Legacy Charger Manual - Bronze DLB & Silver
Contents
1. 2 10 Wcell 28 Current Time 17 Doug WR S DOUGLAS POWER SYSTEM POWER SYSTEM When the battery reaches the gassing voltage the charge continues for one half of the time needed to reach the gassing voltage with a minimum total time of 30 minutes Examples e if the battery reaches the gassing voltage in minute the final charge will continue for 30 minutes e if the battery reaches the gassing voltage in 5 hours the final charge will continue for 2 hours and 30 minutes e if the battery reaches the gassing voltage in 10 hours the final charge will continue for 5 hours If the battery reaches the gassing voltage 11h59m59s the final charge will continue for 5h 59m59s this is maximum total time allowed before going to Emergency state These time limits are ok to use the charger with different battery capacities depending on the time available for the charge from 8 to 16 hours and it s not needed to do adjustments on the board SAFETY TIMER EMERGENCY STOP e If the battery doesn t reach the gassing voltage within 12 hours the charge is terminated by the safety timer and the display shows the error message Time Error If this error message appears it s recommended to call the service for a complete check of the system The cause if this problem may be a wrong setting of the input voltage if the input is set to a certain value for example 610 V but th2. self discharge absent the refresh charge will never be activated In the opposite case if the battery is in bad condition and self discharge 15 significant the refresh charge will be often activated and the battery will be kept charged without problems 22 Douglas Legacy Silver Series Charger NR ree DOUGLAS POWER SYSTEM POWER SYSTEM MANUAL CHARGE TERMINATION While the charge is in progress it s possible to shut down the charger by pressing the red button MANUAL STOP on the front panel The display will show the message Stop e The final values of Voltage cell Time of charge and Capacity Charged remain stored in memory If the MANUAL STOP button is pressed again these values will be displayed in sequence When the charge 15 terminated manually the equalization and refresh functions are automatically disabled 23 Douglas Legacy Silver Series Charger Douglas Legacy Bronze Series Charger 6 SCHEMATICS 24 u 3 9 4 2 192 2 4 2 PEO 16 ADVESTSYISno0 mem ce 5311435 4JA 115 4 5 12 109 Fra IHSIH3 Y AHSLIYH OL et ABP APS Wed HOLLOW LAOS Ace ace eel Age ASF LTA of LOW LNOo ADF ig Douglas Legacy Bronze Series Charger HOLSISSY Aldd 0S AQP ZYE ADEPTE o d
3. a DC output at the correct voltage The charge curve is of the type Wa constant current The operation of the Douglas SILVER BRONZE Series chargers is managed by a microprocessor based electronic board of the latest generation Vi Time CHARGE CYCLE EQUAL Important features of the Douglas SILVER BRONZE series charge controller are Easy Programming by DIP switches Programmable Gassing Voltage Proportional Algorithm for charge time calculation Programmable Equalize System Automatic Pulsed amp Manual Automatic voltage controlled maintenance Wrong battery detection Independent safety timer Automatic data saving in case of black out of the mains Cyclical indication of V cell AMPS Ah returned time Cool down time counter Scrolling messages in plain text The control board monitors the entire charging curve and it incorporates several safety features The front panel of the charge controller contains the digital display 4 Digits the STOP button and the optional MANUAL EQUALIZE button Douglas Legacy Silver Series Charger Douglas Legacy Bronze Series Charger 4 INSTALLATION OF THE CHARGER Conditions of use e Operating temperature 41 F to 113 F 5 C to 45 C e Storage temperature 4 F to 140 F 20 C to 60 C Relative humidity less than 75 Douglas Legacy Silver Series Charger Douglas Legacy Bronze Series Charger POWER SYSTEM Nr a MAT T
4. 21 POWER SYSTEM POWER SYSTEM If a battery 15 not used for a long time example seasonal works holiday periods it should be kept well charged to avoid a reduction of performance therefore it s very important to charge the battery before leaving it in stock for more than 24 hours The self discharge process makes it harder to keep a battery charged when the time of stocking is longer weeks or months The REFRESH function is useful to keep the battery in perfect condition when it s not used for an indefinite time It is sufficient to leave the battery connected to the charger after the charge and the equalization is complete The Douglas SILVER BRONZE Series microprocessor will keep the battery voltage under control and will activate the charger automatically if the voltage drops below a predefined minimum threshold While the battery is monitored by the charger the display will show the scrolling message Volt Control If the voltage drops down below the minimum threshold the charger will give an extra charge cycle to keep the battery in perfect condition and the display will show the scrolling message Refresh Each Refresh charge terminates when the battery voltage reaches a predefined maximum threshold e NOTE With this voltage controlled refreshing system the battery will be kept in perfect condition for an undefined time without any risk of undercharge or overcharge If the battery is in ideal condition
5. 8 240 VAC 480 VAC HAE INPUT TENSION SETTING 440 4 4 4 2089 450 430 508 250 524 DISCONNECT MAIN SUPPLY BEFORE TO ADJUST VOLTAGE SETTINGS Oo 10 Doug RT von DOUGLAS POWER SYSTEM AC INPUT VOLTAGE SETTINGS POWER SYSTEM The POWER TRANSFORMER TAPS and the label with the list of the NOMINAL voltages that are available are located on the left side of the internal panel Depending on the charger model the number of available taps may range from 3 to 5 The following table refers to the 5 taps version only Single phase Three phase Three phase 208 240VAC 208 240 480VAC 600VAC 1 1x 250 VAC 3x 250 VAC 3x 500 VAC 3x 620 VAC 2 1x 240 VAC 3x 240 VAC 3x 490 VAC 3x 610 VAC 3 1x 224 VAC 3x 224 VAC 3x 480 VAC 3x 600 VAC 4 1x 208 VAC 3x 208 VAC 3x 460 VAC 3x 575 VAC 5 1x 200 VAC 3x 200 VAC 3x 440 VAC 3x 550 VAC Using an adequate AC voltmeter measure the value of the REAL AC input voltage available at the mounting location of the charger Identify which of the 5 NOMINAL voltage values is closest to the REAL measured value Example l single phase charger if the measured voltage is 212 VAC the transformer should be connected to the tap that corresponds to 208 VAC Example 2 for three phase charger if the measured voltage is 608 VAC the
6. Douglas Legacy Silver SERIES and Bronze SERIES Chargers USER S MANUAL Douglas Legacy Silver Series Charger Douglas Legacy Bronze Series Charger INDEX 1 INSTRUCTIONS AND GENERAL SHOCK PREVENTION BURN AND BODILY INJURY PREVENTION FIRE AND EXPLOSION PREVENTION ARCING AND BURNING OF CONNECTOR MEDICAL AND FIRST AID TREATMENT 2 Receipt and 3 DESCRIPTION OF THE CHARGER 4 INSTALLATION OF THE AC INPUT CONNECTIONPUT CONNECTION INPUT VOLTAGE SELECTION 208 240 480VAC INPUT VOLTAGE SETTINGS 5 HOW TO USE THE CHARGER PROGRAMMING OF THE GASSING POINT BATTERY CONNECTION VOLTAGE CHECK AND AUTOSTART CHARGE OPERATION SAFETY TIMER EMERGENCY STOP AUTOMATIC DATA SAVING BLOWN FUSE DETECTION AUTOMATIC CHARGE TERMINATION AUTOMATIC SHUTDOWN ON BATTERY DISCONNECTION EQUALIZE 8 REFRESH MODES MANUAL CHARGE TERMINATION 6 Schematics WARNINGS 4 A A 5 Inspection 6 7 CHARGER 8 9 9 9 11 13 13 16 17 18 18 19 19 20 20 23 24 7 spare parts list 27 Doug NR von DOUGLAS POWER SYSTEM POWER SYSTEM 1 SAFETY INSTRUCTIONS AND WARNINGS Before to start using your Douglas SILVER BRONZE Series battery charger please take the time to read these instructions carefully The owner s manual is an important part of the charger It s recommended to keep it in good condition for the
7. NL 11 NR A BLOCKS amp INPUT WIRES 208 240 480 SELECTION BOARD SR4803 ONLY TRANSFORMER TAPS The charger must be connected to the AC input using an adequate cable and plug with disconnect switch and fuses The AC input wires have to be connected to the TERMINAL BLOCKS FOR AC INPUT WIRES which are located on the right side of the internal panel just under the AC input contactor Make sure to tighten the terminal block screws with the proper torque and pull each wire separately in order to verify that they are mounted properly AC INPUT VOLTAGE SELECTION 208 240 480VAC The three phase models can be configured for 208 240 VAC or 480 VAC nominal input voltage This selection can be made with the 220 240 480 VAC SELECTION BOARD that is located at the center of the internal panel near the terminal blocks for the AC input wires e Disconnect the charger from main supply and battery POWER SYSTEM POWER SYSTEM Remove the plastic shielding over the 220 240 480 VAC SELECTION BOARD Remove the three metal bars Place the metal bars in the required position with reference to the following pictures Tighten the nuts with the proper torque Re attached the plastic shielding Connect the charger to main supply SELECTION BOARD SELECTION BOARD IN POSITION IN POSITION 20
8. UALIZE function will extend all the charge cycles by 4 hours and it s suitable to recover batteries that are lightly sulphated It can be enabled by moving the internal DIPSWITCH 1 to position ON see the description of the programmable dipswitches in the previous paragraphs The DAILY EQUALIZE function is DISABLED by default Since the DAILY EQUALIZE is a very intense equalize program and may tend to overcharge the battery it s recommended to limit it to short periods then to return to a normal equalize program It s also recommended to survey the operation of the charger and keep the temperature of the battery under precise control while the DAILY EQUALIZE function is enabled The AUTO EQUALIZE REFRESH function is totally managed by the microcontroller It can be enabled by moving the internal DIPSWITCH 4 to position ON see the description of the programmable dipswitches in the previous paragraphs The AUTOMATIC EQUALIZE REFRESH 15 ENABLED by default If the charge has been completed normally the charger will add 5 short additional charge cycles of 30 minutes with 14 hours and 30 minutes interval between each charge During the time interval between each equalization charge the display will show the scrolling message End Elapsed x x h When the equalization chargers are in progress the display will show the scrolling message equalization charge followed by the indication of the charge current
9. URY PREVENTION The battery produces very high currents when short circuited and will burn the skin severely if in contact with any metal conductor that is carrying this current Do not permit rings on fingers to come in contact with battery terminals or the cell connectors on top of the battery Battery acid is very corrosive Always wear correct eye and body protection when near batteries FIRE AND EXPLOSION PREVENTION When batteries are being recharged they generate hydrogen gas that is explosive in certain concentrations in air the flammability or explosive limits are 4 1 to 72 hydrogen in air Local codes may restrict hydrogen accumulation to much lower levels 1 2 Check with the appropriate authorities having jurisdiction for allowable levels of hydrogen concentration during charging The spark retarding vents help slow the rate of release of hydrogen but the escaping hydrogen may form an explosive atmosphere around the battery if ventilation is poor The ventilation system should be designed to provide an adequate amount of fresh air for the number of batteries being charged This 15 essential to prevent an explosion Always keep sparks flames burning cigarettes and other sources of ignition away from the battery recharging area Do not break live circuits at the terminals of batteries Do not lay tools or anything that is metallic on top of any battery ARCING AND BURNING OF CONNECTOR To prevent arcing and burning of the conn
10. YI HAMHOISM FHL HOLOVLNOO HOLSISSH FOR TY LOA H HOLLING HSMd LidLio 3050 297195 JS LION OHYOH 2 Sond 26 POWER SYSTEM PART NUMBER 2069401 2069402 2069403 2069404 2069405 2069406 2069407 2069408 2069409 2069410 2069411 2069412 2069413 2069414 2069415 2069416 2069417 2069418 2069419 2069420 2069421 7 SPARE PARTS LIST DESCRIPTION CONTROL BOARD same for all the models FUSE 100A UL CERAMIC FUSE 125A UL CERAMIC FUSE 160A UL CERAMIC FUSE 200A UL CERAMIC FUSE 225A UL CERAMIC FUSE 250A UL CERAMIC AC CONTACTOR BF12 24VCC AC CONTACTOR BF12 48VCC AC CONTACTOR BF18 24VCC AC CONTACTOR BF18 48VCC AC CONTACTOR BF18 60VCC CONTACTOR 25 48VCC CONTACTOR 25 60VCC RECTIFIER 100A RECTIFIER 120A RECTIFIER 140A RECTIFIER 160A RECTIFIER 180A RECTIFIER 200A RECTIFIER 300A POWER SYSTEM 2 DOUGLAS BATTERY Connect with a leader Douglas Battery Manufacturing Company 500 Battery Drive P O Box 12159 Winston Salem NC 27117 2159 1 800 211 3684 Visit our website www douglasbattery com M 0342 8 09 2009 Douglas Battery Manufacturing Co
11. al switches number 2 and number 3 are used for the programming of the gassing point 13 Douglas Legacy Bronze Series Charger NR POWER SYSTEM BATTERY CHARGFE POWER SYSTEM To modify the value follow these steps e Disconnect the charger from main supply and battery e Locate the dipswitches on the digital electronic board see next picture Set the dipswitches according with the following table and pictures e Connect the charger to main supply DIPSWITCHES 14 POWER SYSTEM EQUALIZE AUTOMATIC EVERYDAY EQUALIZE amp REFRESH Default OFF Default ON GASSING VOLTAGE PROGRAMMATION Default OFF ON PROGRAMMABLE GASSING VOLTAGE VALUES 2 38 Wcell 2 40 Wcell 2 45 Wcell 2 00 Wcell GASSING POINT 0 0 2 35 0 1 2 40 1 0 2 45 V cell 1 1 2 50 When a battery will be connected to charger programmed gassing voltage will be shown display during the startup sequence 15 POWER SYSTEM POWER SYSTEM BATTERY CONNECTION VOLTAGE CHECK AND AUTOSTART Connect the battery to the charger using an adequate plug When the battery is correctly connected the display turns on and shows the battery voltage If the battery voltage is lower than the minimum threshold of 1 62 V cell the charger doesn t start and the display will show the error message Voltage Low If the battery voltage is higher than the maximum thresh
12. ay HOLSISSH HINNA wo oO HAWHOISNYHL m HOLOFLNOO HOLSISSH LANHS JENIE FO HS141L03H 30010 05 802 4215 Tl DeSeT 2 1 doe Or MOTLIEOd0 7 Lidia 30010 ANd Hwa F3AILWOISN NJE OF HOILDA1S Ss 35 Lidl UHYOH dt 4 5 AILIGOd LNSALSNPo Sond A OBR OP we oc ov J3S HdJJHHL lt a 2 Douglas Legacy Silver Series Charger 25 Douglas Legacy Bronze Series Charger tats lt a 2 Douglas Legacy Silver Series Charger a 2 3 4 2 192 a lt 2 210 JENIE 2 JENIE AHALLYE OL 15 15 mem CHIESSHICH IHSIHIMT Adde 3 SALLWOSN ANALIWA 531945 AZNOUG 05802 OBR Ged T 1111500 99 dL aH 231 5 12 109 TH uyg 2 O4P DEE Lid WI oF JSTHd3S3HHl Low Aldd HIHN
13. e real voltage is lower for example 575 V the charging current will be significantly lower than the nominal value thus causing a longer time to reach the gassing voltage AUTOMATIC DATA SAVING e If during the charge or equalization one or more black outs of the mains happen the microprocessor automatically saves all the relevant information about the state of the charge While the input power is absent and the battery 15 connected to the charger the display will show the message Black Out e When the power supply will be available again the charger will re start automatically from the exact point of interruption and the charge will be normally completed 18 Douglas Legacy Silver Series Charger Douglas Legacy Bronze Series C WR S von DOUGLAS POWER SYSTEM POWER SYSTEM BLOWN FUSE DETECTION If the output fuse is blown or absent the display will show the message Fuse This message may appear also if the battery has been left discharged for long time causing the sulphation process on the plates AUTOMATIC CHARGE TERMINATION e When the charge is complete the charger shuts down and the display shows the scrolling message End Elapsed x x h The time indicated by the display 15 the time elapsed after the charge has been terminated This indication is useful when there are two or more forklift operated with FIFO First In First Out rotation when the user picks up a forklift he wi
14. e wire of the 3 phase line as this makes the equipment frame electrically HOT which can cause a fatal shock If a grounding conductor is part of the power supply cable be sure to connect it to a properly grounded switch box or building ground If not part of the supply cable use a separate grounding conductor Don t remove a ground prong from any plug Use correct mating receptacles Check ground for electrical continuity before using equipment The grounding conductor must be of a size equal to or larger than the size of the line conductors CHARGING LEADS Inspect leads often for damage to the insulation Replace or repair cracked or worn leads immediately Use leads having sufficient capacity to carry the operating current without overheating BATTERY TERMINALS Do not touch battery terminals while equipment is operating Douglas Legacy Silver Series Charger m DOUGLAS POWER SYSTEM POWER SYSTEM ERY CHARGER SERVICE AND MAINTENANCE Shut OFF all power at the disconnect switch or line breaker BEFORE inspecting adjusting or servicing the equipment Lock switch OPEN or remove line fuses so that the power cannot be turned ON accidentally Disconnect power to equipment if it is to be left unattended or out of service Disconnect battery from charger Keep inside parts clean and dry Dirt and or moisture can cause insulation failure This failure can result in high voltage at the charger output BURN AND BODILY INJ
15. ector contacts be sure the charger is OFF before connecting or disconnecting the battery The ammeter should NOT indicate current flow MEDICAL AND FIRST AID TREATMENT First aid facilities and a qualified first aid person should be available for each shift for immediate treatment of electrical shock victims EMERGENCY FIRST AID Call physician and ambulance immediately and use First Aid techniques recommended by the American Red Cross In case of acid in the eyes flush very well with clean water and obtain professional medical attention immediately POWER SYSTEM 2 RECEIPT AND INSPECTION Upon receipt of the charger the information on the shipping carton should be checked against your order Any discrepancies should be reported to the nearest authorized representative Whenever possible move the charger to the installation site before uncrating All chargers can be handled with a lift truck Remove the carton and inspect the charger for damage If there is any damage save carton for inspection and notify the carrier immediately Check nameplate and labels against your order and specifications Any discrepancies should be reported immediately to the nearest authorized Douglas Battery representative Doug NR von DOUGLAS POWER SYSTEM POWER SYSTEM 3 DESCRIPTION OF THE CHARGER Douglas SILVER BRONZE Series battery chargers have been designed to charge Lead Acid batteries These units convert the AC input to
16. lifetime of the charger It should be kept in a dry and clean place always available to the users To indicate important instructions the following blocks are used throughout this manual GENERAL Battery charging products can cause serious injury or death or damage to other equipment or property if the operator does not strictly observe all safety rules and take precautionary actions Safe practices must be learned through study and training before using this equipment Only qualified personnel should install use or service this equipment SHOCK PREVENTION Bare conductors or terminals in the output circuit or ungrounded electrically live equipments can fatally shock a person To protect against shock have competent electrician verify that the equipment is adequately grounded and learn what terminals and parts are electrically HOT The body s electrical resistance is decreased when wet permitting dangerous current to flow through the body Do not work in damp area without being extremely careful Stand on dry rubber mat or dry wood and use insulating gloves when dampness or sweat cannot be avoided Keep clothing dry INSTALLATION AND GROUNDING A power disconnect switch must be located at the equipment Check the data label for voltage and phase requirements If only 3 phase power is available connect single phase equipment to ONLY TWO WIRES of the 3 phase line DO NOT CONNECT the equipment grounding conductor to the third liv
17. ll always chose the one with longest time elapsed after charge termination The final values of Voltage cell time of charge and capacity charged remain stored memory If the red STOP pushbutton 15 pressed the display will show these values in sequence 19 POWER SYSTEM POWER SYSTEM AUTOMATIC SHUTDOWN ON BATTERY DISCONNECTION If the battery is disconnected while the charge is in progress the Douglas SILVER BRONZE Series switches off automatically EQUALIZE amp REFRESH MODES Douglas SILVER BRONZE Series chargers have a complete set of programmable equalize amp refresh functions MANUAL EQUALIZE 4 hours extension of the charge time selected by user DAILY EQUALIZE 4 hours extension of the charge time everyday AUTO EQUALIZE amp REFRESH Weekly equalize cycle long term battery refresh The MANUAL EQUALIZE function is intended for the users that prefer to manage the equalization of the batteries personally It will extend the time of the charge cycle by 4 hours and it can be enabled by pushing the appropriate button located on the right side of the front panel during the first minutes of charge The display will add the message Eq On to the cyclical visualization of the charge parameters and the charge will proceed normally Once the manual equalize has been selected the only way to deselect it is to disconnect and re connect the battery 20 POWER SYSTEM POWER SYSTEM The DAILY EQ
18. old of 2 60 V cell the charger doesn t start and the display will show the flashing error message Voltage High If the voltage of the battery is between the minimum and maximum thresholds the charger will wait for 3 seconds before to start charging while the display will show the programmed gassing voltage If during the charge the voltage of the battery exceeds the maximum threshold of 2 80 V cell the charger shuts down automatically and the error message Voltage High will appear on the display 16 Douglas Legacy Silver Series Charger SR DOUGLAS POWER SYSTEM POWER SYSTEM CHARGE OPERATION When the charge 1s started the digital display will start showing the following parameters Voltage per cell of the battery U Volt e Charge current A Ampere Capacity charged Time of charge h Hours During all the charge cycle these parameters are displayed in sequence as indicated in the picture The letter U A C h indicates which parameter being 15 displayed To display the time the charger uses this format HOURS MINUTE DECADES Examples Time of charge 3h 30minutes Displayed 3 3h Time of charge 7h 50minutes Displayed 7 5h The charge current follows the Wa curve as described in the norm DIN 41774 while the charge parameters continue to be shown on the digital display Voltage Current 2 65 Wcell 1000 Voltage 2 40 Wcell
19. transformer should be connected to the tap that corresponds to 610 VAC For the single phase units the wires to be moved are the TWO that are connected to the AC contactor marked with the letter For the three phase units the wires to be moved are the THREE that are connected to the AC contactors marked with the letters and 11 Douglas Legacy Silver Series Charger Douglas Legacy Bronze Series Charger Single phase units TERMINAL BLOCKS POWER FOR INPUT TRANSFORMER TAPS CABLE POWER TERMINAL TRANSFORMER BLOCKS FOR TAP AC INPUT CABLE OPERATING INSTRUCTIONS DOUGLAS BATTERY Connect with a leader U Gell Voltage Volts A Current h Time hm C Capacity Ah DOUGLAS LEGAC POWER SYSTEM Cod 02031280 PROGRAMMING OF THE GASSING POINT ATTENTION The proper programming of the gassing point is important for the correct operation of the Douglas Silver Bronze Series chargers Only qualified users should modify these settings The possibility to program the gassing point may help the user to adjust the charging curve to the requirements of the battery during all its life The default value is 2 40 Volt cell This value can be modified by moving two dipswitches that are located on the board near the microprocessor and the black heat sink see next picture The dipswitch unit has 4 switches the two centr
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