Stanbury Scarf & Lord Pty Ltd

Transcription

1 2 nd August 2006 Stanbury Scarf & Lord Pty Ltd ABN: Industrial Battery Chargers Unit 7/7 Tucks Road Seven Hills NSW 2147 PO Box 361 Baulkham Hills NSW 1755 Ph: Fx: Web: Hi Steve, Some further details for you. Model case weight (Kg) NG12-25G 1 ph 18 NG12-40G 1ph 18 NG12-50G 1ph 18 NG12-60G 1ph 18 NG12-80G 1ph 24 NG12-100G 1ph 24 NG24-30G 1ph 19 NG24-40G 1ph 22 NG24-55G 1ph 22 N3G24-80G 3ph 26 Case dimensions 1ph 44 x 42 x 61 (cm) 3ph 52 x 42 x 61 (cm) All chargers are high frequency switch mode in operation and the following information may assist you. Let me know if there is specific detail you feel would assist you further. Regards Arthur Scarf

2 A.C. IN AC Rectifier Power PowerPow Switchingp erswitchin switching g PWM board 20 KHz DV/DT Control Board Output Transformers BLOCK DIAGRAM NG/N3G CHARGERS Output diodes DC Out

3

4 Voltage and Current Settings for N*G, UN*G and UM*V Chargers Charger Type: AB*C##/##XYZ AB*C is the Charger Type (e.g. N*G, UN*G, etc.) XYZ is the Control Type (e.g. TAP, CVS, PEI, etc.) MODULE TYPE N*G - Chargers with NG & N3G modules UN*G - Chargers with UNG & UN3G modules UM*V - Chargers with UM3V modules CONTROL TYPE TAP - 3:1 Taper chargers CVS - Standard CV chargers (float charge with no termination) CVT - Timed CV chargers (timed constant voltage chargers) CVB - Boost CV chargers (CV charger with boost charge; no termination) PEI - PEI chargers GENERATOR CHARGERS Generator chargers have a G after the control type (e.g. CVSG). For example, CV12/100GB stands for 1 phase 12 cell 100A constant voltage boost charger for generators. Unless specified otherwise, the following settings are to be used: TAP: (3:1 taper chargers) Taper: Over-voltage: Under-voltage: 2.1VpC at rated current CVS: CVT & CWCV: CVB: Boost Voltage: PEI: (N*G) Constant current setting: Voltage Limit: PEI: (UN*G & UM*V) Constant current setting: Voltage Limit: VpC 2.8VpC 1.667VpC 2.37VpC 2.37VpC 2.37VpC 2.5VpC 2.4VpC 10% of the Rated Current 2.65VpC 2.4VpC 25% of the Rated Current None

5

6 23 March 2004 SERVICE NOTES FOR TECHNICIANS ONLY NG & PEI Battery Chargers NG chargers have a 3-1 taper charge profile. 100% output at 2.1vpc 33% output at 2.6vpc PEI chargers have a charge profile of Constant Power up to a preset battery voltage, then they change to Constant Voltage until the current falls to 10% of the rated current. At this point the charger changes to Constant Current. PEI chargers are supplied with a battery temperature probe. This probe, mounted on the battery causes the battery temperature to control the Constant Voltage level. The higher the battery temperature the lower the Constant Voltage level should be. All stages are monitored on PEI chargers so that they shut down in the event of a battery failing to reach the next stage. Constant Power monitored by DV/DT Constant Voltage monitored by DI/DT Constant Current monitored by DV/DT Charge Termination Under no fault conditions all chargers are terminated by the DV/DT system. DV/DT This means the charge is monitored by comparing the change in battery voltage against time. It uses the fact that when a battery is fully charged the voltage stops rising. DI/DT means the change in charging current is compared against time. Over-ride NG, and PEI chargers all have an electronic timer to stop the charge in 14 hours to protect against a component failure preventing the charger turning off. The over-ride is part of the DV/DT display board. Current Limit NG, and PEI chargers are fitted with current limiting. The current is limited to the maximum rated current. Over Voltage If the battery voltage is too high the charger will not turn on. Under Voltage If the battery voltage is too low the charger will not turn on.

7 TR TR showing on the display board has important information for a service technician. TR with a number following counts down the minutes until the charger will switch off unless the battery voltage rises enough to reset the electronic counter. If the voltage rises enough the reset counter returns to a higher number of minutes then starts counting down again. This process keeps repeating until the vpc stops rising and the countdown can reach 0. When 0 is reached the charger switches off. This whole process is activated once the battery reaches 2.25vpc. It is all achieved in the DV/DT display board. On/Off Switch This switch does not switch the mains. It operates in the battery powered electronic circuit. The Golden Rule FAULT FINDING The most important thing about fault finding is to keep an open mind until firm evidence is available. Looking in the wrong area will never solve a problem. Listen to the operator s account of what is happening but never take it as reliable or accurate. Look and confirm the described condition yourself. Charger Will Not Start Check that the Calculating Process LED is glowing. If not glowing investigate the DC output circuit e.g. DC fuse, DC plug and battery voltage at the charger. Over discharged battery (below 1.7vpc), or a sulphated battery or a faulty battery terminal will also prevent a charger from starting. (a) Low Battery Voltage Should the voltage be between 1.7vpc and 1.5vpc it is possible to start the charger by shorting across the pins shown in diagram No.1. If the charger is going to start under this condition it will start instantly. Apply this short for a split second only. If held on with the charger not starting damage can result. Damage may also result if this short is applied while the battery voltage is under 1.5vpc. (b) Sulphated Battery or Dirty DC Plug Contacts The effects of these two faults are similar. The charger starts and instantly shuts down because the battery resistance or the plug resistance causes the charging current to develop a high voltage. This happens so fast that nothing is recorded on a meter. In a quiet environment a faint tick can be heard as it tries to turn on every eight seconds. Identifying Area of Internal Problem (a) On/Off Switch Short the switch to prove if the switch is the cause of the problem. 2

8 (b) DV/DT Board Short the grey and black wires between the DV/DT board and the power module. If the charger now starts, the DV/DT has been proved faulty. Use a pair of insulated hand held probes and flexible lead to short the grey and black wire terminals. CAUTION! Be most careful to never leave a short between the grey and black wires because the control would be bridged out and the charger could not shut down. If shorting the grey and black wires does not start the charger the problem is not in the DV/DT. If the problem is in the charger it has now been identified as in the power module. Call for an exchange module. (c) DV/DT Settings A replacement DV/DT will probably need vpc and amp readings on the display adjusted. View the DV/DT when mounted on the inside of the door. The left pot controls the vpc reading and right pot controls the amp reading. Set the amps reading when the battery voltage is 2.25 vpc. For BMS-COMMS board, the top pot controls the vpc and the lower right pot controls the amps. Set the amps reading when the battery voltage is 2.25 vpc. DC Fuse Blown It is very rare for a DC fuse to blow. It mainly blows because the battery connection to the charger has been reversed. If this is the case, replacing the fuse is all that is required after correcting the battery plug polarity. In rare occasions the fuse may immediately blow again. Call for an exchange module. AC Mains Check that the AC mains voltage is available inside the charger (all phases). Check the AC fuse, one for single phase and three for three phase chargers. Output Current Low A three phase charger giving approximately one third normal current into a flat battery is most likely to be missing one phase. CAUTION HIGH VOLTAGE INSIDE! Treat all bare metal inside the charger as live. Disconnect from the mains before touching live metal. Discourage operators from disconnecting a battery while the charger is operating. The spark in the plug can ignite the battery gas and cause a violent dangerous explosion. 3

9 4