
Rectifier.
The output voltage of a rectifier is controlled
by changing the firing angle of the SCR.
Output of Rectifier is smoothened by Filter
comprising of Capacitor and Inductors (Choke).
The output of the rectifier supplies the DC
supply to load and at the same time charges
the battery.

Basic components
required for Charger
System.
Termination terminals, Switches/Fuses/MCBS/MCCBS;
Contactors and relays.
Meters Voltage and current both at Input and output.
Transformers Mains and control.
Semiconductor devices ie THYRISTORS & DIODES.
Choke and Capacitors.
Shunts.
Printed circuit boards (PCBS).

FEATURES OF BATTERY
CHARGERS

Soft start (gradual build up of DC at start).

Output DC voltage maintained constant for +/10% AC voltage variation and 0-100% load
variation .
Operation in float and boost charging modes
possible.
Load current limit feature. Output voltage droops
in event of load current exceeding rated current.
Battery current limit.
DC earth fault detection.

FEATURES OF BATTERY
CHARGERS

Constant current charging in boost mode.

Auto changeover to boost mode if desired.

Ripple content of max 2% with battery.

Operation in Auto and manual mode (during
control card failure only in Chabbi Chargers).

Input Section

Input

Switchgear

(Switch

fuse

contactor + thermal overload relay or MCCB)

for isolation & protection

Indications and measuring instruments

Transformer for stepping down the voltage
suitable for the thyristor bridge.

Rectifier Bridge Section

Single Phase, Full Wave, Half
consisting of thyristor & diodes.

Controlled

Bridge

Three Phase, Full Wave, Half Controlled Bridge with

thyristors & diodes.
Three Phase, Full Wave,
consisting of thyristors.
Rectifier protection fuses.

Full

Controlled

Bridge

Filter
Section
Vmax

Filter combination of
choke and capacitor

Vrms
Volts (V)

Time (s)

Designed to reduce
output ripple.(AC
component
that
rides on the DC
output of a rectifier)

Voltage wave form after filter

Vripple

Volts (V)
Time (s)

Control & Alarm

Section
Maintains voltage regulation of 1%
and current
regulation of 2% for load variation of 5-100% and input
variation of 10%
Independent current limit protection for battery and
charger.
Protection for DC over-voltage, AC under-voltage, AC overvoltage and phase fail and phase sequence fail.
Adjustable time settings for boost charging and reverting
back to float mode after boost charging.
Audio Visual alarms and indication with common fault
contact for remote indication.

CHARGER CONTROLS AND

ALARMS

Controls
1.
2.
3.
4.
5.
6.

Regulation of +/- 1% for

load and line variations.
Short circuit/Overload
protection.
Reverse polarity
protection.
Soft start
Battery current limit
Total current limit.

Alarms & Protections

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Input supply fail

DC under-voltage
DC over-voltage (T)
Charger fail (T)
Input under-voltage(T)
Input over-voltage (T)
Earth fault
Rectifier fuse fail
Output fuse fail
Current limit operated.

MODES OF CHARGER OPERATION

Float mode : Normally the charger is in float

mode and supplies the load and charges the
battery. This is constant voltage mode.

Boost mode : During power failure the load is

supplied by battery. On resumption the battery
needs to be boosted to a higher voltage under
current limit. This is done after isolation of the
charger
from
load.
This
is
current
limit/Constant current mode.

TYPES OF
SYSTEM CONFIGURATION

Float Cum Boost Charger.

Float and Float cum Boost Charger.

Dual FCBC with Common Battery.

Dual FCBC with Two Batteries.

Dual Float and Boost Charger with Auto

change over.

FRONT PANEL OF HBL BATTERY

CHARGER

FRONT PANEL OF HBL BATTERY

CHARGER

Dual FCBC with Common

Battery.

CHARGER CONFIGURATION
Dual FCBC with Common Battery.
In each system there are two battery chargers
for redundancy operating in parallel.
One charger is rated to supply the connected
load in case of failure of one charger.
Each charger can operate in float mode and
boost mode.
During an emergency, when AC power fails,
the battery supplies the load & it discharges to
certain extent depending on the load and
duration of emergency.

CHARGER CONFIGURATION

Dual FCBC with Common Battery.

Upon resumption of Mains power the Charger
automatically restarts and develop Float Voltage.
At the time of restoration of input power supply
battery needs to be boost charged. Under such
condition one charger will supply the load and other
charger will be in boost mode charging the battery.
In case of Auto boost facility the charger goes to
boost mode if the battery takes current more than a
set value.
Once the charger goes to boost mode it comes back
to Float mode after a set time.

110V DC CHHABI BATTERY CHARGER

BLOCK DIAGRAM
C1A

O/L1A

Tr.

Fuse

Fuse

SW5
A

Charger A

Tap
cell
diode

C3

SW1A

DCDB

B Diode
MCCB 1B

MCCB 1A

SW 7
80%
C1B

O/L1B

MCCB 1A

Tr.

BATTERY BANK

B Diode

Fuse
SW1B

Fuse
Charger B

SW5 B

MCCB 1B

HBL CHARGERS IN PREP & PXPTA

K1

OLR

Tr.

Fuse

Fuse

SW 2

B Diode
Charger A

K3

Only in MCCB
model

Tap
cell
diode

K4A

SW1
SW 5

80%
K2

OLR

Tr.

K3A

BATTERY BANK

B Diode

Fuse
SW2

Fuse
Charger B

SW 4

K4

HBL CHARGERS IN PREP & PXPTA

There are two Nos. of float cum Boost chargers(Charger-1 and

2) with common battery bank.
The chargers operate in parallel to float charge the battery
and feed the load.
The output of the chargers is fed to a common DCDB.
Each charger can be put in boost mode to boost charge
the battery .
The charger has a facility of Auto as well as Manual mode boost
charging.
In Auto Boost mode if the battery charging current is more than
10% (AH/5) one of the charger will go in to boost charging.
The load output contactor/MCCB of charger which goes into
boost charging will trip and the other charger (float mode)
Battery Contactor/MCCB will trip.
When the time set for boost charging is complete the Charger
which was in boost mode returns to Float mode.

HBL CHARGERS IN PREP &

PXPTA

In Contactor model charger, the output and battery contactor of

respective chargers will get ON after the battery voltage comes to
the float charging voltage.
In MCCB model the MCCB are required to be switched ON
manually.
In case of mains failure of both the charger during boost charging,
all the four contactors will get ON as soon as the battery voltage
comes down to Float voltage.
In case of mains failure of both the charger during boost in MCCB
model charger, Battery to load contactor will get ON and load will
be supplied by the battery bank.
Till the contactor get ON in both the schemes the load is fed by
battery through Tap Cell.

HBL 24 V DC CHARGERS AT CPP (STG)

BLOCK DIAGRAM

O/P SWITCH
S1

BB-1
CHGR - 1

DCDB1

3 PHASE
AC INPUT
CHGR-2

BB
2

DROPPER
DIODE

O/P
SWITCH
S1

DCDB2

DROPPER DIODE
BYPASS CONTACTOR K1

HBL 24 V DC CHARGERS AT CPP (STG)

There are two Nos. of float cum Boost chargers (Charger-1 and
2) with separate battery banks.
The chargers operate in parallel to float charge the battery
and feed the load.
The output of the chargers is fed to two Nos of DC
distribution boards .
Each charger can be put in boost mode to boost charge
its battery .
The charger that is put in boost mode, it has to be disconnected
from the DCDB by switching OFF the Output Switch S1 prior to
putting it in boost mode.
The load is fed via dropper diodes under normal condition so
that reduced voltage is available at the load.
In case of mains failure the load is fed by the battery. The DVR
contactor gets energized the moment the voltage falls below
load requirement. The dropper diodes are shunted once the
contactor energizes.

Fuse

TH relay

SW

3Ph.415V

Fuse

TH relay

3Ph.415V

Charger
-2

Tr.

Charge
r-1

Battery
Bank-1

Tr.

Blocking Diodes

DCDB -1
I/C Bkr-1

DCDB-2
Tie Bkr

I/C Bkr-2

Battery
Bank-2

SW

220V DC Charger System at CPP/

MSQ

220 V DC CHARGER AT CPP/ MSQ WITH

INDEPENDENT BATTERY BANK

There are two float cum Boost chargers viz Charger-1 and Charger2.
The output of each charger is connected to a DCDB through a
incomer breaker/ Switch.
There is a tie breaker/Swtich used to connect the two sections of
DCDB,s whenever required.
Each charger has its own battery bank which is connected to the
respective DCDB
Normally each charger feeds loads connected to its DCDB and float
charge its battery bank. The tie breaker is normally open.
Load of both the DCDBs can be fed from one charger by closing the tie
breaker .
In Case of boost Charging the Tie breaker is closed and the Incomer
from Charger of the battery bank to be boost charged is switched OFF.
Boost charging is switched ON and the battery is boost charged for the
set time.
The Charger comes back to Float mode after the set time. Incomer and
Tie Breakers/Switches are normalised thereafter.

OPERATING PROCEDURE
(Float mode)

SWITCHING ON BATTERY CHARGER IN FLOAT MODE

Ensure that the Auto/Manual switch is in Auto position

Check the DC output switches of both chargers are ON.
Ensure that Main AC input switches for both the chargers in
ON.
Check that all the MCCBs of both the chargers are ON.
Put the chargers On/Off switch to ON position for charger A/B.
Observe that the DC output voltage gradually rises to the set
value.
Switch ON charger B/A and observe that the output voltage
gradually rises to the set value.
Switch ON the battery switch.
Check the load current is within the charger limits.
The chargers will share the load approximately equally .

OPERATING PROCEDURE
(Boost mode)

Normally both charger A and B will be operating in float mode in

parallel sharing the load and trickle charging the battery.
Ensure that the DC output switch of both chargers are ON.
Decide upon the charger to be used as the boost charger (Charger
A/B).
Ensure that the battery current limit pot is in minimum position.
Switch the selected charger to Boost mode by pressing the Boost PB.
The MCCB connected to the load will trip for the charger put on boost.
Adjust the battery current to the desired value using the battery
current limit pot.
Continue boost charging for the set time after which the charger
comes back to the Float mode. It can also be put back to float mode by
pressing the float PB.
Ensure that the load MCCB is switched on again after the charger is
put back on float.

THANKS

Block diagram of three phase SCR controller

of CHHABI Make Charger
Manual voltage
Adjustment
potentiometer

A/M S/W
Trigger pulse
generating unit

Reference
and soft start
Voltage regulating
amplifier

Current regulating
amplifier

Shunt
Phase seq Phase
fail circuit
Power
supply

+12 v

Amplifier for
Current signal

-12v
Auto Voltage
adjustment
potentiometer

3 Ph. 415V
from mains

HV card with PST

Bridge
rectifier

Three phase input

Current limit
adjustment
potentiometer

Filter block