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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: 08 94346621     Fax: 08 94346623 

 

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 

Summary of Contents for MCR-II SERIES

Page 1: ...BATTERY CHARGER Magellan Powertronics Pty Limited AS NZS ISO 9001 2000 68 Cocos Drive Bibra Lake Western Australia 6163 National Tel 08 9434 6621 International Tel 618 9434 6621 Fax 08 9434 6623 Fax...

Page 2: ...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...

Page 3: ...8 94346623 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...

Page 4: ...ipment 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...

Page 5: ...onstant 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...

Page 6: ...e 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 mode...

Page 7: ...isconnect 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...

Page 8: ...ent 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 Adju...

Page 9: ...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 Fa...

Page 10: ...uit 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 p...

Page 11: ...oltage 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 f...

Page 12: ...iver 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 Bre...

Page 13: ...y 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...

Page 14: ...connect 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 a...

Page 15: ...ndicate 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 return...

Page 16: ...e 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 th...

Page 17: ...eys 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...

Page 18: ...m 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 betwe...

Page 19: ...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 man...

Page 20: ...n 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 ala...

Page 21: ...ion 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 S...

Page 22: ...ut 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 Batter...

Page 23: ...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...

Page 24: ...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 DROPPE...

Page 25: ...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 co...

Page 26: ...ery 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 th...

Page 27: ...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 pressi...

Page 28: ...n 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 t...

Page 29: ...s 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 Functio...

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