SINGLE SHIFT & MULTI SHIFT

Transcription

1 Service Manual Ferroresonant Transformer Type Battery Charger SINGLE SHIFT & MULTI SHIFT SERIES I.B Rev. D IND: 813

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3 AC LINE VOLTAGE LETTER CODES The following table describes the code letters to be used in new charger part numbers to indicate the AC line voltage(s) and AC line frequency at which the charger can be operated. Code Letters Voltage(s) (volts rms.) Line Frequency (Hz) Comments A 120/208/ Applicable to all charger families; single phase chargers only. B 208/240/ Applicable to all charger families; single or three phase chargers. D 220/380/ Applicable to all charger families; single or three phase chargers. J 480/550/ Applicable to all charger families; single or three phase chargers. S Special Voltages Unspecified Use only for special designs. Contact the plant for further information. T* Use only for special designs; single or three phase. W* Use only for special designs; single or three phase. X* 240/ Use only for special designs; single or three phase. Y* Use only for special designs; single or three phase. * Replacement part numbers for chargers with such letter codes shall be referred to the charger's tables with code letter "B" SPECIALTY CHARGER OPTIONS LIST Check items included ( ) Suffix Description Kit part #** C6 6 of #10AWG AC Cord with 30 AMP Plug.* (3ph) X (1ph) X C8 8' of #10AWG AC Cord with 30 AMP Plug.* N/A C10 10' of #10AWG AC Cord with 30 AMP Plug.* N/A C12 12' of #10AWG AC Cord with 30 AMP Plug.* N/A CF 10 of #8AWG AC Cord with 50 AMP Plug.* N/A CF12 12 of #8AWG AC Cord with 50 AMP Plug.* N/A CR 6 of #10AWG AC Cord with 30 AMP Plug and 30AMP receptacle.* (3ph) X (1ph) X D Charger with AC Disconnect Switch. HD3 6 of #10AWG AC Cord with 30 AMP Plug.* HD4 6 of #10AWG AC Cord with 30 AMP Plug and Receptacle.* (3ph) X (1ph) X (3ph) X (1ph) X L13 13' of DC cable. See page # 41 L15 15' of DC cable. See page # 41 L18 18' of DC cable. See page # 41 L20 20' of DC cable. See page # 41 L25 25' of DC cable. See page # 41 L30 30' of DC cable. See page # 41 P Parallel DC cables, standard size. See page # 59 PP Charger shipped on a Plastic Pallet N/A Q AC input change Quick Tap N/A S Series DC cables N/A T Block Out Timer switch. WF Ferro Charger with WaterGenius P/N 1003 position front Ferro Charger with WaterGenius P/N 1003 position front, DC cables through bottom. WR Ferro Charger with WaterGenius P/N 1006 position right Ferro Charger with WaterGenius P/N 1006 position right, DC cables through bottom. Stacking Hardware Kit** WFB WRB Wall Mounting Brackets** Adapter, Power Interface to RS-232 X X X *When AC cord is installed at the factory only one input voltage is marked on the charger. **Accessories Note: refer specialty charger part numbers to the standard models contained in this manual. 2

4 TABLE OF CONTENTS AC LINE VOLTAGE LETTER CODES... 2 SPECIALTY CHARGER OPTIONS LIST... 2 IMPORTANT SAFETY INSTRUCTIONS... 4 INSTALLATION... 5 LOCATION... 5 ELECTRICAL CONNECTIONS... 5 THEORY OF OPERATION... 7 POWER TRAIN... 7 FERRORESONANT TRANSFORMER(S)... 7 DIODE BRIDGE... 7 SHUNT... 7 CONTROL BOARD... 7 OUTPUT FUSING... 7 OPERATING INSTRUCTIONS... 8 SILVER/CLASSIC CONTROL BOARD... 8 NORMAL OPERATION... 8 PUSHBUTTON FUNCTION... 8 ERROR CODES... 9 CONTROL UNIT REPLACEMENT AND SETUP PROCEDURES TERMINATION METHOD GOLD/DELUXE CONTROL BOARD NORMAL OPERATION CHARGER FEATURES USER PARAMETER CONFIGURATION SERVICE PARAMETER CONFIGURATION CHARGER FAULTS AC LINE VOLTAGE LETTER CODES VOLTAGE CONVERSION AC INPUT CHANGE (STANDARD) PH WIRING CONN. CHART PH WIRING CONN CHART AC INPUT CHANGE WITH QUICK TAP TM TROUBLE SHOOTING AC FUSE FAILURES DC FUSE FAILURES LOW CHARGE RATE HIGH CHARGING RATE RATE ADJUSTMENT PC BOARD CHECKING COMPONENTS WITH AN OHMMETER MAINTENANCE COMMON REPLACEMENT PARTS SINGLE SHIFT REPLACEMENT PARTS COMMON BY DC OUTPUT COMMON BY AC INPUT MULTISHIFT REPLACEMENT PARTS COMMON BY DC OUTPUT COMMON BY AC INPUT REPLACEMENT CHARGER CABLES PHASE WIRING DIAGRAM STANDARD WIRING QUICK TAP TM WIRING PHASE WIRING DIAGRAM STANDARD WIRING QUICK TAP TM WIRING SCHEMATIC, 1 PHASE, MODEL B SCHEMATIC, 3 PHASE, MODEL B SCHEMATIC, 1 PHASE, MODEL D SCHEMATIC, 3 PHASE, MODEL D SCHEMATIC, 1 PHASE, MODEL J SCHEMATIC, 3 PHASE, MODEL J SCHEMATIC, 1 PHASE, MODEL A SUB-ASSEMBLY PANEL AND WIRING SHUNT & DC FUSE HARDWARE STACK DISCONNECT SWITCH (OPTIONAL) PARALLEL CABLES (OPTIONAL)

5 IMPORTANT SAFETY INSTRUCTIONS 1. This manual contains important safety and operating instructions. Before using the battery charger, read all instructions, cautions, and warnings on the battery charger, the battery, and the product using the battery. 2. This charger has been designed to only charge flooded, lead-acid batteries. (It cannot be adapted for sealed batteries.) 3. Read and understand all setup and operating instructions before using the battery charger to prevent damage to the battery and to the charger. 4. Do not touch non-insulated parts of the output connector or the battery terminals to prevent electrical shock. 5. During charge, batteries produce hydrogen gas which can explode if ignited. Never smoke, use an open flame, or create sparks in the vicinity of the battery. Ventilate well when the battery is in an enclosed space. 6. Do not connect or disconnect the battery plug while the charger is on. Doing so will cause arcing and burning of the connector resulting in charger damage or battery explosion. 7. Lead-acid batteries contain sulfuric acid which causes burns. Do not get in eyes, on skin, or on clothing. In cases of contact with eyes, flush immediately with clean water for 15 minutes. Seek medical attention immediately. 8. Only factory qualified personnel can service this equipment 9. De-energize all AC and DC power connections before servicing the charger. 10. The charger is not for outdoor use. 11. Do not expose the charger to moisture. Operating conditions should be 0º to 104º F; 0 to 70% relative humidity. 12. Do not operate the charger if it has been dropped, received a sharp hit, or otherwise damaged in any way. 13. For continued protection and to reduce the risk of fire, install chargers on a floor of non-combustible material such as stone, brick, or grounded metal. WARNING: The shipping pallet must be removed for proper and safe operation. INSTRUCTIONS DE SÉCURITÉ IMPORTANTES 1. Ce manuel contient des informations importantes sur la sécurité et le fonctionnement. Avant d utiliser le chargeur de batterie, lire toutes les instuctions, les précautions et les avertissements sur le chargeur de batterie, la batterie et le produit utilisant la batterie. 2. Ce chargeur est réglé en usine pour charger des batteries plomb-acide, noyées. 3. Lire et comprendre toutes les instructions de configuration et de fonctionnement avant d utiliser le chargeur de batterie pour éviter de détériorer la batterie et le chargeur. 4. Ne pas toucher les parties non isolées du connecteur de sortie ou les cosses de la batterie pour éviter une électrocution. 5. Pendant la charge, les batteries produisent de l hydrogène qui peut exploser s il est enflammé. Ne jamais fumer, utiliser une flamme vive, ou créer des étincelles à proximité de la batterie. Bien aérer si la batterie est dans un lieu clos. 6. Ne pas connecter ou déconnecter la batterie pendant que la sortie du chargeur est sous tension. Cela pourrait déçlencher un arc et brûler le connecteur entrainant des détériorations du chargeur. 7. Les batteries plomb-acide contiennent de l acide sulfurique qui cause des brûlures. Éviter le contact avec les yeux, la peau ou les vêtements. En cas de contact avec les yeux, rincer immédiatement à l eau claire pendant 15 minutes. Consulter immédiatement un médecin. 8. Seul le personnel d usine qualifié peut entretenir cet équipement. 9. Supprimer la tension des connexions électriques alternatives et continues avant d entretenir le chargeur. 10. Le chargeur ne doit pas être utilisé en plein-air. 11. Ne pas exposer le chargeur à l humidite. 12. Ne pas utiliser le chargeur s il est tombé, s il a reçu un coup violent, ou s il a été détérioré de toute autre manière; appeler ou expédier l appareil au centre d entretien autorisé EnerSys General Battery le plus proche. 13. Pour une protection continue it pour réduir le risque d incendie, installer les chargeurs sur le sol ou sur un matériau non-combustible comme la pierre, la brique, ou du metal mis à la terre. 4

6 Installation INSTALLATION WARNING: The shipping pallet must be removed for proper and safe operation. Location For maximum trouble-free service, choose a location which is free of excess moisture, dust, and corrosive fumes. Also, avoid locations where temperatures are high or where liquids will drip on the charger. Allow six (6) inches of clearance at rear and sides of the charger for air circulation. Do not obstruct the ventilating openings or the space under the charger. STACKING MULTIPLE CHARGERS These chargers can be stacked up to a maximum of 3 units high. Chargers are not designed to be stacked side by side due to ventilation requirements Single Phase chargers require holes drilled on the top. Use drawing template for drills Position the first charger so that a minimum of 6 inches of space is between the charger and any wall, and 12 inches between the charger and any other equipment. Ø.56 (TYP X4) 2. Place the second charger on top of the first. Align the bolt holes on each charger Fasten both charger cabinets together securely using 3/8 bolts and nuts. NOTE: the two bolts toward the back of the charger may be omitted if an after market metal strap (about 8 inches) is used to secure both chargers. Remove existing 1/4" screws of the chargers' sides and attach strap with screws. Refer to picture. Hardware kit # X can be ordered to attach two chargers. 4. Repeat steps 2 and 3 for the third charger Stacked chargers must be fastened to the wall using devices suitable for the wall construction and the bolt holes at the top of the highest charger. NOTE: Ambient temperature at all levels cannot exceed 104 O F / 40 O C. METAL STRAP Electrical Connections To prevent failure of the charger, be sure it is connected to the correct line voltage. ON SINGLE PHASE UNITS Connect power to the charger as follows: Phase A to L1 (fuse block) Phase C to L2 (fuse block) TWO STACKED CHARGERS, RIGHT SIDE VIEW 5

7 Installation ON THREE PHASE UNITS Connect all the charger as follows: Phase A to L1 (fuse block) Phase B to L2 (fuse block) Phase C to L3 (fuse block) CONNECTING INPUT POWER WARNING: Make sure the disconnect is in the OFF position and the battery is disconnected before connecting the input power to the terminals of the charger. Connect the input power to the appropriate terminals, including ground. Follow your local electrical or National Electric Code in making these connections. The figure that follows shows both the top and right side installation options for routing the incoming power cable. IMPORTANT: When the AC Disconnect Switch is factory installed connect the input power to the Switch instead the AC fuse block. AC DISCONNECT The user must provide suitable branch circuit protection and a disconnect method from the AC power supply to the charger to allow for safe servicing. (Even if the charger has an optional factory installed Disconnect Switch) PLUG POLARITY The charging cable is connected to the DC output of the charger with the positive lead marked RED. The output polarity of the charger must be strictly observed when connecting to the battery (read warning above). Improper connection will open the DC fuse. GROUNDING THE CHARGER DANGER: FAILURE TO GROUND THE CHARGER COULD LEAD TO FATAL ELECTRIC SHOCK. Follow National Electric Code for ground wire sizing. Connect a grounding conductor to the lug provided on the horizontal support panel. This lug is marked as shown: 6

8 THEORY OF OPERATION Ferroresonant Battery type Chargers can best be understood by separating the charger into six integrated subsystems, (Power train, Ferroresonant Transformer, Diode Bridge, Shunt, Control board and Output fusing). Refer to wiring diagram of charger. Power Train This version of charger utilizes a series of jumpers to configure the charger for one of three available input voltages. These jumpers are labeled and color coded to facilitate installation. The nameplate shows the input power required by the charger. A detailed step by step process of this arrangement is given under the heading VOLTAGE CONVERSION. Ferroresonant Transformer(s) This line of chargers is based on a regulating ferroresonant transformer to control the output charging current. The single phase unit uses one transformer. The 3 phase unit utilizes a "Scott T" configuration with two transformers - see wiring diagram contained in this manual. The transformer(s) have multiple capacitor tap positions to adjust the finish rate current - see TROUBLE SHOOTING section. Diode Bridge The output of the ferroresonant transformer(s) is rectified in a full wave center tap configuration to output a DC current to charge the battery. These diodes also prevent any back feed when the charger is de-energized. A single phase charger has 2 diode-plates, the three phase charger has 4 diode-plates - see SCHEMATICS contained in this manual. Shunt This line of chargers has incorporated a resistive shunt to monitor the total output current of the charger. It senses current via the voltage drop across the shunt plates due to current passing from the heat sink to the battery cable. The shunt has a voltage output which is proportional to the current. Control Board The Control board incorporates a microprocessor to control and monitor all critical parameters of the charge cycle. A watchdog timer incorporated on the control board guarantees that the charger will turn off after 15 hours. Output Fusing The DC fuse is sized for the Ampere hour rating of the charger. The fuse has a window indicator for visual sign of an open fuse. 7

9 Silver / Classic Control Board OPERATING INSTRUCTIONS Read operating Instructions for the type of control board that matches your charger. SILVER / CLASSIC CONTROL BOARD Normal Operation Make sure that the battery is properly matched for the particular charger. For charger characteristics refer to the nameplate label located on the front panel of the charger. Failure to properly match charger and battery can result in damage to both. 1. Idle Mode: When AC input voltage is applied to the charger, the POWER LED will be lit. 2. Plug the battery connector into the charger connector. Once the battery is connected to the charger, the CHARGING LED will flash for approximately 5 seconds on the LED bar graph. The contactor will engage and charging will begin. Once the charge cycle has begun the CHARGING LED will be steadily lit and the bar graph will indicate the percent charged status of the battery. CAUTION: To prevent arcing and burning at the connector and possible battery explosion, press the START/STOP push-button first to stop the charge cycle before removing a battery that is currently on charge. 3. When the battery reaches Gassing Voltage, the yellow 80% LED will light. 4. For this charger, the battery is equalized manually. Pressing the EQUALIZE button at any time during the charge cycle will activate the equalize function. Once pressed the EQUALIZE LED will begin to flash indicating that a pending equalize cycle will occur once the battery has completed a successful charge cycle. NOTE: Equalize charging extends the recharge time, it is best to do this when additional cooling time is available (example -on a weekend). Consult your factory representative to determine Equalize intervals that meet your needs. 5. When the battery is fully charged the CHARGE COMPLETE LED will light, the CHARGING LED will extinguish and the charger will shut off. At this time the battery is at full capacity and ready for use. Push-Button Function EQUALIZE 1. Pressing the EQUALIZE push-button will add 3 hours of charge to the connected battery. 2. Pressing the EQUALIZE push-button while a battery is charging causes the EQUALIZE LED to flash, indicating that an equalize charge cycle is pending. 3. If an equalize charge is pending, pressing the EQUALIZE push-button will erase it. 4. When the charger is in an equalize charge cycle, the EQUALIZE LED will be steadily lit. 5. Pressing the EQUALIZE push-button after a successful charge cycle has been completed with the battery still connected will cause the charger to add an equalize charge. 6. Pressing the EQUALIZE push-button while the charger is in an equalize charge will have no effect. START/STOP 1. Pressing the START/STOP push-button during a charge cycle or an equalize cycle will turn the charger off. The CHARGING LED will also turn off to indicate that a charge cycle has been stopped. 2. If the charger was stopped by pushing the START/STOP push-button, pressing the START/STOP pushbutton again will cause the charger to start charging again. The CHARGING LED will turn on again to indicate that charging has begun. 3. Pressing and holding the START/STOP push-button for approximately 5 seconds will cause the charger to start a normal charge cycle under any circumstance. 8

10 Silver / Classic Control Board ERROR CODES On error, charger output is zeroed and the LED bar graph flashes. LED Bar Graph Equalize Power Heartbeat* Fault Description Flash Flash ON Flash ON Flash Flash ON ON Blink Flash Flash Flash (every 2 Hot battery/negative dv/dt seconds) X X X ON Watchdog 15 hour charge cycle time limit exceeded "X" Denotes that LED can be in any state * The heartbeat LED is located near the edge of the control board and can only be viewed by opening the charger door FAULT PROTECTION The charger will shut off on any of the following fault conditions: 1. No current is detected by the charger. This would occur if the DC fuse opens or the battery is disconnected. 2. The battery does not reach the 80% point within 8 hours after the charge started. 3. The overall charge cycle time exceeds 14 hours. 4. The main microprocessor malfunctions during a charge cycle, the watchdog will shut down the charger after 15 hours. Since the main microprocessor is defective, the indicating LEDs on the front panel can be in any state. An indication of this condition is when the charger is in the off state and cannot be restarted. The heartbeat LED will be steadily on (Viewed only with the charger door open). See Fault Clearing. 5. The charge cycle will also terminate if a negative dv/dt is detected after 80% is reached. FAULT CLEARING Blink (every 2 seconds) Blink (every 2 seconds) Blink (every 2 seconds) DC fuse open or battery is disconnected Overall 14 hour charge cycle time limit exceeded 8 hour pre-80% charge cycle time limit exceeded 1. The DC fuse open/battery disconnect fault is cleared by replacing the DC fuse or connecting a battery to the charger hour charger cycle time limit fault may be cleared by resetting it. RESETTING PROCESSOR: Remove power from the control board by disconnecting the wire harness connector from the control board at J1, see Figure 1. Reconnect power, if problem persist, replacement of the control board is necessary. 2. Other faults are cleared by disconnecting the battery from the charger. If problems persist refer to the trouble shooting chart. 9

11 Silver / Classic Control Board CONTROL UNIT REPLACEMENT AND SETUP PROCEDURES CHARGER CELL SIZE SETTING Do not attempt to change the cell size setting while a charge cycle is in progress. To stop a charge cycle, press the START/STOP push-button located on the front of the charger. 1. Disconnect the battery from the charger. 2. Open the charger door and remove power from the control board by disconnecting the wire harness connector from the control board at J1, see Figure Locate the jumper JP2, located on the lower left of the control board, and set the jumper according to the number of battery cells. (factory set for 18 cells). NOTE: Make sure that the battery is properly matched for the particular charger. For charger characteristics refer to the nameplate label located on the front panel of the charger. Otherwise damage may result to the battery being charged. 4. Connect the wire harness to the control board at J1 and close the charger door. 80% VOLTAGE PER CELL SETTING Do not attempt to change the 80% voltage setting while a charge cycle is in progress. To stop a charge cycle, press the START/STOP push-button located on the front of the charger. 1. Disconnect the battery from the charger. 2. Open the charger door and remove power from the control board by disconnecting the wire harness connector from the control board at J1, see Figure Located on the right of the control board and set the dip switch per Table A for the approximate 80% voltage per cell operating point. (factory set for 2.37 volts/cell). NOTE: This is an approximate setting. It is an estimate of the battery terminal voltage near the 80% point. Actual voltage readings at the battery terminals may differ slightly due to variances in charger size, cell selection and charger/battery cable length. 4. Connect the wire harness to the control board at J1 and close the charger door. NOTE: DO NOT ATTEMPT TO ADJUST RV1 AND RV2 (Preset by factory technicians) 10

12 Silver / Classic Control Board Figure 1 Classic / Silver Control Board X CL-1 Table A: 80% Gassing Voltage Dip Switch DIP1 Settings 0 = OFF 1 = ON Position 1 Position 2 Position 3 Position 4 80% Volts/Cell* * This value is approximate, and can be affected by cable length, temperature and current 11

13 Silver / Classic Control Board Termination Method The charger can either operate in a time termination mode, a dv/dt mode or both for charge complete. TERMINATION METHOD SETTING Do not attempt to change the termination method setting while a charge cycle is in progress. To stop a charge cycle, press the START/STOP push-button located on the front of the charger. 1. Disconnect the battery from the charger. 2. Open the charger door and remove power from the control board by disconnecting the wire harness connector from the control board at J1, see Figure Locate the jumper JP1 located on the right side of the control board. Set the jumper per Table B for the termination method setting. 4. Connect the wire harness to the control board at J1 and close the charger door. dv/dt Table B: Termination Method Setting Mode Description Jumper JP1 Setting Charge cycle terminates when voltage Jumper across positions 1 and 3 remains constant for a minimum of 40 minutes (Recommended default setting for General chargers) Time Termination Charge cycle terminates 3 hours after the 80% point is reached in the charge cycle (Recommended default setting for Exide chargers) Jumper across positions 1 and 2 Both Charge cycle terminates either 3 hours after the 80% point is reached or when the voltage remains constant for a minimum of 40 minutes, whichever comes first. Jumper across positions 3 and 4 NOTE: DO NOT ATTEMPT TO ADJUST RV1 AND RV2 (Preset by factory technicians) 12

14 GOLD / DELUXE CONTROL BOARD Gold / Deluxe Control Board Normal Operation 1. Make sure that the battery is properly matched for the particular charger. For charger characteristics refer to the nameplate label located on the front panel of the charger. Failure to properly match charger and battery can result in damage to both. 2. Idle Mode: When AC input voltage is applied to the charger and no battery is connected, the POWER LED will be lit. This message will display in rotation on the front panel display. Conn Batt 3. During Idle Mode, toggling the UP or DOWN push-buttons will display the previous charge cycle parameters. Toggle the UP or DOWN to display the total charge time, Amp-hours delivered, highest voltage during the previous charge cycle, the number of charge cycles since the last equalize and the equalize count. Only the charge count and equalize count remains in non-volatile memory. These values will be saved even when AC power is removed. The other values will remain in volatile memory until the next charge cycle begins or if AC power is removed. 4. Plug the battery connector into the charger connector. Once the battery is connected to the charger, the START/STOP LED will flash for approximately 5 seconds while the display shows this message. Strt ## Cells The contactor will engage and charging will begin. The START/STOP LED will light steadily, the LED bar graph will indicate the percent charged status of the battery and the display will now begin to show: ####.# (Charger output current) #### (Amp-Hours returned) ##. ## (Time) #.### (Cell Voltage) These values are displayed in rotation for about 2 seconds each. The display can be changed so that current or voltage, or current and voltage or all the above will be displayed. The default setting is for all the above to be displayed. CAUTION: To prevent arcing and burning at the connector and possible battery explosion, press the START/STOP push-button first to stop the charge cycle before removing a battery that is currently on charge. 5. When the battery reaches Gassing Voltage, the yellow 80% LED will light. 6. When the battery is fully charged the green CHARGE COMPLETE LED will light, the START/STOP LED will extinguish and the charger will shut off. At this time the battery is at full capacity and ready for use. Charger Features AUTO START/DELAYED START Auto Start enables the battery charger to start the charge cycle automatically after the battery is connected to the charger. A programmable delay can be programmed so that Auto Start will begin after a set time period. This delay can be set through the front panel display, refer to d-st in section User Parameter Configuration. Auto start can be delayed anywhere from 0 up to 25 hours, in one-minute intervals. AUTO EQUALIZE CYCLE An Equalize Cycle adds a predetermined amount of time to extend the battery's charge cycle. This charger is equipped with an Auto Equalize function. This is a configurable parameter that can be set 13

15 Gold / Deluxe Control Board through the front panel display, refer to EU-C in section User Parameter Configuration. The factory default setting for the Auto Equalize cycle is 3 hours of charge time for every fifth charge cycle. A charge cycle consists of at least one hour of continuous charging of the battery by the charger. Every time the battery completes a charge cycle the charge counter is incremented. When the charge counter reaches the programmed Equalize count value, a pending equalize cycle will occur immediately after the battery completes its charge cycle. When an equalize charge cycle is pending, the EQUALIZE LED will flash. The EQUALIZE button can be pressed at any time during the normal charge cycle to stop the pending equalize cycle. Once the battery has completed a successful charge cycle, the Charge Complete LED will light and the charger will immediately go into the equalize charge cycle. The EQUALIZE LED will then light steadily. Pressing the EQUALIZE button during the equalize charge cycle will have no effect on the charger. MANUAL EQUALIZE CYCLE With this charger, the battery can also be equalized manually. Pressing the EQUALIZE button at any time during the charge cycle will activate the equalize function. Once pressed, the EQUALIZE LED will begin to flash indicating that a pending equalize cycle will occur once the battery has completed a successful charge cycle. The EQUALIZE button can again be pressed at any time during the normal charge cycle to stop the pending equalize cycle. The equalize counter is reset every time the battery completes a successful equalize charge cycle. NOTE: Since Equalize charging extends the recharge time, it is best to do this when additional cooling time is available (example: on a weekend). Consult your factory representative to determine Equalize intervals that meet your needs. REFRESH CYCLE If a battery remains connected to the charger for a predetermined amount of time after a charge cycle has been completed, a refresh charge cycle will be given to the battery. This is a configurable parameter that can be set through the front panel display, refer to t-rf and rf-i in section Service Parameter Configuration. The factory default setting for the Refresh Cycle is to refresh for 20 minutes every 12 hours. COOL DOWN When a battery completes a charge cycle without error it ideally should cool down before being used. This is a configurable parameter that can be set through the front panel display, refer to CooL in section User Parameter Configuration. The factory default setting for the Cool Down is 1 hour. AC POWER FAIL The charger will not detect an AC power fault, phase loss, or AC fuse open. However, if the AC power fails with a battery connected to the charger during a charge cycle, the charger will recognize the battery and randomly start the charge anywhere from 1 minute to 9 minutes after AC power has been returned. The display will read rnd until the charge starts. User Parameter Configuration ADJUSTING PARAMETER SETTINGS Only while the charger is in idle mode, the charger's user parameters may be configured. In order to do so, press the EQUALIZE push-button and hold for approximately five seconds. The display will read USEr and is now ready for user parameter configuration. When you release the EQUALIZE push-button the display will then read disp. For a list of available user parameters and their definitions, see the table below. You can scroll up through the different parameters by using the EQUALIZE push-button. In order to adjust the parameters press the UP or DOWN push-buttons. If you press and hold the UP or DOWN push-buttons for 3 seconds when adjusting the parameters the options will scroll through at a rapid pace. 14

16 Gold / Deluxe Control Board Release the push-button to return to normal scrolling mode. When finished adjusting parameters, press the START/STOP push-button to exit the parameter configuration mode and save the parameter settings. The display will now read CONN BATT. Parameter Description Range Default disp Display mode 3 = displays current, A-H returned, charge time and battery voltage 2 = displays current and voltage only 1 = displays current only 0 = displays voltage only Delayed start 0 min - 25 Amount of time delay after a battery is connected to the d-st hr..00 charger before charging proceeds. Increments in one minute intervals. Cool Down Time CooL Amount of time after a charge cycle is complete that a 0 hr hr hr EU-C Service Parameter Configuration battery needs to cool down before being utilized. Equalize Count Total amount of charge cycles that need to occur before an equalize charge cycle will take place. ( 0 indicates that no Equalize charge will occur) NOTE: DO NOT ATTEMPT TO ADJUST S1 (Preset by factory technicians) 0-20 charge cycles 5 charge cycles ADJUSTING SERVICE PARAMETER SETTINGS Only while the charger is in idle mode, the charger's service parameters may be configured. In order to do so, press the DOWN and EQUALIZE push-buttons simultaneously and hold for approximately ten seconds. The display will read SEr and is now ready for service parameter configuration. When you release the DOWN and EQUALIZE push-buttons the display will then read t-80. For a list of available user parameters and their definitions, see the table below. You can scroll up through the different parameters by using the EQUALIZE push-button. In order to adjust the parameters press the UP or DOWN push-buttons. If you press and hold the UP or DOWN push-buttons for 3 seconds when adjusting the parameters the options will scroll through at a rapid pace. Release the push-button to return to normal scrolling mode. When finished adjusting parameters, press the START/STOP push-button to exit the parameter configuration mode and save the parameter settings. The display will now read CONN BATT. 15

17 Gold / Deluxe Control Board Parameter Description Range Default Cell Cell Size This is the number of cells that the charger is designed to charge. This parameter should be set to match the cell size rating on the charger nameplate. This parameter is important for cable drop compensation t-80 Time to Gassing 2 hrs - Amount of time before gassing voltage is reached. If this time limit is 10 hrs exceeded before reaching gassing voltage, a fault occurs hrs t-lt t-rf rf-i t-eu 80 -dt Up-t Cb-L Cb-t Cb-C ter TA80 Time Limit Maximum amount of charge cycle time in which a charge cycle is to be completed. If this time limit is exceeded before the charge cycle completes, a fault occurs. Refresh Time Amount of time allotted for a refresh charge cycle. Refresh Interval Amount of time between when a charge cycle completes and a refresh cycle begins. A refresh cycle will occur at the interval until the battery is disconnected from the charger. Equalize Time Amount of time that a charged connected battery will remain in an equalize charge cycle. Gassing Voltage (80% Point) Battery voltage in Volts/Cell that is needed in order to indicate that the gassing voltage (80% point) is reached and will light the 80% LED. -dt Amount of voltage in mv/cell that the battery voltage must drop after the gassing voltage is reached in order to give a Hot Batt error. Can only occur when the termination method is set to TV, or in an equalize cycle. Up Time Detect The programmed time for the battery voltage to stabilize, before the charger determines its state of charge. Battery Cable Length Length of battery cables installed on the charger used in battery cable drop compensation calculations. Length is entered in inches. Battery Cable Type Size of battery cable: 1 = 4/0 cable 2 = 3/0 cable 3 = 2/0 cable 4 = 1/0 cable 5 = #2 cable Battery Cable Configuration This parameter configures the controls to the configuration of the battery cables for the purposes of calculating the battery cable drop compensation: 0 = Cable drop compensation disabled 1 = Single cable 2 = Dual parallel cables Termination Method 1 DVDT -Terminates after no change in voltage is detected in the battery. 2 TV - Terminates 3 hours after the 80% (gassing voltage) is reached. 3 Both Either DVDT or TV whichever occurs first. Time After 80% Amount of time the battery charge cycle will continue after the gassing voltage is reached. This parameter only applies to the TV termination method. 6 hrs - 14 hrs 0-60 min 2 hrs - 24 hrs 30 min - 10 hrs V. 0mV - 100mV 0 min - 10 min 12 hrs 20 min 12 hrs 3 hrs Volts 30mV 2 min hrs - 10hrs 3 hrs 16

18 Gold / Deluxe Control Board DEFAULT SETTINGS 1. Remove power to the control board. 2. Before applying power to the board, hold down the UP and DOWN push-buttons. 3. Reapply power. Hold down the UP and DOWN push-buttons, for approximately five seconds, until the display reads dflt. 4. Release the UP and DOWN push-buttons. Charger Faults The charger control circuitry constantly monitors for several fault conditions. If a fault should occur, the charge in progress is interrupted, and a fault message is displayed on the front panel. A list of the faults and their descriptions follows below. Displayed Fault Description Fault LED Fault Clearing dc FuSE OPEn batt t-1 Err t-2 Err Lo batt Hi batt Hot batt Occurs when the control board does not sense DC output current while battery voltage is present. Usually a result of a blown DC fuse. Occurs when a charging battery is disconnected from the charger without first stopping the charge cycle. Occurs when the time limit to gassing voltage is exceeded. Occurs when the overall charge cycle time limit is exceeded. Occurs when the battery is first connected and the voltage is between 1.0 and 1.8 Volts/cell.* Occurs when the battery is first connected and the voltage is above 2.4 Volts/cell. Occurs when there is negative change in battery voltage. Call Service - YES Bar Graph - Flashes Call Service - NO Bar Graph - Steady On Call Service - NO Bar Graph - Steady On Call Service - NO Bar Graph - Steady On Call Service - NO Bar Graph - Steady On Call Service - NO Bar Graph - Steady On Call Service - NO Bar Graph - Steady On Can be reset by disconnecting the battery from the charger. Replace Fuse. Can be reset by connecting a battery to the charger. Can be reset by disconnecting the battery from the charger. Can be reset by disconnecting the battery from the charger. Can be reset if battery voltage is between 1.8 and 2.4 Volts/cell Can be reset if battery voltage is between 1.8 and 2.4 Volts/cell Can be reset by disconnecting the battery from the charger. * If battery voltage is below 1.0 Volt/cell the charger will not recognize the battery has been connected and the display will continue to read Conn Batt. NOTE: DO NOT ATTEMPT TO ADJUST S1 (Preset by factory technicians) 17

19 Voltage Conversion AC LINE VOLTAGE LETTER CODES The following table describes the code letters to be used in new charger part numbers to indicate the AC line voltage(s) and AC line frequency at which the charger can be operated. Code Letters Voltage(s) (volts rms.) Line Frequency (Hz) Comments A 120/208/ Applicable to all charger families; single phase chargers only. B 208/240/ Applicable to all charger families; single or three phase chargers. D 220/380/ Applicable to all charger families; single or three phase chargers. J 480/550/ Applicable to all charger families; single or three phase chargers. S Special Voltages Unspecified Use only for special designs. Contact the plant for further information. T* Use only for special designs; single or three phase. W* Use only for special designs; single or three phase. X* 240/ Use only for special designs; single or three phase. Y* Use only for special designs; single or three phase. * Replacement part numbers for chargers with such letter codes shall be referred to the charger's tables with code letter "B" VOLTAGE CONVERSION The charger is designed to operate from nominal line voltages as marked on the nameplate. The line voltage to which the charger is to be converted must be one of the voltages shown on the charger nameplate. DANGER: POWER MUST BE DISCONNECTED BEFORE CHANGING AC INPUT CONNECTIONS. CAUTION: THERE ARE DANGEROUS VOLTAGES WITHIN THE BATTERY CHARGER CABINET. ONLY QUALIFIED PERSONNEL SHOULD ATTEMPT TO ADJUST OR SERVICE THIS BATTERY CHARGER AC Input change (Standard) NOTE: Chargers with optional Quick Tap please refer to AC Input Change With Quick Tap. 1. Change AC fuses to the value of the desired line voltage available for this charger. (AC fuse values can be found on the decal inside the charger). 2. Change jumper "L1/V" (red wire), at terminals of the Control Transformer's Primary fuse, to desired line voltage. CAUTION: Failure to perform this step may cause the Control Trans. Primary fuse to open. 3. Change provided jumpers, on the main transformer primary tap location, as shown on the decal inside the door of the charger, or on the following charts. (Jumpers not being used are stored in the manual's envelope inside the charger). 4. Indicate the line voltage change on the decal inside the charger. 18

20 Voltage Conversion 1PH. Wiring Conn. Chart 19

21 Voltage Conversion 3PH. Wiring Conn. Chart 20

22 Voltage Conversion AC Input Change With Quick Tap If available 1. Change AC fuses to the value of the desired line voltage available for this charger. (AC fuse values can be found on the decal inside the charger). CAUTION: CONNECTOR IS KEYED AND PINS ARE FRAGILE. 2. Change Quick Tap plug to the desired line voltage as marked under the sockets. 3. Indicate the line voltage change on the decal inside the charger. 1PH. AND 3PH. WIRING CONN. ILLUSTRATION QUICK TAP WIRE ASSEMBLY PART NUMBERS Voltage Model 1Ph. QT Part Number 3Ph. QT Part Number B X F1B X F3B D X F1D X F3D J X F1J X F3J A X F1A N/A 21

23 TROUBLE SHOOTING Trouble Shooting WARNING: Disconnect AC power and battery before replacing fuse(s) or making component checks. AC Fuse Failures Check fuses and replace with the correct size. DC Fuse Failures Check the fuse connections to be sure they are clean and tight. The connecting cables must be in direct contact with the fuse with no washers between. Thoroughly examine the charging cable and plugs from the battery terminals to the charger terminals. Check the polarity of the battery against the wiring diagram. Correct if in error. Check the main power diodes. See Diodes/Heat sink Assembly, paragraph. Low Charge Rate Failed power rectifier will reduce the charge rate. A defective capacitor will give very low output. See capacitors, paragraph. Low line voltage will reduce the charger output at the start rate. Check line voltage and reconnect transformer following the wiring diagram. High Charging Rate High AC line voltage will cause higher charging rates at the start rate. Check line voltage and reconnect transformer following the wiring diagram. Rate Adjustment CAUTION: 600 VOLTS ACROSS CAPACITORS DURING OPERATION Each power transformer (one on the single phase, two on three phase) has a separate winding (resonant coil in parallel with its capacitor(s)) provided with multiple taps (#7 to #12) to adjust the output rate of the charger. The manufacturer selects the capacitor(s) value(s) based on design to match an average value of the transformer output (voltage versus current). The manufacturer also adjusts each transformer output using a selection of only two taps per each transformer to get an adequate output. (IMPORTANT: In the case of three phase chargers both transformers should be adjusted the same). Transformer output can be set: MAXIMUM OUTPUT SETTING (Increase charging current): Capacitor connected between taps #7 and #12 MINIMUM OUTPUT SETTING (Decrease charging current): Capacitor connected between taps #9 and #10. Any different connection of two taps (one from 7, 8, or 9; and one from 10, 11, or 12) gives a transformer output between the maximum and minimum values. In the field, the transformer output can be set on different tap connection (transformer replacement or customer request for a slightly different output). In this case the adjustment is provided as follows: FINE ADJUSTMENT: TAPS 7, 8 and 9 (lower number represents higher output). COARSE ADJUSTMENT: TAPS 10,11 and 12 (lower number represents lower output). For each new taps selection, the charger start output (rate) is measured first then the finish output (rate). The charger start rate should be 14 to 16 amps per 100 amp-hour. The charger finish rate should be 4 to 5 amps per 100 amp-hour. PC Board See ERROR CODES section for Silver / Classic, or CHARGER FAULTS section for Gold / Deluxe. 22

24 Trouble Shooting Checking Components with an Ohmmeter WARNING: Be sure the AC power is off and the battery is disconnected. Components being checked should be disconnected from the circuit. CAPACITORS To check capacitors, disconnect from the transformer and discharge the capacitor with an insulated screwdriver, then apply the ohmmeter across capacitor terminals. Upon instant contact, the ohmmeter should indicate low resistance and as the capacitor becomes charged, the ohmmeter should indicate high resistance. DIODES/HEAT SINK ASSEMBLY To check the Heat sink Assembly diodes, connect the ohmmeter across one of the aluminum plates on the Heat sink, and the pigtail coming to the shunt. Measure resistance using the lowest scale. Reverse the ohmmeter's leads and measure resistance again. One reading should indicate low resistance and the other reading should indicate high resistance. If the same resistance is obtained in both measurements, at least one of the rectifiers is defective and the whole assembly should be replaced. TRANSFORMERS Transformers can be checked for continuity. Refer to the schematic diagram contained in this manual. AMPS/ 100 Ferroresonant Recharge Characteristic % AH Ret Volts per Cell VOLTS AMPS AH Returned (%) Time (Hrs) < Equalize > MAINTENANCE The charger requires a minimum of maintenance. Connections and terminals should be kept clean and tight. The unit should be periodically cleaned with an air hose to prevent any excessive dirt build up on components. Care should be taken not to bump or move any adjustments during cleaning. Make sure that both the AC lines and the battery are disconnected before cleaning. The frequency of this type of maintenance depends upon the environment in which this unit is installed. 23

25 Replacement Parts REPLACEMENT PARTS CIRCUIT BOARDS: CLASSIC / SILVER X CL-1 DELUXE / GOLD X DGF-1 BASE KITS: KIT DESCRIPTION 1PH 3PH 10 BETWEEN XMR BRACKETS X X BETWEEN XFMR BRACKETS X X SINGLE PHASE PARTS: DESCRIPTION PART NUMBER DESCRIPTION PART NUMBER DOOR X DG TOP/BACK X CAPACITOR PANEL X TERMINAL BOARD E TERMINAL BOARD QT-E CONTROL TRANSFORMER MODEL A X A, or, X TERMINAL BOARD (CAPACITOR) THREE PHASE PARTS DESCRIPTION PART NUMBER DESCRIPTION PART NUMBER DOOR X DG TOP X BACK X CAPACITOR PANEL X TERMINAL BOARD A TERMINAL BOARD B TERMINAL BOARD C TERMINAL BOARD D (CAPACITOR) TERMINAL BOARD QT-A DC CABLE CLAMP (4/0) (CAPACITOR) TERMINAL BOARD QT- B PARTS COMMON TO SINGLE AND THREE PHASE DESCRIPTION PART NUMBER DESCRIPTION PART NUMBER LEFT SIDE X RIGHT SIDE X UPRIGHT X DOOR LATCH X LATCH RIVETS DC CABLE CLAMP (#2, /0, 2/0, 3/0) TERMINAL BOARD KTK TERMINAL BOARD 3AG FUSE REDUCER (<70A W/100A FUSE BLOCK) X FUSE REDUCER (<40A W/60A FUSE BLOCK) X GROUND LUG X CAPACITOR BRACKET B CONTROL TRANSFORMER, MODEL B X B CONTROL TRANSFORMER, MODEL D X D CONTROL TRANSFORMER, MODEL J FUSE, F5, KTK TERMINAL BOARD MODEL J X J X FUSE, F5, KTK TERMINAL BOARD, MODEL B AND D FUSE F6, F7, F8 3AG TERMINAL BOARD X X CONTACTOR (40A) X CONTACTOR (60A) X

26 Replacement Parts Note: The illustration below identifies the location of some important components in 1ph. and 3ph. Standard Chargers. The component P/N may vary from charger to charger. (For a P/N, refer to the 'Replacement Parts' tables). ITEM # DESCRIPTION 1 Control transformer 2 Secondary fuses, Control transformer 3 Contactor 4 Primary fuse, Control transformer 5 Terminal Board Primary, Main Transformer 6 AC Block / Fuses 7 Terminal Board Primary, Main Transformer 8 Capacitor 9 Terminal Board Secondary, Main Trans. 10 Terminal Board Secondary, Main Trans. 11 Capacitor 12 Heat Sink / Rectifier Assembly 13 Shunt 14 DC Fuse 15 DC Output Cables & DC Cable Clamp 16 Panel, Sub-assembly 17 Panel, Capacitor 18 Cross Member, Heat Sink 19 Cabinet, Base 20 Cabinet, Right side 21 Cabinet, Top/Back 22 Door 23 Cabinet, Left side 24 Main Transformer, Teaser 25 Main Transformer, Primary 26 Cross Member, Main Transformers 27 Upright 28 Ground Lug 29 Brackets, Capacitors W-1 Wire Group, Primary Voltage W-2 Wire Group, Capacitors W-3 Wire Group, PC Board W-4 Cable Connecting Heat Sink & Shunt 25

27 26 Replacement Parts

28 Single Shift Replacement Parts Common by DC Output SINGLE SHIFT REPLACEMENT PARTS HEAT SINK / RECTIFIER ASSEMBLY. 1PH. Chargers 3PH. Chargers Ampere-hours Part Number Ampere-hours Part Number R R and up R and up R SHUNT, 1PH. & 3PH. DC FUSE, 1PH. & 3PH. Ampere-hours Value Part Number Ampere-hours Value Part Number X X x 150 X X X X X X X Common by AC Input (Main transformers P/N are located on the tables by each charger model number) Control Transformer Primary Fuse P/N for All Models with Suffix: P/N Control Transformer B (208/240/480 V.) W (240 V.) X (240/480 V.) X B or (64-1) Y (480 V.) X T (208 V.) D (220/380/440 V.) X D or (64-2) A (120/208/240 V.) X A or (64-4) J (480/550/600 V.) X J or (64-3) X Contactor P/N X See note bellow. Ref.* 1, 4, 3 Note: The following chargers are the only ones using a different contactor than X Model P/N Contactor P/N 3PH B X PH D *Refer to item numbers on the previous illustrations. 27

29 Single Shift Replacement Parts 1PH. MODEL B (208/240/480 V.) TABLE 1 Replacement part numbers for chargers with letter codes "T", "W", "X", and "Y" shall be referred to the charger's tables with code letter "B" 1 Phase; Single Shift; Model B Model Transformer X127 CAPACITORS AC FUSES #1 #2 208 Volts 240 Volts 480 Volts MFD P/N MFD P/N I AC Value P/N I AC Value P/N I AC Value P/N F06-175B #N/A #N/A X X X F06-250B #N/A #N/A X X X F06-380B X X X F06-450B X X X F06-550B X X X F06-600B X X X F06-775B X X X F12-225B X X X F12-300B X X X F12-380B #N/A #N/A X X X F12-450B #N/A #N/A X X X F12-450B #N/A #N/A X X X F12-550B #N/A #N/A X X X F12-600B #N/A #N/A X X X F12-775B #N/A #N/A X X X F18-300B #N/A #N/A X X X F18-300B #N/A #N/A X X X F18-450B #N/A #N/A X X X F18-450B #N/A #N/A X X X F18-550B #N/A #N/A X X X F18-600B X X X F18-775B X X X F24-450B X X X F24-600B X X X