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GNB
A division of
Exide Technologies
Industrial Battery Charger
Installation and Operation Manual
S47-0079 REV0410
1
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INDEX Page Section Description 3 - Safety Instructions 4 1.0 Installation 4 1.1 Receiving 4 1.2 Location 4 1.3 Line Voltage Adjustments 6 1.4 AC Service Requirements 6 1.5 Connecting AC Service to Charger 7 1.6 Grounding the Charger 7 1.7 Battery Connector and Charger Cable 7 1.8 Charging Rate Adjustment 8 2.0 Operation 8 2.1 046-0371 Control 13 3.0 Optional Features 13 4.0 Troubleshooting & Maintenance 15
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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. Install and ground the charger in accordance with the National Electric Code and your local electric code. Failure to p
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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 immediatel
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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
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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
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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
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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
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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. W
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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 Charg
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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 SHORTED minutes. #.##VC is the volts per cell at end of cha
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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 vol
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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
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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
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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. Lo
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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
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5.3 Spare Parts List Part Number Description Condensers 008-0002 2 MFD 440 Volt 008-0004 4 MFD 440 Volt 008-0006 6 MFD 440 Volt 008-0008 8 MFD 440 Volt 008-0010 10 MFD 440 Volt 008-0012 12.5 MFD 440 Volt 008-0015 15 MFD 440 Volt 008-0017 17.5 MFD 440 Volt 008-0020 20 MFD 440 Volt 008-0030 30 MFD 440 Volt 008-0040 40 MFD 440 Volt Resistors 037-0017 1.25 Ohm 100 Watt 037-0018 1.2
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Three Phase Charger Schematic # 02-400 18
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Single Phase Charger Schematic # 02-416 19
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02-490 (C1,C2,C3 AND C4) TYPICAL CIRCUIT 2 12 11 10 98 765 43 21 NOTES: 1 RESISTOR OPTIONAL 2 DISCONNECT OPTIONAL 3 WATER VALVE OPTIONAL 4 FAN AND FILTER OPTIONAL 5 SHOWN IN HIGH VOLTAGE SETTING 6 OUTPUT TAP ADJUSTMENT MODELS WITH DUAL VOLTAGE PRIMARY'S 7 WILL ONLY HAVE 1,5 AND 6 TAPS 8 MODELS THAT HAVE A SET VOLTAGE WILL ONLY HAVE 1 AND 6 TAPS 3 PHASE, 4 TRANS, DWG. NO. WIRING DIAGRAM: 9 MODELS THAT HAVE DUAL VOLTAGE OR 4 GANG, STANDARD CONFIGURATION. SET VOLTAGE MAY HAVE A SET VOLTAGE DATE: CH
