Industrial Generator Set Accessories

Transcription

1 Industrial Generator Set Accessories 12/24 Volt, 10 Amp Battery Charger with Meters The battery charger is universal voltage input capable, comes with a standard 120 V/60 Hz AC plug, and charges 12 VDC or 24 VDC battery systems. Four LED lights indicate faults, charger mode, temperature compensation status, and AC input and DC output status. The temperature compensation sensor allows the battery charger to adjust output voltages for optimal charging. Standard Features D 12 or 24 VDC output D Multi--stage charging modes d Float charge d Bulk charge d Absorption charge d AutoBoost D Charges the following type batteries: d Flooded lead acid (FLA) d AGM d Gel cell d High performance AGM d Nickel--cadmium (NiCad) D Analog ammeter and voltmeter D Enclosure with knockouts for customer conduit D 4 LED status indicators D Low output ripple: <1% ripple D Reverse-polarity protection D Short-circuit protection D Temperature compensation D Charge profile configuration: output voltages (12 V or 24 V nominal), cell types and numbers, and application selected by circuit board DIP switches D Code compliance: d UL 1236 Listed d CSA -- C22.2 No d NFPA 110, Level 1 compatible (when appropriately connected to the circuit board relays) d CE DC Output AC Input Shipping Weight Volts (Nominal) Amps Volts (Nominal) Amps Overall Dimensions WxDxH kg lbs 12/ mm x 123 mm x 300 mm (6.5 in x 4.8 in x 11.8 in) G /17a

2 KOHLER CO., Kohler, Wisconsin USA Phone , Fax For the nearest sales and service outlet in the US and Canada, phone KOHLERPower.com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore Phone (65) , Fax (65) mm (6.5 in.) 125 mm (4.9 in.) mm (11.25 in.) 300 mm (11.8 in.) 380 mm (15.0 in.) 63.5 mm (2.5 in.) 4X Ø6 mm (0.24 in.) slots/holes Hinged section for terminal access 130 mm (5.1 in.) Specifications AC Input Frequency Input DC Output Fuse Protection Battery Types Monitoring LED Indications Environmental Operating VAC 50/60 Hz VDC or VDC Voltage ripple: <1% Line regulation: <2% Load regulation: <2% 20 mm, type T, 3.15 A Relative Humidity 20% to 90% Flooded Lead Acid (FLA) AGM Gel Cell High Performance AGM Nickel--Cadmium (NiCad) Charger faults Red LED Charger modes (float, autoboost, off) Yellow LED Temperature compensation Blue LED AC input and DC output status Green LED -- 40C to60c (--40Fto 140F) Battery Connections Lead Length Battery Connections AC Power Connections Lead Length Plug Type Temperature Compensation Lead Length DISTRIBUTED BY: 2.4 m (8 ft.) red and black leads 12.5 mm (.5 in.) ring terminals 1.8 m (6 ft.) Standard US style 3-prong AC plug 3 m (9 ft. 10 in.) Availability is subject to change without notice. Kohler Co. reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. Contact your local Kohlerr generator distributor for availability by Kohler Co. All rights reserved. G /17a

3 Operation and Installation Industrial Generator Sets Models: GM /24 VDC, 10 Amp, Battery Charger Applicable Generator Set Models: Generator Sets up to 3250 kw equipped with the Decision-Maker 550, 3000, or 6000 Controllers TP /17

4 Table of Contents 1 Safety Precautions General Personal safety Prior to Installation and Commissioning Charger Location and Connection Safe Use of the Charger Introduction Features Specifications Installation Mounting Bracket Mounting Kits GM S, GM KA1/KP1, and GM KA1/KP Mounting Kit GM KP1, 10REOZDC Electrical Connections Optional Connections DC Output Leads Input Connections Battery Voltage Sensing Relay Connections Operation Power-Up and POST Sequence Auto Mode Battery Detection Float Mode Battery Check AutoBoost Temperature Compensation DIP Switch Configuration DC Output Calibration DIP Switch Functions DIP Switch Settings LED indicator lights Maintenance AC Fuse Troubleshooting Parts List TP /17

5 Service Assistance For professional advice and conscientious service, please contact your nearest Kohler distributor or dealer. Consult the Yellow Pages under the heading Generators Electric. Visit the Kohler Power Systems website at KOHLERPower.com. Look at the labels and decals on your Kohler product or review the appropriate literature or documents included with the product. Call toll free in the US and Canada Outside the US and Canada, call the nearest regional office. Headquarters Europe, Middle East, Africa (EMEA) Kohler Power Systems Netherlands B.V. Kristallaan ZC Zevenbergen The Netherlands Phone: (31) Fax: (31) Asia Pacific Power Systems Asia Pacific Regional Office Singapore, Republic of Singapore Phone: (65) Fax: (65) China North China Regional Office, Beijing Phone: (86) (86) (86) Fax: (86) East China Regional Office, Shanghai Phone: (86) Fax: (86) India, Bangladesh, Sri Lanka India Regional Office Bangalore, India Phone: (91) (91) Fax: (91) Japan, Korea North Asia Regional Office Tokyo, Japan Phone: (813) Fax: (813) TP /17 3

6 4 TP /17

7 1 Safety Precautions Observe the following safety precautions while performing this procedure. Before using the charger, read all instructions and cautionary markings on the charger, the batteries, and all appropriate sections of the manual. WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative ( ) lead first when disconnecting the battery. Reconnect the negative ( ) lead last when reconnecting the battery. Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or equipment connected to the set, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (-) lead first. Reconnect the negative (-) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer. (Decision-Maker 3+ and 550 Controllers) Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or equipment connected to the set, disable the generator set as follows: (1) Press the generator set off/reset button to shut down the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (-) lead first. Reconnect the negative (-) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch. (Decision-Maker 3000 and 6000 Controllers) WARNING Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid. Battery acid cleanup. Battery acid can cause severe injury or death. Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area. TP /17 5

8 WARNING Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks. Locate the battery in a well ventilated area. Isolate the battery charger from explosive fumes. Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases. Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative ( ) lead first when disconnecting the battery. Reconnect the negative ( ) lead last when reconnecting the battery. Never connect the negative ( ) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together. DANGER Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. WARNING Hazardous voltage. Can cause severe personal injury or death. An ungrounded battery charger may cause electrical shock. Do not operate this battery charger with a two-blade adapter plug or extension cord. After securing the battery connections, plug the AC line cord into an AC outlet that is protected by a ground fault circuit interrupter (GFCI) breaker. Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Ensure you comply with all applicable codes and standards. Electrically ground the generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution. 1.1 General Do not expose the battery charger to rain, snow, or wet environments. The use of any attachment not recommended or sold by the battery charger manufacturer for this model may result in risk of fire, electric shock, injury to persons or damage to property. Do not operate the charger if it has received a sharp blow, been dropped, or otherwise damaged in any way; return to supplier. Do not disassemble the charger; return to supplier when service or repair is required. Incorrect re-assembly may result in a risk of electric shock, fire or faulty operation. If the charger is overheating or emanating an overheating smell, stop using the charger immediately. To reduce the risk of battery explosion, follow these instructions and those published by battery manufacturers and the manufacturer of any equipment you intend to use in the vicinity of the battery. Review cautionary marking on these products and any attached equipment. 6 TP /17

9 1.2 Personal safety Someone should be within range of your voice or close enough to come to your aid when you work near a lead acid or high power battery. Have plenty of fresh water and soap nearby in case battery acid contacts skin, eyes, or clothing. Wear complete eye protection and clothing protection. Avoid touching eyes while working near batteries. If battery acid or chemicals contact skin or clothing, wash immediately with soap and water. If acid or chemicals enter the eyes, immediately flood eyes with running cold water for at least 10 minutes and get immediate medical attention. Never smoke or allow a spark or flame in vicinity of battery. Be extra cautious to reduce risk of dropping a metal tool onto the battery. It may spark or short-circuit the battery or other electrical part that may cause explosion. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with batteries. High power batteries can produce short circuit currents high enough to weld a ring or the like to metal, causing severe burns. Use the charger only for charging battery types as stated on the charger. Do not use the charger for charging dry-cell batteries that are commonly used with home appliances. These batteries may burst and cause injury to persons and damage to property. Never charge a frozen battery. 1.3 Prior to Installation and Commissioning Clean battery terminals. Be careful to keep corrosion from coming into contact with eyes. For lead acid batteries, add distilled water in each cell until the battery acid reaches a level specified by the battery manufacturer. This helps purge excess gas from the cell. Do not overfill. For a battery without cell caps, carefully follow manufacturer s recharging instructions. Study all battery manufacturers specific precautions, such as removing or not removing cell caps while charging and recommended rates of charge. Determine the battery voltage by referring to the engine manual and ensuring this matches the charger s output voltage. 1.4 Charger Location and Connection Never place the charger directly above the battery being charged; battery gases will corrode and damage the charger. When reading specific gravity or filling batteries, never allow battery acid or chemicals to drip on to the charger. Do not operate the charger in a closed-in area or restrict ventilation in any way. The battery charger should be connected to a grounded, metal, permanent wiring system; or an equipment-grounding conductor should be run with circuit conductors not connected to equipment-grounding terminal on the battery charger. Connections to the battery charger should comply with all local codes and ordinances. 1.5 Safe Use of the Charger For safe and correct use of the charger, follow steps below. Should you have any problems or the unit does not function as expected, consult the troubleshooting guide at the end of these instructions. Visually inspect unit for any signs of damage caused by transport or storage. Mount the charger as outlined above, paying attention to ventilation and ambient temperature. Ensure the AC power supply is isolated and ensure the correct rated input voltage before connection. Ensure the charger is grounded at the marked ground terminal/stud. Check batteries in accordance with the manufacturer s guidelines. Check that the battery charger settings are correct for battery type, number of cells, and voltage. Connect the charger to the batteries, observing correct polarity and ensuring a secure and tight connection. Switch on the charger at the AC power supply. TP /17 7

10 8 TP /17

11 2 Introduction This manual covers the installation, operation, and troubleshooting for the battery charger, GM The battery charger outputs 10 amps for one of several 12 VDC or 24 VDC charge profiles, each with Float and AutoBoost voltages that are optimized for the battery type and number of cells. Charge profile configuration is set via circuit board DIP switches. While the battery charger works with multiple battery types, the default settings are set for a six-cell, flooded lead acid (FLA) battery and 12 V or 24 V detection. Note: To use another battery type, change the DIP switch settings. See DIP Switch Configuration. Incorrect battery charger parameters can reduce battery life and battery charging capacity. Ensure that the battery charger parameters match the battery manufacturer s specifications before using. The 10 amp battery charger service kit includes: 10 amp battery charger A stainless steel enclosure (UL-listed) Two analog meters Temperature compensation Mounting bracket and hardware (not included in kit GM KP1) Self-resetting electronic protection against reverse polarity, overload, and short-circuit faults A replaceable anti-surge fuse (20mm, type T, 3.15A) in a circuit board mounted holder Four circuit board LED lights, which indicate operation status, fault conditions, charge mode, temperature compensation, and AC power supply Three-prong plug for 120 VAC input Two ring terminals for 12 VDC or 24 VDC output Save these Instructions. This manual contains important safety and operating instructions for the chargers. Read the entire manual before using. Also read all instructions and cautions for and on the charger, batteries, and equipment in the vicinity of the batteries. Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever. Unless otherwise specified, all units of measurement are metric, followed by the Imperial (U.S.) equivalent. Use the following parts list to identify components during installation. TP /17 9

12 2.1 Features The following list covers the features for the battery charger: Switch mode charging technology. High power efficiency and low heat dissipation, plus wide supply voltage tolerance, in a compact and lightweight package. Multistage charging. Float, bulk, absorption, and AutoBoost stages ensure no compromise between rapid charge recovery and long term battery capacity and life. Low output ripple. <1% ripple, beneficial for flooded lead acid & NiCad cells, essential for VRLA. AutoBoost. Triggered automatically on low charge levels. AutoBoost temporarily increases the charge voltage before returning to float mode. AutoBoost equalizes battery cell charge, maximizing battery capacity and life, without overcharge or gassing. Temperature compensation. Ensures batteries are charged at the optimal voltage, which varies significantly with ambient temperature. The battery charger measures temperature with a battery-mounted sensor and adjusts output voltage to prevent under- or over-charging. Flexible configuration. Automatic or manual configuration of output voltages (12 or 24V nominal), cell types/numbers and charging applications, all in one standard model. Programming is by circuit board links. Display, instrumentation. Analog metering. 2.2 Specifications Power supply Operating voltage: VAC Operating frequency: Hz. DC Charge Output Nominal voltage: programmable 12 or 24 VDC Float/boost voltage: programmable, see DC output calibration table Maximum current limit: 10 A Voltage ripple: <1% Line regulation: <2% Load regulation: <2% Physical Operating temperature: 40 C to +60 C ( 40 F to +140 F) Humidity: 20% to 90% RH Dimensions (W x D x H): mm x mm x mm (6.5 in. x 4.8 in in.) Weights: kg ( lbs.) Electrical safety: 2006/95/EC Electromagnetic compatibility: 2004/108/EC, EN class B (EN , EN ) UL approvals BBGQ: UL1236, CSA 22.2 no BBHH: UL1236 SE 10 TP /17

13 3 Installation The following installation instructions cover the mounting and electrical connections for the battery charger. DANGER Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. Hazardous voltage. Will cause severe injury or death. Before beginning the installation of this product: Disconnect all electrical power to the charger. Make sure the charger cannot operate during installation. Follow all safety warnings of the battery manufacturer. Read and follow all installation instructions. 3.1 Mounting Bracket The battery charger is available in several kits. These kits differ in the mounting bracket and hardware included with the kit and the generator set models with which they are intended to be used. When mounting the battery charger, follow the mounting instructions which apply to the corresponding kit. See Figure 1. Kit GM KA1/KP1 includes bracket GM78810 and mounts to the junction box. Kit GM KA1/KP1 includes bracket GM and mounts to the frame. Kit GM S includes both types of mounting brackets, GM78810 and GM100617, and mounts to either the frame or the junction box depending on the generator set model. Kit GM KP1 for the 10REOZDC generator sets does not include mounting brackets. 1. Mounting to frame, GM bracket 2. Mounting to junction box, GM78810 bracket 2 1 Figure 1 Mounting Options TP /17 11

14 3.1.1 Mounting Kits GM S, GM KA1/KP1, and GM KA1/KP1 Use the following instructions for kits GM S, GM KA1/KP1, GM KA1/KP1. 1. Before working on the battery charger: a. Read and follow the safety precautions in the Safety Precaution section. b. Read and follow the accidental start safety precautions to protect against unexpected starts. c. Confirm that the generator set has been removed from service. d. Confirm that the AC and DC systems are switched off by removing the AC cord from the power outlet. e. Never allow the ring terminals to touch each other. 2. Select the correct mounting bracket for your installation: a. GM mounts to the frame (GM KA1/KP1, GM S). Use with the following: i kw generator sets with MTU engines b. GM78810 mounts to the junction box (GM KA1/KP1, GM S). Use with the following: i kw generator sets with John Deere engines ii kw generator sets with Doosan engines iii kw generator sets with Volvo engines iv kw generator sets with Mitsubishi engines v kw generator sets with MTU engines 3. Determine the location for the bracket installation. The battery charger has 240 cm (96 in.) charging cables, 180 cm (72 in.) power cord, and 300 cm (118 in.) temperature sensor cable. Make sure that all connections can be made when positioning the bracket. Note: Do not drill holes in the frame or junction box. Pre-drilled holes should already exist. a. If replacing an existing battery charger, the new bracket should mount in the same location. b. If installing a new charger, align the bracket to the appropriate holes on the generator set frame or junction box. 4. Secure the bracket either to the generator set frame or the junction box. a. For mounting to the generator set frame, secure the mounting bracket (GM100617) with 10 mm bracket screws (M ), washers (M125A-10-80), and nuts (M ). b. For mounting to the junction box, align the mounting bracket (GM78810) with the threaded inserts and secure with four 6 mm screws (M ). 5. Orient the battery charger with enclosure air vents uppermost. Note: For ventilation and safe heat dissipation, allow a minimum clearance of 40 mm (1.5 in.) above and below and 25 mm (1 in.) at the sides. 6. Set the DIP switches on the back of the charger to match the battery type and voltage. See the section on DIP Switch Settings. Note: The factory default is set for automatic voltage detection on flooded lead acid (FLA) batteries. 7. Use four 6 mm screws (M ) and nuts (M ) to mount the battery charger to the bracket. a. Align to the holes on the battery charger with the holes in the mounting bracket. b. Tighten sufficiently so the battery charger does not become loose during normal operation, for example, due to engine or equipment vibration. 1. Mounting to frame, GM mm screws, M Mounting to junction box, GM mm screws, M Figure 2 Mounting Brackets 12 TP /17

15 3.1.2 Mounting Kit GM KP1, 10REOZDC Kit GM KP1, used with generator set model 10REOZDC, does not include a mounting bracket or mounting hardware. The battery charger is typically mounted outside the enclosure in a location where the charger and temperature sensor leads can reach the battery connections. 1. Before working on the battery charger: a. Read and follow the safety precautions in the Safety Precaution section. b. Read and follow the accidental start safety precautions to protect against unexpected starts. c. Confirm that the generator set has been removed from service. d. Confirm that the AC and DC systems are switched off by removing the AC cord from the power outlet. e. Never allow the ring terminals to touch each other. 2. Determine the location for the installation. Make sure that all connections can be made. The battery charger has 240 cm (96 in.) charging cables, 180 cm (72 in.) power cord, and 300 cm (118 in.) temperature sensor cable. Note: For ventilation and safe heat dissipation, allow a minimum clearance of 40 mm (1.5 in.) above and below and 25 mm (1 in.) at the sides. Important: Never place the battery charger directly above the battery being charged; battery gases will corrode and damage the battery charger. 3. Orient the battery charger with enclosure air vents uppermost. 4. Set the DIP switches on the back of the charger to match the battery type and voltage. See the section on DIP Switch Settings. Note: The factory default is set for automatic voltage detection on flooded lead acid (FLA) batteries. 5. Use four 6 mm screws of the appropriate length and any other hardware such as nuts or washers to secure the battery charger. Note: Ensure that the installation is able to support the weight of the charger. a. Use the four mounting holes in battery charger enclosure. b. Tighten sufficiently so the battery charger does not become loose during normal operation, for example, due to engine or equipment vibration. 1. Mounting holes Figure 3 Mounting Holes, GM KP1 TP /17 13

16 3.2 Electrical Connections DANGER Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. Hazardous voltage. Will cause severe injury or death. When observing the LED operating status, do not touch the AC power supply connections or any other internal battery charger components. Use the Connection Diagrams and the following instructions to connect the positive and negative battery charger output leads and temperature sensor to the battery charger. 1. Before making the connection between the battery charger and the system: a. Read and follow the safety precautions in the Safety Precaution section. b. Read and follow the accidental start safety precautions to protect against unexpected starts. c. Confirm that the generator set has been removed from service. d. Confirm that the AC and DC systems are switched off by removing the AC cord from the power outlet. e. Never allow the ring terminals to touch each other. 2. Check the polarity of the battery posts. The positive (+) battery post usually has a larger diameter than the negative (-) post. 3. Connect the battery charger output leads to the battery posts. Connect the negative (-) lead first. Follow the appropriate diagram in the Connection Diagrams. 4. Place the temperature sensor lead near or between the battery(ies) for accurate ambient temperature. a. Use zip ties to secure the sensor leads. Make sure that the leads do not contact any hot surfaces or sharp edges. 5. Plug the power cord into an electrically grounded 120 VAC power outlet. Note: The AC power connection must comply with national and local electrical codes. 6. To check the controller settings, use the Power On Self-Test (POST) sequence and circuit board LEDs to verify that the battery charger settings match the battery manufacturer s recommendations. The sequence, which the LEDs flash during startup, indicates the charge profile selected. See the section on Power-Up and POST Sequence. Important: Incorrect DC output calibration can reduce battery life and battery charging capacity. Ensure that the battery charger calibration settings match the battery manufacturer s specifications before using. See the sections on DC Output Calibration and DIP Switch Settings. 7. Restore the generator set to service. Note: When disconnecting the battery charger, first disconnect the AC power cord and then remove the black (negative) ring terminal from the negative battery post. Remove the red (positive) ring terminal from the positive battery post last. 1. Battery charger 2. Positive (+) lead (red) 3. Negative ( ) lead (black) 12 V System 24 V System Figure 4 Connection Diagrams 14 TP /17

17 3.3 Optional Connections Some installations require longer cables, battery sensing connections, or optional battery alarms. The following sections show how to connect these options to the three circuit board connection blocks located inside the hinged portion of the enclosure. CN1 is a 4-way connection block for connection of the DC Charge Output. Use a 5 mm (0.2 in.) flat-head screwdriver to tighten/loosen the terminals. For the DC Output (10 Amp max), use 4.0 mm² (13 AWG) or larger connecting wire. CN2 is a 15-way connection block for connection of DC control signals such as DC voltage sensing, temperature compensation remote sensor, control inputs and outputs. Use a 2.5 mm (0.1 in.) flat-head screwdriver to tighten or loosen the terminals. Use 1mm² (17 AWG) or larger wire for these connections. CN3 is a 3-way connection block for connection of the AC live and neutral power supply. Use a 5 mm (0.2 in.) flathead screwdriver to tighten or loosen the terminals. The AC supply ground must be connected to a separate M4 stud (frame ground) on the charger chassis. For all AC supply and ground wiring, use 1 mm² (17 AWG) or larger wire conductors rated for 90 C (194 F). An AC fuse holder is located next to CN3. For fuse details, see the AC Input (power supply) section following. When routing wiring to the connection blocks, use the appropriate enclosure knockouts shown below. To open the hinged portion of the enclosure, remove the two screws holding the hinged cover in place. 1. DC output (CN1) 2. Inputs, outputs, and voltage sensing (CN2) 3. AC input (CN3) Figure 5 Connection Blocks Battery DC DC output sensing Connection block 1 (CN1) pins 1, 2 + DC charge output 3, 4 - DC charge output Connection block 2 (CN2) pins 1. + DC voltage sense 2. - DC voltage sense 3. TC (temperature compensation) sensor 4. Ground (for RTC sensor) 5. Input 1 (not applicable) 6. Input 2 (not applicable) 7. Common power feed for RL RL1 normally open (N/O) contact, standard function: charger failure 9. RL1 normally closed (N/C) contact, standard function: charger failure 10. RL2 normally closed (N/C) contact, standard function: low battery voltage 11. RL3 normally open (N/O) contact, standard function: high battery voltage 12. RL4 common (COM) contact 13. RL4 normally closed (NC) contact, standard function: AC power failure 14. RS-485 A (not applicable) 15. RS-485 B (not applicable) Connection block 3 (CN3) pins 1. AC supply live, 95 to 250 VAC, 47 to 63 Hz 2. AC supply neutral Remote temperature sensor AC supply Notes: AC input fusing (F1): replaceable, circuit board mounted fuse, rating as shown on the product label. DC output fusing: all models include a selfresetting electronic output fuse. DC output is isolated from chassis. Figure 6 Circuit Board Connections TP /17 15

18 3.3.1 DC Output Leads DANGER Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. Before DC connection or disconnection: Ensure AC supply input is isolated. Disconnecting the batteries while the AC supply is live can result in sparking at the battery terminals, ignition of battery gases and serious personal injury. Check that the charger has been configured for compatibility with the battery type and voltage (see Configuration section below). Incompatibility may result in damage to the charger, batteries and serious personal injury. If the application requires longer DC output cables than the 240 cm (96 in.) cables provided, use the following instructions to reconnect output leads to the CN1 connection block. Note: The use of longer cables may require battery sensing leads which allow accurate measurement of battery voltage and automatic compensation for voltage drops in the charging circuit. Refer to the section on voltage sensing connections. 1. Before working on the battery charger: a. Read and follow the safety precautions in the Safety Precaution section. b. Read and follow the accidental start safety precautions to protect against unexpected starts. c. Confirm that the generator set has been removed from service. d. Confirm that the AC and DC systems are switched off by removing the AC cord from the power outlet. e. Never allow the ring terminals to touch each other. 2. Connect the battery charger output to the battery terminals, observing the correct DC polarity and the warnings above. See Figure 7. Important: Frayed cable wires can cause shorts between the positive and negative DC output leads. When reconnecting the DC output leads, ensure that the cables have clean, solid connections at the terminal block and that there are no frayed wires or broken strands. 3. The battery charger includes self-resetting electronic protection against reverse polarity, overload and short-circuit faults. In the event of such faults, the DC output switches off, protecting the charger. After a 4 second delay, the battery charger checks the DC output connection. If the fault has cleared, the output automatically re-activates; if the fault is still present, the output deactivates again, and the delay/check cycle repeats. 4. If the DC output fails to re-activate after a fault has cleared, contact your authorized Kohler distributor or dealer. 1. DC output enclosure knockout 2. + DC charge connections, CN1 pins 1, 2 3. DC charge connections, CN1 pins 3, Figure 7 DC Output Connections 16 TP /17

19 3.3.2 Input Connections DANGER Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. Before AC connection, disconnection, or fuse replacement: Isolate the AC supply. Ensure a good ground connection to the ground stud (marked FG) on the charger s metal chassis. Ensure the AC supply voltage is compatible with the charger s supply rating. Exceeding the rated voltage may result in damage to the charger and connected equipment, and cause serious personal injury. Fit only the fuse types and ratings shown on the product label. Battery chargers are supplied with a 120-volt plug. If connecting a different plug or AC input within the acceptable range (95 to 250 VAC, 47 to 63 Hz), reconnect to the connection block, CN3, using the following procedure. 1. Before working on the battery charger: a. Read and follow the safety precautions in the Safety Precaution section. b. Read and follow the accidental start safety precautions to protect against unexpected starts. c. Confirm that the generator set has been removed from service. d. Confirm that the AC and DC systems are switched off by removing the AC cord from the power outlet. e. Never allow the ring terminals to touch each other. 2. Connect the CN3 terminals to the AC power supply. The AC supply ground must be connected to the M4 stud (frame ground), located inside the charger case near connector CN3. 3. For AC input and ground connections, use 1 mm² (17 AWG) or larger wire conductors rated for temperature 90 C (194 F). The battery charger includes a replaceable anti-surge fuse (20 mm, type T, 3.15A) in a circuit board mounted holder, located next to the CN3 connection block. 1. Fuse 2. AC supply live, 95 to 250 VAC, 47 to 63 Hz 3. AC supply neutral 4. Frame ground (FG) 5. AC input enclosure knockout Figure 8 AC Input Connections TP /17 17

20 3.3.3 Battery Voltage Sensing DANGER Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. Accurate measurement of battery voltage allows the battery charger to automatically compensate for volt drops in the charging circuit by increasing charge voltage. Note: DC voltage sensing is optional and typically used when adding longer DC output cables. 1. Before working on the battery charger: a. Read and follow the safety precautions in the Safety Precaution section. b. Read and follow the accidental start safety precautions to protect against unexpected starts. c. Confirm that the generator set has been removed from service. d. Confirm that the AC and DC systems are switched off by removing the AC cord from the power outlet. e. Never allow the ring terminals to touch each other. 2. To accurately measure battery voltage independently of the voltage drop that can occur between the battery and DC charge output (particularly at higher charge currents, and with longer cables), use pin 1 and 2 on the CN2 connection terminal for voltage sensing. 3. Connect the battery DC Sensing terminals to battery positive and negative using 1 mm 2 (17 AWG) or larger wire. CN2 pin Function 1 + DC voltage sense 2 DC voltage sense 1. CN2 enclosure knockout 2. DC battery voltage sensing 3. CN2 connection terminal Figure 9 DC Battery Voltage Sensing Connections 18 TP /17

21 3.3.4 Relay Connections The battery charger includes four relay outputs, RL1 RL4, located on the CN2 connection block. All output contacts are dry/volt-free (RL1, RL2 and RL3 have a common power feed), rated 30 VDC max. Use a 2.5 mm (0.1 in.) flat-head screwdriver to tighten or loosen the terminals. Use 1 mm² (17 AWG) or larger wire for these connections. These relays are typically used to connect optional alarms, such as high voltage, low voltage, and battery charger fault, for NFPA 110 applications. 1. CN2 enclosure knockout 2. Relay 1 to 4 connections Figure 10 CN2 pin Relay Connections Function 7 Common power feed for RL1 RL3. Connect to the positive or negative DC supply as required. 8 9 RL1 normally open (N/O) contact. RL1 normally closed (N/C) contact. Standard function: charge fail. Relay RL1: Energizes (pin 8 closes to pin 7, pin 9 opens from pin 7) during normal charging conditions. De-energizes (pin 8 opens from pin 7, pin 9 closes to pin 7) if a charge fail fault occurs for longer than 2 minutes. 10 RL2 normally closed (N/C) contact. Standard function: low battery volts. Relay RL2: Energizes (pin 10 opens from pin 7) during normal charging conditions. De-energizes (pin 10 closes to pin 7) if a low battery voltage fault occurs for longer than 2 minutes. 11 RL3 normally open (N/O) contact. Standard function: high battery volts. Relay RL3: De-energizes (pin 11 opens from pin 7) during normal charging conditions Energizes (pin 11 closes to pin 7) if a high battery voltage fault occurs for longer than 2 minutes RL4 common (COM) contact, volt-free/dry. RL4 normally closed (NC) contact, volt free/dry. Standard function: Mains fail. Relay RL4: Energizes (pin 13 opens from pin 12) when the mains AC supply is healthy. De-energizes (pin 13 closes to pin 12) when the mains AC supply is off or failed. TP /17 19

22 Connecting Optional Alarms to the Generator Set Controller DANGER Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. Before working on the battery charger: Read and follow the safety precautions in the Safety Precaution section. Read and follow the accidental start safety precautions to protect against unexpected starts. Confirm that the generator set has been removed from service. Confirm that the AC and DC systems are switched off by removing the AC cord from the power outlet. Never allow the ring terminals to touch each other. Use the following diagrams to connect the battery charger optional alarms (high voltage, low voltage, and battery charger fault) to a given controller. In addition, the user can connect the battery charger optional alarms to user-supplied fault indicators. See Figure 11 for which optional alarms are connectable to the generator set controllers. Note: Some controllers have integrated high battery voltage and low battery voltage sensing and do not require additional connections with the battery charger for these faults. Generator Set Controller Low Battery Voltage (LV) High Battery Voltage (HV) Battery Charger Fault (BCF) Decision-Maker 3+ X * X Decision-Maker 550 * * X Decision-Maker 3000 * * X Decision-Maker 6000 * * X User supplied fault indicators X X X * Controller has integrated low and/or high voltage sensing (no battery charger fault connection is required). Figure 11 Generator Set Controller and Optional Alarms 20 TP /17

23 Low voltage Charger fault TB Controller terminal strip Engine ground RL4 BCF Battery charger connection block, CN2 LV HV Figure 12 Decision-Maker 3+ Controller Fault Connections Charger fault TB4 1 Controller terminal strip Engine ground RL4 BCF Battery charger connection block, CN2 LV HV Figure 13 Decision-Maker 550 and 6000 Controller Fault Connections TP /17 21

24 Charger fault TB1 D13 GND Controller terminal strip RL4 BCF Battery charger connection block, CN2 LV HV Figure 14 Decision-Maker 3000 Controller Fault Connections High voltage Low voltage Charger fault Battery charger connection block, CN2 Customer supply power HV LV BCF Figure 15 User-Supplied Fault Indicators 22 TP /17

25 4 Operation 4.1 Power-Up and POST Sequence DANGER Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. Hazardous voltage. Will cause severe injury or death. When observing the LED operating status, do not touch the AC power supply connections or any other internal battery charger components. At power up, the battery charger goes through a Power On Self-Test (POST) sequence, including status indication using four LEDs located on the main circuit board. See the following sequence chart: 1) LED test: all lit for 2 sec, all off for 2 sec: POST LED display 2) Indication confirming standard battery charger calibrations, 2 sec: Flashing sequence: 3) Indication confirming selected charge profile, 2 sec: Nominal voltage Auto / local Battery type Profile name DIP switch settings (0 = off/down, 1 = on/up) or 24 flooded (wet) lead acid AUTO DETECT (Local) Flashing: Auto / remote AUTO DETECT (Remote) Note: Do not use Flashing sequence: 12V Flooded (wet) lead acid, 6 cells 12V FLA Calcium Calcium, 6 cells 12V CA/CA Lead acid hybrid Sb-Ca, 6 cells 12V LA HYBRID VRLA, AGM, 6 cells 12V VRLA AGM VRLA, Gel, 6 cells 12V VRLA GEL NiCad, 10 cells 10 CELL NiCad V power supply 12V POWER SUPPLY V NiCad, 18 cells 18 CELL NiCad NiCad, 20 cells 20 CELL NiCad Flooded (wet) lead acid, 12 cells 24V FLA Calcium Calcium, 12 cells 24V CA/CA Lead acid hybrid Sb-Ca, 12 cells 24V LA HYBRID VRLA, AGM, 12 cells 24V VRLA - AGM VRLA, Gel, 12 cells 24V VRLA - GEL V power supply 24V POWER SUPPLY TP /17 23

26 4.2 Auto Mode Battery Detection Immediately after power-up, if an Auto charge profile has been selected, the battery charger measures the connected battery voltage and operates as follows: Measured voltage Operation < 1 V No output: battery missing fault signaled. 1 to 16.0 V Charge output: 12 V flooded lead acid to 32 V Charge output: 24 V flooded lead acid. 4.3 Float Mode If measured battery voltage is within normal limits (above 12.5 V for 12 V nominal batteries and above 25.0 V for 24 V nominal batteries), the battery charger adopts float mode charging, indicated by a constantly lit yellow LED. The battery charger maintains the battery at the float voltage (appropriate for the selected battery type), and supplies any additional DC load current (up to the maximum rated 10 amps). 4.4 Battery Check When in float charge mode, the battery charger periodically checks for a battery missing fault. During this check, output current reduces to nominal (12 V or 24 V) for approx. 30 seconds and the yellow LED goes off. The default period for checking battery missing is every 30 minutes. Once the battery charger registers a battery missing fault, it checks for reconnection once every minute (non-adjustable). The battery charger does not check for battery missing during AutoBoost operation, to ensure maximum charge rate is maintained. 4.5 AutoBoost If measured battery voltage falls below the Boost Initiate threshold (below 12.5 V for 12 V nominal batteries, or below 25.0 V for 24 V nominal batteries), the battery charger adopts AutoBoost mode (indicated by a slow-flashing yellow LED) and charge output increases to the higher Boost voltage level. Once the measured battery voltage has increased to the Boost level, the battery charger enters a Boost Extension period (360 minutes on standard units), during which time Boost voltage is maintained and the yellow LED flashes rapidly. At the end of the Boost extension period, output voltage and current reduces, but the yellow LED continues to flash rapidly. In this Boost Decay phase, battery voltage naturally decreases back towards float level. The battery charger then reverts to float mode charging, indicated by a continually lit yellow LED. 24 TP /17

27 4.6 Temperature Compensation The temperature sensor is connected to pins 3 and 4 on the CN2 connection block. With the sensor connected, and the sensor head positioned to give the most accurate or representative measurement of battery temperature, the battery charger automatically varies DC output voltage for optimal charging. CN2 pin Function 3 TC (temperature compensation) sensor 4 Ground (for RTC sensor) Temperature compensation is enabled automatically when the sensor is connected. For each 1 C (1.8 F) change in ambient temperature above or below 20 C (68 F) and within the range -10 C to +50 C (14 F to 122 F), output voltage automatically varies by 3 mv per cell. Increasing ambient temperatures cause decreasing output voltages; decreasing ambient temperatures cause increasing output voltages. If no RTC sensor is connected, temperature compensation is automatically disabled and the output voltage does not vary with ambient temperature. Sensor connection and operating status is indicated by a blue LED. Note: The circuit board jumper J2, located between terminal blocks CN2 and CN3, must be in the correct position. See Figure Temperature sensor connections 2. J2 jumper 3. J2 jumper, correct position 4. J2 jumper, incorrect position: Not for customer use. Temperature measurement by internal sensor, for factory calibration only Figure 16 Temperature Compensation 4.7 DIP Switch Configuration WARNING Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks. Locate the battery in a well ventilated area. Isolate the battery charger from explosive fumes. Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks. AC and DC connections must be isolated during DIP switch configuration. The correct battery type and cell number must be configured correctly before charger power-up and battery connection. Incorrect configuration may result in under or over charge of batteries, which may cause failure or damage to the batteries, charger, and connected equipment, and result in serious personal injury. Battery chargers include a six-way DIP switch for configuration of battery type and cell number. The DIP switch is accessible through a cut-out in the case rear. See Figure 17. TP /17 25

28 Note: Before changing the DIP switches, disconnect the power supply and then the negative and positive output leads, negative lead first, from the battery posts. 1. DIP Switches 1 Figure 17 DIP Switch Location DC Output Calibration Battery type: Float Volts (VDC) Boost Volts (VDC) 12V Flooded (wet) lead acid, 6 cells Calcium-Calcium, 6 cells Lead acid hybrid Sb-Ca, 6 cells VRLA, AGM, 6 cells VRLA, Gel, 6 cells NiCad, 10 cells V Flooded (wet) Lead acid, 12 cells Calcium-Calcium, 12 cells Lead acid hybrid Sb-Ca, 12 cells VRLA, AGM, 12 cells VRLA, Gel, 12 cells NiCad, 18 cells NiCad, 20 cells TP /17

29 4.7.2 DIP Switch Functions 1 4 Sets the charge profile (battery type and cell number) when local mode is selected see switch 5 below. 5 Sets whether the battery charge profile is set in local or remote mode. Battery charger should always be set to 0 or Local mode. Local mode: charge profile set by DIP switches 1 to 4. The default setting is Local, Auto, where battery charger automatically selects 12 V or 24 V operation based on the battery voltage measured at power up see operation below. Remote mode: Not available. 6 Reserved use. Do not adjust from default (0/off/down) setting DIP Switch Settings Nominal voltage Battery type Profile name DIP switch setting (0 = off/down, 1 = on/up) DIP switches 1 4, local mode settings 12/24V Auto (12V or 24V wet lead acid) float (VDC) AUTO DETECT / 27.0 boost (VDC) 14.1/ 28.2 voltage/time settings boost initiate (VDC) 12.5/ 25.0 boost time (min) low alarm (VDC) / V Flooded (wet) lead acid, 6 cells 12V FLA Calcium Calcium, 6 cells 12V CA/CA Lead acid hybrid Sb-Ca, 6 cells 12V LA HYBRID VRLA, AGM, 6 cells 12V VRLA AGM VRLA, Gel, 6 cells 12V VRLA GEL NiCad, 10 cells 10 CELL NiCad V power supply 12V POWER SUPPLY n/a n/a n/a n/a n/a 24V NiCad, 18 cells 18 CELL NiCad NiCad, 20 cells 20 CELL NiCad Flooded (wet) lead acid, 12 cells 24V FLA Calcium Calcium, 12 cells 24V CA/CA Lead acid hybrid Sb-Ca, 12 cells 24V LA HYBRID VRLA, AGM, 12 cells 24V VRLA - AGM VRLA, Gel, 12 cells 24V VRLA - GEL V power supply 24V POWER SUPPLY n/a n/a n/a n/a n/a DIP switch 5: local / remote mode: Local x x x x 0 0 Local mode, profile set by switches 1-4 Remote Auto Remote x x x x 1 0 Not available. Switch should be set to 0. high alarm (VDC) 16.0/ 32.0 DIP switch 6: reserved x x x x x 0 Default setting, do not adjust. TP /17 27