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

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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

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THREE PHASE MCRII SERIES BATTERY CHARGER

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Magellan Powertronics

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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

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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

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Magellan Powertronics

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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

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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)

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THREE PHASE MCRII SERIES BATTERY CHARGER

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Magellan Powertronics

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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

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Magellan Powertronics

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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.

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THREE PHASE MCRII SERIES BATTERY CHARGER

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Magellan Powertronics

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4.0 CIRCUIT DESCRIPTION

See Charger Schematic drawing in the Appendix

The AC input voltage is applied to the power transformer (T1) primary winding via the input

EMI filter and the input Circuit Breaker CB1. Transformer (T1) galvanically isolates the AC

mains input from the DC output and converts the mains voltage into secondary voltage of the

required levels for the power bridge (BR1).

The half controlled thyristor bridge operates in a phase control scheme to rectify and regulate

the output power. The unfiltered DC voltage produced by the bridge is fed to the

Inductor/Capacitor filter network (L1, C1) for smoothing. The filter reduces the ripple content

of the output DC to a very low level. The charger current is sensed by the current shunt. A

separate shunt senses the battery current for the purpose of battery current limiting and

display.

Control and Monitor Circuits

The control circuit monitors the output voltage and current, and compares them with set

values; the thyristor conduction angle is then adjusted to ensure that the output voltage and

current are in accordance with the preset levels.

The control circuit is contained on three electronic circuit boards. The Interface Board (A2)

communicates with the MCRII Microcontroller Board (A3) via a 34 way ribbon cable and

carries out the following functions:

1. buffers and filters and scales the incoming voltage, current and temperature signals

2. buffers and level translates the control output to the SCR Firing Board (A1).

The Interface Card also contains an isolated +/-12V power supply. This power supply is in

turn supplied from two sources, a step down control transformer with 18V secondary and the

battery. This ensures that the control circuit is powered even when either the mains or the

battery is absent. The control power is distributed via the 34 way ribbon cable to the

Microcontroller board.

The Microcontroller Board monitors the battery and charger parameters and generates alarm

signals which are used to drive the alarm LEDs and relays on the relay board A4, if installed.

A common alarm relay situated on the Interface Board (A2) de-energises if an alarm

condition is detected. The common alarm signal also drives a buzzer located on the

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Microcontroller Board (A3). The buzzer sounds for any alarm condition and will stay on for

the duration of the alarm. The buzzer can be muted by depressing the Mute button on the

front panel.

The Microcontroller Board provides voltage and current control references to the Interface

board via a D/A converter. These references are compared with voltage and current feedback

signals. The output signal from the error amplifier is fed to the SCR Firing Circuit (A1) where

it is compared with a reference ramp synchronised to the mains. The output of the comparator

then controls a high frequency oscillator to fire the thyristors through pulse transformers.

All metering functions are generated by the Microcontroller (A3) from filtered inputs

obtained from the Interface Board (A2). These signals are routed through the CPU analogue

inputs and are displayed on the graphical LCD display.

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5.0 OPERATING INSTRUCTIONS

Start up

The following start up procedure should be employed whenever starting the system
after a total shutdown.

1) Switch on Battery Breaker CB3. This will cause the display to come On and go

through the start-up sequence, briefly display the MAGELLAN logo and show the top
page after a delay of a few seconds.

2) Switch on Mains Power input circuit breaker (Refer to the schematic drawing). Please

note that the Thyristor type MCRII battery chargers are input phase sensitive. If
the charger fails to start and the INHIBIT LED on the A1 board is on, the phase
sequence is incorrect. Please interchange the position of two of the input phases
and start the charger again.

3) The charger should now start to deliver some charging current to the battery. If the

batteries are fully charged the voltage will quickly approach the Float level and the

charger current will get reduced.

4) Switch on the Load Circuit Breaker (Refer to schematic drawing).

5) The system should now be delivering the load current and charging the batteries and

all alarms would be reset.

Voltage and Current Display

The following parameters are displayed on the front panel LCD:

Screen 1 Charger voltage, Charger Current, Operating Mode and Fault.

Screen 2 Charger voltage, Charger Current, Load voltage, load current.

Screen 3 Charger voltage, Battery voltage, Thyristor Bridge output Voltage.

Screen 4 Charger voltage, Charger Current, Battery Temperature, Battery Current

Screen 5 Charger voltage, Charger Current, Battery AH Capacity (in % of expected

capacity and measured ampere hours), Last AH Ratio

For two-battery option, the Battery voltage, Current and Temperature values are displayed

alternately.

Cycling through these screens is achieved by operating the Mode/Ack switch on the front

panel. The display will automatically return to Screen 1 in 5 minutes if left on Screen 2 to 5.

Boost Charging Batteries

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Manual operation of the boost charging circuit is achieved by pressing the Boost button on

the front panel. The system will then remain in boost mode until the internal boost timer

completes the preset boost cycle.

The boost mode can be terminated by pressing the Boost button again.

Automatic boost charging of the system commences if the battery charging current exceeds a

selected value for a preset period. Both the battery current value and the preset period are

user adjustable. (See User Programmable Set Point Instructions).

Automatic boost mode is terminated by pressing the Boost button.

Battery Test (Optional)

Battery test operates in two distinct modes as described below:

Mode 1.

This battery test is primarily designed to regularly test the battery and generate an alarm if the

performance of the batteries drops below a preset level.

Momentarily operating the Battery Test switch on the front panel places the system into

battery test mode 1. In mode 1 the charger voltage is lowered to a preset value and a load

resistor (optional) is connected across the battery. The battery then discharges into the

optional load or the connected load. At the end of the test period the battery is subjected to a

high discharge current of approximately 50A to assess the ability of the battery to supply high

current. The high discharge is also optional. The battery voltage is monitored during the test

and if it drops to below the `Battery Ok’ level before an internal pre-settable timer completes

its cycle, the system returns to normal, and the Battery Fail Alarm is given. If the internal

timer completes its cycle before the battery voltage drops to the `Battery Ok’ level, the system

returns to normal without activating the alarm.

The internal timer, `Battery Ok’ level, battery test period and High current discharge are all

user adjustable/selectable. (See User Programmable Set Point Instructions).

The battery test mode 1 can also be programmed to operate automatically from 1 to 99 days.

Mode 2.

This battery test is designed to fully test the battery and record the performance of the battery

in ampere hours and as a percentage of the expected battery capacity. Pressing the Battery

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Test key on the front panel for more than 10 seconds places the system into Battery Test

mode 2.

In Mode 2 the charger voltage is lowered to a safe level for the load and a test resistor

(Optional) is connected across the battery. The battery voltage and current is then monitored

by the microprocessor which constantly calculates the ampere hour capacity of the battery.

The test continues until the battery voltage reaches the `End Voltage’ as specified by the

manufacturer. This value (CAP TEST LEVEL) is pre-settable in the Battery Test Menu .

After the `End Voltage’ is reached the calculated Ah capacity along with the time the test has

been in progress is displayed.

If at any time during test the battery voltage falls below a pre-set level (10% above battery

disconnect level), the test is terminated.

The results of the test are then displayed permanently on the front panel LCD until the Reset

key is operated. The results of the most recent capacity test can be accessed in normal mode

by pressing the Mode key on the front panel (Screen 5).

Battery Test mode 1 and 2 can be terminated at any time by operating the Reset key on the

front panel. Detection of a mains fail will also automatically terminate Battery Test mode 1

and 2.

NOTE: As the charger is still operational (at a lower voltage) during both battery test modes
1 and 2, power to the load will still be maintained even if the battery is faulty or open circuit.

Temperature Compensation

This facility adjusts the charger voltage in accordance with the battery temperature. The
charger voltage is lower at higher temperatures. For the Battery Temperature Compensation
to operate the Temperature probes must be connected to the terminals X5 provided on the
charger. The temperature probes are to be mounted on the battery –ve terminals, ensuring
good thermal contact.

If the battery temperature probes are not connected then the battery temperature indicated on
the LCD panel would be very high.

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Alarm Reset and Mute

Reset

Operating the Reset key on the front panel will reset any latched alarms, reset the alarm mute

and terminate a battery test (if active). All alarm functions (with the exception of Under and

Over voltage trip) may be preset in either a latching or non-latching state.

When an alarm latch is set to the On position (See User Programmable Set Point

Instructions), both the alarm LED and the common alarm will continue to indicate that an

alarm condition exists until the alarm has cleared and the Reset key on the front panel is

activated. When an alarms latch is set to the Off position, the alarm LED and the common

alarm will only indicate while the alarm condition exists.

Under voltage trip is always non-latching, as it also drives an auxiliary relay whose function

is to reconnect the battery as soon as the charging system returns to normal.

(See Alarm Operational Description).

Over Voltage trip is always latching.

Mute

The Mute key will silence the audible alarm while an alarm state exists.

The operation of the alarm mute has two pre-settable modes. (See User Programmable Set

Point Instructions).

In mode 1, the Mute key will continue to silence the audible alarm until a new alarm

condition occurs, or the Reset key on the front panel is activated.

In mode 2, the Mute key will continue to silence the audible alarm until it is reset by the
Reset key on the front panel. Therefore, any new alarm that occurs after the Mute key has
been activated will not operate the audible alarm.

Constant Current Charging

The MCR Series Rectifier has a built-in constant current charging function to enable the user
to perform commissioning charges when new batteries are installed, or when cycling the
existing battery bank.

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In order to perform constant current charging, it is necessary to ensure no load is connected to
the charger (due to the high output voltage). The system has built in protection that will
terminate the constant current mode if any load current is detected.

Select the Constant Current Setting menu. (See User Adjustable Set Point Instructions. A
warning screen will appear informing the user to ensure the load is disconnected. Press the
Mode key on the rectifier front panel to clear the warning.

Set the Constant Current Mode to ON by using the Arrow keys.

Pressing the Mode key will display the period which the charger will operate in Constant
Current Mode. Adjust by using the Arrow keys (if necessary.)

Pressing the Mode key will now display the charging rate at which the charger will operate
while in constant current mode. Adjust by using the Arrow keys (if necessary).

Pressing the battery test key will initiate constant current mode. The charger will remain in

this mode until the preset time has elapsed. The charger will then return to its normal state.

Constant current charging can be manually terminated by operating the Reset key.

Remote Communications (Optional)

The charger can communicate to an external or remote computer or LAN via an optional
communication card. The communication methods available are:
RS-232, DB-9
RS-485
Ethernet RJ-45

All information relating to the communications port is located in the MCRII Remote

Communications Manual supplied with the MCRII Remote Communications Package.

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6.0 ADJUSTMENTS

The Programmable Setpoints can be programmed either from the Keypad LCD panel or from
a computer connected to the charger through the communication card. Some of the settings
are password protected to prevent unauthorised changes from being implemented. This
password protection is not present when using the computer link.

Setting from the Key-pad

• Hold down MODE/ACK, - and + keys together for more than 5 seconds. This will

take the controller to the programming mode.

• Go to the appropriate Sub-menu by operating the -/+ arrow keys. Select by pressing

the MODE key. Pressing the MODE key again will take the screen to the next item
under the Sub-menu.

• Once the desired Setpoint is displayed, adjust by pressing the -/+ keys on the front

panel key-pad for the required setting.

• To save and exit press BACK key.

•

Setting from the Computer

The details are given in the MCRII Remote Communications Manual supplied with the

MCRII Remote Communications Package.

Programmable Set Point Descriptions

Following is a description of the function each adjustable set point.

Sub Menu 1 Float and Boost Charging Settings

The following set points are used to set the charger output voltage settings and to set the boost

operational parameters.

Float Voltage Sets the charger output voltage in float mode

Boost Voltage Sets the charger output voltage in boost mode

Boost Timer Sets the period of one boost cycle.

Battery 1 Boost Activation Current Sets the Battery 1 current level at which Auto Boost is

activated

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Battery 2 Boost Activation Current Sets the Battery 2 current level at which Auto Boost is

activated

Boost Activation Delay Sets the period that the Boost Activation Current must

maintain at before the charger switches to auto boost

mode

Boost Cutout Ratio Sets the voltage (as percentage of boost voltage) at

which the boost mode is terminated, if this voltage is

reached within the `Boost Cutout Period’

Boost Cutout Period Sets the period within which the boost is terminated if

the Boost Cutout Ratio is reached.

Sub Menu 2 Alarm and Trip Settings

The following parameters are used for setting alarm and over/under voltage trip and delay
times.

Hi Voltage Alarm Sets activation voltage of the DC High alarm
Hi Voltage Alarm Delay Sets the delay time (seconds) between alarm detection

and alarm indication.

Low Voltage Alarm Sets activation voltage of the DC Low alarm
Low Voltage Alarm Delay Sets the delay time (seconds) between alarm detection

and alarm indication.

Over Voltage Trip Sets activation voltage of the Over Voltage Trip alarm

and protection relay (optional).

Over Voltage Trip Delay Sets the delay time (seconds) between alarm detection

and alarm indication.

Under voltage Trip Sets activation voltage of the Under Voltage Trip

alarm and protection relay (optional).

Under voltage Trip Delay Sets the delay time (seconds) between alarm detection

and alarm indication.
Charger Fail Delay Sets the activation voltage of Charger Fail Alarm
Battery Topping Temperature Sets the battery temperature at which point the

charging current is reduced by 50% to prevent

overheating. This should be set to 250 if not used.
Battery Over Temperature Sets the battery temperature at which point the

charging is terminated. This should be set to 250 if

not used.
Maximum Impedance Change Percentage Change in the battery impedance value

beyond which the battery is considered to be faulty.

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Sub Menu 3 Diode Dropper Settings

(This feature is optional.)

The following parameters are used for setting the switch-in and switch-out voltages for the
diode droppers.
Note: The settings should be kept just beyond the maximum charger voltage if the diode
dropper is not used.

Diode Dropper 1 On Sets the voltage at which the diodes will be switched

in-line.
Diode Dropper 1 Off Sets the voltage at which the diodes will be shorted.
Diode Dropper 2 On Sets the voltage at which the diodes will be switched

in-line.
Diode Dropper 2 Off Sets the voltage at which the diodes will be shorted.
Diode Dropper 3 On Sets the voltage at which the diodes will be switched

in-line.
Diode Dropper 3 Off Sets the voltage at which the diodes will be shorted.

Sub Menu 4 Battery Test

(This feature is optional.)

The following set points are used for programming the manual and automatic battery test
functions.

Batt Discharge Threshold Sets the voltage which the battery fail alarm will

activate. Also sets the level to which the charger output
voltage is reduced to while the battery is under test.

Battery Test Cycle Sets how often an automatic battery test is activated. (1

to 99 days)
Battery Test Duration Sets the period of the battery test (1 to 60 minutes)
Battery Disconnect Bypass Enables/Disables battery disconnect test function
High Discharge Test Enables the high current pulse test.
Cap. Test Level Capacity test end voltage.

Sub Menu 5 Latches and Inhibit Settings

The following set points program alarm latches and control selected alarm inhibits.

Earth Fault Inhibit Inhibits the earth fault alarm
Low Electrolyte Inhibit Inhibits the low electrolyte alarm
Temp Compensate Inhibit Disables the battery temperature compensation

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function
Boost Inhibit Enables a total inhibit of boost mode operation
Load Sense Boost Inhibit Disables the boost function if a load is connected
Battery Connection Pulse inhibit Inhibits pulsing the battery to find out if it is

connected to the system.
Muted-Alarm Trip Sets the operational mode of the Mute key (see

Operating Instructions)
Impedance Monitoring Enables the Impedance Monitoring option.
Mains Fail O/P Latch On/Off Sets the mains fail alarm output to latching
Earth Fault O/P Latch On/Off Sets the earth fault alarm output to latching
Low Electrolyte O/P Latch On/Off Sets the Low Electrolyte alarm output to latching
Battery Discon. O/P Latch On/Off Sets the battery disconnected alarm output to latching.
DC High O/P Latch On/Off Sets the DC High alarm output to latching
DC Low O/P Latch On/Off Sets the DC Low alarm output to latching
Charger Fail O/P Latch On/Off Sets the charger fail alarm output to latching
Battery Fail O/P Latch On/Off Sets the battery fail alarm output to latching

Sub Menu 6 Constant Current Charging Set up

(This feature is optional.)

The following set points are used to select and set the parameters for constant current battery

charging.

Constant Current Charging on/off Enables constant current charging cycle to be

activated.
Constant Current Time Sets the period in which the charger will remain in

constant current mode.
Constant Current Rate Sets the constant current level

OPERATION AND MAINTENANCE MANUAL

THREE PHASE MCRII SERIES BATTERY CHARGER

Rev: 1.6 03/08/2010 Doc: MAN-3P_MCRII_REV1.6.Doc Page 21 of 29

Magellan Powertronics

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

Sub Menu 7 Charger and Battery Definition Set up

Note: This menu is password protected. Adjustment should only be made in consultation with

Magellan Powertronics.

The following set points are used to set the MCRII Controller to match the charger hardware

(Charger and battery size and type).

Serial Number Serial Number of the Charger
Model Voltage Identifies the charger nominal output voltage
Model Current Identifies the charger maximum output current
Charger ID No Identifies the charger for serial communications

purposes when more than one charger is connected to
the remote communication facility.

Dual Battery Enabled Dual or Single Battery operation
Battery Type Sets the type of battery to be charged by the charger.

(Ni-cad, sealed or vented lead acid)

Temperature Compensation Factor

Sets the temperature compensation in mV/°C/Cell

No of cells Sets the No of cells to be used in the battery bank
Battery 1 Size Sets the ampere hour capacity of the Battery bank 1.
Battery 2 Size Sets the ampere hour capacity of the Battery bank 2.
New Security Code The new value of the security code

Sub Menu 8 Calibration

Note: This menu is password protected. Adjustment should only be made in consultation with

Magellan Powertronics.

The chargers are factory calibrated and the calibration should not normally be changed.

Automatic calibration is available with the Charger Monitoring Software.

The following set points are used to calibrate the LCD metering functions and the charger

voltage control output. Follow the procedure given below to calibrate the metering using the

LCD and Keypad.

To calibrate each setting it is necessary to connect a calibrated meter in circuit to measure the

required meter function. The set point should then be adjusted by the front panel arrow keys

so the set point equals the external calibrated meter measurement. All set points, with the

exception of the Reference Voltage O/P Calibration set point, can be adjusted up or down by

the front panel arrow keys.

OPERATION AND MAINTENANCE MANUAL

THREE PHASE MCRII SERIES BATTERY CHARGER

Rev: 1.6 03/08/2010 Doc: MAN-3P_MCRII_REV1.6.Doc Page 22 of 29

Magellan Powertronics

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

The Charger Control O/P set point (displayed on the LCD Display) will remain fixed, and the

charger output voltage is adjusted up or down to match the setpoint by the front panel arrow

keys.

Load Voltage Calibration Calibrates the load voltage meter reading.

Battery 1 Voltage Calibration Calibrates the Battery 1 volt meter reading

Battery 2 Voltage Calibration Calibrates the Battery 2 volt meter reading

Charger Voltage Calibration Calibrates the Charger voltage meter reading.

Charger Current Calibration Calibrates the charger output current meter

Charger Current Offset Calibration Calibrates the charger output current offset

Battery 1 Current Offset Calibration Sets the zero point on the Battery 1 current meter

Battery 2 Current Offset Calibration Sets the zero point on the Battery 2 current meter

Battery 1 Current Calibration Calibrates the Battery 1 current meter

Battery 2 Current Calibration Calibrates the Battery 2 current meter

Bridge Voltage Calibration Calibrates the SCR bridge output voltage reading

Charger Output Control Calibration Calibrates the charger output control

Temperature Offset Calibration Calibrates the Battery temperature readings.

Sub Menu 9 Communications Set up

This sub menu is used to select and set the parameters for communication with the charger.

Details are given in the MCRII Remote Communications Manual supplied with the MCRII

Remote Communications Package.

Sub Menu 10 Diagnostic Set up

This sub menu is used to set the charger into a self diagnostic mode.

Diagnostic Level 1 Setting to On gives enables the level 1 diagnostic

Diagnostic Level 2 Setting to On gives enables the level 2 diagnostic

OPERATION AND MAINTENANCE MANUAL

THREE PHASE MCRII SERIES BATTERY CHARGER

Rev: 1.6 03/08/2010 Doc: MAN-3P_MCRII_REV1.6.Doc Page 23 of 29

Magellan Powertronics

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

Sub Menu 11 Current Limit Set up

This sub menu is used to set the Charger and Battery Current limits.

Note: This menu is password protected. Adjustment should only be made in consultation with

Magellan Powertronics.

6.1 User Adjustable Set Point instructions.

The following procedure should be employed when adjusting any set point.

1) Select the required set point from the programmable set point descriptions in

Section 6.0 of this manual.

2) Follow the instructions contained in the User adjustable set point instructions

flow chart on page 24 of this manual.

3) Once the set point has been adjusted and programming mode exited, it is a

good idea to check the float and boost settings to ensure they have not been

accidentally changed during set point adjustment.

This should be done with a separate multimeter connected across the battery

terminals.

6.2 Earth Fault alarm

The Earth Fault alarm level is factory set and can not be adjusted.

Ensure that the earth fault alarm is not inhibited by the Micro-controller Board. Connect an

adjustable resistor in series with a multimeter capable of reading 0 to 50mA. Place the

resistor/meter from earth to the charger output (+Ve). Adjust the resistor to obtain the

required earth fault current reading on the multimeter. Observe that the Earth Fault LED (D14

on the Interface board) comes On. Recheck the setting when the resistor/meter is connected

from earth to charger (-Ve).

To inhibit this alarm, set the Earth Fault Inhibit set-point to ON in the Sub Menu 5, Latches

and Inhibit Settings.

6.3 Menu.

(See User Adjustable Set-point Flowchart on the following page.)

• All text following the “=” sign is the current Setpoint.

• When Lead Acid battery type is selected a new menu opens that allows the

temperature compensation factor to be adjusted.

Page

24 of 29

PROGRAMMING
MODE SETTING

PRESS (-), (+) and MODE/ACK KEYS SIMULTANEOUSLY FOR 5 SECONDS. THE CPU BOARD WILL NOW SWITCH OVER TO PROGRAMMING/CALIBRATION MODE. PRESS (BACK) KEY TO REVERT TO NORMAL OPERATION ONCE PROGRAMMING IS COMPLETED.

MAIN MENU

↓

FLOAT and BOOST

CHARGING SETUP

ARROW

KEYS

VOLTAGE ALARM and

TRIP POINT SETTINGS

ARROW

KEYS

DIODE DROPPER

SETTINGS

ARROW

KEYS

BATTERY TEST

SETUP

ARROW

KEYS

LATCHES AND

INHIBIT SETTINGS

ARROW

KEYS

CONSTANT CURRENT

CHARGING SETUP

ARROW

KEYS

CHARGER AND BATTERY

DEFINITION SETUP

ARROW

KEYS

CHARGER METERING

CALIBRATION

ARROW

KEYS

COMMUNICATIONS

SETUP

ARROW

KEYS

DIAGNOSTICS

SETUP

ARROW

KEYS

CURRENT LIMIT

SETUP

↓

↓

↓

↓

↓

↓

↓

↓

↓

↓

↓

SUB MENU 1

SUB MENU 2

SUB MENU 3

SUB MENU 4

SUB MENU 5

SUB MENU 6

SUB MENU 7

SUB MENU 8

SUB MENU 9

SUB MENU 10

SUB MENU 11

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

FLOAT VOLTAGE

HI VOLTAGE ALARM

DIODE DROPPER # 1

ON

BATTERY DISCHARGE

THRESHOLD

EARTH FAULT INHIBIT

*****WARNING*******

SECURED MENU

CODE

SECURED MENU

CODE

SECURITY PASSWORD

DIAGNOSTICS

LEVEL 1

SECURED MENU

CODE

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

BOOST VOLTAGE

HI VOLTAGE ALARM

DELAY

DIODE DROPPER # 1

OFF

BATTERY TEST CYCLE

LOW ELECTRO/AUX

INHIBIT

CONSTANT CURRENT

CHARGING

SERIAL NUMBER

LOAD VOLTAGE

CAL

CHARGER ID NO

DIAGNOSTICS

LEVEL 2

MAXIMUM CHARGER

CURRENT

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

MANUAL BOOST TIMER

LO VOLTAGE ALARM

DIODE DROPPER # 2

ON

BATTERY TEST

DURATION

TEMP COMPENSATE

INHIBIT

CONSTANT CURRENT

LEVEL

MODEL VOLTAGE

BATTERY VOLTAGE

CAL

DNP3 STATION ADDRESS

RETURN TO MAIN MENU

MAXIMUM BATTERY

CURRENT

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

AUTOMATIC BOOST

TIMER

LO VOLTAGE ALARM

DELAY

DIODE DROPPER # 2

OFF

BATT. DISCONNECT

BYPASS

BOOST INHIBIT

CONSTANT CURRENT

TIME

MODEL AMPERAGE

BATTERY2 VOLTAGE

CAL

Ethernet DHCP Enabled

MAXIMUM CHARGER

CURRENT CAL

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

BATT1 BOOST

ACTIVATION CURRENT

OVERVOLTAGE TRIP

DIODE DROPPER # 3

ON

HIGH DISCHARGE

TEST

LOAD SENSE BOOST

INHIBIT

RETURN TO

MAIN MENU

DUAL BATTERY ENABLED

= ON

CHARGER VOLTAGE

CAL

Local IP Address

= 192.168.001.240

MAXIMUM BATTERY

CURRENT CAL

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

BATT2 BOOST

ACTIVATION CURRENT

OVERVOLTAGE TRIP

DELAY

DIODE DROPPER # 3

OFF

CAP TEST LEVEL

BATT CONN PULSE

INHIBIT

BATTERY TYPE

CHARGER CURRENT

CAL

Local IP Mask

= 255.255.255.000

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

BOOST ACTIVATION

DELAY

UNDERVOLTAGE

TRIP

RETURN TO

MAIN MENU

RETURN TO

MAIN MENU

MUTE ALARM ALWAYS

TEMP COMPENSATION

FACTOR

CHARGER CURRENT

OFFSET CAL

Local MAC Address

= 004.163.000.000

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

BOOST CUTOUT RATIO

UNDERVOLTAGE TRIP

DELAY

IMPEDANCE MONITORING

NUMBER OF CELLS

BATTERY CURRENT

OFFSET CAL

Gateway IP Address

= 192.168.001.001

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

BOOST CUTOUT

PERIOD

CHARGER FAIL DELAY

MAINS FAIL O/P LATCH

BATTERY 1 SIZE

BATTERY CURRENT

CAL

Client IP Address

= 192.168.001.000

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

AUTO BOOST PERIOD

BATT TOPPING TEMP

EARTH FAULT O/P LATCH

BATTERY 2 SIZE

BATTERY2 CURRENT

OFFSET CAL

Client IP Mask

= 255.255.255.000

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

RETURN TO
MAIN MENU

BATT OVER TEMP

LOW ELECTROLYTE /AUX

LATCH

NEW SECURITY

CODE

BATTERY2 CURRENT

CAL

RETURN TO

MAIN MENU

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

MAX IMPEDANCE CHANGE

BATTERY DISCONNECT

O/P LATCH

RETURN TO

MAIN MENU

BRIDGE VOLTAGE

CAL

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

BATT IMBAL. TRIP

DC HIGH O/P

LATCH

CHARGER CONTROL

O/P CAL

PRESS MODE KEY

↓

PRESS MODE KEY

↓

PRESS MODE KEY

↓

RETURN TO

MAIN MENU

DC LOW O/P

LATCH

TEMP OFFSET

CAL

PRESS MODE KEY

↓

PRESS MODE KEY

↓

CHARGER FAIL O/P

LATCH

TEMP2 OFFSET

CAL

PRESS MODE KEY

↓

PRESS MODE KEY

↓

BATTERY FAIL O/P

LATCH

RETURN TO

MAIN MENU

PRESS MODE KEY

↓

RETURN TO

MAIN MENU

NOTE: Pressing (RESET) button for more than 30 seconds will restore the factory settings

OPERATION AND MAINTENANCE MANUAL

THREE PHASE MCRII SERIES BATTERY CHARGER

Rev: 1.6 03/08/2010 Doc: MAN-3P_MCRII_REV1.6.Doc Page 25 of 29

Magellan Powertronics

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

7.0 COMMISSIONING

7.1 Start-Up

Before delivery the charger is factory adjusted in accordance with the test sheets. The actual
Setpoints loaded are recorded in the Downloaded System Setpoints in Appendix-2.

The factory settings for float and boost rate charge volts are calculated to correspond with the

number and type of battery cells.

Note:

Before testing the systems functions, the Commissioning Personnel should be familiar

with the factory setting of each set point, including alarm delays and latching functions.

Check that the mains supply matches the supply requirements stated on the Ratings plate.

Connect the mains power. Follow the start up procedure.

7.2 Checking Voltage Levels

Before making any adjustments and to obtain the correct set points of the charger, consult the

Downloaded System Setpoints in Appendix-2. Ensure the battery is fully charged, this

prevents unnecessary waiting time for the voltage to reach the boost level. When checking the

voltage, check that the charger does not operate in current limit or without load. A good rule

is to use a load current of between 5 and 80% of the nominal rated current.

7.3 Checking Float voltage

With the charger set to float, connect a precision voltmeter across the Charger Output

terminals X2 and take a reading.

If adjustment is required refer to the Adjustments section.

Note:

With zero current the charger output voltage may be slightly different from the

set Float voltage. Please take the readings with at least 5% load on the 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 26 of 29

Magellan Powertronics

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

7.4 Checking Boost Voltage

With the charger set to boost, connect a precision voltmeter across the charger output

terminals and take a reading. If adjustment is required refer to the Adjustments section.

The following tests are optional and do not constitute the normal commissioning
procedure.

7.5 Checking Battery Current Limits

This test is to be carried out on one battery at a time.

Discharge Battery 1 for a while by switching the charger off and providing some DC load for

a period of approx. 10 min. This time may vary depending on the size of the DC load

compared to the battery capacity. When the battery has discharged sufficiently remove the

load and switch charger on. The output current from the charger will now rise to the battery

current limit level; check the current limit level. If adjustment is required refer to the

Adjustments section.

Repeat for Battery 2.

Reconnect the load.

7.6 Checking Charger Current Limit

Disconnect the batteries. Connect a load to draw more than the rated current of the charger at

the float level. Switch charger on. The output current from the rectifier will now rise to the

current limit level. Check the current limit setting on the ammeter on the front panel.

Reconnect the battery.

OPERATION AND MAINTENANCE MANUAL

THREE PHASE MCRII SERIES BATTERY CHARGER

Rev: 1.6 03/08/2010 Doc: MAN-3P_MCRII_REV1.6.Doc Page 27 of 29

Magellan Powertronics

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

7.7 Testing Mains Fail Alarm

Simulate a mains failure by isolating the charger at the AC supply distribution board. After a

delay the

Mains Fail

LED will be lit. Check that the mains fail relay on the Relay board A4

(if fitted) has de-energised and that its contacts (see Schematic Diagram) have changed over.

Also check that the common alarm relay has de-energised and that buzzer is sounding. Ensure

that the buzzer can be muted by pressing the

Alarm Mute

key. The mute function can be reset

by pressing the

Reset

key.

Restore mains.

7.8 Testing DC Low Alarm

Disconnect the battery from the charger. Decrease the Float voltage (See User Adjustable Set

Point Instruction Sheet) to a setting just below the DC Low level. The

DC Low

Alarm will be

indicated on the LCD panel after the user programmable alarm delay has expired. Also check

that the DC Low relay on the Relay board A4 (if fitted) have de-energised and that its

contacts (see Schematic Diagram) have changed over, and check that the Common Alarm

relay on the Interface Card has de-energised and that buzzer is sounding. Ensure that the

buzzer can be muted by pressing the

Alarm Mute

key. The mute function can be reset by

pressing the

Reset

key. Now adjust the Float voltage set point to 5 % above the DC Low

alarm set point and ensure that the alarm can be reset.

Readjust the Float voltage to the level shown on the test report and reconnect the battery.

7.9 Testing DC High Alarm

Disconnect all loads from the charger. Increase the Float voltage (See User Adjustable Set

Point Instruction Sheet) to a setting just above the DC High level. The

DC High

Alarm will

be indicated on the LCD panel after the user programmable alarm delay has expired. Also

check that the DC high relay on the Relay board A4 (if fitted) have de-energised and that its

contacts (see Schematic Diagram) have changed over, and check that the Common Alarm

relay on the Interface Card has de-energised and that buzzer is sounding. Ensure that the

buzzer can be muted by pressing the

Alarm Mute

key. The mute function can be reset by

pressing the

Reset

key. Now adjust the Float voltage set point to 5 % below the DC High

alarm set point and ensure that the alarm can be reset.

Readjust the Float voltage to the level shown on the test report.

OPERATION AND MAINTENANCE MANUAL

THREE PHASE MCRII SERIES BATTERY CHARGER

Rev: 1.6 03/08/2010 Doc: MAN-3P_MCRII_REV1.6.Doc Page 28 of 29

Magellan Powertronics

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

7.10 Low Electrolyte.

Ensure the Low Electrolyte Alarm is not inhibited.

Remove the electrolyte probe (if fitted) and check for

Low Electrolyte

fault indication on the

LCD panel. Check that the low electrolyte relay on the Relay board A4 (if fitted) have de-

energised and that its contacts (see Schematic Diagram) have changed over. Also check that

Common Alarm relay on the Interface Card has de-energised and that buzzer is sounding.

Ensure that the buzzer can be muted by pressing the

Alarm Mute

switch. The mute function

can be reset by pressing the

Reset

switch.

Replace the electrolyte probe

7.11 Battery Fail

Disconnect the battery from the charger. Press the

Battery Test

switch and check that after the

test period the

Battery Fail

LED lights up. Check that the battery fail relay on the Relay board

A4 (if fitted) have de-energised and that its contacts (see Schematic Diagram) have changed

over. Also check that the Common Alarm relay has de-energised and that buzzer is sounding.

Ensure that pressing the Alarm Mute switch can mute the buzzer.

Reconnect the battery.

Note:

In order to clear this alarm, the battery must be reconnected and the Battery Test switch

must be pressed to initiate another battery test cycle. The alarm will then clear if the battery

passes the test.

7.12 Diode Voltage droppers (Optional)

This feature is optional.

Australian Technology – Australian Made

68 Cocos Drive Bibra Lake, WA 6163 P: [phone] F: + 61 8 9434 6623

E:

[e-mail]

W:

www.magellan-power.com.au

29

ISO 9001:2000

ISO 9001:2008

Magellan Power Service

DC systems are a vital component of any modern substation, providing power to protection and control
equipment in times of AC power loss. Failure to provide the backup power to protection gear to clear a fault
can be catastrophic.

The problem with batteries is that there is no way of assessing their health by visual inspection alone. Often a
battery recently installed that looks perfect on the outside can be totally corroded inside. The battery charger
also plays a big part in the reliability of the system. A badly regulated or badly filtered battery charger can
damage or even explode a perfectly good battery in a matter of months if not weeks! Metering on the DC
systems can also be misleading. They may be showing the right values but in reality, the battery may be
under or overcharged.

It is therefore essential that DC systems are reliable and ready for action all the time and this necessitates
maintenance both for batteries and chargers.

Servicing Options

Six Monthly Service

This ensures that the charger and the batteries are
operating correctly and can provide protection
power for the switchgear when needed. The six
monthly service includes:

1. Functional check of the charger to
ensure it is working correctly.

2. Assessment of components for stress
and fault.

3. Battery electrolyte assessment (if
applicable) and top up when required.

4. Battery terminal corrosion check and
general battery clean.

5. Float voltage review of each battery cell
and the battery bank.

Note : These tests can be done without
interruption to the normal operation of the charger.

Annual Service

This ensures that the charger is functioning
correctly and measures the present capacity of the
battery. The DC system needs to be shut down
during the annual service and includes all six­monthly service items PLUS:

1. Load testing of the batteries to
determine battery health and identify
replacement needs.

2. SG testing on the battery electrolyte (if
applicable).

Our Service Team

Magellan Power’s service department technicians are the industry’s leading experts in the provision of
outstanding support through an onsite repair service which can eliminate the downtime of your power
equipment.

Our technicians are fully trained in all aspects of AC/DC repair and refurbishment and will bring to you the
collective knowledge and experience of the entire Magellan Power team.