Magellan Power MCRII Series User manual

Rev: 1.15
22/08/2018
Doc: MAN-1P_MCRII
Page 1 of 36
Australian Technology –Australian Made
64 Bushland Ridge, Bibra Lake, WA 6163 P: [phone] F: + 61 8 9434 6623
E: [e-mail] W: www.magellanpower.com.au
OPERATION
AND
MAINTENANCE
MANUAL
SINGLE PHASE MCRII SERIES BATTERY CHARGER
SINGLE PHASE
MCRII SERIES
BATTERY CHARGER
THIS MANUAL SHOULD REMAIN WITH EQUIPMENT

OPERATION AND MAINTENANCE MANUAL
SINGLE PHASE MCRII SERIES BATTERY CHARGER
Rev: 1.15
22/08/2018
Doc: MAN-1P_MCRII
Page 2 of 36
Australian Technology –Australian Made
64 Bushland Ridge, Bibra Lake, WA 6163 P: [phone] F: + 61 8 9434 6623
E: [e-mail] W: www.magellanpower.com.au
OPERATION AND MAINTENANCE MANUAL
Table of Contents
1.0 INTRODUCTION .....................................................................................................5
2.0 GENERAL SPECIFICATIONS ............................................................................... 6
2.1AC INPUT ............................................................................................................. 6
2.2 DC OUTPUT ......................................................................................................... 6
2.3 LOAD REGULATION........................................................................................... 6
2.4 OPERATING ENVIRONMENT ........................................................................... 6
2.5 ALARMS................................................................................................................ 7
2.6 METERING ........................................................................................................... 7
2.7 PROTECTION ...................................................................................................... 7
2.8 CONTROLS .......................................................................................................... 8
3.0 INSTALLATION INSTRUCTIONS.......................................................................... 9
3.1 CABLING............................................................................................................... 9
3.2 INSTALLATION PRECAUTIONS .......................................................................9
4.0 CIRCUIT DESCRIPTION ...................................................................................... 10
4.1 CONTROL AND MONITOR CIRCUITS ........................................................... 10
5.0 OPERATING INSTRUCTIONS ............................................................................ 12
5.1 START UP .......................................................................................................... 12
5.2 VOLTAGE AND CURRENT DISPLAY ............................................................. 12
5.3 BOOST CHARGING BATTERIES.................................................................... 15
5.4 BATTERY TEST................................................................................................. 15
5.5 TEMPERATURE COMPENSATION ................................................................ 17
6.0 ADJUSTMENTS .................................................................................................... 20
6.1 SETTING FROM THE KEY-PAD...................................................................... 20
6.2 SETTING FROM THE COMPUTER................................................................. 20
6.3 PROGRAMMABLE SET POINT DESCRIPTIONS ......................................... 21
6.4 EARTH FAULT ALARM..................................................................................... 28
6.5 USER ADJUSTABLE SET POINT INSTRUCTIONS...................................... 28
7.0 COMMISSIONING................................................................................................. 30
7.1 START-UP .......................................................................................................... 30
7.2 CHECKING VOLTAGE LEVELS ...................................................................... 30
7.3 CHECKING FLOAT VOLTAGE ........................................................................ 30
7.4 CHECKING BOOST VOLTAGE ....................................................................... 31

OPERATION AND MAINTENANCE MANUAL
SINGLE PHASE MCRII SERIES BATTERY CHARGER
Rev: 1.15
22/08/2018
Doc: MAN-1P_MCRII
Page 3 of 36
Australian Technology –Australian Made
64 Bushland Ridge, Bibra Lake, WA 6163 P: [phone] F: + 61 8 9434 6623
E: [e-mail] W: www.magellanpower.com.au
7.5 CHECKING BATTERY CURRENT LIMITS ..................................................... 31
7.6 CHECKING CHARGER CURRENT LIMIT ...................................................... 31
7.7 TESTING MAINS FAIL ALARM ........................................................................ 32
7.8 TESTING DC LOW ALARM .............................................................................. 32
7.9 TESTING DC HIGH ALARM ............................................................................. 33
7.10 TESTING LOW ELECTROLYTE................................................................... 34
7.11 TESTING BATTERY FAIL ............................................................................. 34
8.0RECOMMENDATIONS......................................................................................... 34

OPERATION AND MAINTENANCE MANUAL
SINGLE PHASE MCRII SERIES BATTERY CHARGER
Rev: 1.15
22/08/2018
Doc: MAN-1P_MCRII
Page 4 of 36
Australian Technology –Australian Made
64 Bushland Ridge, Bibra Lake, WA 6163 P: [phone] F: + 61 8 9434 6623
E: [e-mail] W: www.magellanpower.com.au
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 charge, especially boost charge, generate
Hydrogen which has the potential to ignite. Ensure that there
is adequate ventilation available for the hydrogen to escape.
•Do not disconnect the batteries, while the charger is in
operation.

OPERATION AND MAINTENANCE MANUAL
SINGLE PHASE MCRII SERIES BATTERY CHARGER
Rev: 1.15
22/08/2018
Doc: MAN-1P_MCRII
Page 5 of 36
Australian Technology –Australian Made
64 Bushland Ridge, Bibra Lake, WA 6163 P: [phone] F: + 61 8 9434 6623
E: [e-mail] W: www.magellanpower.com.au
1.0 INTRODUCTION
The Magellan Powertronics MCRII Series single phase battery charger / DC power
system utilises 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, Nickel-Cadmium or Lithium Iron 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
SINGLE PHASE MCRII SERIES BATTERY CHARGER
Rev: 1.15
22/08/2018
Doc: MAN-1P_MCRII
Page 6 of 36
Australian Technology –Australian Made
64 Bushland Ridge, Bibra Lake, WA 6163 P: [phone] F: + 61 8 9434 6623
E: [e-mail] W: www.magellanpower.com.au
2.0 GENERAL SPECIFICATIONS
2.1 AC INPUT:
Voltage: 240V ±10%, Single Phase
Frequency: 50Hz ±5%
Current: As per model
2.2 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
2.3 LOAD REGULATION
Static load regulation: ±1% for
1 to 100% Load
±10% Input Variation
5% Frequency Variation
2.4 OPERATING ENVIRONMENT
Maximum operating temp: 50C
Storage temp. -40°C to 70°C ambient
Max humidity 95% R H

OPERATION AND MAINTENANCE MANUAL
SINGLE PHASE MCRII SERIES BATTERY CHARGER
Rev: 1.15
22/08/2018
Doc: MAN-1P_MCRII
Page 7 of 36
Australian Technology –Australian Made
64 Bushland Ridge, Bibra Lake, WA 6163 P: [phone] F: + 61 8 9434 6623
E: [e-mail] W: www.magellanpower.com.au
2.5 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)
Note: For alarm settings please refer to the test sheet
2.6 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 Ampere hour Capacity meter
All Liquid Crystal Display - 1% accuracy
2.7 PROTECTION
AC Input Circuit Breaker
Charger Current Limit
Battery Current Limit
Battery Circuit Breaker
Load Circuit Breakers, individual feeders
Battery Over Voltage Charger Inhibit

OPERATION AND MAINTENANCE MANUAL
SINGLE PHASE MCRII SERIES BATTERY CHARGER
Rev: 1.15
22/08/2018
Doc: MAN-1P_MCRII
Page 8 of 36
Australian Technology –Australian Made
64 Bushland Ridge, Bibra Lake, WA 6163 P: [phone] F: + 61 8 9434 6623
E: [e-mail] W: www.magellanpower.com.au
Battery Over Voltage Mains Trip (optional)
2.8 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 adjustment can be done using on-board potentiometers:
Earth Leakage Current setting
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
SINGLE PHASE MCRII SERIES BATTERY CHARGER
Rev: 1.15
22/08/2018
Doc: MAN-1P_MCRII
Page 9 of 36
Australian Technology –Australian Made
64 Bushland Ridge, Bibra Lake, WA 6163 P: [phone] F: + 61 8 9434 6623
E: [e-mail] W: www.magellanpower.com.au
3.0 INSTALLATION INSTRUCTIONS
Install the battery charger in the allocated position and ensure that sufficient cooling
air is available for natural convection cooling.
3.1 CABLING
Refer to the Charger Schematic and Connection Diagram in the Appendix
1. Connect Single Phase 240V and earth to terminal X1 in accordance with
the schematic diagram. (Refer to "Charger Test sheet" 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.
3.2 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.

OPERATION AND MAINTENANCE MANUAL
SINGLE PHASE MCRII SERIES BATTERY CHARGER
Rev: 1.15
22/08/2018
Doc: MAN-1P_MCRII
Page 10 of 36
Australian Technology –Australian Made
64 Bushland Ridge, Bibra Lake, WA 6163 P: [phone] F: + 61 8 9434 6623
E: [e-mail] W: www.magellanpower.com.au
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.
4.1 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 translate the control output to the SCR Firing Board (A1).
The Interface Board 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