Doc. Ref. No : Rev. No.

Date Sheet

3583 LIST 1 26.10.10 1 of 1

RECTIFIER DIVISION LIST OF DRAWINGS & DOCUMENTS

HBL Power Systems Ltd.

CUSTOMER P.O. NO PROJECT HBL JOB NO. TYPE OF UNIT QUANTITY

: M/s.ABB Ltd,. : 3191297339 : PGCB Bangladesh. : TP 10 3 3583 : 48V TP 75A DFCBC With DVR : 2 NoS.

SL. NO. 1. 2. 3. 4. 5.

NAME OF DRG/DOC: SYSTEM DESCRIPTION TECHNICAL SPECIFICATION BILL OF MATERIALS G.A.D. ELECTRICAL & CONTROL SCHEMATICS

DRG/DOC.NO PEE/P84617 PEE/P88617 PEE/P81617 PEE/P91025 PEE/P51617

NO. OF SHEETS 4 2 4 3 10

REVN. 1 1 1 1 1

Doc. Ref. No : Rev. No. Date Sheet

PEE/P84617 1 26.10.10 1 of 4
RECTIFIER DIVISION SYSTEM DESCRIPTION : M/s.ABB Ltd,.

HBL Power Systems Ltd.

CUSTOMER P.O. NO PROJECT HBL JOB NO. TYPE OF UNIT QUANTITY

: 3191297339 : PGCB Bangladesh. : TP 10 3 3583 : 48V TP 75A DFCBC With DVR : 2 NoS.

PREPARED BY: CHECKED BY: APPROVED BY: -----------------------------------------------------------------------------------------SYSTEM CONFIGURATION The Total DC system consists of 2 nos identical Float cum Boost Chargers Type 48 TP 75 FCBC associated with 2 battery banks. Both the chargers have 3 phase Full wave full controlled bridge modules. On the AC side, each charger is fed from separate 3phase, 4 wire per unit the 400V, 50Hz supply. Input ON/OFF Switch+Fuse+Contactor+TOV is provided at the input side of the each charger. A input voltmeter is provided in each charger to read i/p voltage. On the DC side, charger ON/OFF MCCB,BTY side Fuses & blocking diode is provided. Output voltmeters and output ammeters are provided to read charger output voltage & current respectively. LED display card is provided for alarm annunciation (audio alarms through Buzzer) and visual indication through LEDs on front panel. Alarm acknowledge/ reset and alarm LED test is provided through push buttons on front panel. A common potential free contact is provided for these alarms for users use. Both the chargers are provided with two positions Auto/Manual switches whose positions are as follows and Mode select

Auto/Manual select switch Position 1 : AUTO Position 2 : MANUAL

Mode select switch Position 1 : FLOAT Position 2 : BOOST

Position-1 (Auto): In auto mode, charger will start in float mode & will supply the DC load as well as trickle charge the respective battery. If battery requires boost charging, (sensing through respective battery shunt) the charger will turn into boost mode automatically & boost charge the respective battery. After preset time, (as set by timer provided in control card, settable through dip switches for 0-32 Hrs) the charger will revert back to float mode. For this automatic change over from float mode to boost mode, the positions of K3, K5 & K7 shall be as follows.

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PEE/P84617 1 26.10.10 2 of 4

HBL Power Systems Ltd.

For Boost charging Battery-1 with Charger-1 K3 is Off, K7 is in ON For Boost charging Battery-2 with Charger-2 K5 is Off, K7 is in ON Interlock is provided, such that charger will not operate in boost mode unless above condition is met. Note: The charger will changeover to boost mode depending on battery trickle charging current. In this scheme of two chargers & two batteries, one charger will changeover automatically to boost mode. Another battery charger will not changeover to boost mode i.e. It will remain in float mode & will supply the DC load as well as trickle charge the respective battery. Interlock is provided such that only one charger will changeover to boost mode. After completion of boost charging of one battery set, the another battery charger will changeover to boost mode automatically only if trickle charging current is remains above the set value of it for auto changeover. Alternatively another battery set has to be boost charged manually. Position-2 (Manual): In Manual mode, charger will start in float mode & will supply the DC load as well as trickle charger the respective battery. If Battery requires Boost charging, operate the charger in boost mode through float/boost selector switches. For this manual change over from float mode to boost mode, the positions of K3, K5 & K7 shall be as follows. For Boost charging Battery-1 with Charger-1 K3 is Off, K7 is in ON For Boost charging Battery-2 with Charger-2 K5 is Off, K7 is in ON Interlock is provided, such that charger will not operate in boost mode unless above condition is met. OPERATION UNDER NORMAL CONDITION Under normal condition it is assumed that the both batteries are fully charged. Both chargers operate in float mode supplying load and float charging their respective Batteries. IN CASE OF AC MAINS FAILURE UNDER NORMAL CONDITION In case of Mains failure under normal condition both batteries start supplying load through DCDB.

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PEE/P84617 1 26.10.10 3 of 4

HBL Power Systems Ltd.

UPON RESUMPTION OF AC MAINS POWER Upon resumption of AC mains power the chargers develop float voltages and resume normal operation of supplying load and float charging the batteries. However the batteries may have been discharged and needs boost charging. Their respective charger will monitor the battery current and the batteries will be boost charged one after the other. When one charger is under boost charging its associated battery, other charger and battery will be kept under float charging condition only. On completion of boost charging of first battery bank the second bank can be boost charged. Boost charging is offline by opening the load contactor. In this condition Tie breaker contactor (k7) in ON condition in any one of the contactor in OFF position (Due to boost charging the battery) INCASE ONE OF THE CHARGER FAILURE UNDER NORMAL CONDITION: In the above condition the healthy charger supplies the load while floating associated battery. In this condition Tie-breaker contactor (K7) will be in ON position. INCASE OF BOTH THE CHARGERS FAILURE In case of both charges failure under normal conditions both batteries start supplying the load through contactors K3 and K5. Tie-break contactor (K7) is also in ON in this condition. The battery will take care the total loads without any interruption. INCASE ONE OF THE MAINS FAILURE UNDER NORMAL CONDITION: In the above condition the healthy charger supplies the load while floating associated battery. In this condition Tie breaker contactor (K7) will be in ON position. INCASE ONE OF THE CHARGER FAILURE UNDER OTHER CHARGER IN BOOST CONDITION: In the above condition the healthy charger come back to float mode and start supplies the load and floating associated battery. Tie breaker contactor (K7) will be in ON position and load of the failure charger take care by the healthy charger through K3 INCASE ONE OF THE MAINS FAILURE UNDER OTHER CHARGER IN BOOST CONDITION: In the above condition the healthy charger come back to float mode and start supplies the load and floating associated battery. Tie breaker contactor (K7) will be in ON position and load of the failure charger take care by the healthy charger through K3 BOTH CHARGER IN FLOAT MODE FCBC-1 IN BOOST MODE FCBC-2 FLOAT MODE FCBC-2 IN BOOST MODE FCBC-1 FLOAT MODE FCBC-1 MAINS/CHARGER FAIL K3 ON OFF ON OFF K5 ON ON OFF ON K7 OFF ON ON ON

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PEE/P84617 1 26.10.10 4 of 4
FAIL ON OFF

HBL Power Systems Ltd.

FCBC-2 HEALTHY FCBC-2 MAINS/CHARGER FCBC-1 HEALTHY

ON

DIODE VOLTAGE REGULATOR: Suitable DVR is provided to regulate the load voltage within 10% of nominal voltage ie., between 43.2-52.8V during float mode of operations.

Doc. Ref. No : Rev. No. Date Sheet

PEE/P88617 1 26.10.10 1 of 2
RECTIFIER DIVISION TECHNICAL SPECIFICATION

HBL Power Systems Ltd.

CUSTOMER P.O. NO PROJECT HBL JOB NO. TYPE OF UNIT QUANTITY

Prepared: SR. NO PARAMETER 1 AC input voltage 2 AC input frequency 3 DC output voltage settings: Nominal Float Mode Boost Mode 4 Current Limit 5 Power Conversion

: M/ s.ABB Ltd,. : 3191297339 : PGCB Bangladesh. : TP 10 3 3583 : 48V TP 75A DFCBC With DVR : 2 NoS.
Checked: Approved: SPECIFICATION 400V10%, 3 phase, 4 wire 50 Hz5% 48 Volts DC 56 Volts DC (40X1.4V/ CELL) 68 Volts DC (40X1.7V/ CELL) 75A AC to DC by means of a three phase full wave Full Controlled Bridge consisting of Thyristors-thyristor module. 1% of set voltage for 15% input variations, and 0-100% load variations 70% At rated load i.e at maximum voltage & current. 2% RMS at full load. (Without battery connected) SWITCH+FUSE+CONTACTOR+TOV MCCB FUSES Surge suppressors (RC CIRCUIT) Soft start feature Total current limit Control circuit & voltmeter fuses Rectifier protection fuses Capacitor fuses (96X96Sqmm 1%ACC,Analog type) I/ P VOLTMETER O/ P AMMETER O/ P VOLTMETER

6 7 9 10

Output Voltage Regulation Efficiency Ripple voltage Switchgear: a) Input side b) Output side b) Battery side Protection

11

12

METERS

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PEE/P88617 1 26.10.10 2 of 2

HBL Power Systems Ltd.

SR. NO 13

PARAMETER INDICATIONS

14

15 16

17

SPECIFICATION I/ P ON LEDs O/ P ON LED CHARGER ON FLOAT CHARGER ON BOOST ALARMS FCBC-1 & 2 MAINS FAIL OUTPUT UNDER VOLTAGE OUTPUT OVER VOLTAGE CHARGER FAIL BATTERY LOW CHARGER OVERLOAD GROUND FAULT -VE GROUND FAULT +VE AC OVER VOLTAGE RECTIFIER FUSE FAIL BATTERY FUSE FAIL BLOCKING DIODE FAIL DVR DIODE FAIL All the alarms will be provided through HBL make LED display card. Audio alarm through buzzer, visual indication through LEDs & Alarms ack/ reset and LED test provision is through push buttons. One potential free contact is provided for common fault in each charger. Operating Temperature 0- 50 C PANEL Dimensions 2000(H)X1600(W)X600(D) Protection Grade IP-42 Paint shade RAL-7032 MAGNETICS Insulation class Class F Average winding temp. Rise 90 Deg. C over ambient Insulation break down voltage Type of cooling CABLES: 2KV for 1 Min Natural air cooling 650/ 1100V grade PVC insulated, Multi-strand copper. Ferrules will be provided at both ends of each control wire for identification. Suitable DVR is provided to regulate the load voltage within 10% of nominal voltage ie., between 43.2-52.8V during float mode of operations.

18 19 20

21

DIODE VOLTAGE REGULATOR:

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PEE/P81617 1 26.10.10 1 of 4
RECTIFIER DIVISION BILL OF MATERIAL : M/s.ABB Ltd,.

HBL Power Systems Ltd.

CUSTOMER P.O. NO PROJECT HBL JOB NO. TYPE OF UNIT QUANTITY

PRPD BY: SL. PART NO. NO. 1. TRANSFORMERS 1. T1, 6

: 3191297339 : PGCB Bangladesh. : TP 10 3 3583 : 48V TP 75A DFCBC With DVR : 2 NoS.
CHECKED BY: DESCRIPTION SEPCIFICATION CONSOLE & CHOKES MAIN XMER 2000(H)X1600(H)X600(D) 8.26 KVA PRI: 400V 15%, 11.93A SEC: 71V, 66.75A 50 VA PRI: 400V 15% SEC1: 18V, 1A SEC2: 15V, 1A SEC3: 15V, 1A 10VA PRI: 230V 10% SEC: 0-10V, 1A 0.59 mH AT 75A DC APPRD BY: MAKE HBL HBL QTY 1 2

2.

T2, 7

CONTROL XMER

3.

T3-5, 8-10

SYNCH.XMER

FILTER 2000MFD/100V CAPACITORS (2 IN PARALLEL) THYRISTOR & DIODES WITH SUITABLE HEAT SINKS 1. MOD 1-6 THY-THY MODULE 97A, 600V PIV 2. V1-4 F.W/B. DIODES 150A, 600V PIV 3. MOD 7-10 DVR DIODE-DIODE 100A, 600V PIV MODULE 4. HS 1-6 HEAT SINKS 80AD-150mm 5. HS 7-10 HEAT SINKS 80AD-200mm 6. HS 11-14 HEAT SINKS EIA1717-225mm SWITCHES & MCCB & CONTACTORS & TOV 1. S1, S3 I/P ON/OFF 25A, 3P ON/OFF AC SWITCHES 2. Q1, 2 O/P ON/OFF 100A, 2P ON/OFF DC MCCB

4. L1, 2 CAPACITORS 1. C1, C2

CHOKE

2 RESCON/ ALCON/SARADA HIRECT/ RIR SEMIKRON /IR 4

6 4 4 6 2 4

EIA

KAYCEE/L&T SCHNEIDER/ ABB/L&T/C&S

2 2

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PEE/P81617 1 26.10.10 2 of 4
DESCRIPTION I/P CONTACTORS SEPCIFICATION 3P, 415V AC COIL, WITH AUX. 1NO +1NC, SUITABLE FOR 16A 3P, 110V DC COIL, WITH AUX.1NO +1NC, SUITABLE FOR 100A SUITABLE FOR 11.93A 6A, ON/OFF, 1P CAM TYPE 6A, 4 POSITION, 440V AC 6A, ON/OFF TOGGLE TYPE

HBL Power Systems Ltd.

SL. NO. 4

PART NO. K1, 2

MAKE

QTY 2

K3-7

6 7 8 9

TH1, 2 SW1, 2 VS1, 2 SW3

O/P,DVR & TIE BREAKER ON/OFF CONTACTORS THERMAL OVER LOAD RELAY CHARGER ON/OFF SWITCH VOLTMETER SELECT SWITCH PANEL LTG. ON/OFF SWITCH

2 KAYCEE/L&T (SALZER) 2 2 IEC 1

RELAYS & FUSES 1. RL1, 4 SUMMARY CONTACT RELAYS 2. RL2, 5 MAINS FAIL SENSING RELAYS 3. RL3, 6 CHARGER FAIL RELAYS 4. RL7,8 BOOST RELAYS 5. 6. 7. 8. 9. RL 9, 11 RL 10, 12 F1-3 F16-18 F4-6, F19-21 F30-33 DVR RELAYS VOLTAGE SENSING RELAYS INPUT FUSES RECTIFIER FUSES BTY FUSES

5A, 48V, DC, 3C/O TYPE WITH 11 PIN BASE 5A, 48V DC, 3C/O TYPE WITH 11 PIN BASE 5A, 48V DC, 3C/O TYPE WITH 11 PIN BASE 5A, 24V, DC, 3C/O TYPE WITH 11 PIN BASE 5A, 24V, DC, 3C/O TYPE WITH 11 PIN BASE 5A, 24V, DC, 3C/O TYPE WITH 11 PIN BASE 20A FUSE WITH SUITABLE BASE 125A HRC BOLTED TYPE

PLA/L&T (SALZER)

GE/BUSSMANN

2 2 2 2 2 2 2 2 2 2 2 2 6 6 6

100A FUSE WITH 4 SUITABLE BASE 4 10. F15, 29 CAPACITOR FUSES 32A HRC BOLTED TYPE 2 11. F10, 30 PANEL LTG.CKT 6A, WITH SUITABLE 2 FUSE WITH BASE BASE 2 12. F8-14, CONTROL CKT & TERMINALS WITH 1A RELIANCE/ 14 22-28 V.METER FUSES GLASS FUSES C.W 14 METERS & SHUNTS (Analog TYPE 96X96 Sq.mm, 1.5% ACC, With 90Deg.Deflection) 1. P1, 4 I/P VOLTMETER 0-500VAC AE/RISHABH/ 2 IMP/UBAH 2. P2, 5 O/P VOLTMETERS 0-100VDC 2 3. P3, 6 O/P AMMETERS 0-100ADC 2

Doc. Ref. No : Rev. No. Date Sheet

PEE/P81617 1 26.10.10 3 of 4
DESCRIPTION SEPCIFICATION 100A, 75m V

HBL Power Systems Ltd.

S.N O 4.

BTY &CHARGER SHUNTS INDICATIONS & OTHERS 1. VD1-3 I/P ON LEDs VD5-7 2. VD4, 8 O/P ON LEDs 3. 4. 5. PS1 DS1- 2 IL1- 2 POWER SOCKET WITH SWITCH DOOR SWITCHES ILLUMINATING LAMP SPACEHEATER THERMOSTAT CONNECTOR CORD CONTROL CARD PULSE TXR CARDS MULTI ALARM CARD MAINS FAIL CARD DC-DC CARD MAIN LED CARD SUB LED CARD RC-CARD DVR CARD GENERAL RELAY CARDS DIODE FAIL CARD DVR FAIL CARD FUSE FAIL CARD POTENTIOMETERS INPUT WIRING CAPACITOR WIRING OUTPUT & BTY TO LOAD WIRING CONTROL WIRING (BLACK &GREY)

PART NO. SH1-4

MAKE AE/UBAH RISHABH REPUTED

QTY 4

6. SPH1 7. TSC1 CONTROL CARFS 1. A1, 11 2. A2, 12 3. A3, 13 4. A4, 14 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. A5, 15 A6, 16 A7, 17 A7A, 17A A8, 18 A9,9A, 19,19A A10, 20 A21, 22 A23, 24 A25, 26 PT1-8 CABLES

10mm RED LEDS WITH METAL HOLDERS 10mm RED LEDS WITH METAL HOLDERS 5A, 240V AC, 3PIN RECTANGULAR TYPE 1NC 60W, 230V AC BULB WITH HOLDER 240V, 100W 2-85 DEG.C 69-00360 69-00081(REV-2) 69-00082 69-00083 69-00087 69-00085(48V) 69-00084 69-00090/REV.:0 69-00003 69-00325 69-00333 69-00303 69-00311 69-00123 20K MULTITURN 4 Sq.mm CU 6 Sq.mm CU 25 Sq mm CU 2.5 Sq.mm CU

6 2

CPL/ANCHOR REPUTED ANCHOR REPUTED ELCOM

1 2 2 1 1 2 2 2 2 2 2 2 2 2 4 2 2 2 2 8

HBL

BOURNS REPUTED

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PEE/P81617 1 26.10.10 4 of 4

HBL Power Systems Ltd.

SL. NO. 21.

PART NO.

DESCRIPTION PCB WIRING (BLACK &GREY) EARTHING BUSBAR INPUT TERMINALS BTY TERMINALS LOAD TERMINALS SUMMARY POTENTIAL FREE TERMINALS HARDWARE ENGRAVING PACKING

SEPCIFICATION 0.5 Sq.mm CU 25X3CU BUS BAR M8X60L M8X60L M8X60L 2.5 Sq.mm CLIP ON TYPE

MAKE REPUTED

QTY

23. TERMINALS 24. X/1-8 25. X/9-12 26. 27. 28. 29. 30. X/17-20 X/13-16

REPUTED

8 4 4-R1 4