Magellan MCR-II Operation And Maintenance Manual

OPERATION AND MAINTENANCE MANUAL

(EXAMPLE OF PANEL DISPLAY)

THREE PHASE

MCR-II SERIES BATTERY CHARGER

Magellan Powertronics Pty Limited

AS/NZS ISO 9001:2000

68 Cocos Drive, Bibra Lake, Western Australia 6163

National: Tel: [phone] International: Tel: + 618 9434 6621

Fax: [phone] Fax: + 618 9434 6623

Email: [e-mail]

Web site: www.magellan-power.com.au

OPERATION AND MAINTENANCE MANUAL

THREE PHASE MCRII SERIES BATTERY CHARGER

Rev: 1.6

03/08/2010 Doc: MAN-3P_MCRII_REV1.6.Doc Page 2 of 29

Magellan Powertronics

68 Cocos Drive, WA 6136 Tel: [phone] Fax: [phone]

THREE PHASE MCRII SERIES BATTERY CHARGER

OPERATION AND MAINTENANCE MANUAL

TABLE OF CONTENTS 2

INTRODUCTION 5

SPECIFICATIONS 6

INSTALLATION INSTRUCTIONS 9

CIRCUIT DESCRIPTION 10

OPERATING INSTRUCTIONS 12

Start Up 12

On Line Operation 12

Boost Charging 12

Voltage and Current Display 13

Battery Test 13

Alarm reset and Mute 15

Constant Current Charging 16

Remote Communications 17

ADJUSTMENTS 18

Programmable Set Point Descriptions 18

Float and Boost Charging Settings 18

Alarm and Trip Settings 18

Diode Dropper Settings 19

Battery Test Set up 19

Latch and Inhibit Settings 20

Constant Current Charging Set up 20

Charger and Battery Definition Set up 21

Calibration 21

Communication Set up 22

Diagnostic Set up 22

Earth Fault Alarm 23

OPERATION AND MAINTENANCE MANUAL

THREE PHASE MCRII SERIES BATTERY CHARGER

Rev: 1.6

03/08/2010 Doc: MAN-3P_MCRII_REV1.6.Doc Page 3 of 29

Magellan Powertronics

68 Cocos Drive, WA 6136 Tel: [phone] Fax: [phone]

User Adjustable Set point Instruction Flowchart 24

COMMISSIONING 25

Start-up 25

Checking voltage levels 25

Checking Float voltage 25

Checking Boost voltage 26

Checking charger current limit 26

Testing Charger Fail Alarm 26

Testing Mains Fail Alarm 27

Testing DC Low Alarm 27

Testing DC High Alarm 27

Testing Low Electrolyte Alarm 28

Testing Battery Fail Alarm 28

Testing Diode Droppers 28

OPERATION AND MAINTENANCE MANUAL

THREE PHASE MCRII SERIES BATTERY CHARGER

Rev: 1.6 03/08/2010 Doc: MAN-3P_MCRII_REV1.6.Doc Page 4 of 29

Magellan Powertronics

68 Cocos Drive, Bibra Lake, WA 6136 Tel: [phone] Fax: [phone]

SAFETY PRECAUTIONS

DANGER!

• This equipment contains high DC and AC voltages. Do not

work on live equipment unless authorised

• Isolate AC and DC before working on the equipment. Battery

voltage may be present even when mains is Isolated.

• Give internal capacitors time to discharge (1 minute) before

working on the equipment

• To completely isolate the equipment switch off all Circuit

Breakers and Fuses and allow the internal capacitors to
discharge.

• Batteries on charger especially Boost charge generate

Hydrogen which has the potential to ignite. Ensure that there
is adequate ventilation available for the Hydrogen to escape

OPERATION AND MAINTENANCE MANUAL

THREE PHASE MCRII SERIES BATTERY CHARGER

Rev: 1.6 03/08/2010 Doc: MAN-3P_MCRII_REV1.6.Doc Page 5 of 29

Magellan Powertronics

68 Cocos Drive, Bibra Lake, WA 6136 Tel: [phone] Fax: [phone]

1.0 INTRODUCTION

The Magellan Powertronics MCRII Series three phase battery charger / DC power supply

utilises Switch mode or Phase controlled AC to DC conversion technique together with the

latest micro-processor hardware and software to produce advanced charging systems suitable

for Lead Acid or Nickel-Cadmium batteries.

The MCRII charger is a constant voltage type, with current limit and two voltage levels: float

and boost. The boost level is used to recharge the battery whilst the float is used to keep the

battery in a fully charged condition. For applications using Sealed Lead Acid batteries, the

boost function may be disabled.

The boost mode can be initiated manually or automatically. The manual boost is initiated by

depressing the momentary Boost button and the status is indicated on the LCD display. The

charger then remains in the boost for a period of 0 to 24 hours (selectable) after which it will

automatically revert to float mode. The automatic boost is activated if the current into the

battery exceeds a pre-set limit for a pre-set time. The automatic boost is also controlled by a

boost timer (0 to 24H).

OPERATION AND MAINTENANCE MANUAL

THREE PHASE MCRII SERIES BATTERY CHARGER

Rev: 1.6 03/08/2010 Doc: MAN-3P_MCRII_REV1.6.Doc Page 6 of 29

Magellan Powertronics

68 Cocos Drive, Bibra Lake, WA 6136 Tel: [phone] Fax: [phone]

2.0 GENERAL SPECIFICATIONS

AC INPUT:

Voltage: 415V ±10%, Three Phase

Frequency: 50Hz ±5%

Current: As per model

DC OUTPUT

Nominal: As per model (see test sheet)

Float: As per model (see test sheet)

Boost: As per model (see test sheet)

Output Current: As per model (see test sheet)

Output Ripple 1% without battery connected

LOAD REGULATION

Static load regulation: ±1% for

1 to 100% Load

±10% Input Variation

5% Frequency Variation

OPERATING ENVIRONMENT

Maximum operating temp 50°C

Storage temp. -40°C to 70°C ambient

Max humidity 95% R H

OPERATION AND MAINTENANCE MANUAL

THREE PHASE MCRII SERIES BATTERY CHARGER

Rev: 1.6 03/08/2010 Doc: MAN-3P_MCRII_REV1.6.Doc Page 7 of 29

Magellan Powertronics

68 Cocos Drive, Bibra Lake, WA 6136 Tel: [phone] Fax: [phone]

ALARMS

Mains Fail No Adjustment

Charger Fail No Adjustment

Low Electrolyte No Adjustment (for vented batteries only)

Battery Disconnected No Adjustment

Battery Fail As per model (software adjustable)

DC Low As per model (software adjustable)

DC High As per model (software adjustable)

Over volt Charger disconnect As per model (software adjustable)

Under volts load disconnect As per model (software adjustable)

Earth Fault 10mA (adjustable)

METERING

Charger Voltage

Charger Current

Battery 1 Voltage

Battery 1 Charge/Discharge Current

Battery 2 Voltage (for dual battery systems)

Battery 2 Charge/Discharge Current (for dual battery systems

Load Voltage

Load Current

Battery 1 Temperature

Battery 2 Temperature (for dual battery systems)

Battery Amperehour Capacity meter
All Liquid Crystal Display - ±1% accuracy

PROTECTION

AC Input Circuit Breaker

Charger Current Limit

Battery Current Limit

Battery Circuit Breaker

Load Circuit Breakers, individual feeders
Battery Over Voltage Charger Inhibit
Battery Over Voltage Mains Trip (optional)

OPERATION AND MAINTENANCE MANUAL

THREE PHASE MCRII SERIES BATTERY CHARGER

Rev: 1.6 03/08/2010 Doc: MAN-3P_MCRII_REV1.6.Doc Page 8 of 29

Magellan Powertronics

68 Cocos Drive, Bibra Lake, WA 6136 Tel: [phone] Fax: [phone]

CONTROLS

The following adjustments can be done by the software:

Float Voltage Adjustment

Boost Voltage Adjustment

Boost Timer Adjustment

Charger Current Limit Adjustment

Battery 1 Current Limit Adjustment

Battery 2 Current Limit Adjustment (for dual battery systems)

Load Sense Boost Inhibit

DC Low Alarm Adjustment

DC High Alarm Adjustment

High Volts Inhibit

High Volts Disconnect Adjustment

Low Volts Disconnect Adjustment

Battery Fail Voltage Adjustment

The following adjustments can be done using on-board potentiometers in
chargers provided with optional Hardware Output Over and Under Voltage
Trip:

Over Voltage Trip Level

Under Voltage Trip Level

Over Voltage Trip Delay

Under Voltage Trip Delay

Please refer to the CHARGER TEST SHEET in Appendix 1 for details specific to this
charger.

OPERATION AND MAINTENANCE MANUAL

THREE PHASE MCRII SERIES BATTERY CHARGER

Rev: 1.6 03/08/2010 Doc: MAN-3P_MCRII_REV1.6.Doc Page 9 of 29

Magellan Powertronics

68 Cocos Drive, Bibra Lake, WA 6136 Tel: [phone] Fax: [phone]

3.0 INSTALLATION INSTRUCTIONS

Locate the battery charger in the allocated location and ensure that sufficient cooling air is

available for natural convection cooling.

CABLING

Refer to the Charger Schematic and the Connection Diagram in the Appendix

1. Connect Three Phase 3 wire 415V and earth to terminal X1 in accordance with the

schematic diagram. (refer to "Charger Specifications" for current demand and size
cable to suit).

2. Connect the Battery temperature probes to the terminals X5 1, 2. The details are

given in the schematic drawing and the table provided in the Appendix. Mount the
temperature probe to the negative terminal of the battery. Please also make sure
that battery temperature probe is connected correctly to terminal X5. Wrong
connection of the battery temperature probe will result in incorrect operation of the
charger.

3. Connect the battery bank to the terminal X2. (Please observe polarity). Note: If

Impedance Test or Full Battery Test Facility options are included, please connect
terminal X2 (wire numbers 101 and 102) to the actual battery terminals.

4. Connect Load as per the schematic drawing.

5.

Connect external alarm wiring (if applicable) as per schematic drawing.

INSTALLATION PRECAUTIONS:

• The (optional) battery impedance connections (101, 102, 103 and 104 on

the schematic), used with the optional Battery Impedance Test or Full
Battery Test, must be connected in parallel to the standard battery
connections, as in the schematic diagram.

• MCRII requires that the battery temperature sensor is connected to

operate correctly. If it is not connected, if it is shorted, or if the polarity is
reversed, the charger may not operate, as a safety precaution.

• The Common Alarm relay and optional Alarm Card relays are fail-safe,

therefore are energised under normal operating conditions, and de-energised
under fault conditions. This means that an N/C connection will be open when
no fault is indicated, and close on a fault condition.