DARTPOINT LTD

BATTERY & CHARGER SYSTEM

INSTALLATION, OPERATION AND
MAINTENANCE INSTRUCTIONS
DARTPOINT TYPE: DPS110/5/VTX1M16
(TW Type D)
 CONTENTS

SECTION
1.0 INTRODUCTION
2.0 DATA SHEET
3.0 DESCRIPTION
3.1 Physical
3.2 Power Circuit
3.3 Regulation
3.4 Metering and Indications
3.5 Boost Operation
3.6 Battery Alarm
3.7 Charge Fail Alarm
3.8 Battery Test
4.0 INSTALLATION
4.1 Siting
4.2 Cabling
5.0 COMMISSIONING
5.1 Initial Checks
5.2 Charging the Battery
6.0 MAINTENANCE
6.1 Battery
6.2 Charger Unit
7.0 FAULT FINDING
APPENDICES

Circuit Diagram S4954

Battery Layout S4594
General Arrangement G4593
 1.0 INTRODUCTION

This charger system is designed to maintain a battery in a charged state ready for
discharge duty following a break in the AC mains supply. This is achieved by
charging the battery at a constant voltage (potential). The charger has two voltage
settings: The float setting is used to maintain the battery in a state of readiness over
a long period and also to recharge the battery following a discharge. The boost level
is used to provide a faster recharge or to give the battery an initial high rate
commissioning charge.

The load is connected directly across the battery (via fuses or circuit breakers), the
battery being simultaneously float charged by the charger. The charger output
current rating is sufficient to supply any load current which is present when the
mains supply is healthy (standing load) plus the current required to recharge the
battery within the required time.

The system has been designed to Thames Water F25 Specification.

 2.0 DATA SHEET

SYSTEM TYPE: DPS110/5/VTX1M16

ENCLOSURE: Floor Standing Steel
BATTERY: Type VTX1M16
Manufacturer Alcad
Number of cells in battery 90

CHARGER RATINGS:
AC Supply Voltage 230/240V
Frequency 50/60Hz (single phase)
Charger Output Rating 5 Amps
Recharge time 7 hours (as per Thames Water F25 spec)
Float Voltage 1.42 V per cell; 127.8 V total
Boost Voltage 1.5 V per cell; 135 V total
Output Voltage Range Min: 96.6 V
Max: 138.5 V (as per ENATS 48-4)
Rated Ambient Temperature -10 to +40EC
OTHER DATA
Input AC MCB Rating 16 A Type D (MCB1)
Auxilliary Fuse Ratings 2 A Type NIT2 (F1,5,6,7,8)
Rectifier Protection Fuses Type 38 x 10mm 10A uR(F2)
Main Load Fuses 20A Type NIT20 (F9-16)
Charger Fuses 10A Type NIT10 (F3,4)
BATTERY ALARM
Low Voltage Setting:- 94 V
High Voltage Setting:- 142 V
Charger Trips
(MCB1 opens) above 145V
Earth Fault Setting:- 50 K Ohms
High Battery Impedance Setting:- 1 Ohm
 3.0 DESCRIPTION

3.1 Physical
A floor standing enclosure is provided which houses the charger. The battery is
installed in separate compartments of the same enclosure.

3.2 Power circuit

The power circuit of the charger comprises a double-wound mains transformer
feeding a half-controlled full-wave rectifier bridge. This bridge is made up of two
thyristors and two diodes. Fuses are provided in the mains input circuit, between
the transformer and rectifier, and in the DC output circuit. A choke is fitted in the
power circuit to reduce ripple current.

3.3 Regulation
Regulation of battery voltage and limitation of charger output is achieved by
varying the time in each half-cycle of mains at which the thyristors in the rectifier
bridge are fired. A charger control printed circuit board is fitted to all chargers in
the range and this performs the regulation function and supplies firing pulses for
the thyristors. The output current-voltage characteristic is shown in Figure 1.

VB

VF
VF = Float Voltage

VB = Boost Voltage

IL = Current Limit Level

0,0 IL I

Figure 1 Charger Output Characteristic

The charger control PCB senses the battery voltage and adjusts the firing point of
the thyristors in order to keep the voltage constant. Another section of the circuit
monitors the current flowing from the charger ( by sensing the millivolt drop across
a shunt) and limits this current to a level which is within the rating of the charger
components. This current limiting would only occur when recharging a fully or
partially discharged battery, since, under normal conditions, when the battery
voltage has risen to the float or boost levels, the voltage regulation circuit comes
into operation and the current falls.A block diagram of the control board is given in
Figure 2.
Transformer

Thyristor Choke
Mains Input Controlled Shunt
To Battery
Rectifier
Bridge

Control PCB

Pulse
Shaper Drive
Circuit

Comparator
Ramp Current
Generator I
Feedback
Reference V
Regulator Voltage

Figure 2 Charger Block Diagram

3.4 Metering and indications.

The following are provided:-
CHARGER AMMETER
BATTERY VOLTMETER
LOAD AMMETER
MAINS ON LAMP (white)
BOOST LAMP (yellow)
ALARM LAMPS (red)
ALSTOM BATTERY ALARM
3.5 Boost Operation
During normal operation the charger will be in the float mode. The boost system in
this charger is manually operated by means of the pushbutton fitted to the front
panel and controlled by a timer set to 7 hours. The boost function can be cancelled
by means of operating the battery testing pushbutton.

Boost mode is used in order to provide a faster recharge or to equalise the state of
charge in the cells of the battery. It operates by charging the battery at a higher
voltage and results in increased gassing rate of the cells. Boost will not normally be
required more often than about once every 6 months. Excessive use of boost charge
will result in higher water usage by the battery and more frequent topping-up.

BOOST TIMER TIM1 SETTINGS (7 Hours):

Range: 10h .
Time Setting: 0.7
Function: Mode F

3.6 Battery Alarm

An Alstom model 300 battery alarm unit has been fitted to this charger. This unit
monitors the DC output busbars and gives an alarm on two sets of output contacts
in the event of a fault. The unit monitors Earth Leakage, Over Voltage, Under
Voltage and Battery Impedance.

Details of the battery alarm are in the leaflet supplied.

3.7 Charge Fail Alarm

A relay (RL1) monitors charger output voltage. Should the charger fail, this
de-energises which illuminates the “Charger Output Fail” LED and starts a 30
second timer, TIM2. After the time is up, the timer contacts change over to give
remote indication of Charger Output Fail alarm.

3.8 Battery Test

Whilst the Battery Test pushbutton is operated, a load of approximately 5 Amps is
applied to the battery by means of contactor CON1 and dummy load resistor R6. At
the same time, the charger is switched off. Load current is displayed on the Test
Load Current meter and battery voltage can be monitored on the voltmeter. The
button should be pressed for a maximum period of 10 seconds to avoid overheating
the load resistor.
 4.0 INSTALLATION

4.1 Siting.
The charger should be installed in a sheltered, well ventilated position, away from
direct sources of heat. The maximum ambient temperature stated on the data sheet
should not be exceeded. At least 3" (75mm) should be allowed for ventilation
around the cabinet. The ventilation louvres must not be obstructed.

4.2 Cabling.
A gland plate is provided in the top and bottom of the cabinet. This plate should be
removed, drilled for the cable glands, and refitted. Reference should be made to the
rating of the internal mains fuse (see data sheet) in order to determine cable size for
the AC supply. When sizing the DC cables (to load or remote battery),
consideration should be given to the volts drop which will arise in the cable. For
battery cable, it is usual for the volts drop not to exceed 1% of nominal DC voltage.

IT IS ESSENTIAL TO ENSURE A GOOD EARTH TO THE

TERMINAL PROVIDED.
 5.0 COMMISSIONING

5.1 Initial Checks.

The battery connections should be inspected to ensure that all links are tightened
and that cell polarities are all correct.

NOTE: VANTEX BATTERIES DO NOT HAVE TRANSIT BUNGS.

Check that the electrolyte levels in the cells are correct. Check that the AC supply
voltage is the same as that on the equipment rating plate. Check that there is no
obstruction to ventilation louvres or slots. Check that any plug-in modules or relays
within the charger cabinet are fully pushed home.

5.2 Charging the battery.

The charger may now be switched on. The mains on indicator will light and the
charger ammeter should show a reading. The charger will initially be operating in
float charge mode. To commission a new battery, the boost mode should be
operated for a suggested total period of 24 hours or as directed by the battery
manufacturer.

A period of 24 hours in boost mode can be achieved by one of two options. Either
the boost pushbutton may be operated multiple times with the normal 7 hour setting
to achieve the 24 hours or the the timer settings may be temporarily adjusted as
shown below.

TIMER 1 SETTINGS FOR 24 HOURS COMMISSIONING:

Range: 1D .
Time Setting: 1
Function: Mode F
After the 24 hours has been reached, change back to the normal settings.
TIMER 1 SETTINGS NORMAL OPERATION:
Range: 10h .
Time Setting: 0.7
Function: Mode F
After the boost charge period, the voltage at the battery terminals will fall to the
normal float level given in the data sheet. The battery charge current should
then be at a very low level.
 6.0 MAINTENANCE

6.1 Battery.
The battery manufacturer’s instructions should be followed strictly. The cells
should be topped up with distilled water regularly and the top of the cells kept
clean. Petroleum jelly (Vaseline) or “No-Oxide Grease” may be used to protect
terminals and links from corrosion. In the event of it being necessary to replace a
single cell in the battery, this cell should first be charged, and following
replacement, the whole battery should be boost charged for a few hours to equalise
the cells.

6.2 Charger.
The only routine maintenance required for the charger is to remove any
accumulation of dirt from the enclosure and check that ventilation is not
obstructed.

SWITCH OFF THE MAINS SUPPLY BEFORE OPENING THE

CHARGER DOOR AND TAKE CARE NOT TO SHORT OUT THE
DC WIRING, WHICH MAY STILL BE LIVE. SPECIAL CARE MUST
BE TAKEN WITH DC SYSTEMS OF 110 VOLTS AND ABOVE.
 7.0 FAULT FINDING.

Most faults are due to blown fuses or indicator lamps and may readily be rectified.
In the event of the charger failing to produce an output, the following should be
checked:-

a) Check that all fuses (including the high speed fuses) are intact.

b) Check that the correct mains voltage is present at the mains terminal block and
that the “mains on ” lamp comes on when the switch is operated.

c) Using an AC voltmeter on the 30V range, measure the supply voltage from the
three windings on the auxilliary transformer to the charger control board. Between
pins 1 and 2 at the board there should be 24V. Between pins 3 and 4 and also
between pins 5 and 6 there should be 6V. If any of these voltages are more than 20%
in error, the auxilliary transformer is suspect.

d) Check the voltage between the V+ and V- terminals of the board with a DC
voltmeter. This should be identical to the battery voltage.

e) If no fault shows in the tests a) to d) above and interference with the adjustment
potentiometers on the control board is not suspected, the control board should be
replaced with a spare, which should then be adjusted as follows:

ADJUSTMENT OF FLOAT AND BOOST VOLTAGES AND CURRENT

LIMIT.
a) Set all three potentiometers on the charger board fully anticlockwise.

b) Switch on charger.

c) Using a plastic adjuster turn the current limit pot three full turns clockwise.

d) Ensure the charger is in float and turn the float pot clockwise until a current
appears on the charger ammeter. This should be less than the current limit setting
given in the data sheet. If this is the case, continue turning the float pot a further 10
turns. (it will now be fully clockwise).

e) Adjust the current limit pot to obtain the current limit value on the charger
ammeter.
f) Turn the float pot anticlockwise until the battery voltage is equal to the float
setting in the data sheet. It may be necessary to wait for the battery voltage to rise or
fall, depending on its state of charge.

g) Switch to boost and adjust the boost pot until the correct voltage appears across
the battery. It may again be necessary to wait for the battery to charge to this level.

SPARE PARTS.
Spare parts and further information may be obtained from:-

DARTPOINT LTD.
KITEWELL LANE
LYDD
KENT
ENGLAND
TN29 9LP

TELEPHONE :- 01797 320910

FAX :- 01797 320571
E-MAIL:- [email protected]
 M3
LOAD
CURRENT
+
MCB1 STK1
CHARGER CURRENT 51 A 52
M1 D1 D5
SW1 16A T1 F3 10A
25 78 24 23 35 + 36 39 50 53 F9 20A 83 84
L A SH1
1+
M4 M2
+
F5 F7
TEST LOAD BATTERY F10 20A
2A 2A 85
AC SUPPLY 58 F2 59 A CURRENT 63 VOLTAGE 61 1-
FILTER

230V 10A R1 R2 R4 R5 R3 +
D6
50 Hz G
7 F11 20A
LED1 C1 13 74 + URG. AREVA 90
60 9 12 2+
1
MAINS RL1
A1 81 82
V 80
9 66 N.U. BATTERY 89
ON 4 1 8 ALARM 300
71 TIM2
15 3 F12 20A 91
26 79 27 L1 14 se3 10 2-
N HVT 11 18 - E
37
38
A2 2 5 12 25 6 110V DC
VOLTAGE
B+ D7 OUTPUTS
56 1 67 86
F1 SENSING 28 10 F13 20A
2A MODULE 13 93
3+
TYPE DHR 3 68 65 92
10
RL2 2
47 69
CON1 70 C2 4 13 13 87 F14 20A
EARTH + MCB1 + 14 RL3 RL4 90 Cells 94
2
D3 D4 62 Ni-Cd 16Ah 3-
22 PB1
R
SHT R 4 4
41 TEST 34 35 28 35 35 36 L2 C1 D2 14 14
T2 57
48 C2 64 LED4 D8
1 g1 k1 G2 k2 I+ I- F15 20A
R6 LED3 AC INPUT MCB B- 96
36 4+
V+ CHARGE TRIPPED F6 F8 95
24V 42 PCB1 2A 2A
2 FAIL
55
F16 20A 97
43
3 CHARGER CONTROL PCB 4-
54
6V P2801 110V F4 10A
44 4
45
5
55
6V V-
46
6 C F B B1 B2
19

LED2 20
48 Y
BOOST
SW2 21
A1 18
BOOST 18
s TIM1
49 f 3 42 15
A2

5 8 5 8 5 8
1 4 1 4 1 4

9 12 9 12 9 12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
URGENT ALARM NON-URGENT ALARM COMMON BATTERY CHARGER ALARM
CHARGE FAIL, HIGH VOLTS, EARTH FAULT, (SHOWN FAILED)
LOW VOLTS, HIGH IMPEDANCE CHARGER IN BOOST
(SHOWN FAILED) (SHOWN HEALTHY)

ALL RELAY CONTACTS SHOWN

IN DE-ENERGISED STATE

Last No: 97

Issue Mod. No. Approved Date Title Drawn Approved Date

A As Built mpw 03/04/22
DARTPOINT LTD DPS110/5/VTX1M16 tpm

Drawing No.
MPW 03/04/22

Kitewell Lane, Lydd, Kent TN29 9LP TRIPPING BATTERY & CHARGER S6232
Tel: 01797 320910 Fax: 01797 320571 Email: [email protected]
 INTERNAL LAYOUT
OF CHARGER SECTION
(FRONT VIEW)
SEE SCHEMATIC S6232 TOP VIEW
FOR COMPONENT REFS

EARTH
50
STUD
110V DC
230V AC ALARMS TO LOADS
LN MCB1 1 to 18 B+ B- 1+ to 2-
FILTER F9 F11 F13 F15

150 Gland Plate

TERMINALS

D5 D7

F1 F3 F4 F5 F6 F7 F8
F10 F12 F14 F16 300
D6 D8
Charger
CHARGER CURRENT BAT T ERY VOLT AGE LOAD CURRENT

TIM1 TIM2 BATTERY

PCB1 ALARM

F2 RL1 RL2 RL3 RL4 300

T EST LOAD
CURRENT

CON1 T2
SPARE

0
1

AC SUPPLY MAINS CHARGE AC INPUT BOOST BOOST BAT T ERY T EST

ON ON FAIL MCB T RIPPED SELECT PUSH 5 SEC. MAX.

D1

C1
HVT R4 & R5 R2 R3
STK1

R1

T1
L1 R6
L2

Notes:
25

25

Protection to IP41
Weight: 250Kg approx. with battery installed.
2050 Paint Finish: RAL7035 light grey structured.

BOTTOM VIEW

Batteries Batteries

GLAND PLATES Cable 4 OFF FLOOR

IN TOP, BOTTOM Duct FIXING HOLES
& PARTITION 425 14mm DIA.

100 35
550
600
520 600

ALL DIMENSIONS IN mm PLINTH WITH REMOVABLE FRONT/BACK

Issue Mod. No. Approved Date Title Drawn Approved Date

A As Built mpw 22/08/22

DARTPOINT LTD DPS110/5/VTX1M16
tpm
Drawing No.
MPW 22/08/22

Kitewell Lane, Lydd, Kent TN29 9LP 110V TRIPPING BATTERY UNIT
Tel: 01797 320910 Fax: 01797 320571 [email protected]
G6346
 PLAN VIEW

- TO CHARGER +
+
+ 1 2

+
2 1
+
TOP TIER
+
+ 1 2

1 - 5 CELL BLOCK
2 - 10 CELL BLOCK
+
2 1
+

+
+ 1 2
BOTTOM TIER
+
2 1
+

Issue Mod. No. Approved Date Title Drawn Approved Date

A DARTPOINT LTD 110V BATTERY LAYOUT

90 CELLS VTX1L15,
tpm
Drawing No.
MPW 10/3/15
Kitewell Lane, Lydd, Kent TN29 9LP
Tel: 01797 320910 Fax: 01797 320571 Email: [email protected] VTX1M16, VTX1M24 or VTX1M32 S4594