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Operator Manual, Supercharger 60 R3.0
TABLE OF CONTENTS
1. INTRODUCTION AND SYSTEM DESCRIPTION .................................................................. 5
2. CONDENSED OPERATING INSTRUCTIONS ....................................................................... 8
2.1 Constant Current Charge (normal mode) ............................................................................................... 8
2.2 Constant Voltage ....................................................
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Operator Manual, Supercharger 60 R3.0 4.20 DS5A - FULL: .......................................................................................................................................... 21 4.21 DS5B - DISCH: ........................................................................................................................................ 21 4.22 DS6A - CAP FAIL: ....................................................................................................................
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Operator Manual, Supercharger 60 R3.0 8.8 DISCHARGE VOLTAGE CUT-OFF. ................................................................................................... 38 8.9 FULL DISCHARGE. .............................................................................................................................. 39 8.10 CURRENT TRACKING. ........................................................................................................................ 39 8.11 VOLTAGE CONTROL. ...
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Operator Manual, Supercharger 60 R3.0 TABLE OF FIGURES Figure 1 - Block Diagram ...................................................................................................................................... 7 Figure 2 - Front Panel .......................................................................................................................................... 20 Figure 3 - Line Voltage Wiring, 115V ...................................................................
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Operator Manual, Supercharger 60 R3.0 1. INTRODUCTION AND SYSTEM DESCRIPTION Congratulations! You now own the finest battery Charger-Analyzer available today. The Supercharger is a precision instrument designed to charge and analyze NICKEL-CADMIUM, LEAD-ACID and other rechargeable batteries exactly as recommended by the battery manufacturers. The simple to set controls plus the condensed operating procedure found on the front panel makes the Supercharger a very easy to operate CHARGER
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Operator Manual, Supercharger 60 R3.0 The TIMER provides all the required timing functions related to the charge and discharge durations. Digital time and speed selectors provide the external inputs, while the four digit readout of the CLOCK provides the elapsed time display. The CURRENT CONTROL interprets the programmed current values and controls the angle of firing of two SCR's to maintain a constant current in accordance to the feedback received from a precision shunt. Displa
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Operator Manual, Supercharger 60 R3.0 Figure 1 - Block Diagram Page 7 of 62
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Operator Manual, Supercharger 60 R3.0 2. CONDENSED OPERATING INSTRUCTIONS CAUTION: Disconnect power and batteries before performing any internal maintenance. Failure to observe this caution may result in serious damage to the unit and injury to the operator. NOTE 1: Depress the RESET button before turning the power on, or before connecting or disconnecting the battery. NOTE 2: The current selector potentiometers display three digits indicating XX.X AMPS. e.g.: in order to selec
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Operator Manual, Supercharger 60 R3.0 2.2 Constant Voltage 2.2.1. Battery Voltage 2.2.1.1. Enter the nominal battery voltage using the cell selector (see chart on page 19). 2.2.1.2. Program the charge (maximum) current in the Topping Current selector. 2.2.1.3. Program sufficient time in the Total Time selector to allow the battery to reach the required charge under constant voltage charge (consult battery manufacturers specifications). Verify that the Timer Speed is consistent with t
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Operator Manual, Supercharger 60 R3.0 2.3 Peak Voltage Charge 2.3.1. Nominal Battery Voltage 2.3.1.1. Enter the nominal battery voltage using the cell selector (see chart on page xxx). 2.3.1.2. Select transfer from Main to Topping on Peak or stop on Peak. 2.3.1.3. Program the Main and Topping Charge currents as required. 2.3.1.4. Program the Main and Total Time selectors to allow the battery to reach the required charge level (consult battery manufacturers specifications). Verify that
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Operator Manual, Supercharger 60 R3.0 2.4 Discharge NOTE 1: Do not place batteries on the Temp-Plate during discharge. Due to the normal heating of the battery a false Overtemp may be generated later during the charge process. NOTE 2: Do not attempt to discharge with the voltage mode selector in the Float or Peak voltage modes. Voltage and current faults will occur depending on the battery voltage and the cell selector setting. 2.4.1. Number of Cells 2.4.1.1. Enter the number of cells
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Operator Manual, Supercharger 60 R3.0 3. SPECIFICATIONS 3.1 CHARGE 3.1.1. CONTROL: SCR, air cooled. 3.1.2. MAXIMUM CURRENT: 50 AMPS. 3.1.3. MINIMUM INCREMENT: 0.1 AMP. 3.1.4. ACCURACY and STABILITY of settings: ±1% of reading, ±0.1 AMP. 3.1.4.1. FLOAT: • The reference voltage is set at the equivalent of 2.33V/cell (Lead- Acid). • The Cell Selector provides the basic reference as nominal battery voltage, e.g.: a 24V battery is entered as 24 on the Cell Selector. • Current reduction f
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Operator Manual, Supercharger 60 R3.0 3.1.5. MODES: 3.1.5.1. Main and topping for Constant Current 3.1.5.2. Constant Voltage 3.1.5.3. Peak Voltage. 3.1.6. TIMER: 3.1.6.1. 1 to 9 hours for MAIN charge time and 1 to 60 hours for TOTAL time. 3.1.6.2. Time can also be programmed in minutes by selecting the FAST mode in the TIMER SPEED selector switch (Front Panel). 3.1.6.3. NOTE 1: Topping charge time equals the total charge time minus the main charge time (TOTAL = MAIN + TOP). 3.1.6
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Operator Manual, Supercharger 60 R3.0 3.1.12.1. 3 AMPS idling plus ½ the value of the charging current; e.g. when charging 40 AMPS the line current is 23 AMPS (Note: nominal values, line voltage and frequency dependent). 3.2 DISCHARGE 3.2.1. CONTROL: Transistors, air cooled. 3.2.2. MAXIMUM CURRENT: 3.2.2.1. 60 AMPS. Total power dissipation must not exceed 1.2KW (1200 watts, the product of battery voltage and battery current). 3.2.2.2. NOTE: Discharge current is automatically limited t
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Operator Manual, Supercharger 60 R3.0 3.2.6. TERMINAL VOLTAGE: 3.2.6.1. Programmable, in accordance with the number of cells selected, at the equivalent of 1 VOLT/cell. 3.2.6.2. TOLERANCE: ±1% ±0.1 VOLT. 3.2.6.3. NOTE 1: Due to cable/connector losses the voltage registered by the Charger-Analyzer will be lower than the actual battery voltage (up to 0.2V depending on current). 3.2.6.4. NOTE 2: Terminal voltage is ignored in the full discharge mode. 3.2.7. OVERHEAT PROTECTION: 3.2.7
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Operator Manual, Supercharger 60 R3.0 3.3.2.4. NOTE: The colon flashes at the rate of one cycle per second regardless of the selected mode. 3.3.3. ACCURACY AND STABILITY: 3.3.3.1. ±0.01% 3.3.4. POWER FAILURE PROTECTION: 3.3.4.1. An internal rechargeable battery maintains (for several hours) the clock and other vital circuits for a dependable resumption of operation after a power failure. 3.3.4.2. The colon will be lit in case of a power failure. 3.3.4.3. NOTE: Do not operate the Cha
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Operator Manual, Supercharger 60 R3.0 3.5 DIGITAL PANEL METERS 3.5.1. VOLTMETER: 3.5.1.1. Accuracy (system): ±0.25% of reading, ±0.1V in the 200V scale, ±0.01V in the 20V scale, ±0.005V in the 2V scale. 3.5.1.2. Input impedance: 1 M-OHM. 3.5.1.3. Scale 2V, 20V and 200V (1.999V, 19.9V and 199.9V) for external measurements and 20V and 200V for internal (battery) measurements. 3.5.2. AMMETER: 3.5.2.1. Accuracy (system): ±0.5% of reading, ±0.1A 3.5.2.2. Scale: 200A (199.9A) 3.5.3. SHUNT
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Operator Manual, Supercharger 60 R3.0 4. CONTROLS AND DISPLAYS 4.1 M1 - Ammeter 4.1.1. 0 to 199.9ADC DIGITAL PANEL METER. 4.1.2. Positive sign indicates charge current. 4.1.3. Minus sign indicates discharge current. 4.2 M1 - Voltmeter 4.2.1. 0 to 1.999VDC, 0 to 19.99VDC and 0 to 199.9VDC DIGITAL PANEL METER. 4.2.2. Indicates battery voltage in the internal (20/200V) position and voltage present at the RED (+) and BLK (-) jacks in the 2/20/200V external positions. Positive sign indic
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Operator Manual, Supercharger 60 R3.0 4.8 SW4 - CELL SELECTOR: 4.8.1. Two digit selector to program the battery terminal voltage as a function of the number of cells. 4.8.2. Rate: 1.75 volts per cell for charge and 1.0 volts per cell for discharge. 4.8.3. Used also in the Float and Peak Voltage modes to enter nominal battery voltage. 4.9 SW5 - DIGITAL VOLTMETER INPUT SELECTOR: 4.9.1. External, 2/20/200V scale. 4.9.2. Internal, 20/200V scale. 4.10 SW6 - VOLTAGE MODE SELECTOR: 4.10.1
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Operator Manual, Supercharger 60 R3.0 Figure 2 - Front Panel Page 20 of 62
