MSA PCH-205 User manual

Tel.: [phone] [email protected]
26E, Kibalchicha St., St Petersburg
Russia, 192174 Fax: [phone] www.unicont.com
“NPK Morsvyazavtomatica”LLC”
Power Supply unit / charger
PCH-205
Operating manual

Operating manual
Page 2
Table of content
INTRODUCTION.........................................................................................................................3
1DESCRIPTION AND OPERATION OF THE PRODUCT...............................................4
1.1 Description............................................................................................................................4
1.2 Main technical specifications................................................................................................4
1.3 Operation and structure of the Product .................................................................................6
1.4 Measurement tools, instruments and consumables.............................................................12
1.5 Marking and sealing............................................................................................................12
1.6 Packaging............................................................................................................................12
2USAGE OF THE PRODUCT..............................................................................................13
2.1 Operational constraints........................................................................................................13
2.2 Usage preparations..............................................................................................................13
2.3 Usage of the product ...........................................................................................................14
3TECHNICAL SERVICE OF THE PRODUCT.................................................................20
3.1 General description .............................................................................................................20
3.2 Safety features.....................................................................................................................20
3.3 Maintenance routine............................................................................................................20
3.4 Preservation.........................................................................................................................22
4CURRENT REPAIR OF THE PRODUCT........................................................................23
4.1 General description .............................................................................................................23
4.2 Safety features.....................................................................................................................23
4.3 Current repair of the Product...............................................................................................23
5STORAGE.............................................................................................................................25
6TRANSPORTATION...........................................................................................................26
7DISPOSAL.............................................................................................................................27
ANNEX A (MANDATORY) OUTLINE AND INSTALLATION DIMENSIONS OF THE
PRODUCT.............................................................................................................................28
ANNEX B (MANDATORY) DESCRIPTION AND FUNCTIONS OF ADDITIONAL
UNITS ..................................................................................................................................29

Power Supply unit / charger
PCH-205
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INTRODUCTION
This operating manual (hereinafter referred to as OM) is intended to describe the
structure, operating principles, technical specifications and service of power supply / au-
tomatic battery charger PCH-205 (hereinafter referred to as the Product, PCH).
In addition to the instructions given in this document, the safety regulations and
rules applicable in the field shall be observed.
Only those who have read and understood this document and those who have
had special training shall be permitted to operate with the PSU according to the applica-
ble regulations.
Terms and abbreviations:
OM –operating manual;
PCH –Power Supply unit / charger PCH-205;
DTS-135 –Temperature sensor DTS-135;
BPC-136 –Accumulator batteries control panel BPC-136 (BPC-136-01);
AU-106 –Remote Alarm unit AU-106;
AU-206 –Remote Alarm unit AU -206;
LCD –liquid crystal display;
SB –storage battery;
TS –technical service;
CL –check list;
SC –short circuit;
CU –charging unit;
PSU –power supply unit;
LFSG –large fine-pored silica gel granular.

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1DESCRIPTION AND OPERATION OF THE PRODUCT
1.1 DESCRIPTION
The Product is designed to operate with single-phase mains 50 (60) Hz
110; 220 V AC and provide regulated voltage of 24 V DC to different shipborne and in-
dustrial equipment. The PCH ensures charge of connected storage batteries in automatic
mode.
1.2 MAIN TECHNICAL SPECIFICATIONS
1.2.1 The Product ensures:
a. charge of connected storage batteries; load power supply with regulated voltage
of 24 V DC;
b. in case of a main power failure the Product automatically switches over the
load to the storage battery and vice versa;
c. charge current and voltage of SB can be set up using a keyboard located on the
Product’s casing, see Figure 1;
d. the following additional units can be connected:
‒BPC-136 to provide remote settings and control of the PCH, and to repeat the
alarm signaling;
‒AU-106 (AU-206) to repeat the alarm signaling of PCH;
‒DTS-135 to control SB temperature.
Note –General technical specifications of these units are represented in
Annex B;
e. short circuit protection of the output contacts;
f. light and visual alarm in case of:
‒power mains failure;
‒SB reverse polarity connection;
‒PCH switching on when SB is disconnected or SC circuit rupture;
‒excessive voltage in power circuit;
‒overload or SC in SB circuit;
‒exceeding the limits of charge current or voltage;

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PCH-205
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g. built-in protection in case of:
‒voltage overload in power mains;
‒reverse polarity power connection;
‒reverse polarity SB connection;
‒overload or SC in SB circuit;
‒SC in load connection circuit.
1.2.2 Technical specifications of the PCH are represented in Table 1.
Table 1 –General technical specifications of the Product designs
Parameter
Value
PCH-205
(integrated control)
PCH-205
(basic design)
Input voltage AC, frequency
50 (60) Hz, V
220
(180…264)*
110
(90…132)*
220
(180…264)*
110
(90…132)*
Output voltage DC, V
24 ± 10 %
Output voltage if powered
from Storage battery (here-
inafter –SB), V
SB 24 V
19.2…30.0
SB 12 V
9.8…18.0
Output current of built-in charger, А
0.2…20.0
Output voltage of built-in charger, V
9.0…30.0
Rated output current, А
37
Rated power of built-in power
supply, W
1000
Rated power of built-in charger, W
600
Power consumption, W
1826
Capacity of connected SBs,
A·h
SB 24 V
200
SB 12 V
200
SB charge time up to 80 % capacity,
hours
max 10
Number of terminals to connect load to
built-in power supply, pcs.
7
Terminals of built-in charger to connect
SB, pcs.
1
Operating temperature, °С
–15...+55
Limiting temperature, °С
–60...+70
IP rating
IP22
Mounting type
wall
Discharge
current, А
accuracy ±0.2
voltage, V
accuracy ±0.1

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Parameter
Value
PCH-205
(integrated control)
PCH-205
(basic design)
Built-in protection
-galvanic isolation of output power from power mains;
-reverse polarity SB connection;
-deep discharge protection of SB (at option);
-overheating protection if applied DTS-135
Functions of control and monitoring
-keyboard to control SB
charge current and volt-
age;
-select of deep dis-
charge mode;
-digital LCD for SB’s
current and charge;
-LEDs for operation
modes;
–built-in sound and light
alarm signaling;
-alarm mute button
(sound)
-LED for operation
mode;
-built-in sound and light
alarm signaling;
-alarm mute button
(sound)
Alarm signal sources
-built-in: relay contacts, sound signal, light indicator
(LED);
-external (connected additional units): AU-106
(AU-206), BPC-136
Alarm
-loss (failure) of power supply voltage;
-exceeding the preset limits of SB charge current and
voltage;
-no connection to SB (SB circuit rupture, reverse po-
larity SB connection, SC in SB circuit);
-SB discharge
Note –«*» means that power supply voltage range is given in brackets.
1.3 OPERATION AND STRUCTURE OF THE PRODUCT
1.3.1 General information
The Product consists of two modules: a power supply unit and battery charger.
The modules are self-contained; they are connected by switching unit.
When power supply is available, the switching unit connects load to power sup-
ply unit; in case of power supply loss it automatically switches the load to SB power
supply. Once the power supply is restored, the switching unit automatically switches the
load to the power supply unit; the storage battery charge continues in automatic mode.
The Product allows for automatic charging of connected SBs and, at the same
time, ensures output voltage of 24 V DC to power the load.

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PCH-205
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SB is charged according to the combined method: operation is carried out in the
mode of current stabilization in the phase of main charge, with switching over to volt-
age stabilization mode in the final phase.
1.3.2 Controls and LEDs
The Product’s appearance is represented in Figure 1.
Figure 1 –Functional elements, controls and indication of the PCH with an integrated
control

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Figure 2 –Functional elements, controls and indication of PCH basic model
Table 2 –Description of the functional elements, controls and indication of the PCH
N.
Element
Identifier
Description
1
Piano type switch
«ON / OFF»
Piano type switch to turn power on (off), with
backlight
2
LEDs
«Power»
Power mains available
«Normal»
Glowing green at the final phase of SB charge,
i.e. when the charger is in the phase of voltage
stabilization. By this time SB voltage reaches
the voltage value which was set up by a user.
«Charge»
Glowing yellow during the main phase of SB
charge, i.e. when the charger is in the current
stabilization mode.
«Alarm»
Glowing red when SB is discharged or Product op-
erates in abnormal mode.
Button
«Mute»
Mute the sound alarm.

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N.
Element
Identifier
Description
3
LCD
«Voltage, V»
Displays current charge (discharge) voltage of
SB
«Current, A»
Displays present charge current
LEDs
«Power»
Glowing when power supply is available.
«Normal»
Glowing green at the final phase of SB charge,
i.e. when the charger is in the phase of voltage
stabilization. By this time SB voltage reaches
the voltage value which was set up by a user.
«Charge»
Glowing yellow during the main phase of SB
charge, i.e. when the charger is in the current
stabilization mode.
«Alarm»
Glowing red when SB is discharged or Product
operates in abnormal mode.
Buttons
«Select»
Button to select main menu items
« »
Navigation buttons to set up the values in the
relevant menu items.
« »
«Set / Mute»
Button to confirm or save the selected value of
the relevant menu item and mute sound signal
when the sound alarm is actuated.
4
Cable glands

To connect PCH to power mains; to connect to
PCH –DTS-135, BPC-136,
AU-106 (AU-206)
5
Grounding stud
М5х25
The main element of Product grounding.
Note –See the numbers in Figures 1 –2.
1.3.3 Connection diagram
PCH’s Connection diagram of additional units and description of connector ter-
minals are represented in Figure 3 and in Table 3.

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Рисунок 3 –Connection diagram of additional units to PCH
Table 3 –Description of PCH’s connector terminals
Connector
Terminal №
Description
J1.2
+
To connect SB
–
J3.1
+
To connect Load 3
–
J3.2
+
To connect Load 1 and 2
–
+
–
J3.3
+
To connect Load 7
–
J3.4
+
To connect Load 6
–
J3.5
+
To connect Load 5
–

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Connector
Terminal №
Description
J3.6
+
To connect Load 4
–
J5 (CU’s PCB)
To connect remote switch on button
J5 (PSU / CU
PCB)
L
To connect input power
N
J8
–Rx
To connect BPC-136 to transmit data
+Rx
–Tx
+Tx
J9
+24
To connect DTS-135
–Rx
+Rx
0
J11
+
To connect AU-106 (AU-206)
–
J14
+24
To connect BPC-136 power
–24

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1.4 MEASUREMENT TOOLS,INSTRUMENTS AND CONSUMABLES
Amount of consumables required for TS is represented in Table 4.
Table 4 –Amount of consumables required for TS
Name of consumables
Amount of consumables
Note
Cleaning cloth
0.10 kg
To clean surfaces of the unit
Technical ethyl alcohol
0.01 l
1 To clean severe contamination from
surfaces of the unit;
2 To clean by rubbing surfaces with paint
coating damage
Varnish
0.05 kg
To cover surfaces of the unit in case of
paint coating damage
Abrasive cloth
0.06 х 0.06 m
To polish surfaces of the unit in case of
paint coating damage
1.5 MARKING AND SEALING
The nameplates are located on the Product, where the user can find a serial
number, date of manufacturing, weight, protection degree, input voltage and output
voltage if operated from power mains, output voltage if operated from SB, SB’s rated
output power and CU’s rated output power.
The sealing of the Product is not provided
1.6 PACKAGING
At the time of delivery the Product is packed in a corrugated board box and in-
ner packaging (air bubble film) ensuring its transportation and storage at the warehouse.
Transport packaging is also used as a returnable packaging for transportation of
the Product to the repair location and back.
The sealing of transport packaging is not provided

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2USAGE OF THE PRODUCT
2.1 OPERATIONAL CONSTRAINTS
The Product shall be installed only according to its overall and installation di-
mensions.
Select the installation site in compliance with operational constraints (operating
temperature and protection degree –IP).
Caution! Distance between the installation site and magnetic compass shall not
be less than 1 m!
2.2 USAGE PREPARATIONS
2.2.1 Safety features
While preparing the Product for operation, check it visually after unpacking;
mechanical damage shall be absent.
Connection to power mains shall be provided only in compliance with input
power requirements.
Before connecting the Product shall be switched off and have a proper ground-
ing.
While using the Product the staff shall follow “The technical rules for operation
of electric installation” and “Safety rules for operation of electric installation” while
testing electrical circuits and insulation resistance.
2.2.2 Visual check procedure
Before switching the units on, the staff shall:
–observe visually the cable integrity and initial position of the controls on the
front panels;
–check the absence of dust and dirt on the Product casing; clean with a soft
cloth if necessary;
–check that cable connectors are securely connected to the Product.
2.2.3 Switching on instructions
While connecting the PSU and preparing it for operation follow the steps below:
-transfer circuit breakers of main power and PSU on the power mains switchboard
to “OFF” position;

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-connect de-energized cable of main power and SB to input terminals;
-transfer circuit breakers of main power and SB on the power mains switch-
board to “ON” position;
-transfer a piano type switch on the Product’s casing to “ON” position;
-check that the Product is connected properly and main power is available by
green LED glowing on the piano type switch, located on the Product casing;
-check the Product’s operability by present indication of «Normal» or
«Charge»LEDs located on the Product casing and by absent dry contact alarm;
-once the Product is powered on, it transfers to operation mode and display
current values of SB voltage;
-set up the value of charge current (compliant with that of the connected SB) in
the menu, see 2.3.1.2 and 2.3.1.3. Make sure that the Product operates normally: current
and voltage shall not exceed the preset values, green and yellow LEDs shall be glowing
(the last condition is available only for PCH with integrated control).
Switching off is carried out in the reverse order: transfer piano type switch on
the casing to “OFF” position, then transfer circuit breakers of main power and SB on the
power mains switchboard to “OFF” position, disconnect the cables.
2.3 USAGE OF THE PRODUCT
2.3.1 Settings of the Product
2.3.1.1 The structure of PCH menu with an integrated control is shown in
Figure 4 and Table 5.
The Product has the following operation modes:
-menu item «Pdd» has a value «ON» –SB is switched off if SB voltage is de-
creased to 19.2 V;
-menu item «Pdd» has a value «OFF» –SB is switched off in case of power
mains failure (cut off);
-menu item «Pdd» has a value «OFF» and jumper is set on J5 terminal on the
PCB, in case of power mains failure –power from SB until the full discharge.

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Figure 4 –Structure of the Product’s menu
Table 5 –Description of the menu items
Menu item
Description
Charge current «I»
Select of SB charge current which changes within 0.2…20.0 А
Charge voltage «U»
Select of SB charge voltage which changes within 9.0…30.0 V
Operation mode «Pdd»*
SB deep discharge protection:
–«ON» SB is switched off in case of voltage decrease to 19.2 V;
–«OFF» SB is switched off in case of power mains failure
*For the Product’s normal operation this menu item shall always have «ON»status.
2.3.1.2 Setting up charge current for PCH with an integrated control
To set up charge current, use a keyboard located on the Product’s casing. To set
up the required value, follow the next steps:
–press «Select» unless the left LCD displays letter «I». The right LCD will dis-
play the previous charge current;
–using «▲» and «▼» set up the required charge current value;
–press «Set / Mute» button to confirm the set value and record it to the non-
volatile memory of the Product.

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2.3.1.3 Setting up charge voltage for PCH with an integrated control
To set up charge voltage, use a keyboard located on the Product’s casing. To set
up the required value, follow the next steps:
–press «Select» unless the left LCD displays letter «U». The right LCD will
display the previous charge voltage;
–using «▲» and «▼»set up the required charge voltage value;
–press «Set / Mute» button to confirm the set value and record it to the non-
volatile memory of the Product.
2.3.2 Recommendations to set up charge current
To recharge the SB, set up the current value recommended by the SB manufac-
turer.
If manufacturer’s parameters are unknown, it is recommended to set up charge
current value not more than 10 % from SB capacity.
If the SB capacity (С) –150 А·h, charge current shall be equal to С150 0.1 = 15 А.
This value will prevent the SBs from damage if too high current is supplied.
2.3.3 Recommendations to set up charge voltage
The SB charge voltage is set up according to the SB documentation.
If manufacturer’s parameters are unknown, it is recommended to set up charge
voltage 28.4 V for 24 V SBs, and 14.2 V –for 12 V SBs.
The given charge voltage is optimal for the major part of shipborne SBs.
Note –If he Product is operated without DTS-135, control the SB temperature
after setting up the recommended charge voltage to the CU and during the first opera-
tion day; in case of obvious overheating a user shall decrease the preset charge current
and voltage unless the optimal heating mode is found. DTS-135 shall be mandatory in-
stalled in case of gel cells application, connected by the buffer circuit (i.e. if load is
powered from CU and SB, without power supply unit).
Caution! The manufacturer strongly suggests using the relevant SB documen-
tation every time while setting up charge values
By default the Product is delivered with settings to connect SB with operating
voltage 24 V and has the following preset values: U = 28.4 V, I = 20 А.

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2.3.4 The Product’s alarms
The Product includes light, sound and relay alarms signaling about abnormal
operation / emergency, see Table 6.
Table 6 –Abnormal operation / emergency alarms
Emergency type
Indicator
(red)
Buzzer
Jumper on PCB
(NC/NO)*
PCH input voltage failure (loss)
Blinking
Signal
NO
PCH is switched on with disconnected SB or
SB rupture (polling interval is 5 mins)
Glowing
Signal
NC/NO
Reverse polarity connection of SB (actuates
only if the Product is switched on)
Glowing
Signal
NC/NO
Overvoltage in PSU power circuit
Blinking
Signal
NC/NO
Current overload or SC in SB circuit
Glowing
Signal
NC/NO
Overvoltage in SB circuit
(polling interval is 5 mins)
Blinking
Signal
NC/NO
Charge current exceeds the preset values
Blinking
Signal
NC/NO
* Relay contacts status is selected by JP6 jumper on the PCB: «NO» –normally opened,
«NC» –normally closed.
In case of any abovementioned emergencies the Product automatically activates
built-in alarms, as well as external signaling units AU-106 (AU-206), BPC-136, if pre-
sent. To deactivate sound alarm, press «Mute» button; light alarm continues operation
unless the cause of alarm is removed.
2.3.5 Alarms in case of switchover to standby power source
The PCH, as well as BPC-136 and AU-106 (AU-206), provides built-in visual
and sound alarms which are activated in case of power mains failure and switchover to
standby power source. Built-in alarms are powered from standby electric power source.
As soon as power mains supply is restored, the alarm automatically stops and re-
sumes initial operation.
Sound alarm signaling can be muted (manually).
The Product in the alarm mode functions in the following way:
a. in case of power mains failure, see Table 7;

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Table 7 –Status of alarm units
Product
Visual alarm
Sound alarm
Relay contacts
PCH-205
Red blinking LED «Error»
Intermittent (peri-
odic) sound signal
Closed
BPC-136
Red blinking LED «AC
Alarm»
Intermittent (peri-
odic) sound signal
Actuation if relay contacts
are opened (if analog chan-
nel is used)
AU-106
Red blinking LED in but-
ton «NO Power»
Intermittent (peri-
odic) sound signal
Actuation if relay contacts
are opened or closed
AU-206
Red blinking LED «Emer-
gency»
Intermittent (peri-
odic) sound signal
Actuation if relay contacts
are opened or closed
b. mute (switching off) of alarm signal is carried out using the following con-
trols, see Tables 8 and 9.
Table 8 –Controls of alarm and alarm signaling muting
Unit
Control element
PCH-205
Button «Set / Mute»of PCH with an integrated con-
trol, see Figure 1.
Button «Mute»of PCH (basic design), see Figure 2
BPC-136
Button «Mute / Test»
AU-106
Button «Mute»
AU-206
Button «Mute»
Table 9 –Status of signaling units after muting the alarm
Product
Visual alarm
Sound alarm
Opening of re-
lay contacts
PCH-205
Red LED glowing:
–«Error» of PCH with an integrated control;
–«Alarm» of PCH (basic design)
No sound signal
+
BPC-136
Red LED glowing «AC Alarm»
No sound signal
–
AU-106
(AU-206)
Red LED glowing in the button «Mute»
No sound signal
–
Notes
1 «+» means that relay contacts are opened.
2 «–» means that these Products do not have relay contacts.
2.3.6 SB’s deep discharge protection
The Product ensures the protection of SB against deep discharge, which allows
for using the SB’s capacity parameters with maximum efficiency. It also enables to
maintain its life time as long as the manufacturer stated.
The SB’s deep discharge protection is based on the following: the SB is discon-
nected from the load as soon as it reaches the min. charge level of 19.2 V (for 24 V SB).

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PCH-205
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Discharge lower than this value leads to the SB power loss, reduced life time and failure
due to irreversible damage of the inner parts.
Note –The Product is delivered from the Manufacturer’splant with an activated
function of deep discharge protection.
2.3.7 SB’s current temperature view
The PCH with an integrated control allows a user to view temperature of the bat-
tery being charged. The SB’s heating is controlled by DTS-135 which is connected to
the product on one side and fixed (mechanically) to the SB on the other side.
To activate this function do the following: once a user presses «▼» in the main
operation mode, the left LCD will display «t» and the right - current SB temperature (if
temperature sensor is not available the right LCD will show «– ––»).
In 10 sec the Product transfers to the main operation mode and LCDs show cur-
rent charge voltage and current values; if a user presses «▼» the second time while
viewing the temperature, the Product transfers back to the operation mode.