Regd. Office & Factory : E-66, MIDC, Jalgaon - 425 003 (Maharashtra) INDIA.

QUALITY
Tel : 91-257-2210626/ 27/ 28, 2270174/75 Fax : 91-257-2213434 ASSURED
COMPANY
Email : chhabi_jal@sancharnet.in, Web site : www.chhabi-india.com ISO:9001-2000
International Standards
Certifications
Lic. No. QAC/R91/0100

Format No. : QF/DD/06

DOCUMENTS TRANSMITTAL SHEET Rev.No. : 00
W.E.F. : 01/04/2006

TO, Our Ref. No. : CE2417/0413/2010/PMP

EMERSON PROCESS MANAGEMENT Date : April 05, 2010
WINDSOR IT PARK, GROUND FLOOR, Your Ref. No.:
TOWER A, A-1 SECTOR - 125, Date :
NOIDA - 201 301 Your P.O. No.:
Date :
Kind Attn. : Mr. Rajeev Srivastava. Legends:
[A] For Information Only
PROJECT:- 6X135MW CPP ANGUL, ORRISA PROJECT [B] For Approval
[C] For Final Approval
Dear Sir,

We refer to the above subject. We are sending herewith Drawings & documets Listed below for your approval:

Sr. Rev. No. of

Doc. No. Description / Title Of Drawing & Documents Remark
No. No. Prints

1 - 2 Refer Annexure-I enclosed. 3 C

Kindly expedite the final approval of the same within one week and send us one set duly approved drawings &
documents for our reference/record.

Thanking you & assuring you of our best & prompt attention all the times.

Yours Truly, CC :
For Chhabi Electricals Private Limited 1) Chhabi Electricals Pvt. Ltd., New Delhi
Kind Attn.: Mr. P.K. Jain (G.M.)

D.J. Patil
(Manager – Design)

Regional Offices :
Mumbai : 20, Anupam Indl. Estate no. 3, L.B.S. Marg Mulund (W) Mumbai - 400 080 (Maharashtra) - INDIA.
Phone No. : +91-22-2561 4435/5945, Fax No. : +91-22-2568 0513, Email : chhabi@mtnl.net.in
Delhi : F-12, First Floor, Pankaj Grand Plaza, Mayur Vihar Phase-1, Delhi - 110 091.
Phone No. : +91-11-4215 1213 - 14, Fax No. : +91-11-4215 1215 Email : chhabindl@chhabi-india.com
Bangalore : 120, First Floor, “Ajantha” 6th C Main Road, Remco Layout Vijayanagar 2nd Stage Bangalore - 560 040 (Karnataka) - INDIA.
Phone No. : +91-80-2314 0031, Fax No. : +91-80-2314 0031 Email : chhabiblr@chhabi-india.com
Kolkata : 16/1A Bose Pukur Road, Kolkata - 700 042 (West Bengal) INDIA.
Phone No. : +91-33-24411375, Email : chhabikol@chhabi-india.com
Bhubaneshwar : A/62, Nayapalli, NS-5, Bhubaneshwar - 751 003 (Orissa) - INDIA. Email : chhabibbsr@chhabi-india.com
 BILL OF MATERIAL

W.O.NO. : CE 2417

REV. NO. : 02

DATE : 04.04.2010

UNIT : BATTERY CHARGER FOR 24V BATTERY CHARGER

TYPE : FLOAT CUM BOOST A&B : CP-CC 24V / 250A-350A (100A+250A)

REF.DRG. NO. : C11848A, C11848B, C11848C.

CLIENT : EMERSON PROCESS MANAGEMENT INDIA PVT. LTD., NOIDA

P.O.NO. :

PROJECT : 6 X 135MW CPP ANGUL, ORRISA PROJECT.

QTY : 6 NOS.

SR.
CODE NO. DESCRIPTION RATING
NO.

TERMINAL PLATES & LINKS

415V 3 Phase 4 wire AC input Terminal for incoming power Suitable for 1 x 3½C x 25
1 TB1
supply of charger. (R Y B) T1 -T3) Sq.mm. Cu. Cable
Suitable for 2x1Cx400
2 TB2 DC output Battery Terminals (T4-T6) (+ve, -ve)
Sq.mm. Cu. Cable
Suitable for 2x1Cx400
3 TB3 DC output Load Terminals (T7-T8) (+ve, -ve)
Sq.mm. Cu. Cable
230V 1 Phase 2 wire AC input Terminal for Auxiliary power Suitable for 1x2Cx2.5
4 TB4
supply. (L N) (T9-T10) Sq.mm. Cu. Cable
Suitable for 1x2Cx2.5
5 TB5 Terminal for charger trouble (T11-T12)
Sq.mm. Cu. Cable

FUSES :

1 FS1-3 Glass cartridge Fuses with suitable fuse fitting for LED1-3 100mA

2 FS4-9 Semiconductor fuses for the MR1. GS450/400

3 FS10 HRC fuse with suitable fuse fittings for FC1. 125A

4 FS11-12 HRC fuse with suitable fuse fittings for DC Output. 400A

REV.2
5 FS13,13A HRC fuse with suitable fuse fitting for DC control supply. 4A

6 FS14 HRC fuse with suitable fuse fitting for AC control supply. 2A

7 FS15-16 HRC fuse with suitable fuse fitting for Fan1& Fan2. 2A

CHHABI ELECTRICALS PVT. LTD., JALGAON - 425 003 SHEET NO. : LC3977 / 1 OF 5
 SR.
CODE NO. DESCRIPTION RATING
NO.

8 FS17 Glass cartridge Fuses with fitting for the VM1 100mA

9 FS18 HRC fuse with suitable fuse fitting for Contactor C1 2A

INDICATING LEDS

1 LED1-3 AC `ON' indicating LEDs. 230V

2 LED4 DC 'ON' indicating LED. 24V

TRANSFORMERS, CHOKES

Double wound impregnated, naturally air cooled Three 21 KVA

1 TR1
phase mains transformer. (456V/42V)

2 CH1 Filter choke for FCB charger 350A

3 TR2 Auxiliary transformer for mV amplifier & ACOR ckt.supply. 20VA (270V/18-0-18V)

RECTIFIERS & BLOCKER DIODES

3phase, Full controlled full wave rectifier bridge complete 250A/1000PIV

1 MR1 with RC surge suppression network and suitable heat sinks HS: 80AD/300MM
for Charger. Suitable RC Network
400A/1000PIV
2 MR2 Charger silicon blocker diode with suitable heat sink.
HS: HS209/300MM
300A/1000PIV
3 MR3 Charger silicon battery tap diode with suitable heat sink.
HS: HS209/200MM
300A/1000PIV
4 D1-D10 Voltage dropping diode
HS: Suitable Size

REV.2 18A/600PIV
5 D11-D14 Diode for Buscoupler Contactor supply
HS: HS208/150MM
RESISTANCES, POTENTIOMETERS & FILTER
CONDENSER

1 RB1 Bleeder Resistance 50V/300W

Wire wound potentiometer to adjust output voltage in float

2 RV1 10K/3W
mode.
Wire wound potentiometer to adjust the output current
3 RV2 10K/3W
limit in boost mode.
Wire wound potentiometer to adjust the DC output voltage
4 RV3 10K/3W
in manual mode.

5 RF1-4 Voltage Dropping resistance for FFD 200E/50W

6 FC1 Filter condenser Test Selected

SWITCHES / MCCB

1 MCCB1 3 pole ON/OFF AC incoming MCCB 50A / 10KA

2 pole ON/OFF DC Output MCCB (4 Pole MCCB - 2 Pole

2 MCCB2 250A / 10KA
connected in parallel)

CHHABI ELECTRICALS PVT. LTD., JALGAON - 425 003 SHEET NO. : LC3977 / 2 OF 5
 SR.
CODE NO. DESCRIPTION RATING
NO.
2 pole, 2 way ‘NO OFF’ cam type Auto/Manual mode
3 SW1 10A
selector switch for controller.
2 pole Isolator for isolation of load (4 Pole isolator - 2Pole
4 SW2A/B 250A
connected in parallel)

5 SW3, 4 1 pole ON/OFF toggle switch for cubical lamp & heater. 10A

6 SW5, 6 1 pole ON/OFF switch for FAN 1-2 10A

REV.2 1pole, 2 way ‘NO OFF’ cam type Auto/Manual mode

7 SW7 10A
selector switch for CH.A/B

REV.2 1pole, 2 way ‘NO OFF’ cam type Auto/Manual mode

8 SW8 10A
selector switch for Buscoupler

METERS & SHUNTS (ACCURACY CLASS- 1.0%) 96 sq.mm. 90 deg. Deflection

DC moving coil Voltmeter to read the charger output

1 VM1 0-50V DC
voltage
DC moving coil ammeter to suitable shunt to read the
2 AM1 0-400A
charger o/p current.
DC moving coil Ammeter with suitable shunt to read the
3 AM2 400A-0-400A
discharge /charge of the battery.
Shunt for the Charger output current, Load current & Batt.
4 SH1-3 0 - 400A / 75mV
Voltage
PRINTED CKT.BOARD, ELECTRONIC RELAY, FFDS &
CONTROL CARDS.
Fuse Fail Detector Circuit of solid state sensing type for FS4-
1 FFD1,2 24V
9
Fuse Fail Detector Circuit of solid state sensing type for
2 FFD3 24V
FS10
Fuse Fail Detector Circuit of solid state sensing type for
3 FFD4 24V
FS11-12
HV & PF PSR
4 High Voltage & Phase fail/phase sequence reversal ckt. 25VA/415V
CKT.
3-phase SCR controller for constant voltage/current mode
5 CPC1 24V
of operation.
DISPLAY
Charger Monitoring & Annunciation circuit for displaying
UNIT WITH
6 voltage/current parameters on LCD as well as Window type 24V
ANNUNCIAT
Annunciation with RS485 communication.
OR
Millivolt amplifier circuit for battery current limit in float
7 mV Amp 4A
mode

REV.2 Automatic change-over relay for auto float/boost mode

8 ACOR 24V
change-over.

CONTACTOR'S & AUXILARY RELAY

Auxiliary contactor for AC mains fails annunciation &

1 CA1, CA2 4A/415V AC Coil
interlocking purpose.

2 CA3 Auxiliary contactors for Float / Boost selection. 4A/24V DC Coil

3 CA4 Auxiliary contactor for charger DC O/P failure annunciation. 4A/24V DC Coil

CHHABI ELECTRICALS PVT. LTD., JALGAON - 425 003 SHEET NO. : LC3977 / 3 OF 5
 SR.
CODE NO. DESCRIPTION RATING
NO.

4 C1 3 pole in parallel DC Contactor for interlocking purpose. 125A/24V DC Coil

REV.25
C2 3 pole in parallel DC Contactor for Buscoupler 125A/24V DC Coil

MISCELLANEOUS

1 L1 Cubicle Fluorescent lamp. 11W/240V AC

2 H1 Space strip heater. 100W/240V

3 TH1 Energy regulator for heater. 240V AC

4 S1 3 Pin socket with switch. 6A/240V AC

5 FAN1,2 Exhaust fans for air circulation. 240V

24V DC COIL
6 T1 Solid state timer.
0-10 Hrs.

7 TS1 Temperature sensor 65°C

8 PB1-2 Float / Boost mode of operation selector push buttons 4A / 415V AC

9 PB3-6 Accept, Test, Reset & Hold push buttons for Display Unit 4A / 415V AC

CHHABI ELECTRICALS PVT. LTD., JALGAON - 425 003 SHEET NO. : LC3977 / 4 OF 5
 MAKE OF COMPONENTS

SR.NO. DESCRIPTION MAKE

1 DC POWER ISOLATORS & SFU C&S

2 CONTROL SWITCHES Kaycee

3 FUSE LINKS GE Power / C&S

4 DIODEs/SCRs Ruttonsha / Semikron

5 FILTER CONDENSER Alcon

ELECTRONIC CONTROLLER, SOLID STATE

6 SENSING TYPE CIRCUIT FFD, ANNUNCIATION, Chhabi (Our Own Make)
DISPLAY UNIT

7 FILTER CHOKE Chhabi (Our Own Make)

8 TRANSFORMER Chhabi (Our Own Make)

9 INDICATING LEDS Teknic

10 CONTROL TERMINALS Elmex

11 POTENTIOMETERS Pankaj

12 MCB Indo Asian

13 TIMER Selectron

14 CONTACTOR C&S

15 MCCB Schneider

16 Meters AE / IMP / Rishab

17 Fan Rexnold

18 Temp Sensor Radix

19 Heater, TH, Socket & CFL Lamp Reputed Make

REV. 2

PREPARED BY : P.M.P.

CHECKED BY : D.J.P.

APPROVED BY : R.S.K.

DATE : 05.04.10

W.O.NO. : CE-2417

CHHABI ELECTRICALS PVT. LTD. JALGAON - 425 003 SHEET NO. 5 OF 5

 OPERATION WRITEUP
The System comprises of 2x100% Float Cum Boost Chargers (Charger-A & Charger-B), 1x100% DC Distribution
Board & 2x100% Battery.
The float-cum-Boost Chargers A&B, DC Distribution Board and Battery are connected in parallel. The battery charger-
A&B will float charge respective battery &Charger-A supply the load connected through DCDB.
Each Float cum Boost charger has i) Constant Current & ii) Constant Voltage mode.
Normally, in float mode the charger will float the batteries at 1.4V per cell within a stabilization of ±1% of the floating
voltage. The float charger-A will supply the trickle charging current required for the batteries and will also feed the DC
continuous load as required. During this time, the float charger-A and the battery are across the DC load terminals.
When Charger-A fails the bus coupler will close automaticaly( depend on position of Switch SW 8) & load will be
supplied by battery charger -B as well as both batteries will be trickle charge by charger-B Or When Charger-B fails
the bus coupler will close automaticaly( depend on position of Switch SW 8 , by selection of this switch one can close
the bus coupler manualy also) & load will be supplied by battery charger -A as well as both batteries will be trickle
charge by charger-A.
When Both the AC source fails then buscoupler C2 will close automatically depending on the position of SW-8
( Auto/ Maual Closing selection of Bus coupler )& both batterie will get discharge to certain extent depending upon
the duration of power failuer & Load current.
After resumption of AC power both chargers will operate inetially in float mode. The battery draws higher current, this
Higher current will be senced by the ACOR ( Automatic Change Over Relay) which will operate the charger in boost
mode automatically , when Switch SW-7A/B is at Auto Float -Boost position.One can operate the charger in boost
mode Manualy by selecting the switch SW 7 at Manual float -boost mode through the push buttons. During boost
charging of batteries DC Contactor C1 A/B gets open & the load will be supplied through the dropping diode by
maintaing the load voltage within the range of 20V-31Volts
When battery gets full charger the ACOR gets rest & Charger will revert back in float mode.If the ACOR fails to
revert back the charger in float mode then the suporting Timer T1 will revert back the charger in float mode when the
set time on the timer laps.Thus the batterise are prvented from geting over charge.
When charger operateds in float mode DC contactor C1A/B remains closed.
When the power resumes, the battery has to be recharged. Regharging of batteries is automatic as well as
manual.Automatic boost charging selection will be through ACOR & Manual Boost charging operation will be through
push buttons. During boost charging of batteries the load will be supplied through the dropping diodes.. Interlock is
provided such that when both the chargers are healthy then only ( Charger -A& Charger-B) will operate in Boost
Mode.

For detail operation of charger refer LOGICAL SIMULATION TABLE attached.

PROTECTIONS PROVIDED:
1 AC MCCB
2 DC SWITCH+FUSES
3 DC CURRENT LIMIT
4 BLOCKER DIODE FOR REVERSE VOLTAGE BLOCKING
5 FUSES FOR RECTIFIER, CAPACITOR, CONTROL SUPPLY

DISPLAY UNIT :

The Display unit consist of

a) 4 Line LCD display : The Upper 2 lines are utilised for Metering purpose & Lower 2 lines are utilised for Battery
Cell Status display.
The Metering Parameters will be displayed are as follows,
i) Charger A DC V
ii) Charger A DC A
iii) Charger B DC V
iv) Charger B DC A
v) Load DC V
vi) Load DC A
The Battery Cell status parameters will be dispalyed as follows,
i) Cell No.
ii) Cell Voltage
iii) Cell status (High / Low / Normal)

1-2
 PARAMETER
VALUE
CELL NO. / CELL VOLTAGE
STATUS (HIGH / LOW / NORMAL)

b) Inputs / Outputs
i) Analog Input - 7Nos.
[ i) Charger A DC V, ii) Charger A DC A, iii) Charger B DC V, iv) Charger B DC A, v) Load DC V, vi) Load DC A, vii)
Cell Voltage ]
ii) Digital Inputs - 18Nos. [Annunciation Faults - 14Nos. + ATRH]
iii) Digital Outputs - 15Nos.[Annunciation Faults - 14Nos. + Bz]
iv) RS485 Modbus serial communication port

The Digital inputs for Annunciation will be as follows

a) CH.A AC MAINS FAIL
b) CH.A RECTIFIER FUSE BLOWN
c) CH.A FILT. FUSE BLOWN
d) CH.A DC FAIL
e) CH.A FLOAT MODE ON
f) CH.A BOOST MODE ON
g) CH.A DC FUSE BLOWN
h) CH.B AC MAINS FAIL
i) CH.B RECTIFIER FUSE BLOWN
j) CH.B FILT. FUSE BLOWN
k) CH.B DC FAIL
l) CH.B FLOAT MODE ON
m) CH.B BOOST MODE ON
n) CH.B DC FUSE BLOWN

The Digital ouputs for Annunciation will be as follows

a) CH.A AC MAINS FAIL
b) CH.A RECTIFIER FUSE BLOWN
c) CH.A FILT. FUSE BLOWN
d) CH.A DC FAIL
e) CH.A FLOAT MODE ON
f) CH.A BOOST MODE ON
g) CH.A DC FUSE BLOWN
h) CH.B AC MAINS FAIL
i) CH.B RECTIFIER FUSE BLOWN
j) CH.B FILT. FUSE BLOWN
k) CH.B DC FAIL
l) CH.B FLOAT MODE ON
m) CH.B BOOST MODE ON
n) CH.B DC FUSE BLOWN
o) LOAD DC UNDER VOLTAGE
p) LOAD DC OVER VOLTAGE

c) Power Supply : 24V DC

BHMS

The Battery Health Monitoring System comprises of the Battery data collector & transmits the same to the dispaly
unit.
The data collector will select the data of individual cell which will be transmitted to the LCD dispaly & the LCD dispaly
will dispaly the same as above.

2-2
 LOGICAL SIMULATION TABLE

CHARGER-A CHARGER-B CONTACTOR CONTACTOR BUS COUPLER LOAD BATTERY-A BATTERY-B REMARK
C1A C1B C2
AC Mains/DC Fail AC Mains /DC CLOSE CLOSE CLOSE By Battery __ __ Load will be supplied by both the Battery
Fail Banks.
Float Mode AC Mains/DC CLOSE CLOSE CLOSE By Charger-A Trickled charged Trickled charged Charger-A will operate in float mode &
Fail by Charger-A by Charger-A will supply load as well as trickle charge
both the Battery set.
AC Mains/DC Fail Float Mode CLOSE CLOSE CLOSE By Charger-B Trickled charged Trickled charged Charger-B will operate in float mode &
by Charger-B by Charger-B will supply load as well as trickle charge
both the Battery set.
Float Mode Float Mode CLOSE CLOSE OPEN By Charger-A Trickled charged Trickled charged Charger-A will operate in float mode &
by Charger-A by Charger-B will supply load as well as trickle charge
battery-A & Charger–B will trickle
charger Battery B.
Boost Mode Float Mode OPEN CLOSE OPEN By Charger-A Battery will be Trickled charged Charger-A will boost charge the battery-
(Manually by Boost charged by Charger-B A as well as supply load through the
PB1A by Charger-A dropping diodes. Bus coupler will
/Automatically remains open. Charger-B will trickle
through ACOR- charger battery-B. During this condition
A) if the charger-B fails, Charger-A will
revert back in float mode & will supply
the total load & also trickle charge both
the battery banks by closing C1A & Bus
coupler and load will be supplied by
Charger-A.

Float Mode Boost Mode CLOSE OPEN OPEN By Charger-A Trickled charged Battery will be Charger-B will boost charge the battery-
(Manually by by Charger-A Boost charged B. Bus coupler will remains open.
PB1B by Charger-B Charger-A will trickle charger battery-A.
/Automatically During this condition if the charger-A
through ACOR- fails, Charger-B will revert back in float
B) mode & will supply the total load & also
trickle charge both the battery banks by
closing C1B & Bus coupler and load will
be supplied by Charger-B.