F Tech Spec 30 V 100 AH Battery Charger 2011
F Tech Spec 30 V 100 AH Battery Charger 2011
F Tech Spec 30 V 100 AH Battery Charger 2011
30 V, 100 AH STATIONARY
BATTERIES AND BATTERY CHARGING EQUIPMENT.
INDEX
1) Scope
2) Service conditions
3) Standards
4) Part-I, Batteries
5) Part II, Battery Charger
6) Testing facilities
7) Inspection
8) Drawings
9) Schedules
Schedule A
Schedule B
1. Scope : The specification covers the design, manufacture, testing at the Manufacturer’s
works, Inspection, delivery, erection and commissioning of 30 V, 100 Ah stationary
batteries and battery chargers to required for various 33/11 KV Sub-stns. in Rural
Electrification System of Maharashtra State Electricity Distribution Company Ltd.
APPLICATION:
The system requires a reliable and uninterrupted D.C. supply for supplying D.C.. Power to
emergency lights, closing and tripping coils of circuit breakers, relays semaphores etc.
2. Service conditions:
3. Standards:
Unless otherwise specified, the equipment shall conform to latest applicable Indian
standard of equivalent IEC, British of USA standard and in particular to the following
standard (or equivalent IEC British, USA standard):
a) IS: 1651/1991 Specification for stationary lead acid ( with Tubular plate ).
b) IS:3895/1966 specification for the rectifier equipment in General.
c) IS:9224 Specification for HRC fuses.
d) IS: 1248 Indicating instrument.
e) IS:375 /1963 Specification for wiring.
f) IS: 4540/1968 Monocrystaline semiconductor rectifier assemblies
g) IS:4540/1968 Monocrystaline semi-conductor rectifier assemblies and equipment.
h) IS:2026 Transformers.
i) IS: 13947/ 1993 Contactors for voltage not exceeding 1000V
j) IS:13947/1993 Air break switches.
k) IS: 5/1978 Colour for ready mix paint.
l) IS: 5421/1981 Printed Circuit Board.
m) IS: 8828/1993 Miniature circuit Breakers.
The tenderer shall clearly static the standard to which the equipment offered by him
conforms.
4.1 Low maintenance type of Lead Acid stationary Batteries incorporating Special Grid Alloy
of lead selenium with Tubular positive plates assembled in 2 Volt containers with a
capacity of 100 Ampere –hour at 10 hour rate of discharge to an end voltage of 1.85 V
per Cell having Electrical performance as per IS:1651/1991 or its latest version amended
upto date.
4.2 Each Cell shall be fitted with one acid level-indicating float. The terminals of the battery
shall be
suitable for receiving cable lugs. 15 Nos. of 2 volts 100 Ah Cell connected in series
shall form one set of 30 volts 100 AH. Each battery set of 30 volts shall be supplied with
the following accessories.
4.3 The expected life span of the batteries shall be minimum, 10 years.
4.4 The container shall be of hard rubber and shall be sufficiently robust and free from flaws.
4.5 Electrolyte: The Electrolyte shall be battery grade conforming to IS:266 or its latest
version amended upto date.
4.6 Life : The tenderer shall quote in his offer the guaranteed life of the battery when
operating under the conditions specified in the specification.
4.7 Wooden Stand: Battery racks and stand constructed out of teak wood and painted with
atleast 3 coats of acid resistant paint. The construction of the racks shall be suitable for
fixing to flat concrete floor. The racks shall be rigid, free standing type and free from wrap
and twist. The assembled racks shall be suitable for being bolted end to end to form
continuous row.
4.8 Battery shall be transported in dry , uncharged condition . The electrolyte shall be supplied
separately in non-returnable container of acid resistant material. Each battery set shall be
supplied with operation / commissioning manual.
These are to be performed at manufacture’s works and shall include the following tests .
These tests shall be performed in presence of purchaser’s representative from the sample
selected from the lot offered for supply.
4.10.3. : If the tenderer have already carried out the type test of same design and type of batteries
against MSEDCL’s past orders in that case, the waival for carrying out of Type Tests
shall be obtained from office of the C.E. (Stores ) before commencement of supply.
PART II
5.1 SUPPLY : AC input : 240 volts +20 % & - 25%, 50 HZ +/- 5% , Single phase supply.
5.2.2 During boost charging, voltage across the battery terminal will go higher at the order of
about 35-42 volts for which suitable automatic solid state transistorized dropping device
shall be provided (maintain 30 Volts + / - 2 volts across the load terminal.
5.2.3 Battery Charging Equipment shall be fully automatic for Float and Boost charging facility
with suitable indication on front of the panel by means of LED indication. For this
automatic solid state changeover relay shall be provided. During AC main fail, Battery
supplies the load and gets discharged. The extent of discharge depends on the time of
power failure and the current drawn by load, when the mains are restored after power
failure. Battery shall put on automatically on boost mode. During this time , load voltage
shall be maintained by load regulator 30 V +/- 2 Volt. After the Battery gets fully charged
i.e. its voltage reaches 40-42 Volts, it should automatically switch over to trickle mode &
when Battery voltage falls below 30 volts, the charger should automatically switch over
to quick mode.
5.2.4 The manual mode should be fully independent so that no element of electronic controller
comes into it’s operation. This shall also include an independent full wave bridge rectifier
of suitable rating output of which will be connected to load and battery by means of a
contactor controlled switch on the front panel. Output of the charger in manual mode to
be maintained below 35 volts by means of selector switch , the suitable tap on the
secondary side of power transformer by the operator.
5.3 RATING :
a) At Load Terminal :
During Float charging or Boost charging, the load voltage shall be maintained 30 V ± 2
Volt. For AC input voltage variation of +20 & -25 % and load variation of 0 to 100 %.
Also system shall provide 6 Amps continuous current and also momentary current of 30
Amps for one second.
b) At Battery Terminal :
i) Trickle charge voltage 32-34 volts (2.16 V/2.25V per cell ) at 200 mA maximum.
ii) Quick charge voltage 35-42 volts ( 2.35V/2.75 V per cell) at 6/10 amps.
c) RIPPLE :
The ripple content in the DC output of Battery Charger shall be limited to 5 % RMS.
5.4 COMPONENTS :
The Battery charger shall comprise of following components but not limited to the same :
a) Double pole AC circuit breaker for AC incoming of the battery charger (MCB).
b) ON/ MAIN lamps/ LEDs for AC Mains supply charger ‘NO” lamp/ LED for DC
output.
c) Single phase, double wound, Air Natural Cooled, Vacuum impregnated transformer of
CRGO lamination and copper winding.
d) Single phase, full wave SCR bridge 25 A rating (Silicon controlled rectifier ) together
with suitable heatsinks and RC suppression network..
e) Automatic solid state voltage / current controller for automatic control of voltage and
current during float/ boost charging the batteries complete with manual control facility.
f) Auto /manual mode selector switch (25 A AC rating) with Indication lamp/ LED for
respective position.
k) DC moving coil or digital voltmeter of 0-50 V rating with selector switch and HRC
fuse to measure voltage of Charger/ Battery and Load.
l) Solid state automatic load voltage regulator to maintain the load voltage of 30 V +/ -2
V( rating of the regulator shall be 6A continuous and 30 A for one second) during
Float charging or Boost charging of the Batteries.
p) Fuse fail indication lamp/ LED for load and Battery fuses.
5.5 DC DISTRIBUTION BOARD
DC Distribution Boards feeders shall be mounted on the charger cubicle itself with
following rating.
a) One No. of outgoing feeder with double pole circuit breaker of 63 A rating (MCB)
suitable for 3 kA rupturing capacity at 48 V DC.
b) 2 Nos of outgoing feeders with double pole circuit breaker of 32 A
rating (MCB).
c) One No. of outgoing feeder with double pole circuit breaker of 16 A rating (MCB).
d) Battery fuse fail & load fuse fail and charger trip due to overload indication on the
front panel shall be brought alongwith reset switch.
5.6 Charger cubicle shall be supplied completely wired upto terminal block for purchaser’s
external connection using solder less crimping type copper lugs. All wiring shall be carried
out with 1100 V grade single shall be flame/ vermin and ridden proof. All wiring shall be
neatly bunched without affecting access to equipment/ components mounted within the
cabinet. Suitable two earthing terminal and outgoing terminal shall be supplied to connect
the external supply cables.
a) All printed circuits boards used in the Battery charger shall be solder marked, glass,
epoxy, , FR 4 grade copper clad material having age type gold plugging connectors
conforming to latest IS-IEC specifications. All assembled PCD conforming coating on
component side & epoxy varnish on the other side.
b) Transformer shall be with class –B insulation having a continuous rating atleast 125%
of the rating of the charger. Reactance of the transformer shall be suitable to take care
of regulation and surges.
c) Tenderer shall furnish full description and illustration of all components complete
with quantity, make , rating , type, tolerance etc. including, but not limited to the list of
components given above.
d) Electronically controlled circuitry should have a built in feature of soft start so that
whenever a charger is switched on the output voltage should increase gradually. This
circuit shall have also built- in current limiting circuit to drop the cutout voltage on
current more than 100% of the rated voltage and the charger should be protected against
short circuit across the load terminal/ Battery charger terminal.
f) The charger cubicle will be indoor type with all associated and auxiliary equipments
mounted therein.
g) The charger cabinet shall be 2 mm. Thick sheet steel enclosed and shall be dust
weather and vermin proof of suitable thickness indicated in the specification. The
minimum overall dimension of the charger shall be height 1100 mm. Width – 600
mm. And depth 400 mm.
h) The cabinet shall be free standing floor mounting type as well as wall amounting
type the enclosures of the cabinet shall provide high degree of protection IP-42 as
specified in IS:13947.
i) All doors removable covers and plates shall be gasketted all around with neoprene
gasket. Louvers, when provided shall have screens and filters. The screen shall be of
fine wire mesh made of G.I. wire.
j) All sheet steel works shall be degreased, pickled phosphate and then applied with two
coats of Zinc primer and two coats of finishing synthetic enamel paint of light gray as
per IS : 631, both inside and outside.
k) All fuses shall be the HRC cartridge types conforming to IS: 2208 mounted on plug
type fuses bases.
l) Electrical indicating instruments shall be flush mounted on panel with only flanges
projecting. Dial shall be white with black number and lettering.
n) Indicating lamps shall be filament type having double contact bay net caps/ LED type
with low watt consumption. The lamps / LEDs shall be provided with series resisters
to prevent short-circuiting of control supply on filament.
o) Strip type space heaters of adequate capacity shall be provided inside each cabinet to
prevent moisture condensation.
p) Charger cabinet shall be supplied completely wired of suitable size ready for
purchasers external connections at the terminal blocks. All wiring shall be carried out
with 1100 V grade PVC insulated standard conductors.
q) All door mounted equipments as well as equipment mounted inside the cabinet shall
be provided with individual labels with equipment designated engraved.
r) Battery charger cabinet shall be provided with two separate suitable earthing
terminals.
s) The supplier of battery charger shall fully co-ordinate with the supplier of battery in
the event of the purchaser deciding not to place order for both equipments on the
same supplier.
u) All Deviations form this specification shall be set out by the tenderer and should be
brought out clearly.
5.8 Method of cooling of charger equipment shall be specified by the bidder and various
tests to be conducted on batteries as per relevant applicable standard.
5.9.1 Two earthing studs of M.S. 50 mm long & 12 mm dia shall be provided for external earth
connections. These should be complete with plain washer, spring washer, nuts etc.
Earthing Bolts must be welded to prevent removal of the same form the Box.
5.9.2 All live connections shall be carried out on the Battery Charging equipment.
1) Physical checking of charger as per approved drawing.
2) Insulation resistance test.
3) High voltage test ( 2.0 KV).
4) Line regulation test at NO Load and full load in test at load in Flat/ boost mode.
5) Full load ripple content measurement test at load terminals in float and boost mode.
6) Voltage regulation test at load terminal and Battery terminals in float and boost mode.
7) DC short circuit test without blowing HRC fuses and without tripping MCBs at load
terminal and also at Battery charger output terminals with observation of total current
limit.
8) Efficiency measurement test at full load and 20% load.
9) Checking of automatic operation Float to Boost, Boost to float mode as per Battery
condition.
10) Checking of Battery voltage, load voltage and Load current Boost Mode at different
charging current.
11) Temperature rise test of complete charger at full load current ( 10+6) A @ ambient
temperature.
12) Checking of battery & Load Terminal voltage in manual Mode operation at different
position of Manual Mode Selector Switch.
13) Checking of automatic connection of Battery to load in case of ‘Mains Failure’ or
Charger Trip’ conditions.
14) Checking of Float voltage setting range and Boost current setting Range in Automatic
Mode.
15) Any other routine test shall be carried as per IS : 4540 on the complete battery
Charging equipment.
5.10.2 For acceptance of lot all above routine tests and below mentioned PCB Tests shall be
carried out on selected 2 samples.
PCB Test : Each assembled PCB shall subject to following test at manufacture’s work..
a) Burn in at 70 degree C for 72 hours.
b) Rapid temperature cycling at 70 degree C & 0 degree C for 30 minutes at each
temperature ( 5 such cycles) facility for conducting the above tests shall be clearly
mentioned in the offer.
The tenderer must clearly indicate what testing facilities are available in the works of
manufacture and whether the facilities are adequate to carry out all Routine, Acceptance
and Type tests. These facilities should be available to MSEDCL’s Engineers, if deputed to
carry out or witness the tests in the manufacture’s works. If any of the tests can not be
carried out in the manufacturer works, the same should be clearly stated.
6.0 Inspection :
All tests and inspection shall be made at the place of manufacturer unless otherwise
specially agreed upon by the manufacturer and the purchaser. The manufacturer shall
provide the purchaser all reasonable facilities , without charge to satisfy him that the
material is being supplied in accordance with this specification.
7.0 Drawings :
The bidders will have to submit the tender drawings ( General Arrangement ,
constructional details, mounting and bill of material for battery and charger with offer. The
successful bidder will have to submit the final drawings for approval of office of the Chief
Engineer (Stores) and shall get it approved within 15 days.
8.0 Schedules:
The tenderer shall fill in the following schedules, which is part and parcel of the tender
specification and offer. If the schedules are not submitted duly filled in with the offer, the offer
shall be liable for rejection.
Schedule A ----- Guaranteed Technical Particulars.
Schedule B ------ Tenderer’s Experience.
Schedule ‘A’
Tenderer shall furnish here a list of similar orders executed under execution by him to
whom a reference may be made by purchaser in case considers such a reference necessary.