BATTERY CHARGERS & BATTERY BANKS
#1

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BATTERY CHARGERS & BATTERY BANKS
INTRODUCTION
NEED OF BATTERY CHARGERS & BATTERY BANKS

Station battery charger is used to supply the control power to the electrical switchgear like breakers etc which need the DC supply for it’s operation and in case of failure of electrical power the control power is continued to be fed by the battery.
Battery Charger consists of
1) Float Charger
2) Boost Charger
Schemes for Battery Chargers
1) FC & FCBC scheme
2) FCBC & FCBC scheme
SINGLE LINE DIAGRAM OF FC & FCBC SCHEME
Different Conditions under which charger works
• Case 1: Normal Conditions
• Case 2:Mains Power Failure to Float Charger under normal condition
• Case 3:Float Charger Failure under normal conditions
• Case 4:Upon Resumption of Mains Power to Float Charger
• Case 5: Mains Power Failure to both the Chargers under Normal Condition
• Case 6: Upon Resumption of Mains Power to Both the Chargers
• Case 7: Mains Power Failure to Float Charger during Boost charging by Float cum Boost Charger
• Case 8: Float Charger Failure during Boost charging by Float cum Boost Charger
• Case 9: Float cum Boost Charger Failure during Boost Charging
• Case 10: Mains Power Failure to Both the Chargers during Boost Charging by Float cum Boost Charger
SINGLE LINE DIAGRAM OF FCBC & FCBC SCHEME
Different Conditions under which charger works
• Case-1: Normal Conditions
• Case-2: Mains Power Failure to Both the Chargers under Normal Conditions
• Case 3: After Resumption of Power Supply
• Case 4: Mains Power Failure of Float Charger under Boost charging by Other
• Case 5: Failure of any Charger under Normal condition
• Case 6: Both the Chargers Failure under Normal Condition
• Case 7: FCBC-1 Failure during Boost charging by FCBC-2
• Case 8: FCBC-2 Failure during Boost charging by FCBC-1
Different cards used in chargers:
69-0003 (R.C. card)
• Snubber
• Surge Supressor
69-00242 (Mother Board)
• PCB’s Connector card
• Power Supply
• Control Card
• Firing card
• 69-00069 (Delay Card)
• Delay for control supply and power supply
• Pulse inhibit
69-00141 (Auxiliary Card)
• Voltage Feedback
• E/F Sensing Signal
• Battery Alarm Signal
• 69-000118 (Control Card)
• Voltage Selection
• Float/boost/Extended mode
• Current Selection
• Float/Boost/Extended mode
• Total Charge Current Limit
• Auto/Manual, Float/Boost Selection
• Alarm Circuit
• Low DC, High DC, Charger Fail, E/F positive, Battery low DC
69-000120 (Power Supply Card)
• Unregulated Voltage
• Regulated Voltage
• AC Alarm Circuit
69-000319 (Firing Card)
• Synchronising Signals
• Firing Pulse
69-00040 (Pulse Txr Card)
• Firing Pulse Isolation
69-000133 (General Relay Card)
• Relay ON/OFF
• Interlock Circuit
69-000115 (Relay Card)
• Fault Alarms
• Potential Free Contacts NO/NC
69-000251 (Mains Fail Card)
• Mains Fail Alarm
• 69-00013 (Display Card)
• Alarm Visual Indication & Audio
• Summary Contacts
69-00325 (DVR Card)
• Voltage Sensing Contactor ON/OFF
69-00122 (Multi Alarm Card)
• Alarm Card
• Low DC/ High DC/ Charger Fail/ Earth-Fault
• 69-00076 (DC-DC Converter)
• Alarm Circuit Voltage
• 12V Supply
The charger is protected by the following:
• AC input fuses
• AC input overload relay
• DC output fuse (or Breaker)
• AC surge supressor
• Snubber (RC circuit)
• Automatic current limiting
• Reverse battery protection
Types of Batteries
• Primary Battery
• Secondary Battery
Following are the various batteries used in secondary cells:
• Sealed lead acid.
• Unsealed lead acid.
• Silver cadmium.
• Sealed nickel cadmium.
• Vented nickel cadmium.
• Nickel zinc.
• Alkaline manganese rechargeable.
• Silver zinc.
• Nickel hydrogen.
• Silver hydrogen.
• Zinc chlorine.
• Zinc air.
• Sodium sulfur.
• Lithium-chlorine.
• Lithium-sulfur.
Out of these, two types of secondary rechargeable batteries which are lead acid and nickel cadmium are generally used in the industries.
The basic cell reaction of these two batteries are:
PbO2 + Pb + 2H2SO4 2PbSo4 + 2H2O
2 Ni (OH)2 + Cd (OH)2 2 NiOOH + Cd + 2e-
Lead Acid Batteries
The lead acid battery is made up of plates, lead and lead oxide with a 35% sulfuric acid and 65% water solution.
Types of Lead-Acid batteries
• Regular
• Sealed Flooded cells
• Deep cycle flooded cells
• VRLA
• Gel
• Absorbed Glass Mat (AGM)
Ni-Cd Batteries
Types of Ni-Cd batteries

• Vented Ni Cd
• Valve regulated Ni-Cd
• Sealed Ni-Cd
Types of Plates used in Ni-Cd Batteries:
• Pocket
• Sintered
• Foam
• Plastic-bonded
• Fiber
Here, stationary pocket plate vented Ni-Cd batteries are used.
The Ni-Cd pocket plate battery is available in different designs optimized with regard to the required discharge time.
The main categories are:
• High rate: For discharge periods of less than 10 mins.
• Medium rate:For discharge periods of more than 10 mins.
• Low rate: For discharge periods of more than one hour.
Ventilation:
The ventilation system is required to limit hydrogen accumulation less than 2% of the total volume of the battery area.
The maximum hydrogen evolution rate is 0.000269 ft3/min per charging ampere per cell at 25°C and the maximum
evolution is calculated by:
0.000269 * I* N
where I is the charging current at the end of high rate charging and N is the no. of cells in the battery.
Types of charging:
• First charging.
• Separate charging.
• High rate charging.
• Overcharging.
• Undercharging.
Capacity:
The capacity of the battery will vary according to current at which it is discharged. The higher the current being taken out of the battery, the lower the available capacity.
Typical Problems observed in Ni-Cd and Lead Acid Batteries
Memory Effect-The memory effect is a reduction in capacity of a Ni-Cd battery, which occurs after the battery has been subjected to repeated shallow discharges. Restricted to cells with sintered negative plates and involves both crystalline effects and reactions between cadmium and nickel.
Float Effect-Applies to the positive active material itself and is not specific to any specific plate design.They describe the overcharge phenomenon in which the charged nickel positive material is transformed from the ß-form of NiOOH to the g-form.Due to formation of gNiOOH, the discharge voltage plateau is lower and hence the available capacity is reduced.
Capacity Fading -Temporary effect resulting from incomplete recharge between successive discharges. This effect is seen predominantly in vented Ni-Cd batteries (as well as vented lead-acid) and can lead to a progressive imbalance between the positive and negative electrode capacities.
Second Discharge Plateau-This memory like effect is associated with the positive electrode but is a very isolated phenomenon. When this effect is present, the cell begins discharging normally, but at some point there is drastic voltage drop from the normal level of approximately 1.2V down to about 0.8V. The voltage stabilizes to produce a second discharge plateau, at which the residual capacity is discharged.
This effect is limited to plates that have been physically impregnated such as pasted foam electrodes and that it is not seen in sintered plates in which the active material has been electrochemically deposited.
Coup de Fouet- Coup de fouet (coo duh fway) is a phenomenon observed in lead acid batteries.Here, sharp voltage dip is observed in the first seconds or minutes of discharge.This is followed by a partial recovery up to the normal plateau of the discharge curve.
In lead acid batteries, this effect is seen during the initial discharge of a positive electrode in which no lead sulphate is already present. Pb2+ ions form a supersaturated solution at the plate surface until the initial ‘critical seed’ crystals of lead sulphate are formed.
Sulphation- This problem is observed in lead acid batteries that are not fully recharged. A layer of lead sulphate can form in these cells and inhibit the electro-chemical reaction that allows to charge/discharge batteries.
Corrosion - Corrosion is a problem observed in lead acid batteries due to corrosive nature of sulfuric acid.
COMPARISON OF LEAD ACID BATTERY AND NICKELCADMIUM POCKET PLATE BATTERY
Lead Acid Battery Ni-Cd Pocket Plate Battery
• Acidic Basic
• High rate charge & Suitable for high rate charge &
discharge is not discharge.
possible.
• Shorter life. Longer life.
• Comparatively cheap. Costly.
• More maintenance is Less maintenance required.
required.
• Difficult to maintain Easy to maintain.No such
due to acid as it operational hazard.
involves operational
hazard.
• Unreliable. Fairly reliable.
• Performance affected No problem with overcharging.
due to overcharging.
• Conversion efficiency Conversion efficiency of Ni-Cd
is much higher than is lower than lead acid cells.
Ni-Cd batteries.
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#2
A battery which is used in 132kv grid station?
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#3

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