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DEC200 SERIES
INDUSTRIAL BATTERY
CHARGER I&O MANUAL
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TABLE OF CONTENTS TITLE Page 1. Important Operating Instructions 2 2. Introduction 3 3. Receiving Instructions 3 4. Location and Installation of Charger 3 5. Stacking 3-4 6. AC Electrical Supply 5-8 6.1 Branch Circuit Protection 5 6.2 AC Voltage Connections 8 6.3 Ground Connection 8 7. DC Output 8 8. Fault and Display Codes 8 9. DEC200 Standard Charger Operation 9 10. Charger Functional Description 10 10.1 LED Descriptions 10 10.2 Pause Push Button 10 10.3 Smart Start Stag
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DEC200 SERIES INDUSTRIAL BATTERY CHARGERS 1. IMPORTANT OPERATING AND SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS a) Before using the battery charger, read all the instructions in addition to the CAUTION, WARNING, and DANGER markings on the charger, battery, and all the associated equipment. b) Do not touch un-insulated parts of the DC output connector or the battery terminals, as there is a possibility of electric shock. c) Connect or disconnect the battery plug only when the
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2. INTRODUCTION The GNB® DEC200 battery chargers are fan cooled, solid state, microprocessor controlled, SCR regulated chargers designed to make battery charging simple. They are designed to charge flooded lead-acid batteries. The charger has a comprehensive self-checking diagnostic program to control all charger functions, monitor the quality of charge and check its own safety conditions. 3. RECEIVING CHARGER Examine the charger thoroughly before using, to make sure that no parts h
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b) Remove the bolts from the top cover of the base unit, but do not discard these, as they will be required to fix the two units together. c) Use an appropriate lifting sling to lift the second unit on to the base unit, inch the second unit over the base unit and align the holes before resting the second unit on top. d) Secure the two units together using the bolts removed from the top cover of the base unit. Use the access between the two units or inside the second unit using the
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6. AC ELECTRICAL SUPPLY The charger must be connected to either a single phase or three phase, 60 Hertz (± 2%) AC power source. Three phase chargers cannot be powered with a single phase source. The following transformer options are available: TABLE 1 – INPUT VOLTAGE CHOICES Single phase Three phase 208/240/480VAC, 60Hz 208/240/480VAC, 60Hz Only the AC input wire configuration for multi-input chargers can be changed. Follow Figure 1 (page 6) for single-phase input or Figure
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FIGURE 1: SINGLE PHASE INPUT WARNING: IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE DAMAGE TO THE CHARGER AND BATTERY NOTE: Live connection ‘L’ Must be connected to the breaker. The mains input are the only user configurable connections. PCB connections must NOT be altered from factory setting. 208 VAC 60Hz CONFIGURATION (208/240/480V INPUT) 208 0 240 480 PCB Mains Input (Black) N N (Blue) (Black) L L (Brown) 240 VAC 60Hz CONFIGURATION (208/240/480V INPU
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FIGURE 2: THREE-PHASE INPUT WARNING: IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE DAMAGE TO THE CHARGER AND BATTERY NOTE: PCB connections must NOT be altered from factory setting. 208VAC 60 Hz CONFIGURATION (208/240/480V INPUT) 208 480 N 240 480 208 24 0 208 240 480 PCB (Brown) L Mains Input (Black) L1 (Blue) N (Black) L2 (Black) L3 240VAC 60 Hz CONFIGURATION (208/240/480V INPUT) 208 480 N 240 480 208 24 0 208 240 480 PCB (Brown) L Mains Input (Black) L1
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6.2. AC VOLTAGE CONNECTIONS To connect the input AC voltage, route the AC conduit through the knockout hole provided. Continue the AC wiring to the breaker terminals L1 (N) and L2 (L) (single phase input) or L1, L2, and L3 (three phase input). For proper connection, torque the screws to approximately 25 inch-pounds. 6.3. GROUND CONNECTION It is a requirement to ground the chassis while the charger is connected to AC power. The charger comes with a threaded M6 hole, clearly mark
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9. DEC200 STANDARD CHARGER OPERATION DISPLAY CHARGE CONDITION FUNCTION BUTTON DISPLAY SELECTION LED DEFAULT CHARGING A A, Ph Y TERMINATION rEdy G TERMINATION/ FAULT CODE rEdy / F R*, G Charge SETTING EQUALISE EqAL for 5 seconds then default display stage EQUALISE CHARGE A / EqAL G*, Y AUTO BALANCE StSt / A StSt / V G Lobt CHARGE PERIOD Lobt / A Y* Lobt OFF PERIOD Lobt / V CRITICAL FAULT CODE F R NONE CRITICAL FAULT CODE F Charge continues R* A = Output current
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10. CHARGER FUNCTIONAL DESCRIPTION 10.1. LED Descriptions LED Description Yellow Flashing High Rate Current Yellow Solid 80% Charged Green Solid Charge Complete Red Fault – See page 15 for codes 10.2. PAUSE PUSH BUTTON This PAUSE push button will halt the charge cycle. The battery can then be safely unplugged for up to 10 minutes. If the battery is still connected after this time, the charger will continue with the present charge cycle. 10.3 SMART START If the time to
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10.6 EQUALIZE PUSHBUTTON Equalize charge can be enabled/disabled, when the FUNCTION button is depressed > 5 second at anytime whilst a battery is connected. Only one equalize charge per recharge cycle is permitted. CAUTION: DO NOT EQUALIZE MORE OFTEN THAN REQUIRED BY THE CONDITION OF THE BATTERY, AS SPECIFIED IN THE BATTERY MAINTENANCE INSTRUCTIONS. EXCESSIVE EQUALIZING MAY DAMAGE THE BATTERY. 10.7 LOW BATTERY OVERRIDE/RECOVORY 10.7.1 CONFIGURATION There is the ability to
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11 MAINTENANCE The charger requires minimum maintenance. ENSURE THE CHASSIS IS SECURELY GROUNDED per the local/federal Electrical Code. Do not allow excessive dust to accumulate on the components inside. Blow out with clean compressed air when necessary. The chargers are designed with a breaker and fuse for the AC input and DC output respectively. Should this fuse fail or breaker trip, the cause must be determined before they are corrected or replaced. Never replace the fuse or breaker
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APPENDIX A – FAULT CODES CODE STATUS DESCRIPTION F01 N Over discharged battery (<1.90vpc after 30 seconds of charge) F02 N Deep discharged battery (<1.90vpc after 30 seconds of charge > 1.90vpc) F03 N Sulphated battery F04 S Charger over heating F05 S Mains failed during charge F06 R No output current F07 C Incorrect battery < 1.70 F07 (+Y led on) C Incorrect battery > 2.25 F09 C Bulk charge time-out F10 C Second stage time-out (Profile Dependant) F11 Incorrect Mains Frequency C
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APPENDIX B – DEC200 TROUBLESHOOTING POSSIBLE SYMPTOM EXPLANATION / ACTION CAUSE No Display No AC Power Check Input Power. Check Breaker. Mains fuse on Control Board Deeply Battery Voltage less than 1.9 volts per cell initially but rose above this F01 Discharged level within the first minute. Check battery condition and Equalize. Battery Battery less than 1.9 volts per cell after the first minute of charge. Check F02 Over discharge battery condition and Equalize Make sure your ba
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APPENDIX C –TECHNICAL DATA AC AMPS (RMS) @ AC Amp-Hour Rating SHIPPING DATA Model Numbers VOLTS @ 2.4 VPC DC DC WEIGHT 10 12 14 Volt Amps 208 240 480 Cabinet Hour Hour Hour Vac Vac Vac Size Lbs KG Single Phase DEC200-24V-40AS1H 330 400 470 24 40 11.4 9.8 4.9 M4 94.8 43 DEC200-24V-75AS1H 625 750 880 24 75 21.3 18.4 9.2 M4 134 61 DEC200-24V-95AS1H 790 950 1120 24 95 27 23.4 11.7 M4 145 66 DEC200-24V-115AS1H 955 1150 1350 24 115 32.6 28.3 14.1 M4 163 74 DEC200-24V-135AS1H 1125 1
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480V 240V 208V 480V 240V 208V 480V 240V 208V N APPENDIX D Component No: DRAWING TITLE: CLT6006 GNB [UL] 3phase wiring diagram KEY For 208V input connect to 208V bl BLUE connections on T1 L1 bk BLACK L1 br BROWN For 240V input connect to 240V L2 gy GREY L2 rd RED connections on T1 wh WHITE L3 L3 YL/G YELLOW / GREEN For 480V input connect to 480V OR connections on T1 L1 L1 YL/G L2 L2 L3 L3 bl br gy br bl bl T1 PCB1 CON1 4 3 2 1 FS1 bl gy 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 wh '2'
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240V 480V 208V 240V 2 V 08 120V 0V 0V 0V APPENDIX D Component No: DRAWING TITLE: CLT6005 GNB [UL] Single phase wiring diagram Fuse / Breakers KEY bl BLUE N For 120V input connect to 120V bk BLACK connections on T1 br BROWN gy GREY rd RED For 208V input connect to 208V wh WHITE connections on T1 L YL/G YELLOW / GREEN OR For 240V input connect to 240V connections on T1 N N For 480V input connect to 480V YL/G connections on T1 OR L L 240V gy br bl bl OR PCB1 br CON1 bl 4 3 2 1 FS1 gy
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APPENDIX E – DIMENSIONS CABINET DIM. A DIM. B DIM. C DIM. D DIM. E Size M4 19.69” 26.65” 16.93” 17.54” 12.99” Size M5 23.62” 26.65” 20.87” 21.48” 16.93” 18 Sales • Service • Recycling 1-888-563-6300
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SALES – SERVICE - RECYCLING 1-888-563-6300 TOLL FREE GNB Industrial Power A division of Exide Technologies U.S.A. Tel: 877.462.4636 GNB Industrial Power A division of Exide Technologies Canada Tel: 800.268.2698 V19CIL5200ULD 2004-05 www.gnb.com
