Energy to power up

Battery Charger
From 5 A upto 2500 A
24, 48, 110, 220, 360 VDC

To Provide Innovative Solutions for a better Tomorrow.

Company Profile
Chhabi Electricals, is India's most preferred company in
the field of DC Power Solutions. or the last four decades,
it has been supplying variety of standard as well as
customised DC Power solutions to all types of Power
Stations, Distribution and Industrial applications.
Chhabi is registered and approved vendor with all the
major engineering consultants, thanks to its capability to
handle customization and unmatched project execution
skills.Export to more than 26 countries has broadened
our geographical reach, apart from our pan India
presence with installation of more than 10,000 systems.
After sale support from our 10 offices, ensures quick
response to customer needs and offers other services like
AMC, Up-gradation etc.
CHHABI's modern manufacturing facility is spread
across 50,000 sq. ft. at Jalgaon, Maharashtra with
adequate test set up and power back up facility.
In the past Chhabi has been conferred with the
prestigious 'Udyogshree', 'Order of Merit', 'Global Arch
Excellence', 'District Award' by Maharashtra Government
and 'IEEMA SME Quality Commendation' from IEEMA for
2013.
CEPL Manufacturing Plant at Jalgaon

Four Decades in Power Business

Innovative Designs

Approved by Leading Engineering Consultants

Registered & Approved Vendor for Major EPC Companies

Specialises in Customised DC Power Solutions

Supplied Indias Largest Rated Charger for Power Plant

Modern Manufacturing Facility

Exporting to more than 21 Countries

All India Sales and Service Network

Winner of SME Quality Commendation Award ISQA 2013 from IEEMA

An ISO 9001 Company

Introduction
Chhabi produces a wide range of rugged DC power
systems for use in the industrial market sector to
provide DC uninterruptible supply in conjunction with
batteries to 24 V, 48 V, 110 V, 125 V, 220 V, 360 V
critical loads.
The range of DC Systems are generally custom
designed to provide a rugged, reliable and efficient
power solution for critical loads to prevent expensive
Outages.
These types of power systems are widely used in the
harsh operating environments encountered in the
power generation and distribution, oil and gas,
industrial instrumentation and onshore or offshore
petro-chemical applications.
DC Systems
Chhabi offer a range of standard DC power systems
based around battery charger products. The DC
power solution can be customize to meet the most
demanding of client requirements. Chhabi is
renowned for their technical expertise and
manufacturing capability to provide the optimum
solution.
Power Conversion
The AC to DC power conversion element of the system
is typically configured from thyristor or switch mode
technology depending on the performance and size
constraints.
The range of thyristor based systems are highly
rugged industrial systems, suitable for the most
demanding of environmental and operating
conditions. The thyristorised range of single phase

and three phase input charger products capable of

operating on 24 V to 360 V DC nominal voltage with
output currents up to 2500 A. Other ratings are also
available as per customers requirement. Charger
with CMU103T Digital Controller
Standard Features offered :
l

Overload and short-circuit electronic protection

Very good time response for step load

Very high efficiency

Temperature compensation of battery

charging voltage

Programmable charging curves

Embedded controller with

ARM Cortex-M3 processor

RS485 interface for remote monitoring

Single phase / Three phase input options

6 pulse / 12 pulse / 24 pulse charger designs

Alarms with annunciation windows

Options available
l To meet client specific dedicated requirements
and specifications, the DC system is custom
designed and configured. Custom designed systems
can be configured from numerous options available.
These include but are not limited to ;
l

Differing enclosure sizes and colours

Enclosure (IPxx) protection ratings

Alarm and system monitoring schemes

Charger and battery redundancy schemes

Customer specific distribution

Battery monitoring

Configurable remote alarms

isolation transformer. The set of thyristors is protected

by a very quick-acting semiconductor fuses. The
central control unit CMU103T is responsible for the
operation and supervision of the rectifier unit. It
provides drive to the thyristors, monitors, the
components of the rectifier unit. A separate microcontrolled unit DAA takes care of measurement,
alarms, annunciation etc. It provided digital
monitoring facility and it can be interfaced with PC
using MODBUS. A proprietary software is available
to monitor the charger remotely.

DC power supplies comprise rectifier units and the

appropriate batteries.
Function
Thyristor regulated rectifier units are designed for a
3-phase input and constructed with a fully- controlled
3-phase bridge circuit (see basic circuit diagram
below). Connection to the AC mains supply is made
via a contactor in the rectifier unit input. A soft-start
facility prevents high-voltage transients being passed
through to the loads at the time of switch-on. The
loads are electrically separated from the input by an
L1

D1

Choke
T1

415 VAC
3 Phase
50 Hz

T3

Shunt

T5

R
Y
B

Load

C1
T4

Battery
Shunt

T2

T6

Shunt

6 Pulse Gate
Drive Pulse
Transformer Output

(I)

(I)

(V)

(V)

(I)

Bridge
Current

Charger
Voltage

Battery
Voltage

Battery
Current

Charger
Current

Battery
Temp.

R
Y

ZCD Circuit

Firing Angle ADC 12 bit

Computation 6 Channel
Analog I/P

SCR Firing
Logic

Microcontroller

EEPROM

LED Indication
8 Nos

MODBUS
RS 485

LCD Keypad
Logic

Relay O/P
4 No.
Potential Free

Digital I/P
5 Nos
Opto Isolated

CAN
bus

Keypad

16 x 2 LCD
Display

Block diagram for 6 pulse Rectifier

Charging methods
For the enhanced performance different charging methods are pre programmed in the charger controller. For
example, IU and I.U I.U. charging methods are shown in the diagram. All the relevant parameters, according to
battery requirements, are user configurable using the front panel keypad.

Volts 2.75 V PC

UI

UI

2.27 V

Current
100%

Current
100%

Current
50%

Duration

I.U I.U. Characteristic

Duration

IU Characteristic

Monitoring, Alarming, Data Logging and Remote monitoring

Chhabi battery charger is supplied with micro-controller
based Digital Analog Annunciation and Controller called
DAA. It is a sophisticated combined solution for the Metering,
Annunciation and Remote monitoring of various parameters
for the charger and battery. It is specifically designed keeping
in mind the different requirements for the DC Power system
and battery charging applications.
DAA provides a complete solution for alarm and monitoring in
the DC power systems. The built in functions of DAA are user
programmable via front display panel / keyboard and up to
24 different external alarms can be monitored making DAA
extremely flexible and highly configurable supervisory
module.
The DAA can be configured for use with an optional expansion
relay module for additional remote relay alarm contacts.
DAA has MODBUS RS 485 interface port for monitoring the
charger remotely for SCADA, DCS, DDCMIS. Chhabi has
developed a proprietary software, which helps in monitoring
the charger remotely on a standard PC. Typlical configuration
of PC being Pentium IV, with
1 GB RAM and 250 MB hard disk installation space, operating
system Windows XP or higher.

During past four decades Chhabi has supplied various rating

battery chargers (FCB) to variety of Industries, Power plants and
power distribution sector. Ratings varies from 5 A upto 3000 A.
Our latest microprocessor based controller CMU 103 T is
compatible with all our earlier designed battery chargers (FCB) and
DC systems. The retrofitting of this controller will enhance the over
all performance of the FCB and DC system, as well as it will provide
fascilty for the remote monitoring of various parameters.
For more details on the same, please send your charger details
along with installation date for our best proposal at
[email protected]

Battery Charger Configurations

The rectifier must be designed in such a way, that it
can supply the load and at the same time, the battery
should be able to boost charge, even if it is at fullydischarged condition.
When the AC mains supply fails, the battery takes
over the load without any interruption and without
any switching operation. The different schemes,

which are normally used, depends on the criticality of

loads and the site requirements.
Following different configuration of Chhabi battery
charger, are the standard offerings. A separate
operation table provided, describes the functioning
of each schematic under different operating
conditions.

Float cum Boost charger - Single Batt - Single load

FCB

Battery

AC

AC

FCB

BATT

LOAD

VDD

ON

Float

Close

Float

FCB

Bypass

ON

Boost

Open

Boost FCB + VDD In circuit

OFF

OFF

Close

Disc

Batt

Bypass

System
Load

Float and Float cum Boost charger - Single Batt - Single load
FCB

Battery

AC 1 AC 2

AC2

C
FC

FC

FCB

BATT

LOAD
FC/FCB

ON

ON

Float

Float

Close

Float

ON

ON

Float

Boost

Open

Boost

FC

OFF

ON

OFF Float*

Close

Float

FCB

ON

OFF

Flaot

OFF

Close

Float

FC

OFF

OFF

OFF

OFF

Close

Disc

Batt

* Boost operation not allowed

AC1
System
Load

Dual Float cum Boost charger - Single Batt - Single load

FCB 1
C1

AC1
C2

System
Load
FCB 2
AC2

Battery
C1

C2

AC 1 AC2

FCB1

FCB2

C1

C2

ON

ON

Float

Float

Close

Close

Float*

Boost

BATT

LOAD

Float FCB1/2

ON

ON

Close Open

Float

FCB1

ON

ON

Boost Float* Open Close

Boost

FCB2

OFF

ON

OFF

Float

FCB2

Float*

Close

Close

ON

OFF Float*

OFF

Close

Close

Float

FCB1

OFF

OFF

OFF

Close

Close

Disch

Batt

OFF

* Boost operation not allowed

Dual Float cum Boost charger - Two Batt - Single load

FCB 1

Battery 1

AC1

C1
System
Load
C2

FCB 2

Tap Diode

AC2
Battery 2

AC 1 AC2

FCB1

FCB2

C1

C2

BATT1

BATT2

LOAD
FCB1/2

ON

ON

Float

Float

Close

Close

Float

Float

ON

ON

Float*

Boost

Close

Open

Float

Boost

FCB1

ON

ON

Boost

Float*

Open

Close

Boost

Float

FCB2
FCB2

OFF

ON

OFF

Float*

Close

Close

Disch

Float

ON

OFF

Float*

OFF

Close

Close

Float

Disch

FCB1

OFF

OFF

OFF

OFF

Close

Close

Disch

Disch

Batt1/2

* Boost operation not allowed

Float cum Boost charger - Single Batt - Single load

Dual Float cum Boost charger - Two Batt - Two load
FCB 1

FCB

Battery

AC

Battery 1

AC1
System
Load 1

C1

VDD

System
Load

FCB 2

AC

System
Load 2

C2

AC2

Battery 2

AC 1 AC2

FCB1

FCB2

C1

C2

BATT1

BATT2

LOAD 1

LOAD 2

ON

ON

Float

Float

Close

Close

Float

Float

FCB1

FCB2

ON

ON

Float*

Boost

Close

Open

Float

Boost

FCB1

FCB1**

ON

ON

Boost

Float*

Open

Close

Boost

Float

FCB2**

FCB2

OFF

ON

OFF

Float*

Close

Close

Disch

Float

Batt1

FCB2

ON

OFF

Float*

OFF

Close

Close

Float

Disch

FCB1

Batt2

OFF

OFF

OFF

OFF

Close

Close

Disch

Disch

Batt1

Batt2

* Boost operation not allowed

** Through bus coupler

FCB

BATT

LOAD

VDD

FCB

Bypass

ON

Float

Close

Float

ON

Boost

Open

Boost FCB + VDD In circuit

OFF

OFF

Close

Disc

Batt

Bypass

Technical Specifications for Three phase battery charger

(IU,IUI.U.)

Output : DC V , DC A
Battery : DC V , DC A
AC I/P : AC V , AC A (Optional)

blown, DC Overvoltage, DC Undervoltage,

(Optional)

(other on request)

Battery Charger Ratings

With Single Phase input

With 12 Pulse design

With 6 Pulse design

With 24 Pulse design

Note : Higher ratings as per customers specifications

Reference
Chhabi is a name associated with chargers, since 1965, is India's top five company in the field of
DC Power Solutions. For last four decades, it has supplied variety of standard as well as customised
DC Power solutions to various industry verticals.

THERMAL POWER STATIONS

Sipat, Barh, Korba, Trombay (Tata Electric), Chandrapur,

Kahalgaon (L&T), Vindyachal, Khaparkheda, Ukai,
Gandhinagar, Paricha, Kutch Lignite, Vijaywada,
Talchar, Kota, Dadri, Simhadri, Aravli, Durgapur,
Koderama, Mauda, Rihand, Anpara
REFINERIES, CHEMICAL,
PETROCHEMICALS & FERTILIZERS INDUSTRIES

BPCL, HPCL, IOCL, IPCL, ONGC, SPIC, Zuari Agro,

GAIL, GSFC, GNVFC, IFFCO, Bongaigaon Refineries
Cochin Refinery, Mangalore Refineries, Madras Refinery,
Reliance Petrochemicals, Sun Petrochemicals, Tata Chemicals,
Coromoandel Fertilizers, CFCL, RCF, Paradeep Phosphates,
Godavari, Deepak Fertilizer
SUB-STATIONS - Power Distribution companies, SEBs

Madhya Pradesh, Haryana, Uttar Pradesh, Rajasthan,

Karnataka, Kerala, Tamilnadu, Maharashtra, Gujrat,
Andra Pradesh, Bihar, Punjab, Orrisa, Delhi Vidyut Board,
BEST, Ahmedabad Electricity Board
HYDRO ELECTRIC POWER STATIONS / PROJECT

Upper Sindh, Bhandardara, Terwanmedhe,

Kanher & Dhom, Koyna, Ranganadi, Obra,
Anandpur Sahib, Hirakud, Karajwan, Hemavati,
Tons & Birsingpur, Tala Hydro Project - Bhutan,
Koteshwar, Koldam

EPC COMPANIES

ABB, Alstom, Areva T&D, Aker Kvaerner, BHEL, Desein, EIL,

GE Fanuc, Instrumentation Ltd, Jacob H&G, L&T, MECON,
Petrofac Int., Siemens, Technimont ICB, Thermax, LANCO,
Thyssen Krupp, Toyo Engineering, Yokogawa, Punj Lloyd,
TCE, IVRCL Infrastructure, Gammon India, Mukand Ltd.,
Emerson Process Management, Corrtech International
STEEL INDUSTRIES

Durgapur, Bhilai, Bokaro, Rourkela, Visakhapatanam Steel

Plants, SAIL, Lloyds Steel, Sunflag Iron & Steel, Tata Steel,
Malvika Steel, Ispat Industries, Zenith Steel Pipes,
Essar Steel, Monet Ispat, Jindal Steel
PUBLIC SECTOR

NPCIL, BALCO, NALCO, NMDC, GMDC, NHPC,

Mazgaon Docks, Power Grid Corporation,
Bhakra Beas Management Board
INDUSTRIES

Reliance Industries, Nicco Corporation, Tata Electric,

Kirloskar Brothers, Jindal Strips, Amco Batteries, Tata Motor,
Ballarpur Industries, Crompton Greaves, Indian Rare Earth,
Samsung Engineering, P. T. Indo Bharat Rayon, Hindalco,
Hindustan Dorr Oliver, Cipla, Bajaj Auto, Maruti Udyog Ltd.,
CEMENT INDUSTRIES

ACC, Gujarat Ambuja, Grasim, India Cement,

Shree Cement, Prerna Cement, Laxmi, Orient,
Saurashtra, Indo Rama, Manikgarh
PIPE LINE PROJECTS

HPCL : Vizag - Vijaywada,

BPCL : Mumbai - Manmad
HMPL : Mundra - Bhatinda

Our other products

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Battery Chargers up to 500 KW rating

SMPS based Modular Battery Chargers
DC to DC Converters
Solar Charge Controller
Cell Boosters
Battery Monitoring System
Battery Discharger
Digital Analogue Annunciator
Stabilux - Energy Saving Equipment
Dry type Transformers
ACDB, DCDB
Complete DC Power solution

Transformer

DAA

Since 1965

Regional Offices :
Northern Region
Eastern Region
Western Region
Southern Region

:
:
:
:

DCDB

Stabilux

Regd Office and Factory : E - 66, MIDC, Jalgaon 425 003 (M. S.) INDIA
T +91 257 2210626 / 27 / 28, F +91 257 2213434
E [email protected] www.chhabi-india.com

+91-11-42151213/14, Fax : +91-11-42151215, email : [email protected]

+91-33-24411375, email : [email protected]
+91-22-25812591-92, Fax : +91-22-25812593, email : [email protected]
+91-80-23140031, Fax: +91-80-23140031, email : [email protected]

Solar
Charge controller

QUALITY
ASSURED
COMPANY
ISO:9001-2008
International Standards
Certifications
Lic. No. QAC/R91/0100

24 X 7

HELP LINE

1800 123 1965

ser
m
vice
@chhabi-india.co

ModularDC/Dec15/200/V2.0

All India Sales and Service Network