|
GNB
A division of
Exide Technologies
Industrial Battery Charger
Installation and Operation Manual
S47-0079 REV0410
1
WARNING
THIS EQUIPMENT CONTAINS LETHAL VOLTAGE LEVELS. INSTALLATION AND
SERVICING MUST BE PERFORMED BY QUALIFIED PERSONNEL
IMPORTANT: SAVE THESE INSTRUCTIONS!
READ AND FOLLOW ALL INSTRUCTIONS BEFORE INSTALLING, OPERATING, OR
SERVICING CHARGER. ANY DEVIATION CAN CAUSE SERIOUS AND PERMANENT
DAMAGE. FAILURE TO FOLLOW THE INSTRUCTIONS VOIDS THE WARRANTY.
1.
2.
3.
4.
Install and ground the charger in accordance with the National Electric Code and your local
electric code. Failure to properly ground the charger could result in a fatal electric shock.
To reduce the risk of fire, install chargers on a surface of non-combustible material, such as
concrete, stone, brick or grounded metal.
This charger has been designed to only charge flooded, lead-acid batteries. It should not be
used for charging other types of flooded batteries or sealed batteries.
Connect only batteries of the same number of cells and ampere-hour rating as listed on the
charger nameplate. Damage to the battery could occur, particularly if the battery has fewer cells
than the rating of the charger.
5.
6.
Do not touch uninsulated parts of the output connector or battery terminals. A possibility of
serious electrical shock exists.
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.
7.
8.
Do not connect or disconnect the battery plug while the charger is on. Doing so will cause
arching and burning of the connector resulting in charger damage or battery explosion.
Lead-acid batteries contain sulfuric acid, which is caustic and can cause chemical burns to the
skin. Refer to the battery manufacturers instructions for safe handling of batteries. Use proper
personnel protective equipment. 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.
9.
Do not operate the charger with the door open or with any panels removed. De-energize all AC
and DC power connections before servicing the charger.
10.
11.
The charger is not for outdoor use. Do not expose the charger to water spray, rain or snow.
Do not operate the charger with damaged cables, including cables with exposed conductors or
damaged connectors. Replace damaged cables before operation.
12.
Do not operate the charger if it has been dropped, received a sharp blow, or otherwise damaged
in any way. Call your service representative.
3
SECTION 1 - INSTALLATION
1.1. Receiving
Immediately upon receipt of the charger, check it against the shipping invoice to ensure the shipment is
complete and undamaged.
Examine the outside of the packing for signs of rough handling before accepting the charger from the
carrier.
If there is evidence of damage, the receipt should be signed, and both copies (carrier's and receiving
copies) marked "Shipment Received Damaged". The carrier's representative should be called
immediately and asked to make a "Carrier's Damage Report".
If concealed damage is later detected, the carrier should be called and requested to make a "Carrier's
Inspection for Concealed Damage Report".
After inspection by the carrier, arrangements should be made with the charger representative to have
the charger repaired before placing it in service.
When contacting your charger representative for assistance on a damage claim or shipment error,
provide the Model, and Serial Number of the charger, and a full description of the damage or error.
It is good practice to move the charger to the installation site before uncrating. When using bars,
hammers, etc. for uncrating, use care to avoid damage to the charger.
WARNING: To reduce the risk of fire, install the battery charger on a non-combustible surface
such as concrete, stone, brick, or steel. DO NOT operate the charger on its shipping skid
materials.
1.2. Location
For the best operating conditions and longest life, take care in selecting an installation site. Avoid
locations exposed to high humidity, temperature extremes or dust. Moisture condensing on machine
parts and electrical components can cause corrosion, which seriously affects operation, efficiency and
life. All units are designed for floor mounting. Standard cases may be stack-mounted if required, up to 3
high. If so, optional stacking brackets are required and available. Consult factory.
Dust and dirt will also decrease heat radiation from heat-generating components, such as transformers
and diodes. This will result in higher operating temperatures and shorter life. Adequate air circulation is
needed at all times in order to ensure proper operation. Provide a minimum of 6 inches of free air space
at the sides and rear of the charger. The front of the charger must remain unobstructed for serviceability.
1.3. Line Voltage Adjustments
All chargers are shipped with the AC line voltage jumper wires set for the AC voltage specified on the
purchase order. Before connecting the charger to the AC service, it should be verified that the internal
AC voltage connections match the available AC service voltage. If necessary change the AC voltage
jumper wires shown in Figs. 1.3.1 through 1.3.3.
NOTE: For 50 Hz. Single or three phase fixed voltage chargers, there are no adjustments.
CAUTION: It will be necessary in most cases to change the AC fuses when the AC voltage
jumpers are changed. Refer to the fuse chart on the inside door of the charger for the correct fuse
rating.
4
NOTE: When a 120/208/240 AC input unit is set for 120VAC a fuse neutral (brass tube) is required in
the Line 2 (neutral) fuse position.
Fig. 1.3.1.
A.C. Voltage Adjustments
1 Ø 60Hz. (120/208/240)
“A” Voltage Code
Fig. 1.3.2.
A.C. Voltage Adjustments
1Ø & 3Ø 60Hz. (208/240/480)
“B” Voltage Code
Fig.1.3.3.
A.C. Voltage Adjustments
3 Ø 60Hz. (480/575)
“K” Voltage Code
POWER TRANSFORMER SETTING
L1
L2
L1
L2
1 2 3 4 5 6
1 2 3 4 5 6
480
575
1 2 3 4
CONTROL
1 2 3 4
CONTROL
TRANSFORMER
TRANSFORMER
5
1.4. AC Service Requirements
Follow local code requirements if they are different than the instructions in this manual. After checking
the transformer connections as described in Paragraph 1.3, refer to Table 1-1, to determine the correct
ratings for the AC cable, AC fuses, and AC service disconnect switch for the line amperes as listed on
the nameplate of the charger for the available AC voltage
TABLE 1-1
Line Amperes
Disconnect Switch
Fuse Size Amps
000.0 - 02.5
003.0 - 04.5
005.0 - 07.5
008.0 - 11.0
011.5 - 15.5
016.0 - 18.0
018.5 - 22.0
022.5 - 27.0
027.5 - 32.0
032.5 - 40.0
040.5 - 48.0
048.5 - 64.0
065.0 - 80.0
081.0 - 95.0
096.0 - 125.0
30A
30A
30A
30A
30A
30A
30A
60A
60A
60A
60A
80A
100A
125A
150A
05
07
10
15
20
25
30
35
40
50
60
80
100
125
150
For voltages up to 240, use a 240 volt disconnect switch.
For voltages greater than 240 to 600, use a 600 volt disconnect switch.
•
•
Two conductors and ground wire required for single phase.
Three conductors and ground wire required for three-phase
1.5. Connecting AC Service to the Charger
1.5.1 Single-Phase Models
Connect the AC service to the L1 and L2 terminals located at the end of the AC fuse block.
Note: If the charger has been ordered with an AC input door-mounted disconnect switch, the AC input
wires will be connected to the L1 and L3 terminals at the top of the switch body.
1.5.2 Three-Phase Models
Connect the AC service to the L1, L2 and L3 terminals located at the end of the AC fuse block.
Note: If the charger has been ordered with an AC input door-mounted disconnect switch, the AC input
wires will be connected to the L1, L2 and L3 terminals at the top of the switch body.
6
1.6 Grounding the Charger
The charger must be grounded to the AC system ground for personnel safety.
The green ground wire in the AC input wiring must be connected to the charger ground stud
(Identified by a green dot and ground symbol).
1.7 Battery Connector and Charging Cable
Verify that the connectors on both the battery and the charger are attached so that the positive
output terminal of the charger is connected to the positive battery terminal.
CAUTION: If the polarity is reversed, the DC fuse will blow.
If in doubt, check the polarity with a DC voltmeter.
1.8 Charging Rate Adjustment
Note: Charging rate adjustments may be necessary to compensate for locations of extreme AC line
variation or may be used to tailor the charger output for aging batteries.
The charging rate has been set at the factory; therefore, field adjustment should not be necessary.
If there appears to be a charging rate problem, refer to the troubleshooting chart, Section 4.
If it is necessary to either increase or decrease the charging rate, a rate adjustment terminal block is
provided on the top rear of the transformer mounting bracket.
Change only one step at a time and observe the effect on the battery before making a second change.
The charging rate is increased by moving to the next higher tap setting in Table 1-2.
The charging rate is decreased by moving to the next lower tap setting.
No adjustments should be made without consulting the factory.
TABLE 1-2
CHARGING RATE ADJUSTMENTS
CONNECT RED
JUMPER WIRE TO
CONNECT
BLACK WIRE TO
OUTPUT
9
9
12
11
10
8
HIGHEST
9
9
NORMAL
LOWEST
12
11
12
12
10
9
7
SECTION 2 - OPERATION
The charger utilizes a standard ferro-resonant transformer, which provides isolation from the AC service
line and regulates the charging current. The transformer output is connected to a full-wave bridge of
silicon diodes, which provides DC charging current to the battery.
The starting charge amps and length of time required for a charge vary depending on the charger model.
See the data plate on the charger for information.
2.1.1 046-0371 Control Feature Summary
•
•
•
•
•
•
•
•
•
•
Charges flooded or sealed batteries.
Automatic start when battery is connected or manual start (if selected).
Automatic stop when charge is finished.
Fully charges partially discharged batteries without overcharging.
Dead battery ‘jump start’ for overly-discharged batteries.
Equalize charge by user request or automatic equalize settable from 1-30 charges.
Automatic refresh charging when set time has elapsed.
Automatically resumes charge after a power failure (if auto-start selected).
Displays charging amps and volts per cell during the charge cycle.
End Voltage, end current, AH, and run time can be displayed during charge, at the end of charge, or after
disconnecting the battery.
•
•
•
Delayed start adjustable from 0 to 24 hours (if auto-start selected).
Displays code if an abnormal charge indication is detected.
Cool down timer after the charge is complete (if selected).
2.1.2 Description
The front panel has a 16 character LCD display which normally shows charging amps and volts per
cell along with a periodic message showing the charger state. This display also presents messages if an
abnormal charge indication is detected. A yellow ‘Charging’ indicator lights while the charger is charging.
A green ‘Complete’ indicator lights when the charge is complete. A red ‘Fault’ indicator lights if an
abnormal charge indication is detected.
The front panel has STOP, =, EDIT and INFO buttons. A charge can be stopped by pressing STOP
and resumed by pressing STOP again. While charging, an equalize charge can be requested by pressing
= and turned off by pressing =. During or after charge, the charge information may be obtained by
pressing INFO.
2.1.3 Operation
The 046-0371 control is used in ferro-resonant taper chargers to provide fully automatic battery
charging. The control has a charging profile that handles standard flooded lead-acid batteries. The
charging profile, or algorithm, uniquely monitors the output current and voltage to optimally charge the
battery, based on battery manufacturer’s recommendations.
The control offers several safeguards to protect the battery. If a wrong voltage battery is connected,
the charger does not start and a Low-Battery-Voltage (F3) or High-Battery-Voltage (F4) message is
displayed. While charging, if the battery voltage exceeds a profile-specific cut-off value, the charge
terminates with an end on voltage message.
2.1.4 Normal Daily Charge
When no battery is connected, the LED indicators are off and the LCD display shows ‘0A 0.00VC’.
With the auto-start feature enabled, connecting a battery to the charger causes it to begin a charge cycle.
The charger first performs a self-diagnostic test to verify the control is working properly. During this time a
lamp test is performed causing all display segments and indicators to light. This allows the operator to
8
observe any defective segments or indicators. When the self-diagnostic is complete, the charge starts if
no delay is set, and the yellow ‘Charging’ indicator lights. The display shows the charging amps and
battery volts per cell along with a message to indicate the charger is in phase 1 of the charge cycle. If
auto start is disabled, the display shows ‘CHARGER OFF’. Press STOP to manually start the charge.
When the battery is 80% charged, the charger starts phase 2 of the charge cycle.
When a charge is finished, the charger automatically turns off. The yellow ‘Charging’ indicator goes
out. If cool down is enabled, the display shows the cool down time remaining. If cool down is disabled or
the time has elapsed, the display shows ‘0A x.xxVC’ along with a message indicating the battery is ready
and the green ‘Complete’ indicator lights.
2.1.4.1 Disconnecting the Battery
Warning: Risk of explosion. Do not disconnect the battery while the charger is running. Hydrogen gas
produced by the battery during charging can be ignited by arcing that occurs when the battery cable is
disconnected.
If the battery must be disconnected before the end of the charge cycle, the charger should be turned
off first. Press STOP, and verify the yellow ‘Charging’ indicator goes out. The LCD display shows
‘CHARGER OFF’. The battery may then be safely disconnected. If the green ‘Complete’ indicator is lit,
the battery may be disconnected at any time.
2.1.5 Equalize Charge
Over time batteries can develop inequalities in cell charge. This can lower the effective capacity of
the battery and shorten life. An equalizing charge re-balances the charge in the battery cells. Perform an
equalize charge if any of the following conditions exist:
1. On flooded batteries the specific gravity of any cell at the end of charge is 20 points less than the average
of all the cells.
2. The on-charge voltage of any cell at the end of charge is 20 millivolts less than the average of all the cells.
3. The battery has been stored for 30 days.
The 046-0371 control can perform an equalize automatically if auto equalize is enabled. Normal
equalize consists of an additional 3 hour charge time at the end of a normal charge cycle. The 046-0371
control can also perform an equalize charge when requested manually. First connect the battery and
allow the charge to start normally. Then press =. The display shows ‘=’ on the left side and the charge
time is extended by 3 hours to allow the cells to equalize their charge.
The auto-equalize or manual equalize cycle can be cleared by pressing = while in the normal charge
cycle. The ‘=’ indication on the display turns off. The next auto equalize charge occurs after the set
number of charge cycles if auto equalize is enabled. If the set number of charge cycles have been
completed, the charger attempts to equalize after the next charge cycle and continues to attempt to
equalize until an equalize cycle has completed.
The default setting for automatic equalize is every 7 cycles. To change the number of charge cycles
for automatic equalize, refer to the programming section.
2.1.6 Delayed Start
The delayed-start feature allows the operator to delay starting the charge cycle. This might be
desired to reduce peak energy surcharges if the charger were ready to start during a peak energy period.
The delay time could be set to keep the charger from starting until after the peak period ends.
To view or change the delayed start setting, refer to the programming section.
2.1.7 Auto- Refresh Charge
9
The 046-0371 control can provide an auto-refresh charge as long as the battery remains
connected to the charger if enabled. If AC power is lost during the wait period, the control resumes from
where it left off after power is restored. During the auto-refresh charge, the amp-hours and charge time
are added to the original charge. The refresh charge consists of 30 minutes at the equalize current. To
change the auto-refresh settings, refer to the programming section.
2.1.8 Viewing Charge Information
Additional charge information is available any time by pressing the INFO button. This information
is retained after the battery is disconnected until the next battery is connected. After 20 seconds the
display returns to the default display of amps and volts per cell. The following information can be viewed:
Parameter
Charger State
Amps
DISPLAY
XXXXXX
DESCRIPTION
Message describing charger state.
CHARGER DC AMPS Charger current in amps.
AA: xxxA
Volts/Cell
Amp Hours
Charge Time
Percent Return
Voltage
BATTERY V/C
VC: x.xxVC
Battery voltage in volts per cell (v/c).
ACCUMULATED AH Amp Hours returned for the current (or last) charge cycle.
AH: xxxxAH
CHARGE TIME
TC: xx:xxHM
% AH RETURNED
PR: xxx%
BATTERY VOLTS
VV: xx.xV
Charge time for the current (or last) charge cycle in hours and minutes.
Percent of Amp Hours returned as a function of battery AH rating.
Total battery voltage in volts.
End Current
End Voltage
Software
CHARGE END AMPS End current for the last charge cycle (current amps if charging)
EA: xxxA
CHARGE END VOLTS End voltage for the last charge cycle (current voltage if charging)
EV: x.xxVC
10
2.1.9 Charge Indications
The following indications are not necessarily a result of a charger problem. They are typically caused by
external problems such as AC line, poor battery conditions, connections, etc. If abnormal charge conditions are
detected, the charge is terminated, the red fault LED lights and the display shows:
DISPLAY DESCRIPTION
POSSIBLE CAUSE
Battery voltage did not reach 2.00 V/C within 30
- Shorted Cell
F0
minutes. #.##VC is the volts per cell at end of charge
and ##:##HM is the charge time.
- Open diode
SHORTED
CELL
#.##VC
- Low Charging amps
- Low AC line voltage
- Wrong size battery
- Battery over-discharged
- Shorted Cell
##:##HM
Battery did not reach gassing voltage within the
allowable time. #.##VC is the volts per cell at end of
charge and ##:##HM is the charge time.
F1
- Open diode
SHORTED
CELL
#.##VC
- Low Charging amps
- Low AC line voltage
- Wrong size battery
- Battery over-discharged
- Wrong size battery
- Battery over-discharged
- Voltage jumper setting incorrect
##:##HM
Low battery voltage, less than 1.60 V/C at start up.
###A is the charger current and #.##VC is the battery
volts per cell.
F3 LOW
VOLTS
###A
#.##VC
F4 HIGH
VOLTS
###A
High battery voltage, more than 2.40 V/C at start up.
###A is the charger current and #.##VC is the battery
volts per cell.
- Wrong size battery
- Battery fully charged
- Voltage jumper setting incorrect
#.##VC
F5 NO DC
CURRENT
###A
No charging current to the battery. ###A is the current - Faulty AC line contactor
at the end of charge and #.##VC is the volts per cell at
end of charge.
- Open diode
- Faulty resonant capacitor
- Poor battery connections
- Open cell
#.##VC
- Faulty control board
- Incorrect control setup
- Open diode
- Low Charging amps
- Low AC line voltage
- Wrong size battery
- Battery over-discharged
F6
Long charge, the charger ran longer than the allowed
time. #.##VC is the volts per cell at end of charge and
##:##HM is the charge time.
F7 LONG
CHARGE
#.##VC
##:##HM
Charger stayed on when control requested it to shut off. - AC line contactor stuck on
F8
CHARGER
ON
###A is the charger current and #.##VC is the battery
volts per cell.
- Open shunt sense lead or loose connection
- Incorrect control setup
- Missing or damaged current sensor
- Faulty control board
- Faulty keypad
###A
#.##VC
F9 BAD
KEYPAD
###A
Faulty keypad detected. One or more buttons are stuck
on. ###A is the charger current and #.##VC is the
battery volts per cell.
- Faulty control board
#.##VC
- High charging amps or high AC line voltage
- Missing or damaged current sensor
- Incorrect shunt size
- Open shunt sense lead or loose connection
- Faulty control board
11
Note: F3 and F4 clear automatically if the battery voltage falls within acceptable limits. All indications
except F8, F9 and F10 can be cleared by disconnecting the battery. For F8, F9 and F10, correct the
condition that caused the indication and disconnect the battery to clear the indication.
CAUTION: If F8 is showing, and the charger is providing current to the battery, remove AC power
from the charger before disconnecting the battery.
2.1.10 F3 (Low Battery) Override
If battery voltage is below 1.60 volts per cell the charger does not start automatically. If this is due to
an overly discharged battery of the correct voltage, the F3 indication can be manually overridden by
pressing ‘STOP’ while the F3 message (Low Battery) displays.
2.1.11 Jumper Settings
CAUTION: Remove AC and DC power from the charger before changing any jumper settings.
Refer to figure 1 for location of jumpers.
- Jumper J5 should be set to match the battery voltage.
Volts
80V
72V
64V
48V
36V
24V
12V1
SP2
1For non-standard battery voltages above 80V, the jumper is set on 12 and a resistor is installed in the charger wire
harness based on the following calculation: R = 1250 x (Nominal Battery Voltage) – 15000.
2For non-standard battery voltages between 12V and 80V, the jumper is set on SP and resistor R9 is installed on the
control based on the following calculation: R9 = 1250 x (Nominal Battery Voltage) – 15000.
- Jumper J4 is used to lock out several parameters in the programming mode.
- Header J1 is used to select the charger type.
PARAMETER LOCKOUT
LOCKED
CHARGER TYPE
FERRO
HF*
UNLOCKED
J1
J1
J4
J4
*J1 used for interface to HF module
Caution: Placing jumpers on any other position on J1 or J4 may damage the control and voids the
warranty.
12
2.1.12 Programming
To enter programming mode, press and hold the EDIT button and while holding it, press the INFO button. The
display shows a message describing the current parameter followed by the parameter‘s value. While in
programming mode, the buttons have the following functions:
STOP: Exit programming mode and save all parameters
=: Shift position of parameter being edited
EDIT: Change value of current position of parameter being edited
INFO: Change parameter to edit
Some of the parameters may be locked out in the programming mode. If a parameter is locked, the parameter is
displayed along with the current value and a lock is displayed on the left side of the display. The parameter can not
be changed. Refer to jumper settings section for information on locking out parameters. The following parameters
are available for editing:
PARAMETER
MESSAGE
RANGE
100-2200AH
12-999V
NOTES
LOCK
BS
VR
SR
BATTERY AH SIZE
BATTERY VOLTAGE
SHUNT RATING
●
●
0-600A
A setting of 0 enables current sensor operation
0: Manual Start
AS
AUTO START MODE
0-2
1: Auto-Start
2: Auto Start (restart on AC power)
CR
SA
TP
FA
FV
CV
CABLE RESISTANCE
START A/100AH
80% TRIP POINT
FINISH A/100AH
FINISH VOLTAGE
CUTOFF VOLTAGE
0-25mΩ
5.0-50.0 A/100AH
2.35-2.45 V/C
0.1-10.0 A/100AH
2.50-3.00 V/C
2.50-3.00 V/C
●
●
●
●
●
●
Exceeding this voltage terminates the charge immediately.
Exceeding this time results in an F1 if F1 is enabled and ends
normally if F1 is disabled. (see N1 parameter)
ST
80% TIMEOUT
0:00-24:00
Exceeding this time results in an F7 if F7 is enabled and ends
normally if F7 is disabled. (see N7 parameter)
*DO NOT EXCEED RATING OF CHARGER
Maximum return based on battery AH size. Setting this to 0 disables
the charge factor.
●
FT
MP
CF
CHARGE TIMEOUT
MAX POWER RATING
CHARGE FACTOR
0:00-24:00
0.1-25.0 kW
0-150%
●
●
DS
CT
DELAY START TIME
COOL DOWN TIME
0:00-24:00
0:00-24:00
Each period is 5 minutes. Setting this to 0 causes the charge to
terminate when the trip point is reached. (opportunity charge)
0: Equalize disabled
●
●
CU
EM
DVDT PERIODS
0-15
0-1
EQUALIZE MODE
1: Normal equalize
EI
ET
EC
N1
N3
N4
N6
N7
AR
EQUALIZE A/100AH
EQUALIZE TIME
0.1-10.0 A/100AH
●
●
0:00-24:00
0-30
EQUALIZE CYCLES
F1 FAULT DISABLE
F3 FAULT DISABLE
F4 FAULT DISABLE
F6 FAULT DISABLE
F7 FAULT DISABLE
REFRESH TIME
Setting this to 0 disables automatic equalize.
0: Enabled, 1: Disabled
0: Enabled, 1: Disabled
0: Enabled, 1: Disabled
0: Enabled, 1: Disabled
0-1
0-1
0-1
0-1
●
●
●
●
●
0-1
0: Enabled, 1: Disabled
Setting this to 0:00 disables automatic refresh.
00:00-72:00
13
SECTION 3 - OPTIONAL FEATURES
3.1 Fusible Door-Interlock Switch (JIC Switch)
The door interlock switch assembly connects the AC service to the charger’s input fuses for each AC line.
The switch is mechanically latched by the door so that it must be in the OFF position before the door can
be opened. Operation of the charger is identical to that of the standard model, except the charger cannot
be energized if the door is open.
3.2 Remote Control
The remote control option makes it possible to operate the charger at a point within 15 feet of the charger.
It includes a box equipped with the control option ordered, and 15, 20, or 30 feet of jacketed control
harness. Operation is identical to that of a standard charger except that the control is not mounted on the
front of the charger.
3.3 Watering Valve
On chargers ordered with the 046-0172 control, an optional 24VAC watering solenoid can be ordered.
The valve will activate at the end of the charge cycle. It works in conjunction with an automatic watering
system that is supplied by others. Note: Watering valves have a one year part replacement warranty only.
3.4 Charger Stand
The charger stand is a metal frame that is designed to bolt the charger cabinet on top of it. It raises the
cabinet up to the operator’s level, rather than having the cabinet sitting on the floor.
SECTION 4 – TROUBLESHOOTING & GENERAL MAINTENANCE
Caution: There are lethal voltages exposed when the charger is energized with the door open.
Always disconnect the AC service voltage to the charger before opening the door. The following
chart lists the most probable cause of a malfunction.
SYMPTOMS AND POSSIBLE CAUSES
4.1. No charging current, the control has no display, contactor does not operate.
POSSIBLE CAUSE
A. Blown AC fuse.
B. No AC service voltage.
C. Incorrect AC voltage.
D. Control transformer output fuse blown.
E. Defective control transformer.
F. Defective control board.
4.2. No charging current, control has a display.
POSSIBLE CAUSE
A. Blown DC fuse.
B. Defective ammeter.
C. Open battery cell.
D. Defective diode.
E. Defective capacitor.
F. Shorted power transformer secondary.
14
4.3. AC fuse blows.
POSSIBLE CAUSE
A. Incorrect fuse rating.
B. Incorrect AC voltage.
C. Fuse Block holding clips loose.
D. Shorted transformer winding.
4.4. DC fuse blows.
POSSIBLE CAUSE
A. Reversed battery connector.
B. Incorrect fuse rating.
C. Shorted diode.
4.5. Excessive water loss in battery.
POSSIBLE CAUSE
A. Charging rate is too high. See Section 1.8.
B. Charger amp-hour rating exceeds the battery amp-hour rating.
C. Battery has defective cells.
4.6. Low specific gravity at the end of the charge cycle.
POSSIBLE CAUSE
A. Battery was over-discharged.
B. Charger amp-hour rating is less than the battery AH rating.
C. Defective open diode.
D. Charging rate is too low. See Section 1.8.
E. Battery has defective cells.
F. Battery has been over-watered.
4.7. Charger does not turn off when the control terminates the charge cycle.
POSSIBLE CAUSE
A. Defective control.
B. AC contactor has welded contacts.
4.8. General Maintenance
The charger requires a minimum of maintenance. Connections and terminals should be kept clean and
tight. The charger 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 on the environment in which this unit is installed. If any cabinet sheet metal panels
are removed for cleaning, be certain they are properly reinstalled upon completion.
15
SECTION 5 – REPLACEABLE PARTS
5.1 Ordering Information
The following information must be supplied when ordering a replacement part from your service agent in
order to ensure that the correct part is supplied:
A. Model or Spec. number of charger (Located on charger data plate)
B. Serial number of charger (Located on charger data plate)
C. Schematic reference symbol or part
D. Description of part
5.2 Recommended Spares
The quantity of spares stocked should be increased as the number of chargers increases.
The following chart is the minimum quantity recommended per model for multiple charger installations:
# OF CHARGERS
# OF SPARE PARTS KITS
1-3
4-10
1
2
3
4
5
11-25
26-50
51-100
SCHEMATIC REF
SYMBOL
DESCRIPTION
QUAN. USED
QUANTITY RECOMMENDED
ACF
AC FUSE, 1 PH.
AC FUSE, 3 PH.
2
4
ACF
DCF
3
6
DC FUSE
1
2
1
1
2
3
0
0
1
1
CONTROL
AK
CONTROL BOARD
A.C. CONTACTOR
SILICON DIODE, 1 PH.
SILICON DIODE, 3 PH.
TRANSFORMER, 1 PH.
TRANSFORMER, 3 PH
CAPACITOR
1
1
SD1,SD2
SD1-SD6
TP
2
6
1
TP
3
VARIES
1
C
CT
CONTROL TRANSFORMER
16
5.3 Spare Parts List
Part Number
Description
Condensers
008-0002
008-0004
008-0006
008-0008
008-0010
008-0012
008-0015
008-0017
008-0020
008-0030
008-0040
2 MFD 440 Volt
4 MFD 440 Volt
6 MFD 440 Volt
8 MFD 440 Volt
10 MFD 440 Volt
12.5 MFD 440 Volt
15 MFD 440 Volt
17.5 MFD 440 Volt
20 MFD 440 Volt
30 MFD 440 Volt
40 MFD 440 Volt
Resistors
037-0017
037-0018
037-0015
037-0010
1.25 Ohm 100 Watt
1.25 Ohm 200 Watt
2.50 Ohm 100 Watt
2.50 Ohm 200 Watt
Diodes
024-0001
024-0003
70 A 600 Volt
150 A 600 Volt
Contactors
A09-0020
A09-0021
A09-0049
30 Amp 3 Pole
30 Amp 2 Pole
60 Amp 3 Pole
Controls
P46-371
4 Button control
Control Transformers
A03-1210
A03-1211
240/480P, 24S, 50 VA
120/240P, 24S, 50 VA
480/600P, 24S, 50 VA
A03-1213
DC Fuses
011-0243
011-0044
011-0045
011-0046
011-0047
011-0048
011-0049
80 Amp, 130 Volt
100 Amp, 130 Volt
150 Amp, 130 Volt
200 Amp, 130 Volt
250 Amp, 130 Volt
300 Amp, 130 Volt
400 Amp, 130 Volt
17
Three Phase Charger Schematic # 02-400
18
Single Phase Charger Schematic # 02-416
19
(C1,C2,C3 AND C4) TYPICAL CIRCUIT
2
12 11 10
9
8
7
6
5
4
3
2
1
NOTES:
RESISTOR OPTIONAL
1
2
3
DISCONNECT OPTIONAL
WATER VALVE OPTIONAL
FAN AND FILTER OPTIONAL
SHOWN IN HIGH VOLTAGE SETTING
OUTPUT TAP ADJUSTMENT
MODELS WITH DUAL VOLTAGE PRIMARY'S
WILL ONLY HAVE 1,5 AND 6 TAPS
MODELS THAT HAVE A SET VOLTAGE
WILL ONLY HAVE 1 AND 6 TAPS
4
5
6
7
8
3 PHASE, 4 TRANS,
4 GANG, STANDARD CONFIGURATION.
DWG. NO.
WIRING DIAGRAM:
9
MODELS THAT HAVE DUAL VOLTAGE OR
SET VOLTAGE MAY HAVE A SET VOLTAGE
CONTROL TRANSFORMER
CHK:
DR.
02-490
REV.
DATE: 01/08/98
CMP
10 TRANSFORMER THERMAL OVERLOAD
DRY FORM "C" RELAY - OPTIONAL
DATE
DESCRIPTION
REMOVED THERMAL OVERLOAD
11
D
01/08/05
# DENOTES POSITION ON 4 POLE TERMINAL BLOCK
* WATERING NOT AVAILABLE ON ALL CONTROLS.
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