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GSCR Charger I&O Manual Single Phase

1. 4 8 Normal Performan e mn RII e eee re E Re eb iicet relie 4 9 Description ot saat ste ows east leon ec ELE EE ot we 5 Ee RR EE e E 5 Rectifier Secuon u rtr 5 Control Module 5 d Filter EE wa E SECTION Ill TROUBLESHOOTING 1 CAUTION Notce eet tin acess caine ret et pt oe 6 2 Troubleshooting Procedure ertet ENEE 6 3 i Vestine OF Components EEN 6 External Circuit Wiring uen Deer e esti e eee dee eg 6 bs Power Pransformer 4 m Unus mA nae eS 7 c Circuit Breakers CB de Lee exe aede rasa edes re 7 d Surge Suppressors 551 SS2 eedem asas usu 7 e cRecutier Diodes SCRI SUR2 reet eter tette de Eege 8 I SCR Diodes SCRI s ee e ER 8 g Control Module u Ee eee xU eee e OR e RE I ena bete eO Suq 9 Current Sensing Resistor GI 9 15 DC M2 asas eee e eec eere OR ERU E EE UR ERR EYE ER EN IE e E Ee 9 DC Ammeter M l Z uuu yy ee tette de 10 m Filter Capacitors TE 10 B Internal te c oe eee utr eI DM 10 SECTION IV SYSTEM ADJUSTMENTS 1 Voltage Adjustments and Response ener tnnt as i nennen 11 Float E
2. 19 15 Current Limit Alarm Relay 137 EE 20 16 Cabimnet Heater Strips 10145 a uuu eret e ERRARE LEE HARE HE 20 17 High and Low AC Voltage Alarm Relays 10155 20 18 Over Temperature Alarm Relay 0439 20 19 Combined Alarm Status Monitor CASM PC Board Assembly EJ0837 21 SECTION VI COMPONENT DESCRIPTIONS 1 Component Description SCR SCRF Series Battery Charger Mainframe Single Phase Input 22 23 2 Component Description SCR SCRF Series Battery Charger Options Single Phase Three Phase 24 26 SECTION VII TABLES DIAGRAMS FIGURES Table A Troubleshooting Chart tee a e a arti 27 Diagram SCR SCRF Series Battery Charger Mainframe Schematic Input JE5076 00 28 Figure 1 Component Layout for Control Module SCR SCRF Battery Charger GK0058 29 Diagram Schematic Single Phase Control Module 0573 30 Figure 2 Typical Waveforms of Single Phase Control Module PC Board 31 Diagram Transformer T1 Schematics Single Phase SCR SCRF Battery Charger EH0552 00 32 Diagram Remote Alarm Terminal Block Legend for TB3 and TB15 EH0423 00 33 SECTION VIII OPTION SCHEMATICS Option Page No Option Page No Optio
3. OTHER ALARMS 85 7 NOTES L THE COMMON ALARI CELAY MAY ACTIVATED BY AMY DELAY wire WE CHARGER RELAY USES ALAEM RELAY LE ACAL LE USED THE COMMON ALARM RELAY i ERIT E utem A 1 ksz T 2 d 3 1725 ense rum um STEET Gar ee 45 Option Schematics CONTACTS SHOWN IM NON AGARIA COMMON ALARM RELAY W SUZZER 2 tered Et s rur SC KREE RRE er n s CONTACTE IN MON non d Aur mar ACTIVATED 47 THE BATTERY n Of VOLTAGE OF DISCHARGE ALARM RELAY E INDICATING LIGHTS 46 SCR SCRF Series Battery Charger cae 1 Q OF HEATERS 120 VAC INPUT SUPPLIED NOTES UTR RED THO FoR i WEATS TITLE CABINET HEATER STRIPS 3 Taser ue 5 er rary SS Ss pma pene om ges pepe 5 4 ti m DETECTOR BOMED ANG ge ALARM awtefr
4. H3OHVHO AH311V8 di 31ndOW 120 6 3 1782 1 5 LNOAVT LN3NOdWOO i dzwog bilt 1810 32V sip podio suns 3 21217 5122 ba ppumivisrin NINA talon Agviassy 3309 20 9900 X THe 10 9000 NOIGIA3U WV10 NOILVIUVA NO 3unoi3 e H M CIE 29 Section VII avos 12vua Carter FINGON OHINOO 25 ASVHd 0 OLLVA3H2S 37411 4809 10 9900 NO 10 9900 HD NO aaen 142 30 FIGURE 2 TYPICAL WAVEFORMS OF SINGLE PHASE CONTROL TRIGGER BOARD GK0058 XX See Section IIL 3 g DEPENDS CHARGER VOLTAGE RATING 13g 00 c 50H3 3WVN3 113 00 c8850H3 SIN ON 00 550 9 3393VH2 A3311V8 305 895 3SVHd 37DNIS dws dav SSINVAaS DL S3HONI NI SNOTSNAWIO 03103 3SIMB3HID SSS Mi 20521 839 ON 31 0 N23 EJ 85111 0 0 v8LIOI SOILVW3SHOS CIL SSWADSSNVAL 5862 1 Wd 971411 NUTIL23f 8d SEI 58 190 021 3NUN IAWN JVA 1 41 0 ino xnv SX IX EUR JOA 1 91 0
5. SNBILJ3NND3 890 053 Cl Lvt SH IH E 2 SIE SH SH SNUILJ3NND3 JVA 021 ex ABVONO3S H 09 05 CA IA JOA ind xnv SX IX SNBILJ3NND3 1 310N 335 JOA 9 802 1ndin JAS SH Ovc OEc SH vH 2H 022 SH IH EH IH SH ZH 1 01 SH 5 1123 02 JVA 9 NI ex ABVONO23S P SH Adv WIad 021 Le 686211 SX IX 1 SH UNI Sa3WanJsNval Iv NO dvl JHL S33v d3d INANI 903 3WVS 3Hl LNdNI 80 304 SNOILISNNOD Aa3VWISd 1 20521 JVA UI ANV ino xnv SX IX ONT JOA MI SNUILJ3NNQJ ASVOND23S VH EH O8b 097 VH CH 15144 0 17 SH EH VH Ovc 0Ec SH CH GH 022 002 013 IA INON JVA SNOILJJNNOI AaVWIsSd gel 3 SH IH SH IH SH IH SH IH SH IH 3NI1 cx AaVONOIAS 9x e
6. O3NISWDUJ bev 1 55 0694 vIOON3 48 DC OUTPUT VOLTAGE VDOC OUTPUT VOLTAGE vs TEMPERATURE TYP gt LEAD ACIO BATTERIES PERCENT OF 25 C VALUE 20 TEMPERATURE 40 CALIBRATION PROCEDURE 1 PERFORM ALL OTHER FINAL TESTS BEFORE FINAL ADJUSTMENT OF FLOAT AND EQUALIZE VOLTAGES 2 ADJUST FLOAT VOLTAGE AT 50 LOAD AND NOMINAL LINE TO VALLE SPECIFIED ON ORDER DR LISTED IN SPEC 3 SET CHARGER TO EQUALIZE MODE AND ADJUST EQUALIZE VOLTAGE TO VALUE SPECIFIED ON ORDER OR LISTED IN SPEC D 4 RETURN CHARGER FLOAT MODE MEASURE AND RECDRD AMBIENT TEMPERATURE IN DEGREES CELCIUS 2 REFER TO THE APPROPRIATE VOLTAGE TEMPERATURE CURVE ADJUST THE FLOAT VOLTAGE AT 50 LOAD AND NOMINAL LINE TO THE PROPER VALUE FOR THE AMBIENT TEMPERATURE 3 070293 051393 THIRD ANGLE PROJECTION SC R3 1 CW FLOAT ADJUSTMENT je NOMINAL COMPONENT VALUES OUTPUT c VDC 12 24 48 6 8 38 R7 11 22 40 R8 25 C 10 0 30 100 100 200 0 0 0 NOTES THIS NETWORK REPLACES R2 IN VOLTAGE DIVIDER THE FEEOBACK AVERAGE TEMPERATURE COEFICIENT 2 5 nV V C 3 3 nV CELL F 2 4 VPC SEE SHEET 2 OF 2 FOR MECHANICAL ASSEMBLY AND WIRING INSTRUCTIONS 010890 pr 052293 101088 wKB WKB 062893 TITLE SC
7. Option Schematics 7850 CURRENT LIMIT CURRENT UMIT ALARM DC Souen 455 A S OMAE AT Pez HOES 1 ADJUST ga THAT Ti Y eowracs SAM AN ALARM RELAY KZ 5 ACTIVAYED AT CURRENT initi CURRENT LIMIT r PHASE BEES WEE ROREM KEE DL LL 2l ee 4 mis pee mem o uu eed we ees Tree wreoved aspas amis 644 785 CURRENT LIMIT PC ASSY AM CONTE MORRE AT MONS 1 ADJUST o THAT CONTACTS D WOM ALARI ALARM K24 M ACTIVATED AT CURRENT them Eu pel s TT L1 pee prenne eaa 62 9137 wan of ales pem mv sp aet Lee a e 44 SCR SCRF Series Battery Charger arv 4 USED METERS RATED OVE 50 ADC 2 THREE TERMIMAL TR REPLACES THE STANDARDO Tey 122 SHOWN SCHEMATIC TIME ZERO CENTER AMMETER FCP um BATTERY LOAQ MONITORING Gees Ee ee cl BE ES BEC eres So ee CONTACTS SHOWN IN NON MARM
8. EJ 0895 0 1 ACCURACY 3 5in LED DIGITAL DC METERS SURGE WITHSTAND FILTER SWC PER IEEE 472 CUSTOM DC METERS kAIC AC kAIC DC CIRCUIT BREAKERS STANDARD COLOR CODED PVC WIRING 200 AC FUSING 1PH 2 POLE 3PH 3 POLE CB0002 SWITCHBOARD INSULATION SYS CODED WIRING AC DC CET BKR AUX CONTACTS EJ 0085 AC POWER FAILURE ALARM amp INDICATOR LIGHTS COPPER GROUND BUS BAR w LUG S CUSTOM AC FAILURE ALARM FUNGUS PROOFING PER 0004 00 EJ 0837 1 CASM PC BOARD w ONE 1 FORM C CONTACTS SPECIAL NEMA CABINET TYPE EJ 0837 1 CASM PC BOARD w TWO 2 FORM C CONTACTS in RELAY RACK MOUNTING ASSY EJ 0083 7 HIGH LOW DC VOLTAGE ALARM amp IND LIGHTS SPECIAL FLOOR WALL MOUNTING ASSY EJ 0127 1 CHARGER FAILURE ALARM NO Adc amp IND LIGHTS CUSTOM TAG PLATE 5 HLVA CFA amp IND LIGHTS EJ 0083 amp EJ 0127 ENGRAVED FUNCTIONAL NAMEPLATES EJ 0094 4 GND DET SWITCH FOR DC VOLTMETER INDICATION EJ 5007 WHITE CHARACTERS ON BLACK BACKGROUND EJ 0089 5 GND DET IND LIGHTS w GROUND amp LAMP TEST EJ 5007 BLACK CHARACTERS ON WHITE BACKGROUND EJ 0086 4 GND DET RELAYS w RESET SWITCH amp IND LIGHTS PARTS DATA PACKAGE PER MFG SWITCHBOARD COPY OF TEST DATA PER NEMA PE5 1985 L EJ 0592 1 HIGH DC VOLTAGE CHARGER SHUTDOWN EXTRA INSTRUCTION MANUALS EJ0141 COMMON ALARM RELAY CONTACTS CUSTOM DRAWING PACKAGE CAD DISK EJ0141 COMMON ALARM RELAY CONTACTS w BUZZER CERTIFIED TEST DATA PER NEMA PE5 1985 EJ 0967 COMMON ALARM BUZZER FOR CASM PC BOARD CERTIFI
9. JO 5195 OML Q3I ddfls SI 5191 1 NO HLIM 539 9 3 80123 02 2105 1151534 20 2 Asc vS O 09195 SLIVINOI NOTLIONOD Wav lv NUN NI NAUHS SL2VINOJ 5181 S310N 40133 9 2105 v 39 JV NUII23130 JOVLIOA MD I HSIH DND 30 01 30 1 31DN 33S mu oN ON 2 UN JN UN JN ON 2 UN 2 SLIVLNOI WdV V a3W lsr 26191 15151117 auo CASVHd 1 0824 1919 IV 21 105 1 CASVHd CA 11 21 1 2 DAT JUAH 31UN 335 26181 WNOTLdO 825181 LNVONNOSa EA OA 3SN3S 9 SISSVHJ 5 COUR BE 130 059 SA vA ea 7 E 5 9 L 8 B 0 OI 18 510 I 39v1 DA 1531 1 OZMS VI v CBS or 01 ITVS OESO LMS 318 510 w 130 ON IESO 130 46 2 130 OND ZESO 52 GE 1 6250 JJV LIDA 9 110 8250 20 H9IH 39v1 DA 39v1 DA 20 2250 H9IH sts Ead A 209 U Dn 20 9250 50 m ee wld 581 lt AOLINOW SNLVLS Wav
10. Once the system is balanced the two chargers will equally share any changes in the load If either charger is shut down or becomes inoperative the other will assume the total load up to the point where its current limit circuit operates It is possible to operate each charger independently by setting the LOAD SHARE ON OFF switch SW10 to the OFF position 18 12 ZERO CENTER DC AMMETER FOR BATTERY LOAD MONITORING EJ0138 Purpose and Description The zero center dc ammeter M7 lies within the negative return lead of the battery A current sensing shunt SH2 is provided when the range is greater than 50 Amperes M7 indicates the direction and amount of the battery current Indication on the ammeter is to the right of center when the charger is charging the battery and to the left when the battery is furnishing current to the load discharging 13 HIGH DC VOLTAGE CHARGER SHUTDOWN ALARM RELAY W IND LIGHT EJ0592 Purpose The High DC Voltage Shutdown option functionally disables and locks out the battery charger whenever the output DC voltage exceeds the preset upper limit of charging voltage This option is designed to protect the batteries and or load from an over charge or over voltage condition In the case of parallel redundant chargers with charger shutdown this option selectively detects and shuts down the faulty charger rectifier only The option provides a front panel indicating light and alarm contacts wired to TB3 terminals 53
11. and the previous checks in Table on page 27 VOLTAGE ADJUST INEFFECTIVE have been made without locating the fault switch the AC breaker CB1 to OFF Switch the DC breaker CB2 to OFF or disconnect the battery and proceed as follows Check the battery with a portable voltmeter of one percent accuracy to insure that it is not higher than the rated float voltage For proper operation the open circuit voltage of the battery must be slightly lower than the rated float voltage If the battery voltage is higher than the float voltage range check the number and type of cells connected to the charger making certain the proper number and type of cells are not exceeded Close the DC breaker CB2 or connect charger to battery Close the AC breaker If battery voltage is now within the float voltage range or is slightly lower and some output current exists proceed with Section IV 1 a 2 below If the battery voltage is slightly lower or within the float voltage range switch the charger to the equalize mode If still no output appears or the potentiometer R5 does not produce a rise from the previous value turn equalize charge control fully clockwise and if still no voltage rise is obtained or no output appears proceed again with the check sequence in Table A trouble shooting chart If the voltage increased or output was obtained when the charger switched to evaluate proceed with the voltage adjustments a Float Adjustment 1 S
12. with front panel voltmeter within 2 and must be correct values for Float your battery If the charger is using a temperature compensation probe Vdc see the curve in Section VII of user s manual to determine correct Equalize battery voltage Vdc Measure at battery terminals using ac voltmeter set to milliVolts scale Check against specification listed on charger s Data Nameplate mVac Amps Equalize OK Verify voltage setting per battery manufacturer recommendations Utilize float and equalize potentiometers to make any required Float OK adjustments See Section IV of user s manual Equalize OK Close and latch front panel door L1 OK Restore charger to normal operation OOK See Section V of SCR SCRF Series battery charger user s manual for L1 HVDC OK calibration of alarms LVDC OK See service instruction JD0036 00 for CASM alarm adjustments Test integrity of LEDs by pressing lamp test button on front panel O OK Internal temperature compensation network wiring See instruction JA5022 00 and Section VII of user s manual Temperature compensation remote probe See instruction JA5022 00 and Section VII of user s manual See supplied Parts Data Package report or standard replacement parts table for battery charger manufacturer s part number of optional dc filtering electrolytic capacitors C1 C2 Order and replace capacitors GNB Industrial Power The Indust
13. 121 00 PART No SCHEMATIC DC SwC FILTER CB2 XXA DC SwC FILTER COMPONENTS CI c2 C3 16 OTHER COMPONENTS PART DF CHARGER MAINFRAME CONNECTION DIAGRAM DC SwC FILTER DC CIRCUIT SWC FILTER 2 BREAKER 32 _ JEO121 00 FILENAME 0121 00 1 SWC FILTER 2 DC DLITPLIT 082092 THIRD 6 ANGLE WAH PROJECTION 110890 120403 Ui WKB 295 BY MCR 070188 SCR SCRF SERIES BATTERY CHARGER FILTER OPTION THREE PHASE INPUT WAH APPROVED DRAWING No Yo QOOR PANEL GROUNDS 082685 NZA UNLESS OTHERWISE DIMENSIONS ARE IN INCHES TOLERANCES ARE JEO126 00 A PART No 52 JE0126 00 FILENAME JEO1285 00 PRTJ ELECTRICAL RATINGS AND REPLACEMENT PARTS SCR SCRF Series Battery Charger Single Phase Mainframe PLEASE CONTACT YOUR SALES REPRESENTATIVE FOR DATA ON MODELS NOT LISTED 120Vac 2 6 3 8 6 0 7 5 5 7 8 8 16 26 39 59 bean V 240 1 3 1 9 3 0 3 8 2 8 4 4 7 4 13 19 480Vac m 9 1 5 1 9 1 4 2 2 4 7 6 5 9 7 SYMBOL DESCRIPTION MANUFACTURER S PART No C1 C2 FILTER CAPACITOR RP0019 01 SNUBBER CAPACITOR RP0023 00 AC INPUT 120Vac RE0015 03 RE0015 03 RE0015 04 RE0015 04 RE0015 04 RE0015 04 RE0015 06 RE0015 09 RE0015 12 CB1 CIRCUIT BREAKER 208 240Vac 0015 03 RE0015 03 015 03 RE0015 04 RE0015 03 RE0015 03 RE0015 04 RE0015 0
14. 54 amp 55 Description The high DC voltage detector PC Board assembly A13 is an HVA alarm module which closes a circuit on alarm and energizes the shutdown relay K21 The shutdown relay disconnects the Control Module A1 from its AC supply thus removing the SCR trigger signals to the rectifier This disables the charger and output current goes to zero After shutdown the circuit must be manually reset before restarting the charger A push button CHARGER RESET momentary switch SW14 is provided on the front panel for this purpose The high DC voltage detector circuit has a built in several second time delay to prevent charger shutdown due to transient voltage surges Adjustment for the shutdown circuit is provided by a potentiometer R4 on the A13 assembly It can be field adjusted using the same procedure as for the HVA portion of the EJ0083 option on page 14 The factory preset thresholds for HDCV charger shutdown are as follows unless otherwise specified 2 40 volts cell for LEAD ACID 1 65 volts cell for NICKEL CADMIUM The above set points are the same as the High DC Voltage Alarm HVA If HVA and High DC Voltage Shutdown options are ordered on the same charger the shutdown thresholds are set as follows unless otherwise specified 2 45 volts cell for LEAD ACID 1 70 volts cell for NICKEL CADMIUM 14 END OF DISCHARGE ALARM RELAY EJ0143 WITH OPTIONAL INDICATOR LIGHT Purpose and Description The End of Discharge alarm opt
15. DESCRIPTION CONTROL MODULE PC BOARD UNFILTERED CONTROL MODULE PC BOARD FILTERED ELIMINATOR SUPPRESSION CAPACITOR 24 48 130 VDC SUPPRESSION CAPACITOR 260 VDC AC ON INDICATOR XA FLOAT ADJUSTMENT POTENTIOMETER TO ORDER PARTS PLEASE CONTACT YOUR SALES REPRESENTATIVE PLEASE ORDER BY QUANTITY PART NUMBER AND CIRCUIT SYMBOL FROM TABLES ABOVE HAVE YOUR BATTERY CHARGER MODEL NUMBER AND SERIAL NUMBER AVAILABLE 56 REPLACEMENT PARTS SCR SCRF Series Battery Charger Options 1PH 3PH BATTERY CHARGER NOMINAL OUTPUT 12 Vdc 24 Vdc 48 Vdc 130 Vdc 260 Vdc OPTION CIRCUIT NUMBER SYMBOL DESCRIPTION MANUFACTURER S PART NO TO ORDER PARTS PLEASE CONTACT YOUR SALES REPRESENTATIVE PLEASE ORDER BY QUANTITY PART NUMBER AND CIRCUIT SYMBOL FROM TABLES ABOVE HAVE YOUR BATTERY CHARGER MODEL NUMBER AND SERIAL NUMBER AVAILABLE 57 EJ0120 EJ0121 EJ0123 EJ0127 EJ0131 EJ0133 REPLACEMENT PARTS SCR SCRF Series Battery Charger Options 1PH 3PH BATTERY CHARGER NOMINAL OUTPUT 12 vac 24 Vdc 48 Vdc 130Vdc 260 OPTION CIRCUIT NUMBER SYMBOL R71 Ballast Resistor for A5 MANUFACTURER S PART NO RJ0007 52 RJ0035 34 RJ0022 04 0023 04 25 40 Adc 50 60 SH3 DC Current Shunt 75 Adc 100 150 Adc 175 250 Adc 300 400 Adc 6 20 Adc 25 30 Adc 35 60 Adc DC Output Terminal EJ0617 00 0006 01 0006 01 0006 01 0012 00 0012 00 0012 0
16. Heater Strip s High Low AC Voltage Alarm PC Board w Relays AC Detector PC Board Socket for Low AC Voltage Indicator Light High AC Voltage Indicator Light Voltage Dropping Resistor Voltage Dropping Resistor Thermostat Over Temperature Alarm Relay Over Temperature Buzzer Buzzer ON OFF Switch High DC Voltage Detector PC Board Socket for A13 Charger Shutdown Alarm Relay Charger Shutdown Indicator Light Charger Reset Switch Voltage Dropping Resistor Combined Alarm Status Monitor CASM PC Board Socket for A24 High DC Voltage Alarm LED Low DC Voltage Alarm LED High AC Voltage Alarm LED Low AC Voltage Alarm LED Charger Failure Alarm LED Positive Ground Detection LED Negative Ground Detection LED Voltage Dropping Resistor Voltage Dropping Resistor Voltage Dropping Resistor Voltage Dropping Resistor Voltage Dropping Resistor Voltage Dropping Resistor Lamp Test Switch Remote Alarm Terminal Block s B indicates recommended operating spare part 26 SECTION VII YOLONGNI dal 1ld Harl ld YSLAWWY 20 ONILSAL LN3NOdIWOO SNILOOHS 29700 HOH NOLLO3S OL H3d3H ONIHIM TVNWHA LINI S9NILOOHS HO HOLIMS LYON V 318V H3 LJWINV HO LNNHS isnrav INauufno V 15 SINHOJ SAVM SuosSsauddfis ADVLIOA jo
17. a on page 6 if no AC voltage is indicated Check the wiring connections to ascertain that unit has the proper primary tap connections for the line voltage indicated Turn on the AC circuit breaker Check that the voltage at the primary is the same as that of the line If not or the wiring between it and is open In this case proceed with checks under Section III 2 c 1 below 2 Using an AC voltmeter check AC secondary voltage on the main transformer T1 See Table B below for expected voltage values If secondary voltages are much less than indicated then either is at fault or the power regulating devices SCR1 or SCR2 are faulty TABLE B SECONDARY VOLTAGE OF TRANSFORMER T1 Expected Voltages AC Leads or Locations Approximately 2 times float voltage 1 to X5 120 Vac 1 to Y2 NOTE The X of Table B voltages should be measured as they terminate on the full wave bridge components Where power rectifier fuses are employed in the larger power chargers see custom diagrams and parts list these fuses should also be checked and replaced if unserviceable c Circuit Breakers CB1 CB2 1 AC Circuit Breaker CB1 When an AC voltmeter of suitable range is connected between leads L1 L2 and indicates line voltage but does not indicate when connected to the output terminals of when closed the circuit breaker is probably defective Deenergize the AC supply to the charger and remove the leads to the
18. Board assembly A24 TB15 AUX is supplied if the customer s remote alarm wiring SEE ddp ebe requirements exceed the specifications of the standard 23 4 5 87 e o pop papi 1516 7 8 terminal block TB15 Contacts 1 18 TB15 AUX are CNC NO C NC NO C NC NU C NC M C NC ND C NC ND HIGH DC LDW DC GROUND 1 1 CHARGER COMMON wired directly to contacts 1 18 of 15 on A24 TBI5 VOLTAGE VOLTAGE DETECT FAILURE ALARM AUX terminal blocks feature 6 32 binder head screw terminals and will accept 22 16 AWG wire CUSTOMER ALARM CONTACTS If you have a grounded battery disable the Ground Detection Alarm circuit by moving jumper J7 to pins 1 2 and by removing wire 836 GR from R107 to CHASSIS GROUND see EJ0837 XX Putting J7 on pins 2 3 enables the Ground Detection Alarm circuit 21 SECTION VI COMPONENT DESCRIPTION SCR SCRF SERIES BATTERY CHARGER SINGLE PHASE MAIN FRAME Circuit Symbol Note 2 1 1 501 C2 XC2 C6 CB2 CRI CR2 051 Fl 2 2 11 L2 MI M2 HER Component Description Single Phase Input Main Control Module PC Board Holder for Control Module PC Board A1 Socket for Control Module PC Board A1 Filter Capacitor SCRF models only Filter Capacitor Bracket SCRF models only Battery Eliminator Filter Capacitor SCRF E models only Battery
19. EJ0138 4 0 CENTER DC AMMETER FOR BATT LOAD MONITOR 7 208 240 480 Vac 60 Hz INPUT EJ0143 4 END OF DISCHARGE ALARM amp INDICATOR LIGHT 0 Vac Hz INPUT CUSTOM EJ0145 5 CABINET HEATER STRIPS F REDUNDANT DC FUSE PROTECTION 1 2 EJ0155 1 VOLTAGE ALARM 6 INDICATOR LIGHTS B STANDARD DC CIRCUIT BREAKER F1 CB2 EJ0439 1 OVER TEMPERATURE ALARM w BUZZER IND C CUSTOM DC PROTECTION EJ0615 1 DC POWER ON INDICATOR LIGHT 1 EJ 0450 MANUAL FLOAT EQUALIZE SWITCH 082 1 INTERNAL TEMPERATURE COMPENSATION PB NICD 2 EJ 0093 MANUAL FLOAT EQUALIZE SWITCH amp IND LIGHTS EJ1123 2 4 20 TRANSDUCER Adc Vdc 3 EJ 0097 0 72 HR MANUAL EQUALIZE TIMER EJ1165 1 HIGH AC RIPPLE ALARM INDICATOR LIGHT 4 EJ 0869 MAN EQUALIZE TIMER w F E SWITCH amp IND LIGHTS EJ1234 1 AC INPUT LIGHTNING ARRESTOR 1 3PH 5 EJ0131 AC FAILURE AUTO EQUALIZE TIMER amp IND LIGHTS EJ1247 1 VENT FAN CONTROL RELAY amp IND FROM EQUALIZE 6 EJ 0096 0 72 HR MANUAL EQUALIZE TIMER amp IND LIGHTS 1303 1 BATTERY OPEN ALARM amp IND LIGHT 0 CUSTOM EQUALIZATION EJ1398 1 EXTERNAL TEMP COMPENSATION PROBE PB NICD 2 ACCURACY 3 5in ANALOG DC METERS EJ5005 1 0 72 MAN EQ TIMER amp IND w REMOTE EQ 1 ACCURACY 3 5in ANALOG DC METERS EJ5012 1 0 999 HR MAN EQUALIZE TIMER w SW amp IND LIGHTS 1 ACCURACY 4 5in SWITCHBOARD DC METERS EJ5087 1 2 AUXILIARY CONTACTS TB15 AUX ON CASM 0837
20. Eliminator Filter Capacitor Bracket SCRF E models only Snubber Capacitor EMI Suppression Capacitor AC Input Circuit Breaker DC Output Circuit Breaker Polarity Diode Blocking Diode AC ON Indicator Light Main DC Fuse Fuse Holder for F1 Redundant DC Fuse not supplied if dc breaker option is selected Fuse Holder for F2 Main Inductor Filter Inductor SCRF models only DC Output Ammeter DC Output Voltmeter gt w 22 Circuit Symbol Note 2 R2 R3 R4 R5 SCRI SCR2 SHI 551 552 SWI TBI TB2 TB3 5 15 NOTES SE Component Description Bleeder Feedback Resistor Voltage Divider Resistor Float Adjustment Potentiometer Voltage Divider Resistor Equalize Adjustment Potentiometer Silicon Controlled Rectifier Diode Module Silicon Controlled Rectifier Diode Module DC Ammeter Shunt supplied with 50 Adc nominal dc output or greater DC Output Surge Suppressor AC Input Surge Suppressor Standard Manual Float Equalize Switch not supplied when other equalize option provided Power Isolation Transformer AC Input Terminal Block DC Output Terminal Block Remote Alarm Terminal Block supplied as required with alarm relay options Internal Signal Connection Terminal Block Remote Alarm Terminal Block supplied as required with EJ0837 CASM option Wire Harness Cabinet Heat Sink s 1 A ind
21. PART OF PART OF X FUSEHOLDER PANEL RE0013 00 013 00 RE0013 00 EI0053 00 10053 00 10068 00 E10068 00 o PANEL Jun iNDucTOR AP0339 00 06 00 06 00 565 00 0565 00 79 01 481 00 AP0833 00 0827 00 12 INDUCTOR 0339 00 06 00 06 00 565 00 0565 00 79 01 481 00 AP0833 00 9 00 DC OUTPUT AMMETER 0003 08 RB0003 01 RB0003 02 RB0003 03 RB0003 04 RB0003 05 RB0003 06 RB0003 07 RB0003 08 DC OUTPUT VOLTMETER RB0002 02 0002 03 BLEEDER FEEDBACK RESISTOR Ge Ce VOLTAGE DIVIDER EN RESISTOR RJ0004 12 RJ0008 21 SCR1 SILICON CONTROLLED SCR2 MODULE 0001 01 RM0002 01 RM0002 01 RM0001 00 RM0001 00 RM0001 00 RM0001 01 0001 01 RM0001 01 DC OUPUT SURGE SUPPRESSOR AC INPUT SURGE TEE Md e x SUPPRESSOR 380 480 RK0038 01 POWER ISOLATION 120220240 1632 00 AA0656 00 AB1556 00 AB1540 00 AB1540 00 AB1256 00 AB1258 00 AB1552 00 AB1548 00 TRANSFORMER 480Vac AB1516 00 AA0657 00 AB1558 00 AB1542 00 1542 00 1257 00 AB1259 00 AB1554 00 AB1550 00 AC INPUT part of I 74 Rc0012 00 RC0012 00 RC0014 00 RC0014 00 part of TERMINAL BLOCK pane 20006 01 0006 01 RG0012 01 RC0012 01 0014 01 RC0014 01 0314 00 1O panel DC OUTPUT par
22. The Auto Equalize timer is designed to automatically provide an equalizing cycle when the ac input has been interrupted longer then 10 seconds The operation of this equalize timer is as follows Toggle switch SW1 to the AUTO EQUALIZE position and the battery charger in the FLOAT mode When AC power is interrupted for a period longer than 10 seconds and returns the battery charger is placed in the EQUALIZE charge mode for a pre selected period of time 0 to 999 hours The timer now energized displays time remaining and completes the equalize charge period Once the timer reaches 0 the charger will switch to the FLOAT mode The timer will shut its self down and remains ready to repeat the operation for the same number of preset hours The charger may also be returned to the FLOAT mode by pushing the FLOAT RESET switch SW11 The schematic diagram 131 shows the circuit details Relay TM2 is 10 second time delay relay which latches itself closed 10 seconds after the AC power fails When the AC power returns the timer operates As long as is latched closed the charger is in EQUALIZE mode When TM1 times out it opens the latch circuit of TM2 and returns the charger to FLOAT mode The timer clutch then disengages and the timer TM1 returns to start position Placing switch SW1 in the EQUALIZE position overrides the timer function and manually puts the charger into EQUALIZE mode FLOAT and EQUA
23. battery voltage If any set of contacts closes the alarm sounds A switch SW 13 is provided to turn off the audible alarm if desired 9 COMMON ALARM RELAY EJ0141 WITH OPTIONAL BUZZER Purpose The Common Alarm Relay circuit provides an alarm indication via relay contacts and optional buzzer when any one of the alarm circuits being monitored goes into its alarm state Description The individual alarm contacts that are closed when in the non alarm condition are wired in a series loop configuration with the common alarm relay and its DC source If one of the alarm circuits activates its relay contact will open and de energize the common alarm relay providing a common alarm condition One set of contacts of the common alarm relay is connected to the remote alarm terminal strip TB3 at terminals 28 29 amp 30 If the optional buzzer AUI is required an additional set of contacts is used to activate it A switch SW13 is provided to turn off the optional audible alarm if desired 10 MANUAL FLOAT EQUALIZE SWITCH WITH INDICATOR LIGHTS EJ0093 Purpose Front panel lights indicate whether the charger is in a FLOAT or EQUALIZE charging mode Description A double pole double throw switch SW7 is substituted for the normal FLOAT EQUALIZE switch SW1 The second section of SW7 is wired to provide voltage to the proper instrument panel light to denote the FLOAT or EQUALIZE position of SW7 11 PARALLEL CHARGER OPERATION WITH 2 FO
24. circuit breaker Use a voltohmmeter to check for continuity between the circuit breaker terminals with breaker manually closed Zero resistance should be indicated if the unit is operative If unit checks OK check performance by measuring the AC voltage drop across each pole of the breaker This voltage should be under 0 1 volt when the load current is normal If a higher voltage drop is found replace the breaker 2 DC Circuit Breaker CB2 When the DC circuit breaker is suspected of being inoperative or at fault a similar test to that made for the AC breaker will determine the operating condition of the breaker 3 If the polarity protection diode is shorted the battery will discharge into which will trip the DC circuit breaker CB2 Check with an ohmmeter both polarities for a shorted condition and replace if required d Surge Suppressors SS1 SS2 1 The metal oxide varistor MOV type of surge suppressor is used throughout these battery chargers instead of the older selenium type This is because of personnel safety When a selenium device fails and arcs or burns very toxic selenium fumes are given off which are very poisonous if inhaled The has a much sharper limiting knee characteristic and performs a better protection function If an surge suppressor fails during a high energy transient it may explode This is an obvious failure and the part must be replaced 2 If the suppressor is
25. clearance from all obstructions on all sides of the battery charger Keep area in front of battery charger clear for at least 4ft 1 3m Connect or disconnect the battery only when the battery charger is off to prevent arcing or burning De energize all AC and DC inputs to the battery charger before servicing Do not operate battery charger if it has been damaged in any way Refer to qualified service personnel only 10 Do not disassemble battery charger Only qualified service personnel should attempt repairs Incorrect reassembly may result in explosion electrical shock or fire 11 Do not install the battery charger outdoors or in wet or damp locations unless specifically ordered for that environment 12 Remove all jewelry watches rings etc before proceeding with installation PLEASE READ AND FOLLOW ALL SAFETY INSTRUCTIONS TABLE OF CONTENTS Page No SCR SCRF BATTERY CHARGER SPECIFICATIONS 0026 00 inside front cover IMPORTANT SAFETY INSTRUCTIONS asta Da Donau ete Eton i TABLE OF el CT ii iii SECTION INSTALLATION AND OPERATION 1 S E ee 2 25 dn e e TEE 2 EH e EE 2 4 DEE Leer pe PO RETE de eode ee 3 5 Adjustments of Float amp Equalizing Charge sessi nene nenne 3 6 Manual Equalize Timer a eet er etre ee 3 7 Maintenance te ERE eegen
26. good practice to keep the DC leads as short as possible and to keep them together as a pair to obtain low inductance Likewise it is good practice to avoid sharp bends and to run both DC leads together if run in conduit d Input Power These chargers are nominal 120V 208V 220V 240V 50 60 HZ or 480V 60 Hz AC single phase If the AC input data as supplied with the charger does not agree with the AC supply voltage at the installation site do not connect the charger to the AC line The AC voltage must be within 1096 of the rated input voltage of the charger If not consult your power company or the battery charger manufacturer 4 PLACING CHARGER IN SERVICE a With the AC and DC breakers OFF and the system in float mode install the charger making AC and DC connections as described in Section IL 3 and in accord with local regulations as they apply b After connecting the lead from the positive battery terminal to the positive terminal on the charger and the lead from the negative battery terminal to the terminal on the charger observe the voltmeter It should read the correct polarity and be approximately the battery open circuit voltage this is 2 0 volts per cell for lead acid batteries and 1 2 volts per cell for nickel cadmium batteries For example a 60 cell lead acid battery should read about 2 x 60 cells 2 120 volts This is a check that all cells are in a true series none connected in reverse and all connection
27. that the charger output is regulated at all times The firing angle of the SCRs is controlled by the action of the control module Both the SCRs and the diodes are protected from AC and DC surge voltages by means of the metal oxide varistor surge suppressors c The Control Module This printed circuit board generates the single phase phase fired gate signals that turn on the SCR diodes in response to the charging requirements of the battery load The output voltage of the charger is monitored by the voltage feedback circuit and advances or retards the phase angle of the trigger pulses so that the output voltage is maintained essentially constant This is accomplished by comparing a small portion of the output voltage to a stable voltage reference An error signal is created proportional to the differential voltage This error signal is then used to alter the phase angle of the SCR gate trigger pulses in order to correct the output voltage The load current is also monitored by the circuit so that when its value exceeds an arbitrary value 110 rated current the system is phased back to limit the output current to no more than 110 of its rated value d The Filter Section 1 Depending on the application the charger may be unfiltered In this case one filter choke L1 is utilized not for filtering but for phase correction of the highly leading current voltage condition created by the batteries during the charging pulses The batteries represent a
28. to the anode and to the cathode and adjust to the direct reading scale of the ohmmeter If a low resistance is observed reverse the leads and again check the resistance If this reading is also low the SCR is shorted and should be replaced 4 An SCR can also be checked for operation with a Simpson Model 260 voltohmmeter With the black lead in common and red lead in put polarity switch to DC Connect the red lead to the anode and the black lead to the cathode The meter should now indicate high resistance above 50 000 Ohms when on the R x 10 000 scale With the leads connected as above set the function switch to R x 1 and touch the gate to the anode This should fire the SCR and give a reading of approximately 5 20 Ohms This shows the SCR has been turned on On very small SCRs this reading will hold after removing the gate lead This is latched on and can be unlatched by opening the cathode lead Larger SCRs will not stay on with the current available with Simpson meter The Simpson may not have enough current to gate or turn on extremely large SCRs 400 Ampere and up 5 If the charger output is too high unplug the control module and turn on the charger With no gate signals the charger should have zero output If there is still current output one or both SCRs are defective 6 The above checks can be used to confirm that a suspected SCR is indeed bad However occasionally an SCR might check OK in all these tests and still break down or f
29. very large capacitor in shunt with a resistive load This creates out of phase current problems for the SCR diodes causing non uniform triggering problems particularly at low load currents The single filter choke corrects this condition and also aids the ratio of average current to RMS current flowing in the circuit 2 For filtered units the objective is to remove the charging ripple at the battery terminals To accomplish this a T or double L section filter consisting of inductors L1 and L2 capacitors and C2 are used and C2 may consist of one or more individual capacitors The degree of filtering required dictates whether the T or double L configuration is used The double LI section filter is normally used to reduce the ripple to 0 06 of nominal output voltage when the charger is operated as a filtered eliminator SECTION III TROUBLESHOOTING 1 CAUTION NOTICE Before troubleshooting always isolate and de energize the charger by opening the AC circuit breaker CB1 and the DC circuit breaker CB2 This avoids the possibility of high short circuit current damaging the charger tools test equipment or injuring personnel NOTE Circuit breaker terminals CBx printed circuit boards Ax and terminals terminal blocks TB1 TB2 TB3 TB5 amp TB15 have dangerous voltage across them even when both circuit breakers are open After isolating the charger check that the voltage across the filter capacitors C1 C2 is
30. 0 0012 00 0012 00 0012 00 0012 00 RC0014 00 0014 00 RC0014 00 RC0014 00 RC0014 00 75 Adc 0314 00 0314 00 0314 00 part of I O Panel 208 240 Vac 380 480 Vac AC Voltmeter SW5 Phase Selector Switch RB0006 05 0006 05 RB0006 05 RB0006 05 RB0006 05 0006 21 0006 21 RB0006 21 RB0006 21 RB0006 21 RD0005 00 RD0005 00 RD0005 00 RD0005 00 RD0005 00 Common Alarm Buzzer RAO004 00 8 0004 00 RA000400 0004 00 RAO0004 00 SW13 Buzzer ON OFF Switch RD0001 00 RD0001 00 RD0001 00 RD0001 00 RD0001 00 Charger Failure Alarm Control PC Board GK0055 01 GK0055 01 GK0055 01 GK0055 01 GK0055 01 Charger Failure Alarm Indicating Light 0001 00 0001 01 0001 01 RA0001 06 RA0001 06 Ballast Resistor for A3 RJ0028 37 RJ0015 33 RJ0022 04 RJ0022 05 Ballast Resistor for DS7 RJ0028 24 RJ0008 13 EJ0617 00 Load Sharing Control PC Board EJ0144 00 EJ0144 00 EJ0144 00 EJ0144 00 EJ0144 00 swio Load Sharing ON OFF Switch 00001 00 RD0001 00 RD0001 00 RD0001 00 800001 00 Load Sharing Signal Terminal Block RC0005 02 0005 02 0005 02 0005 02 8 0005 02 TO ORDER PARTS PLEASE CONTACT YOUR SALES REPRESENTATIVE PLEASE ORDER BY QUANTITY PART NUMBER AND CIRCUIT SYMBOL FROM TABLES ABOVE HAVE YOUR BATTERY CHARGER MODEL NUMBER AND SERIAL NUMBER AVAILABLE 58 REPLACEMENT PARTS SCR SCRF Series Battery Charger Options 1PH 3PH BATTERY CHARGER NOMINAL OUTPUT 12 Vdc 24 Vd
31. 1 HIGH DC DETECTOR 013 67R81 CONNECTION MADE L1 2 IN UNFILTERED BOARD ASSY CHARGERS AND 1292 IN FILTERED CHARGERS 2 5 SHOWN IN NON ALARM CONDITION 3 RBI NOT USED 12Vdc CHARGERS 4 ADJUST R4 A13 BOARO OBTAIN CHARGER SHUTOOWN AT DESIRED BATTERY VOLTAGE TB3 120403 THIRD ALARM PROJECTION TERMINAL BLOCK NOTE 2 050994 060685 Ir OPTION SCHEMATIC HIGH DC VOLTAGE CHARGER SHUTOOWN W INOICATOR 073192 wkB A vED 060685 DRAWING No REV 122184 wan Ke EJOSS2 XX 5 xxr Ejo582 xx FILENAME EJOSS82 XX PRTJ 48 1 3AVN3 v SIN day a orafa NOILISOd V32 1 NI NMUHS 185 AY S3DNV83 DL NI 962020 XX L 80F 3 SE SNDISN3WID D3IUN 3SIMBOHID SS3TNT STIVI30 303 61 5 NDLLOSS 338 952020 SN 967011 NOILISOd 5 8 NI NMOHS 9 B398VH2 431198 531815 4 25 25 C NSV2 5 15 0341840 066160 VIO 464210 A NQ ISN A8012V3 303 SI OIF 5 ST1V130 61 5 1123 wien 355 De Se NOILISOd 378VN3 NI NMOHS 97 AD 5 v 100101 O31S3nm03 512 1 02 2 W
32. 190 5B REV DA DRAWING No EJO 1 27 XX A BART EJ0127 XX 1 9 5 FILENAME 0127 1 MCT UNLESS OTHERWISE NOTED DIMENSIONS ARE IN INCHES TOLERANCES ARE SCALE NTS TRANSFORMER CREF EQUALIZE DSO6 NOTES 1 CONTACTS SHOWN IN AUTO EQUALIZE POSITION FLDAT MODE gt 2 IN MAINFRAME SCHEMATIC IS RELABELEU AND REWIRED AS SHOWN 3 amp R56 NOT USED IN 24V CHGRs 070903 lt gt R4 REF lt gt REF TM2 TIME DELAY RELAY THIRD 032202 ANGLE PROJECTION MCT 022693 DRAWN BY TITLE 051385 SCHEMATIC 0 72 AC LINE 061490 FAILURE DIGITAL AUTO EQUALIZE TIMER W IND WKB 051385 052288 ECN No DATE APP DRAWING No EJO131 XX A PART No WKB SCALE UNLESS OTHERWISE NDTED DIMENSIONS ARE IN INCHES TOLERANCES ARE 4l NTS EJO131 XX FILENAME EJO131 XX PRTJ NOTES 1 EACH LOAD SHARING UNIT BATTERY CHARGER REQUIRES ITS OWN LOAD SHARE BOARD AB AND BOTH UNITS MUST BE OF IDENTICAL DESIGN 2 5 10 2 CONNECTS 501 9 ON IPH UNITS CONTROL SW10 2 CONNECTS 501 4 3PH UNITS CIRCUIT REF 3 INTERCONNECTION OC OUTPUT TERMINALS TB2 SUPPLIED BY END USER AND SHOWN HIDDEN 4 POTENTIOMETER R13 CAN BE USED TO CORRECT SMALL INEQUALITIES TH
33. 3 00 Kette 120Vac 0015 06 0015 09 RE0015 12 RE0015 13 RE0015 15 015 19 0217 02 RE0015 09 RE0015 17 OUT BREAKER 208 240Vac RE0015 05 0015 06 RE0015 09 RE0015 09 RE0015 10 RE0015 17 REOO15 17 REO015 06 0015 12 380 480Vac 0015 03 0015 04 0015 06 RE0015 06 0015 06 015 08 015 09 0015 05 0015 07 DC OUTPUT EG ue 0015 24 RE0015 25 0015 38 015 26 8 0015 28 015 31 015 34 0015 24 015 38 cr oam DIODE 0009 04 RK0009 04 RK0009 04 RK0009 04 RK0009 04 RK0013 04 RK0017 04 009 05 RK0009 05 cm DIODE RK0009 04 RK0009 04 RK0013 04 RK0013 04 RK0013 04 RK0014 04 RK0017 04 RK0009 05 RK0013 05 cmo DIODE of SCR1 SCR2 F1 F2 DC FUSE 0001 19 001 20 001 21 RE0001 22 RE0003 01 003 04 004 06 002 09 RE0002 11 A DC FUSEHOLDER 0013 00 RE0013 00 013 00 013 00 10053 00 El0053 00 0068 00 013 05 0013 01 L1 MAIN INDUCTOR AP0306 00 06 00 AP0604 00 APO872 00 0604 00 0950 00 0482 00 AP1114 00 APO872 00 L2 FILTER INDUCTOR 0306 00 06 00 AP0604 00 0872 00 APO604 00 0950 00 482 00 AP0306 00 0872 00 DC OUTPUT EN RB0003 01 RB0003 02 RB0003 03
34. 4 HUDICATAJG LIGHTS Ep p EZ i 3 eset UM gt me meen TE 2 72 ges PERCENT 222 dm 670735 eu a 34 SCR SCRF Series Battery Charger TE AC FAILURE ALARM BELAY oe 9 EG Ls oer age ES KE s E EE peser ERR edd APDUMD DETECTION 9 fas cm 5 resch 2 CONTACTS SUAM ALARIA CONDITION TE GROUND DETECTION ALARM RELAYS WITH RESET SWITCH d INDICATING LIGHTS 35 Option Schematics DETECTION 250 TS 258 GROUND DETECTION INDICATING LIGHTS DET C as 258 36 SCR SCRF Series Battery Charger tQuaLizg NOTES SW AZ ELDAT PuZITIGAZ SW QEFLACEZ SW IN FLOAT Z EQUALIZE INDICATING LIGHTS EE murem Ec Lee Dee mea a Ei 785 TBS ZA NEG GNO OuTPuT NOTE UPON USING THIS OPTION ON THE MAINFRAME 5 ZEWIRED AS SHOWN ABOVE GROUND DETECTION SWITCHES FOE DC VOLTMETER INDICATION 74 EJ 205 SE ME ev 283 ar
35. 6 RE0015 07 380 480 0015 03 RE0015 03 RE0015 03 RE0015 04 RE0015 03 RE0015 03 15 03 RE0015 04 RE0015 05 DC OUTPUT CIRCUIT BREAKER RE0015 24 RE0015 25 RE0015 26 RE0015 28 0015 24 RE0015 25 RE0015 28 RE0015 34 RE0015 36 POLARITY DIODE RK0010 02 RK0009 02 RK0009 02 RK0009 02 RK0010 02 RK0009 02 RK0009 02 RK0017 04 RK0017 04 BLOCKING DIODE RK0010 02 RK0009 02 RK0013 02 RK0013 02 RK0010 02 RK0009 02 RK0013 02 RK0017 04 RK0017 04 yea RECTIFIER DIODE part of SCR1 SCR2 1 2 DC FUSE 001 19 0001 20 001 22 0003 01 001 19 001 20 0003 01 004 06 004 09 EN DC FUSEHOLDER 0013 00 0013 00 013 00 EI0053 00 013 00 0013 00 EI0053 00 El0068 00 0068 00 va iNDucTOR AP0564 00 AP0564 00 AP0565 00 AP0565 00 AP0564 00 564 00 0565 00 481 00 0808 00 L2 FILTER INDUCTOR AP0564 00 AP0564 00 AP0565 00 AP0565 00 AP0564 00 564 00 0565 00 481 00 0314 00 DC OUTPUT AMMETER 0003 01 0003 02 RB003 04 003 04 0003 01 RB0003 02 003 04 RB0003 06 RB0003 07 DC OUTPUT VOLTMETER 0002 01 0002 02 BLEEDER FEEDBACK RESISTOR VOLTAGE DIVIDER RESISTOR RJ0003 98 RJ0004 12 SCR1 SILICON CONTROLLED scR2 RECTIFIER MODULE 0002 01 RM0002 01
36. AT MAY EXIST BECAUSE OF DIFFERENCE IN SHUNTS SYSTEM PARAMETERS FOR BOTH UNITS TO LOAD SHARE CONNECT TB4 DF CHARGER A TO TB4 DF CHARGER USING SUPPLIED INTERCONNECTION CABLE CONNECTION CREF CABLE DETAIL gt T1 YI T1 Y2 CHARGER A CHARGER 01 NOTE 2 PARALLEL LOAD SHARE PC BDARD LOAD SHARE ASSY AB NDTE 1 OFF 5 10 TO BATTERY LOAD NOTE 3 112503 mn a 5 082394 er we 071802 SCHEMATIC PARALLEL CHARGER DPERATIUN WITH 27 FORCED LOAD SHARING INPUT 042189 071802 DRAWING No 052286 UNLESS OTHERWISE NOTED DIMENSIONS EJO133 OO 7 ARE IN INCHES TOLERANCES ARE FILENAME CEJO133 00 PRT1 WIRE LIST NOTES CODE FROM 12 EACH LOAD SHARING UNIT CHARGER REGUIRES ITS OWN LOAD SHARE BOARD BK 6 3 WH UR A6 5 2 WIRE 531 CONNECTS SW10 2 TO 501 9 PU 4 ON UNITS AND 5 10 2 TO 501 4 3PH UNITS WH RD AB 1 501 NOTE 2 531 WH YE LOAD SHARE 3 LOAD SHARE INTERCONNECTION CABLE ASSEMBLY IS 2 PART EHOB03 00 YE 7 BK TB4 2 BR 84 1 PARALLEL YE 6 LDAD x SHARE Bk Sw10 2 PC BDARD ASSY AB 1 CHARGER A CHARGER B pret
37. ATOR R5 RJO014 06 EQUALIZE ADJUSTMENT POTENTIOMETER SUPPRESSION CAPACITOR 24 48 130 VDC 01 EJ0617 00 PLUG FOR 1 BOARD Swi RD0001 00 MANUAL FLOAT EQUALIZE SWITCH RA0001 05 AC ON INDICATOR EJ0616 00 PC BOARD HOLDERS 8 0014 06 FLOAT ADJUSTMENT POTENTIOMETER 0068 00 FILTER CAPACITOR BRACKET RP0046 12 SUPPRESSION CAPACITOR 260 VDC TO ORDER PARTS PLEASE CONTACT YOUR SALES REPRESENTATIVE PLEASE ORDER BY QUANTITY PART NUMBER AND CIRCUIT SYMBOL FROM TABLES ABOVE HAVE YOUR BATTERY CHARGER MODEL NUMBER AND SERIAL NUMBER AVAILABLE 55 ELECTRICAL RATINGS AND REPLACEMENT PARTS SCR SCRF Series Battery Charger Single Phase Mainframe PLEASE CONTACT YOUR SALES REPRESENTATIVE FOR DATA ON MODELS NOT LISTED SCRISCRFBATTERYCHARGERMODEL 12 AC INPUT CURRENT 1 0 MAXIMUM E 480Vac SYMBOL DESCRIPTION MANUFACTURER S PART No SNUBBER CAPACITOR 120Vac AC INPUT CB1 208 240Vac E CIRCUIT BREAKER 380 480Vac Ekel DC OUTPUT CR4 XF1 DC OUTPUT AMMETER DC OUTPUT VOLTMETER BLEEDER FEEDBACK RESISTOR VOLTAGE DIVIDER RESISTOR SCR1 SILICON CONTROLLED SCR2 RECTIFIER MODULE DC OUPUT SURGE SUPPRESSOR AC INPUT SURGE SUPPRESSOR 380 480Vac POWER ISOLATION Ti TRANSFORMER Deeg AC INPUT TERMINAL BLOCK DC OUTPUT TERMINAL BLOCK PARTS COMMON TO ALL SINGLE PHASE SCR SCRF SERIES CHARGERS
38. CATE OF CONFORMANCE E15030 31 DRIP SHIELDS STYLE 1A 1B CABINET 0220 221 BURN IN OR HEAT RUN HOURS EI5032 DRIP SHIELDS STYLE 2 CABINET EB0222 IN HOUSE INSPECTION BY OUTSIDE PERSONNEL E15033 DRIP SHIELDS STYLE 3 CABINET EB0123 EXPORT PACKING PER FS0001 00 E15034 DRIP SHIELDS STYLE 4 CABINET EB0163 CUSTOM PACKING 15035 DRIP SHIELDS STYLE 5 CABINET EB0198 EXTENDED WARRANTY PER JF5001 00 GENERAL SPECIFICATIONS ADDITIONAL FEATURES OPTIONS NOTES Regulation or 0 596 no load to full load Regulation or 0 5 for or 10 AC line variation Regulation 196 for combined load line amp temp variations Ambient Temperature Range 0 C to 50 Relative Humidity up to 95 without condensation Altitude up to 1 000m above sea level 1 2 3 4 5 7 8 9 IMPORTANT SAFETY INSTRUCTIONS Before using the battery charger read all instruction and cautionary markings on A battery charger B battery C equipment connected to charger and battery This manual contains important safety and operating instructions and therefore should be filed for easy access Do not touch any insulated parts of the battery charger especially the input and output connections as there is the possibility of electric shock During normal operation batteries may produce explosive gas NEVER smoke use an open flame or create arcs in the vicinity of the charger or battery Maintain at least 1ft 0 3m
39. D CIRCUIT SYMBOL FROM TABLES ABOVE HAVE YOUR BATTERY CHARGER MODEL NUMBER AND SERIAL NUMBER AVAILABLE 53 ELECTRICAL RATINGS AND REPLACEMENT PARTS SCR SCRF Series Battery Charger Single Phase Mainframe PLEASE CONTACT YOUR SALES REPRESENTATIVE FOR DATA ON MODELS NOT LISTED 52 82 14 18 29 40 51 7i 94 AG 240Vac 26 41 70 9 0 15 20 26 36 47 480Vac 13 20 35 45 73 10 13 18 24 SYMBOL DESCRIPTION MANUFACTURER S PART No C1 C2 FILTER CAPACITOR RP0019 01 SNUBBER CAPACITOR SE AC INPUT 120Vac RE0015 17 0015 04 RE0015 06 RE0015 06 RE0015 08 RE0015 10 RE0015 13 0015 17 0015 19 CB1 CIRCUIT BREAKER 208 240Vac RE0015 10 0015 03 RE0015 04 RE0015 05 RE0015 06 RE0015 07 RE0015 08 RE0015 12 0015 13 380 480 RE0015 06 RE0015 03 RE0015 03 RE0015 03 RE0015 04 RE0015 04 RE0015 05 RE0015 07 RE0015 08 DC OUTPUT CIRCUIT BREAKER RE0217 03 RE0015 24 RE0015 25 RE0015 38 RE0015 28 RE0015 31 RE0015 34 RE0015 36 0217 03 CR1 POLARITY DIODE 0017 04 RK0010 04 RK0010 04 RK0009 04 RK0009 04 RK0013 04 RK0017 04 RK0017 04 RK0017 04 BLOCKING DIODE 0017 04 RK0010 04 RK0009 04 RK0013 04 RK0013 04 RK0014 04 RK0017 04 RK0017 04 RK0017 04 yii RECTIFIER DIODE part of SCR1 SCR2 Fi F2 DC FUSE 0004 10 001 19 001 20 001 21 003 01 003 04 004 06 0004 09 004 10 XF1
40. EMATIC PHASE WIRING NOILIVSN3dADJ Seir val3dw3l CHASSIS GROUND CHASSIS GROUND Ely ASSV JILVW3H2S Jd 50158130 39V1 A 50 H9IH 5l SCHEMATIC AC SWC FILTER SwC FILTER COMPONENTS SwC FILTER 1 5 15 INPUT CHASSIS GROUND OTHER COMPONENTS PART OF CHARGER MAINFRAME CONNECTION OIAGRAM 1PH AC SwC FILTER AC INPUT SWC FILTER 1 CHASSIS GROUNO AC CIRCUIT BREAKER 120403 SCHEMATIC DC SWC FILTER CB2 DC SwC FILTER COMPONENTS OTHER COMPONENTS PART OF CHARGER MAINFRAME CONNECTION DIAGRAM DC SwC FILTER DC CIRCUIT SwC FILTER 2 BREAKER EECH 110890 THIRD c ANGLE WKB PROJECTION SWC FILTER 2 DC OUTPUT 030389 por 120403 DOOR PANEL GROUNDS 071288 WAH SCR SCRF SERIES BATTERY CHARGER FILTER OPTION SINGLE PHASE INPUT DRAWING No TPP UNLESS OTHERWISE NOTED DIMENSIONS ARE IN INCHES TOLERANCES ARE SCHEMATIC 3PH AC SWC FILTER 3PH AC SwC FILTER 073088 SWC FILTER 1 C4 cS C6 LSA B C AC INPUT T CHASSIS GROUND OTHER COMPONENTS PART OF CHARGER MAINFRAME CONNECTION DIAGRAM 3PH AC SWC FILTER AC INPUT swe FILTER CHASSIS GROUNO AC CIRCUIT BREAKER 120403
41. INDICATING LIGHT Trees enn ae Ter EJ 0120 EI 32 894 rao P Se emma cme CAT 39 Option Schematics OPERATION Md WILL INDICATE THE e TD VOLTAGE SELECTED B THE PHASE SELECTOR SWITCH ws SWS CONNECTS TO OUTPUT OF CEI 4 WiLL WOICATE VOLTAGE ONLY WHEN 2 mede e 5 RN eco Eege 947 T TLE VOLTMETER PHASE SELECTOR SWITCH EA ee COMMON ALARM BUZZER E a ae 4 22850 Wan 4 0193 TTA 7 2184 ler es gt ou oro les eng Y zz LEET LEE E ESE 40 TBSC A TBSC gt o R17 ALARM THRESHOLD L1 INDUCTOR CREF AUXILIARY WINDING C CHARGER FAILURE PC BDARD ASSY A CHARGER FAILURE 0507 6 080701 XX NOTES 12 ALL CONTACTS ARE SHOWN IN THE NON ALARM CONOITION 2 R52 IS NOT USED ON EJ0127 01 AND EJO127 11 12VOC 2 R85 IS ONLY USED ON 0127 15 4 CHGR EJ0127 17 260 0 CHGR gt SE 012996 THIRD ANGLE PROJECTION 50 031085 TITLE MCT PORN 071394 CHARGER FAILURE ALARM SCHEMATIC 5 071394 WITH ONE 1 FORM C CONTACTS amp INDICATUR BAPPROVED 071394 032
42. LIZE indicating lights mounted on the instrument panel are standard to indicate the charging mode c PERCENT EQUALIZE TIMER WITH INDICATOR LIGHTS EJ0084 The Equalizing Timer is used for certain types of batteries that required a period of equalizing charge every 72 hours The timer is an electro mechanical timer whose dial reads from 0 to 100 and whose drive motor rotates internal cams once every 72 hours If the operator sets the percent dial for 1096 for example the timer will operate the cams such that the EQUALIZE charge contacts will be closed for 7 2 hours 10 out of the 72 hour continuously cycling rotation period There is a manual FLOAT AUTO EQUALIZE switch SW4 which interrupts the motor circuit when the batteries are to be left in FLOAT charge FLOAT and EQUALIZE indicating lights mounted on the instrument panel are standard to indicate the charging mode The timer is used to drive a DP DT relay One set of the relay s contacts control the float equalize charging while the other set of contacts control the indicating lights 8 COMMON ALARM BUZZER EJ0123 Purpose The Common Alarm Buzzer is a charger mounted audible alarm which is activated when any of several different alarm circuits goes into an alarm state Description This circuit simply utilizes set of contacts on each separate alarm relay of the contacts are wired in parallel and connect the audible alarm AUI to the
43. NING ARRESTOR SSS AC CIRCUIT CBI BRAKER LIGHTNING ARRESTOR 1 8U R 2 BU R 3 8U R 2 3eflivadw3l FILENAME LEJI234 XX PRT Ov 02 EJ1234 XX PART No EJI234 XX 3 PHASE SCHEMATIC 3 PHASE WIRING SCR SCRF SERIES BATTERY CHARGERS DRAWING No UNLESS OTHERWISE NOTED DIMENSIONS ARE IN INCHES TOLERANCES ARE SCALE NTS AC INPUT LIGHTING ARRESTOR OPTION CHASSIS GROUND TITLE SNOTLINALSNI_ 8350 S3I3311V8 012 0 31 803 00 2205 335 SA 1ngin CSS Xj SC 30 v ONV E 519995 335 2262 30 1 33 3 230A 5 39v1 DA 30 CHASSIS GROUND THIRD ANGLE PROJECTION 061493 9NISIM 3 SHI9N3 318VJ lad 8W3SSV 8 80151538 Ba L3 98 MINN V 1804 v 30 2 19365 335 dA 4 711329 Lech 672 1491213305 39V33AV CE OW APPROVED U3HSVO SINGN dWDJ 354383538 3393VHJ 4331198 305 095 2 O3TIVISNI LON SI 38094 024431 N3HM Sv8l 50959 O3IddflS A SI 24 B30IAIO 2080333 JHL NI S32V 1938 2PIDMISN LIGHTNING ARRESTOR APP SSS 5910 AC CIRCUIT BRAKER LIGHTNING ARRESTOR DATE 1 8U R 2 BU R py 7 iwy gt REV PHASE SCH
44. OLTAGE ALARM 3 FAILURE ALARM 4 CHARGER FAILLIRE ALARM ALARM CHARGER FAILLIRE ALARM BATTERY DISCHARGING ALARM CLIRRENT LIMIT ALARM ALARM END DF DISCHARGE ALARM REMOTE DC VOLTMETER REMOTE OC AMMETER HIGH AC VOLTAGE ALARM LOW AC VOLTAGE ALARM EQUALIZE MODE REMOTE INDICATION OVER TEMP ALARM NOTES HIGH AC RIPPLE ALARM 1 TERMINALS LABELED IN NON ALARM CONDITION 2 TB15 TERMINAL BLOCK IS USED FOR COMBINED CHARGER SHUTDOWN ALARM ALARM STATUS CHARGER MONITOR ONLY ALL OTHER ALARMS ARE TERMINATED TB3 TERMINAL BLOCK 3 WHEN ADDITIONAL SETS OF FORM C CONTACTS ARE SUPPLIED REDUNDANT TB3 OR TBIS TERMINAL BLOCK S ARE PROVIDED AS REQUIRED THIRD ANGLE PROJECTION DRAWN BY YW 121086 1E REMOTE ALARM TERMINAL BLOCK LEGEND FOR TB3 AND 5 APPROVED WKB 121086 RANNER UNLESS OTHERWISE NOTED DIMENSIONS EH042 3 00 ARE IN INCHES TOLERANCES ARE FILENAME EH0423 00 PRT 33 Option Schematics 1 t eg 1 ze WARG ALTY wores 1 CONTACTS SHOWN M MOM ALARM TE HIGH LUW DC E OIMBICATING LIGHTS MOET 1 COMTACIS Silent in 2 Swi
45. ORT CIRCUIT ACROSS THE SECONDARY TERMINALS 4 HIGH LOW DC VOLTAGE ALARM RELAYS EJ0083 W OPTIONAL INDICATOR LIGHTS Purpose The HIGH LOW DC Voltage Alarm HLVA provides alarm indication for the DC system in the event of a malfunction of the battery charger which causes the battery voltage to rise or drop to a dangerous level Relay contacts and optional front panel lamps provide alarm indications Description The HLVA printed circuit board consists of two independent operational amplifier circuits one monitoring the battery voltage for a high voltage condition and the other monitoring for a low voltage condition The board obtains its operating voltage 12VDC from the battery terminals and if required an externally mounted dropping resistor R57 There are two potentiometers on the HLVA PC board A2 Viewed from the component side of the board the potentiometer near the top left of the board is the LOW voltage alarm LVA threshold adjustment The right hand potentiometer at the top of the board is the HIGH voltage alarm HVA threshold adjustment If it is necessary to adjust the LVA threshold in the field the user must load the battery bank and allow the battery voltage to drop while decreasing the float voltage adjustment to the desired cut off potential The LVA potentiometer is then adjusted so that the LVA relay is activated into the low voltage alarm condition Note that there is a delay time up to 30 seconds before the relay
46. R SCRF SERIES SCHEMATIC INTERNAL TEMPERATURE COMPENSATION NETWORK LEAD ACID 121887 UNLESS OTHERWISE NOTED DIMENSIONS DRAWING No EJOB26 XX te A ARE IN INCHES TOLERANCES ARE REV M1 DC AMMETER 1 TERMINAL BLOCK gt SCRIC TBSC TBS 031000 071195 THIRD ANGLE PROJECTION MCT SCALE PART E J0825 XX FILENAME LEJOB26 XX NDTES 1 not used 2 IF CB2 IS NDT USED THIS CONNECTION LEADS 2 1 3 TD PROVIDE EXTERNAL PDWER TD DIGITAL METERS REMOVE JUMPERS AND APPLY 120VAC e 3VA METER TERMINALS 2 AND 051694 061693 TITLE SCHEMATIC SCR SCRF SERIES 0 1 ACCURACY DIGITAL DC METERS 083093 ED WKB 062493 DRAWING No REV EJOBSS XX SA UNLESS OTHERWISE NDTED DIMENSIONS 061693 WKB ARE IN INCHES TOLERANCES ARE 50 2 SCALE NTS PART NO EJ0895 XX 1 FILENAME EJOB8S XX PRT 1 JAVN3 0 Sav SSONVSIIOL S3HONI NI JJV V v2 XX BBE 173 SNDISNGWID O3IUN SSIM lossen 38084 NOLLVSN3dWOJ 1VN331X3 ep 531838 4 25 425 WV359V10 Z JIIVW3HOS 109120 XIW 0 0 6113 JONY 6 Dat LIGHT
47. RB0003 04 RB003 04 RB0003 05 RB0003 06 RB0003 01 RB0003 03 DC OUTPUT SE RB0002 04 RB0002 05 BLEEDER FEEDBACK RESISTOR VOLTAGE DIVIDER ES RESISTOR RJ0008 32 RJ0008 40 SCR1 SILICON CONTROLLED ERES lee EIER MODUEE RM0002 01 RM0001 00 RM0001 00 RM0001 00 RM0001 00 RM0001 00 001 01 0001 01 RMO001 01 DC OUPUT SURGE 591 SUPPRESSOR RK0038 00 RK0038 01 AG NBT SURGE 120Vac RK0031 00 SE 208 240Vac 0038 00 380 480 RK0038 01 POWER ISOLATION 120220240 AB1498 00 AB1499 00 AB1266 00 AB1266 00 AB1266 00 AB1584 00 AB1600 00 AB1528 00 AB1268 00 e 480 AB1594 00 AB1532 00 AB1267 00 AB1267 00 AB1267 00 AB1586 00 1602 00 AB1530 00 AB1269 00 AC INPUT RC0012 00 0012 00 0012 00 0014 00 0014 00 0012 00 0014 00 RC0012 01 RC0012 01 RC0012 01 RC0014 01 0014 01 0314 00 FB0314 00 RG0012 01 RC0014 01 00 OUTPUT RC0012 00 0012 00 RC0012 00 0012 00 RC0012 00 RC0014 00 0014 00 0012 00 0012 00 TERMINAL BLOCK RC0012 01 RC0012 01 RC0012 01 RC0012 01 RC0012 01 0014 01 0014 01 0012 01 RC0012 01 PARTS COMMON TO ALL SINGLE PHASE SCR SCRF SERIES CHARGERS DESCRIPTION GK0058 8 CONTROL MODULE PC BOARD UNFILTERED RJ0003 84 VOLTAGE DIVIDER RESISTOR 1 GK0058 82 CONTROL MODULE PC BOARD FILTERED ELIMIN
48. RCED LOAD SHARING EJ0133 Installation Using the interconnection cable supplied with the charger equipment interconnect charger A and charger B via the load share signal terminal block as shown EJ0133 on page 42 Also refer to any instructions supplied with the manual for the option DC load cables to be provided by the user Purpose This option permits connecting two battery chargers in parallel to a common battery bank load in order to increase the total load capability or to provide redundancy for system reliability Description The principle of operation is based on the ability to sense the current furnished by each charger and to electronically force the two currents to be equal within a small percentage Each individual charger s current is sensed by means of the shunt associated with the ammeter The resultant voltages are differentially amplified by the op amp on each charger s paralleling printed circuit board The output of the op amp in each charger is connected to the Control Module A1 input This output is combined with the feedback signal from the front panel FLOAT and EQUALIZE potentiometers R3 R5 The net effect is to adjust each charger so that the current furnished is sensed as being equal The rectangular potentiometer R13 on the paralleling printed circuit board can be used to correct for any small inequalities that may exist because of difference in shunts or system parameters
49. RM0001 00 RM0001 00 RM0002 01 RM0002 01 RM0001 00 RM0001 01 0001 01 DC OUPUT SURGE SUPPRESSOR AC INPUT SURGE ee AT m SUPPRESSOR 380 480Vad RK0038 01 POWER ISOLATION 190220240 AA0650 00 AA0652 00 0654 00 AA0654 00 AA0656 00 AA0686 00 ABT250 00 AB154000 AB125600 TRANSFORMER 480 0651 00 AA0653 00 AA0655 00 0655 00 0657 00 AA0657 00 AB1251 00 1542 00 1257 00 AC INPUT RC0012 00 RC0012 00 RC0012 00 RC0014 00 TERMINAL BLOCK RC0006 01 RC0006 01 RC0006 01 3960645 RC0006 01 RC0006 01 RC0012 01 RG0014 01 DC OUTPUT RC0012 00 RC0012 00 RC0014 00 Ee RC0006 00 RC0006 00 80012 00 RC0006 00 RC0006 00 80012 00 0014 00 FB0313 00 PARTS COMMON TO ALL SINGLE PHASE SCR SCRF SERIES CHARGERS DESCRIPTION DESCRIPTION CONTROL MODULE PC BOARD UNFILTERED R4 RJ0003 84 VOLTAGE DIVIDER RESISTOR CONTROL MODULE PC BOARD FILTERED ELIMINATOR Rs RJo014 06 EQUALIZE ADJUSTMENT POTENTIOMETER SUPPRESSION CAPACITOR 24 48 130 VDC 501 EJ0617 00 PLUG FOR A1 PC BOARD SUPPRESSION CAPACITOR 260 VDC Sw1 RD0001 00 MANUAL FLOAT EQUALIZE SWITCH AC ON INDICATOR XA EJ0616 00 PC BOARD HOLDERS RJ0014 06 FLOAT ADJUSTMENT POTENTIOMETER 0068 00 FILTER CAPACITOR BRACKET TO ORDER PARTS PLEASE CONTACT YOUR SALES REPRESENTATIVE PLEASE ORDER BY QUANTITY PART NUMBER AN
50. Section 93 20 2011 11 JA0132 00 uw a te gt amp goot lt Z u O gt d 2 8 qo Sp 0 On 98 o SIVANVW A Division of Exide Technologies IupusrRiAL Power SCR SCRF SERIES BATTERY CHARGER SPECIFICATIONS M emm IO TT TTT I memes D items A F req d CORE BB A B C D E F G H J K L M N 1 Serial Number and Core BB calculated by factory U UNFILTERED DC OUTPUT 0088 4 GROUND DETECTION INDICATOR LIGHTS F FILTERED DC OUTPUT 30 mV RMS w BATTERY 0095 4 2 ACCURACY 3 5in AC VOLTMETER 1PH E BATTERY ELIMINATOR DC OUTPUT FILTERING 0120 4 BATTERY DISCHARGE ALARM 6 IND LIGHT 1 120 Vac 60 Hz INPUT SINGLE PHASE ONLY 0121 4 2 ACCURACY 3 5in AC VOLTMETER 3PH 2 208 240 Vac 60 Hz INPUT EJ0123 4 COMMON ALARM BUZZER 3 220 240 50 60 Hz INPUT SINGLE PHASE ONLY EJ0134 4 2 ACCURACY 3 5in AC AMMETER 1 4 380 416 Vac 50 60 Hz INPUT THREE PHASE ONLY EJ0135 4 2 ACCURACY 3 5in AC AMMETER 3PH 5 480 Vac 60 Hz INPUT EJ0137 4 5 CURRENT LIMIT ALARM amp IND LIGHT 1PH 3PH 6 120 208 240 60 Hz INPUT SINGLE PHASE ONLY
51. T 11 b Equalize EE 12 2 Current Limit Response and 13 Checks and AdJ s ment z L ee t uet eta edere ER Seas ie he a 13 b Checks to Make Malfunctontng 13 SECTION V CUSTOMER OPTIONS 1 Ground Detection Circuits 0088 EJ0089 EJO094 70086 14 2 AC Power Failure Alarm Relay EJ0085 15 3 Single Phase AC Input Voltmeter EJ0095 Single Phase AC Input Ammeter 134 15 4 High and Low DC Voltage Alarm Relays 0083 15 16 5 Charger Failure Alarm Relay EJOTZ nk teh etr eret 16 6 Battery Discharging Alarm Relay 0120 16 7 Equalize Timers EJ0097 EJ0096 70869 10131 70084 17 8 Common Alarm Buzzer EJO123 NEE 18 9 Common Alarm Relay BIOTA wis cc a n eret Ee ette re dede e oce reed vine ela 18 10 Float and Equalize Indicating Lights 70093 18 11 Parallel Charger Operation with 2 Forced Load Sharing 70133 18 12 Zero Center DC Ammeter for Battery Load Monitoring 0139 19 13 High DC Voltage Charger Shutdown with Alarm Relay 0592 19 14 End of Discharge Alarm Relay 0143
52. The text describes the basic operational philosophy and theory of operation Block diagrams or schematics for these options are shown in Section in numerical order of the EJ specification number 1 GROUND DETECTION CIRCUITS Purpose The purpose of a ground detector circuit is to indicate to the user when either the positive or negative output terminal of the battery charger or its connected load is grounded This is important for many applications where a full floating system is required for operation or safety reasons There are several methods of indicating a grounded output terminal These will be outlined below with an explanation of how each works Descriptions a POSITIVE NEGATIVE GROUND INDICATOR LIGHTS 0088 The simplest form of a ground detection system is the two lamp method This utilizes two lamps of voltage equal to the battery charger output voltage connected from the positive terminal to ground and from negative terminal to ground Under normal conditions each bulb will have half voltage applied and glow dimly at quarter brilliance Upon a ground the lamp indicating the grounded terminal will glow at full brilliance The other lamp will go out b POSITIVE NEGATIVE GROUND INDICATOR LIGHTS W TEST SWITCH EJ0089 This is a variation of EJ0088 above so that the two lamps not continuously connected in the circuit A double pole double throw momentary center off switch SW12 is util
53. a Leer eee re Ten am 37 Option Schematics MOTE Ad 15 CONNECTED TO TIME OUTPUT OF CBI THEREFORE Vis w L VOLTAGE ONLY MEM CBs 15 CLOSED TITLE AC VOLTMETER Lg INPUT EI 6270095 ki DIE C Im ES pss 7 QAI lt lt near TIMER Ji 5 f CONTAUTS SHOWN IM FLOAT MODE 2 547 MAINFRAME SCHEMATIC 15 REPLACE TITLE 0 T Hg MANUAL EQUALIZE TIMER BESSER INDICATING LIGHTS J Gel EJ 009 ee drs Luassl wan zcv ecw meme 38 SCR SCRF Series Battery Charger PII ICE EE CONTRETS v MODE SWI MAING R AME SCHEMATIC AE REPLACED BY TMI KOCH 0 72 MANUAL EGUALIZE TIMER Ep a IVO Ce wee ES Son PRACT 4 Orem ev e 2 To Suen Barr 4 CBZ 505 Scugemaric 782 TASEA EI E T TD r83 22 79 23 MED ASSY wen 1 NOTES 1 COMTACTS SUUN ALARM CONDITION 2 THREE 782 REPLACES THE STANDARD Twe SHOWA GN PARER AME SCHEMAT C PENES OM PUER RE ra THE BATTERY DISCHARGING ALARM
54. age does not change after several hours of operation 6 MANUAL EQUALIZE TIMER OPTIONAL a This timer is provided to obtain a charge up to 72 hours at a slightly higher value than the ordinary float voltage The timer may be used for recharging older batteries or for a freshening charge on new batteries For a detailed explanation of operation see Section V Customer Options 7 MAINTENANCE a This charger is designed to require a minimum of maintenance There are no rotating parts except in the optional timer and all components have a nominally indefinite life with no expected aging effect It should be kept clean dry and checked periodically to make sure all connections are tight If necessary dry air may be used to blow dust out of the interior In the event of any irregular operation examine and tighten if necessary all internal and external connections and check circuits for continuity see schematic diagram on page 28 If the difficulty cannot be remedied contact the manufacturer 8 NORMAL PERFORMANCE a Assuming that the charger has been operating in the float position an indication of normal performance can be obtained by setting the FLOAT EQUALIZE switch in the equalize position turn timer off zero Increased charge current will show on charger ammeter until the battery reaches the equalize voltage At this point the current should slowly decrease b If the charger has been operating in the equalize voltage position tu
55. ail in the charger circuit during normal operation Any SCRs suspected should be replaced 2 Control Module PC Board Assembly A1 One preliminary note that should be kept in mind The action of the overall feedback circuit controls the battery charger output voltage so that the feedback voltage from the slider of the FLOAT ADJUST potentiometer R3 to the control module board matches the 6 4 Volt reference voltage on the module Measure this voltage and if it is not approximately 6 4 Volts the feedback circuit or related circuits are not functioning Proceed as follows using the GROUND ISOLATED oscilloscope described in Section 2 f 2 on page 8 Make the following tests in the order shown 1 If the gate signals were not checked as described in Section 2 f 2 do so at this time If one or more of the gate signals are absent when attempting to operate the charger in a normal manner make the following checks Refer to FIGURE 1 on page 29 for component layout and test point locations on the trigger board 1 See schematic on page 30 for related circuit diagram 2 Check DC voltages at test points A 10 volts and B 10 volts referred to board ground GND If either or both voltages are missing check fuse F1 transformer and diodes CR1 CR4 the PCB for malfunction If ok proceed as follows 3 The following waveform tests must be made using the oscilloscope set with vertical sensitivity set at 2V CM and the horizon
56. alize value and remain so 2 check the system response turn the AC breaker to OFF to simulate line voltage failure Charging current will return to zero on the instrument panel ammeter M1 and the voltage should reduce slightly Place a load on the battery and discharge it heavily for a short period of time until the voltmeter drops to float value or slightly lower Return the AC breaker CB1 to ON and observe that charge ammeter again reads 110 of charge rate and voltage is less than the equalizing level If current is greater than or less than 110 of rated charge open the cabinet and locate the CURRENT LIMIT potentiometer on the control trigger PC board A1 Reference the component layout on page 29 and schematic on page 30 The CURRENT LIMIT is labeled R11 on single phase control PC boards GK0058 and R65 on three phase control PC boards GK0048 Adjust this control for 110 charge current Repeat the AC circuit breaker CB1 ON OFF sequence listed above If charge rate is still 11096 rated value for which it was set close the cabinet Restore the charger to float mode b Checks to Make if Malfunctioning If all of the above adjustments were attempted and a high current persists the current limit circuit on the control trigger board or the ammeter or shunt used for current sense may be defective The interconnecting wiring may also be faulty Make the following checks to isolate the fault 1 Turn the current limit con
57. c 48 Vdc 130 Vdc 260 Vdc OPTION CIRCUIT NUMBER SYMBOL DESCRIPTION MANUFACTURER S PART NO EJ0134 CT1 AC Current Transformer 75 Aac max Ce CT1 CT3 AC Current Transformer 75 5 ratio 0137 Current Limit Alarm PC Board Ces ELE SH2 DC Current Shunt 101 200 Adc TO ORDER PARTS PLEASE CONTACT YOUR SALES REPRESENTATIVE PLEASE ORDER BY QUANTITY PART NUMBER AND CIRCUIT SYMBOL FROM TABLES ABOVE HAVE YOUR BATTERY CHARGER MODEL NUMBER AND SERIAL NUMBER AVAILABLE 59 REPLACEMENT PARTS SCR SCRF Series Battery Charger Options 1PH 3PH BATTERY CHARGER NOMINAL OUTPUT 12 Vdc 24 Vdc 48 Vdc 130 Vdc 260 Vdc OPTION CIRCUIT NUMBER SYMBOL DESCRIPTION MANUFACTURER S PART NO Ca a L w p s Lm x o ose ms massam messes Tass memes eenean mena es es EJ0592 GK0045 01 specify dc voltage m _ meets numero sees Tass mones Less Iesse TO ORDER PARTS PLEASE CONTACT YOUR SALES REPRESENTATIVE PLEASE ORDER BY QUANTITY PART NUMBER AND CIRCUIT SYMBOL FROM TABLES ABOVE HAVE YOUR BATTERY CHARGER MODEL NUMBER AND SERIAL NUMBER AVAILABLE 60 REPLACEMENT PARTS SCR SCRF Series Battery Charger Op
58. conds Alarm contacts are wired to TB3 terminals 19 20 amp 21 and an optional front panel indicator DS7 is available Description Charger output current is sensed by means of an auxiliary winding on the main inductor L1 The CFA PC Board assembly A3 detects the voltage signal from L1 When the voltage signal indicates that the current has dropped to below 2 an on board relay switches to provide the alarm indication When the output current is restored to a value above 2 the alarm will be automatically reset 6 BATTERY DISCHARGING ALARM RELAY WITH INDICATOR LIGHT EJ0120 Purpose The Battery Discharging Alarm indicates the condition when the battery is no longer receiving adequate charging current from the charger and has become a source of current for the load Alarm indication is provided by a front panel lamp DS10 and relay contacts Alarm contacts are wired to TB3 terminals 22 23 amp 24 Description This is accomplished by monitoring the direction of current flow in a DC meter shunt SH3 connected in the main battery lead When this current polarity changes from negative to positive the alarm circuit is activated EJ0120 shows the connection diagram of the alarms An op amp voltage comparator senses when the input signal from SH3 changes from negative to positive polarity The op amp output goes high and activates the alarm The alarm board derives its power from the battery terminals If necessary voltage dropping resist
59. e Relay Switching Relay 0 72 Hour Auto Timer Time Delay Relay Timing Resistor Voltage Dropping Resistor Zener Diode Float Reset Switch Float Indicator Light Equalize Indicator Light Load Sharing Control PC Board Load Sharing Signal Terminal Block Load Sharing ON OFF Switch AC Current Transformer Single Phase AC Ammeter B B AC Current Transformer line 1 AC Current Transformer line 2 AC Current Transformer line 3 Line Selector Switch Three Phase AC Ammeter B B B A E A Current Limit Alarm PC Board w Relay Socket for A18 Auxiliary Alarm Relay Current Limit Indicator Light Voltage Dropping Resistor DC Zero Center Ammeter AR 582 DC Current Shunt TB2 3 Position DC Output Terminal Block batt load load bat 45 K8 Common Alarm Relay R63 Voltage Dropping Resistor 25 Option Number EJ0141 w Buzzer EJ0143 EJ0145 EJ0155 EJ0439 EJ0592 EJ0837 NOTES 1 Ref Page Circuit Symbol Spare Note 1 B i B oT onc Component Description Common Alarm Relay Common Alarm Buzzer Buzzer ON OFF Switch Voltage Dropping Resistor Voltage Dropping Resistor End of Discharge Alarm PC Board w Relay Socket for A8 Voltage Dropping Resistor Voltage Dropping Resistor End of Discharge Indicator Light Heater Strip AC Input Circuit Breaker Thermostat Heater Strip Input Terminal Block Interface Terminal Block
60. e attempting to check the output ripple it should be determined that in all other respects the charger is operating normally Having determined this the ripple may be checked as follows Connect a sensitive AC voltmeter digital type preferred to the battery terminals and measure the AC ripple voltage If it measures more than 30 milliVolts RMS check the following a That the battery connected to the output terminals of the charger has an Ampere hour rating of at least four times the rated capacity in amperes of the charger b The ripple is measured at the terminals of the battery c Check capacitors and C2 as follows Switch the VoltOhmmeter to the Rx100 scale and connect the red lead to the capacitor plus terminal marked by a red dot or plus sign and the black lead to the negative terminal The meter should initially swing up scale toward zero Ohms then come back as the capacitor charges A reading of zero Ohms indicates a shorted capacitor while no initial swing means an open capacitor Either an open or shorted capacitor should be replaced n Internal Wiring 1 Check internal wiring for obvious mechanical faults or wear Follow the schematic diagram on page 28 and check continuity with an ohmmeter to determine open connections Check wiring against ground also and remove any grounds 10 SECTION IV SYSTEM ADJUSTMENTS 1 VOLTAGE ADJUSTMENTS AND RESPONSE When abnormal output voltage exists or no output current is present
61. er INTER CUNNEC T ION CABLE ASSEMBLY NOTE 3 FOR BOTH UNITS TO LOAD SHARE CONNECT 4 DF CHARGER A 4 CHARGER B USING SUPPLIED INTERCONNECTIUN CABLE CABLE IS 15 FEET LONG AND CONSISTS OF 4 16 INSULATED WIRES WITH BATTERY 6 INSULATED RING TERMINALS BATTERY amp LOAD amp LOAD LOAD SHARE SIGNAL OUTPUT THIRD ANGLE PROJECTION DRAWN BY MCR 071802 CONNECTION DIAGRAM PARALLEL CHARGER OPERATION WITH 2 FORCED LOAD SHARING 1PH 3PH INPUT APPROVED H 071802 DRAWING No REV UNLESS OTHERWISE NDTED DIMENSIONS EJO133 00 7 A ARE IN INCHES TOLERANCES ARE SCALE NTS PART No 0133 00 SHEET 2 FILENAME EJO133 00 PRTJ 42 SCR SCRF Series Battery Charger NOTE f OPTION WIRED TO LOAD OF 2 wor rog METERS RATED OR LESS TITLE AMMETER PHASE INPUT EE __ ___ ________ epee 3 7723 ennert mers 2 225 vea tes mS rer rev mre Lee ouem EE 627 VUAMSA ram Teaver Ca dA yw a Berg NOTE WIRED TO LOAD SIDE UF CGI WWE AMMETER WITH PHASE SELECTOR s poze 8 5 4 ugs _ SWITCH THREE PHASE 3339 4 4 4 ee c M RR lee penc EEE eet Gu 43
62. get false alarms if your normal load is very low or if you have two chargers connected in parallel To change the Charger Failure Alarm mode set the switch SW1 on A24 to the desired mode To change the interval of the self test in True Charger Failure mode move jumper J11 on A24 to the desired position 4 minutes or 8 5 minutes You can remove the Charger Failure Alarm from the Common Alarm circuit by moving jumper J6 to pins 2 3 This reduces the incidence of false common alarms if your system has little or no continuous load current and you chose the Zero Current mode This does not affect the operation of the Charger Failure Alarm relay or panel indicator DS30 Installation Remove the mating plug from the alarm terminal block 15 Wire remote alarm indicators to contacts 1 18 TB15 according to drawing EJ0837 XX If you ordered two form C contacts wire both plugs TB15A amp 15 according to the drawing Be sure that your monitor or other load does not exceed the relay contact rating on 15 Optional Wiring The standard alarm terminal block 15 supplied on the CASM features solder less plug in 1815 gt 3 2 5 6 e terminals accepting 18 14 AWG wire An optional auxiliary alarm contact terminal block TB15 AUX or a 6 IER g g blocks TBISA AUX amp TB15B AUX may be supplied 2 2 2 a a a 2 2 a e a 2 3 212 2 2 external to the CASM PC
63. he battery DC voltage or must utilize a series dropping resistor to compensate for the difference in voltage between the battery and indicator lamp 3 AC INPUT VOLTMETER EJ0095 EJ0121 AND AMMETER EJ0134 EJ0135 OPTIONS Purpose These options are to permit the user to monitor the input AC line voltage and line current to the battery charger This may be done for either single phase or three phase input power Descriptions a Single phase 10095 shows the connections to the ac voltmeter and 134 shows connections to the AC ammeter The ammeter is usually connected to the AC line via a current transformer if the line current is over 50 Amperes b Three Phase AC 10121 shows the connections to the ac voltmeter and 0135 and shows the connections to the AC ammeter Both show the connections utilizing a single meter one to monitor the three phase to phase voltages and one to monitor the three line currents A two pole three position switch SW5 is used to switch the voltmeter from phase to phase to check all three input voltages The ammeter switch SW6 is a special switch which shorts all unused current transformer secondaries Upon changing switch position it shorts the current transformer CT1 secondary in use before transferring the ammeter to a new position This prevents very high voltage arcs when the secondary is open circuited CAUTION NEVER OPERATE A CURRENT TRANSFORMER WITHOUT A SECONDARY LOAD OR SH
64. hensive cost effective method to monitor the integrity of the battery charger and the dc bus Description The CASM combines the monitoring and alarm functions of the High Low AC Voltage Alarm High Low DC Voltage Alarm Ground Detection Relay Alarm Charger Failure Alarm and a Common Alarm Relay into one printed circuit board assembly A24 Each alarm in the CASM PC board operates similarly to the alarms in the equivalent stand alone option see previous descriptions One or two form C relay contacts are provided for each alarm function These contacts TB15 1 thru 18 have a contact rating of 0 5A 125 VAC VDC resistive Panel indicators 0526 0532 are provided for each alarm function except the Common Alarm In addition a front panel push to test switch SW20 checks the front panel indicators SW20 tests only the CASM indicators relays reset automatically when the alarm condition is corrected All alarm relays have a 15 second time delay except the Charger Failure Alarm You may operate the CASM Charger Failure Alarm in either of two modes 1 True Charger Failure Alarm In the True Charger Failure mode the CASM PC board does not report an alarm when the charger output current is zero unless the charger actually has failed The CASM performs a periodic self test to accomplish this 2 Zero Current Alarm In the Zero Current mode the CASM reports an alarm whenever the charger output current decreases to zero In this mode you may
65. icates recommended start up spare part B indicates recommended operating spare part 2 For component placement of circuit symbols refer to Single Phase SCR SCRF Series Mainframe Schematic JE5076 00 on Page 28 3 For mainframe replacement parts refer to Section IX starting on Page 53 23 NOTES COMPONENT DESCRIPTION SCR SCRF SERIES BATTERY CHARGER OPTIONS SINGLE THREE PHASE 1 indicates recommended operating spare part 2 For component placement of circuit symbols refer to SCR SCRF Series Option Schematics in Section VIII starting on Page 34 3 For option replacement parts refer to Section IX starting on Page 57 Option Number EJ0083 EJ0084 10085 10086 10088 10089 10093 10094 10095 Ref Page 38 Circuit Spare Symbol Note 1 DS2 R54 DS8 DS9 R50 R51 SW7 DS5 056 59 M epe B Component Description High Low DC Voltage Alarm PC Board w Relays Socket for A2 Low Voltage Indicator Light Hi Voltage Indicator Light Voltage Dropping Resistor Voltage Dropping Resistor Percent Equalize Timer Float Auto Equalize Switch Switching Relay Float Indicator Light Equalize Indicator Light AC Failure Alarm Relay AC Failure Indicator Light Voltage Dropping Resistor Positive Ground Detection Alarm Relay Negative Ground Detection Alarm Relay Reset Switch Voltage Dropping Resistor Voltage Dropping Resistor Voltage Dropping Re
66. in a bridge are found defective When diodes fail it usually is because of surge voltages Therefore surge suppressors SS1 SS2 should also be checked to determine that they are operative Refer to Section 2 d on page 7 f SCR Diodes SCR1 SCR2 also see Section 2 1 These devices are part of the SCR diode module s described in Section 2 e above Power regulating devices SCR1 and SCR2 are silicon controlled rectifiers which cannot be checked using the same method as used with rectifier diodes by forward and reverse resistance checks since the SCR will always show a high resistance until triggered 2 The operation of the SCR can be checked with an oscilloscope The gate firing voltage signal is produced by the control module assembly 1 The oscilloscope should be GROUND ISOLATED for these tests This is normally done by using a line isolation transformer in which the secondary that powers the oscilloscope is UNGROUNDED Alternatively a battery powered portable oscilloscope can be used The gate signal may be checked on the control module see Section 2 g or where the twisted pair trigger leads terminate on the SCR diode module The same signal should appear at both points Absence of the signal indicates that the control module is defective not the SCR 3 If the charger AC input breaker trips immediately and a shorted SCR 15 suspected a simple check with an ohmmeter can be made Turn off CB1 and CB2 Connect
67. ince the charger must be operable for this adjustment preceding checks in Section IV 1 above must indicate a serviceable charger Set switch SW1 to FLOAT Use a portable voltmeter of one percent accuracy Connect the battery supply leads to the battery and close the DC battery breaker CB2 Set the AC breaker to ON 2 Since the EQUALIZE and FLOAT potentiometer control settings interact with each other it is always necessary to adjust the FLOAT control first and then the EQUALIZE control afterward Never finalize a voltage adjustment with the charger output in excess of 100 rated output current 3 Turn the control clockwise watching the response on the voltmeter Clockwise rotation should cause the charger output current to increase rapidly while the voltage should rise slowly The rate of voltage rise depends upon whether the battery is fully charged the size of any connected load and the size of the charger versus the size of the battery After getting several volts response in battery voltage rise turn the FLOAT control counterclockwise This should result in a rapid drop in charger output current and eventually in a slow decrease in battery voltage Now adjust the voltage for the desired float setting and tighten the locknut on the potentiometer 11 b Equalize Adjustment 1 Since the equalize adjustment will not affect the float voltage adjustment and requires a higher voltage it should always be made after the f
68. ion utilizes a printed circuit board assembly A8 to provide low limit threshold voltage set at the lowest safe voltage to which the batteries may be discharged Alarm contacts are wired to TB3 terminals 31 32 amp 33 These may be used to operate a system load disconnect circuit by tripping a shunt trip DC load circuit breaker or opening a DC load contactor An optional END OF DISCHARGE front panel indicator lamp 0512 may also be provided The factory preset thresholds for alarm condition are as follows unless otherwise specified 1 75 volts cell for LEAD ACID 1 00 volts cell for NICKEL CADMIUM 15 CURRENT LIMIT ALARM RELAY W INDICATOR LIGHT EJ0137 Purpose The Current Limit Alarm provides an alarm signal whenever the battery charger output reaches the maximum limit set by the current limit circuit An indicator lamp DS24 mounted on the instrument panel also lights when the current limit alarm is activated Description The CLA PC Board assembly A18 continually monitors the output of the current limit circuit on the charger control module A1 When the current limit circuit indicates that the charger output is in current limit the circuitry of A18 closes a relay K24 This provides an alarm condition at terminals 25 26 amp 277 of TB3 A several second delay is built into A18 so that brief excursions into current limit caused by load changes will not result in an erroneous alarm indication When the battery charger comes out of c
69. irst be certain the connections are tight If still no indication turn CB1 and CB2 breakers to OFF disconnect the charger ammeter and or shunt and substitute a precision ammeter of suitable range Be certain to make solid connections clip contacts may not carry sufficient current or may make poor contact and cause the reading to be inaccurate 2 A reverse scale indication of the meter indicates the charger is inoperative or internally shorted and that the battery is discharging through the rectifier or that the meter leads have been reversed Turn and CB2 to OFF and check wiring and meter connections Then check meter operation using a 1 1 2 Volt D cell as the power source Momentarily touch the D cell terminals with proper polarity to meter terminals and observe meter deflection m Filter Capacitors C1 C2 filtered chargers only NOTE Capacitors and C2 may consist of one or more parallel connected capacitor units as needed by the filtering requirements C2 normally is used only in chargers with the filtered eliminator option CAUTION The filter capacitor is on the charger side of the blocking diode CR2 and is NOT charged by the battery when 2 is turned ON When the charger is turned OFF opened the capacitor will hold a charge until discharged by bleeder resistor R1 Capacitors C1 and C2 should always be discharged before servicing in the event the R1 has opened and no longer serves as a bleeder 1 Befor
70. ized Activating SW12 down will connect the two lamps in series across the battery with the center attached to chassis ground This performs as the two lamp system 0088 as described above Activating the SW12 up serves to test the lamps c GROUND DETECTION SWITCH FOR DC VOLTMETER INDICATION EJ0094 This method uses the existing panel DC voltmeter M2 and two double throw switches SW8 SW9 to utilize the voltmeter in both functions SW8 establishes the meter function output voltage or ground detection and SW9 switches the voltmeter between or terminals to chassis ground reversing the meter polarity to maintain up scale indications The voltmeter used in the ground detection mode will indicate the DC voltage potential between the corresponding output terminal and chassis ground For cases of partial grounds the voltmeter will indicate the difference of the terminal DC voltage and the voltage of the partial ground d GROUND DETECTION ALARM RELAYS EJ0086 W OPTIONAL INDICATOR LIGHTS This method utilizes two DC relays which monitor the and terminal voltage to chassis ground and will energize if the opposite polarity terminal is grounded To insure that the relays will not energize on half voltage when there is no ground present series resistances are used to reduce the relay pull in sensitivity However once pulled in by a ground condition the relays will not drop out when the ground is removed because the drop
71. k the charger for normal performance as described in Section II 8 e In addition to those symptoms listed in Table A the following procedure should be followed for any condition Check voltage of the AC supply to insure that it is within 10 of the value of the specified input voltage Examine charger for any evident loose or improper connections particularly at the control unit transformer T1 input and output terminal board Check continuity of battery circuit by comparing voltage at charger terminals with total of cell voltages e Check accuracy of voltmeter and ammeter on the charger 3 TESTING OF COMPONENTS a External Circuit Wiring 1 When no line voltage exists between TB1 L1 and TB1 L2 check the AC line back to source 2 With no output or a low output the external DC wiring may be at fault Check the wiring between charger and battery to see that it is properly installed Make certain that terminals are tight and clean and that the DC wiring is free from grounds The total operating voltage drop in the loop or leads between the charger and battery terminals should never exceed 0 5 volt at rated charge current and preferably should be kept considerably below this limit by using a sufficiently large wire size b Power Transformer T1 1 With the AC and DC circuit breakers open or OFF open the cabinet and carefully check the line voltage across the line terminals TB1 L1 and TB1 L2 Refer to Section 2
72. le precision digital voltmeter and measure the voltage drop across the current sensing resistor With a rated current output indicated on the panel ammeter a nominal voltage drop of approximately 30mV in proportion to rated current should be observed If the voltage drop is higher or lower than the nominal indication replace the ammeter or shunt and recheck the voltage drop j DC Voltmeter M2 1 The DC voltmeter is of the 2 percent accuracy type It is connected across the charger output to the battery and should indicate regardless of whether or not the charger is operating or the DC breaker is ON If it does not use a precision voltmeter of the 1 accuracy type connected across the meter terminals An indication on the test meter will show that the panel meter is open Check the wiring for an open circuit or replace meter if circuit wiring is complete 2 A shorted voltmeter will show no indication Battery current through a shorted meter will cause a visible indication such as smoke from burning wire insulation Disconnect the charger from the battery and AC source and replace the meter and damaged wiring 3 If the meter calibration is in doubt checking against a precision meter will determine if the panel voltmeter is off calibration more than two percent k DC Ammeter M1 1 The charger DC ammeter is connected in series between the charger output and battery If open it will indicate zero or if shorted it will also indicate zero F
73. ll of its products GNB INDUSTRIAL POWER A Division of Exide Technologies
74. loat voltage is determined Use a portable voltmeter of one percent accuracy as in the float adjustment Set switch SW1 to EQUALIZE Close the DC battery breaker CB2 Set the AC breaker to ON 2 In attempting to set the equalize voltage one thing must be kept in mind It will be impossible to set the equalize voltage if the batteries are in a discharged condition If fact they must be at near full charge This is to prevent the charger from going into a current limit condition Current limit reduces the charging voltage and no matter if the EQUALIZE potentiometer is increased to a full clockwise position the charger voltage will not increase 3 Therefore it is suggested that the batteries be placed on equalize charge for several hours so that the charger is no longer in current limit This should be observed using the portable 1 accuracy voltmeter and the charger panel ammeter When the charging current falls below the 100 rated value of charger current observe the voltage and set carefully for the desired equalize voltage If upon readjustment the current again goes into current limit wait for the batteries to continue their charge cycle Continue this adjustment procedure until the desired voltage is reached and the current is less than rated current When the final setting is determined tighten the lock nut on the EQUALIZE potentiometer 2 CURRENT LIMIT RESPONSE AND ADJUSTMENT a Checks and Adjustments Make ce
75. mber of lead acid nickel cadmium or nickel iron cells as long as the desired float and or equalize voltages are within the range of the charger 3 INSTALLATION a Location Select a clean dry location for the charger It may be located in the battery room but not over the battery and must be mounted upright The openings for ventilation in the top bottom and sides of the cabinet should not be obstructed as they provide convection cooling and ventilation Ambient temperatures between 32 F and 122 F and elevations up to 3 300 feet above sea level will not affect the performance of the charger Operation at higher temperatures or at higher elevations is possible if the ampere output is de rated in accordance with published information and if the charger is custom ordered for these operating ambient conditions b Wire Sizes AC Wire sizes for the AC wiring may be selected by consulting the data on the nameplate for input amperage Local electrical or NEMA standards should dictate appropriate wire size Most codes specify that the AC wiring size must match the current rating of the input circuit breaker or fuses c Wire Sizes DC The size of the charger leads should be selected to a carry the charger ampere current rating and also b provide less than 0 5 volt total drop at rated current in the loop or leads between the charger and battery terminals Choose the larger wire size that meets conditions a and b Do not undersize It is
76. n Page No Option Page No EJ0083 34 EjJ0096 38 43 EJOLTS 2 uu 47 EJ0084 34 EJOO Torenia 39 EJ0135 u 4 BJ0430 sen 48 10085 35 0 20 0 39 EJ0137 44 BJ0592 iet 48 EJ0086 35 JEJOT21 dere A0 137 det EJOS83 eere 49 EJ0088 36 10123 40 EJ0138 nu 45 EJ0826 50 0089 36 BIJ0127 sn 41 45 50 2 37 uan 41 EJO141 w buzzer 46 EJI23 4s eee 51 EJ0094 e 37 0133 schematic 42 eene 46 11398 51 EJ0005 KEE 38 0133 wiring 42 47 SWC filter 52 SECTION IX REPLACEMENT PARTS Electrical Ratings and Replacement Parts SCR SCRF Series Battery Charger Mainframe 53 55 Replacement Parts SCR SCRF Series Battery Charger Options 57 61 SECTION X MANUAL SPECIFICATIONS document control information Document Number Revision 62 On Line Availability erento det a uqa kia sta 62 Parts Listu Drawing Notes eo fe ted a
77. oa MGH LOW VOLTAGE ALARM Pc BOAED ASSY A BOTES Om An ge dr av AC Z AMRIT Act ov avd AE 3 ANd mt AC MONE TIME weien L W AC VOLTAGE ALARM oe INDICATING LIGHTS eng ome KREE EE ech aemeoveo ee ER o 047 47 TH2 220 F 2 120 FROM TI 3 K18b DVER TEMP NOTE 3 4 BUZZER ENABLE Y OFF TEST ES TEMPERATURE OVER ALARM CONTACTS SHOWN IN NON ALARM CONDITION CONTACT RATING 0 5 125 RESISTIVE TB3 THERMOSTAT TH2 CLOSE ON RISE 220 F IS SELF RESETTING ALARM 4 3 K18b PROVIDES CALL BACK FEATURE TERMINAL BLDCK WHEN OVER TEMPERATURE IS CORRECTED RESET SEE 1 SWITCH Sw17 ENABLE POSITION 091903 an OSI 5 061796 2 061785 im SCR SCRF SERIES OPTION SCHEMATIC OVER TEMPERATURE ALARM W BUZZER 021794 061785 Fag ES 030893 UNLESS OTHERWISE NOTED DIMENSIONS EJ0439 01 6 ARE IN INCHES TOLERANCES ARE FILENAME 0438 01 CHARGER RESET 5014 CHARGER SHUTDDWN 0520 SINGLE PHASE CONTROL MODULE 1 THREE PHASE CONTRDL MODULE
78. ontact your sales representative for drawing availability from the battery charger manufacturer Any job specific custom drawings supplied with this battery charger and or this manual supercede the standard drawings featured on pages 28 and 32 52 The standard drawings and corresponding page numbers featured in these sections may not be included with custom printed manuals when job specific custom drawings are supplied 62 JD5022 00 MAINTENANCE DATE Step standard features Clean battery charger Check all electrical connections and wiring Check ac input voltage Check dc output voltage Check ripple voltage Exercise front panel controls Check voltage settings Step optional features Check alarm settings Combined Alarm Status Monitor CASM Check integrity of remote wiring Step 10 year repair Replace capacitors SCR SCRF Series Battery Charger Preventive Maintenance Procedure PERFORMED BY All vents clean and open OOK Remove dust and debris from inside of unit TB1 and TB2 connections all tight OK Internal wiring connections tight slip on connectors fully seated Wire OOK and lug insulation in good condition Terminations at battery or bus are tight and corrosion free Measure at TB1 L1 TB1 L2 amp TB1 L3 3 Phase only using ac Input voltmeter Value must be within 10 12 of nominal Vac Measure at TB2 and TB2 using dc voltmeter Value should agree
79. operates once the threshold voltage is reached It will be necessary to raise and lower the battery voltage several times to ascertain that the potentiometer setting is correct Similarly the battery bank will have to be charged at a high equalize rate in order to set the HVA threshold At the equalize rate the charger may go into a current limit condition depending on the state of charge and it may be impossible to reach the desired high voltage alarm voltage If this 1 the case it will be necessary to substitute a resistive load bank with paralleled capacitance in place of the batteries Adjust the output voltage of the charger by using the EQUALIZE potentiometer R5 and then set the HVA potentiometer accordingly It will be noticed that there is an operational delay time and a hysteresis zone dead zone between the drop out voltage and the pull in voltage of the alarm circuits This is natural and desirable to prevent chattering of the relays when the threshold voltage is reached The factory preset thresholds for alarm conditions are as follows unless otherwise specified LVA 2 00 volts cell for LEAD ACID 1 14 volts cell for NICKEL CADMIUM HVA 2 40 volts cell for LEAD ACID 1 65 volts cell for NICKEL CADMIUM 5 CHARGER FAILURE ALARM RELAY EJ0127 WITH OPTIONAL INDICATOR LIGHT Purpose The Charger Failure Alarm provides an alarm indication whenever the charger output current decreases to below 2 of rated current for more than 30 se
80. ors are used to properly match the battery voltage 16 7 EQUALIZE TIMERS Purpose Equalize Timers are used to switch the charger into equalize charging mode for a set period of time when required by the batteries FLOAT and EQUALIZE indicating lights mounted on the instrument panel can be included with all timers to indicate the charging mode There are three basic timers described below These Equalize Timers replace the standard FLOAT EQUALIZE switch SW1 featured in the charger mainframe and referenced elsewhere in this manual Descriptions a MANUAL EQUALIZE TIMER EJ0097 W LIGHTS EJ0096 W LIGHTS amp SW EJ0869 To operate this 0 72 hour timer turn the timer control knob TM1 clockwise to the number of charge hours desired This will start an AC clock driving two cams which operate two contacts One contact provides AC to the clock motor the other changes the voltage sensing network to the higher equalizing voltage Upon completion of the time period when the timer control knob reaches the clock motor is stopped and the voltage sensing network is returned automatically to the float voltage value Option EJ0096 features the aforementioned manual equalize timer along with FLOAT and EQUALIZE indicating lights Option EJ0896 features the aforementioned manual equalize timer and indicator lights along with a manual FLOAT EQUALIZE switch b AC LINE FAILURE AUTO EQUALIZE TIMER WITH INDICATOR LIGHTS EJ0131
81. out voltage of a DC relay is always less than the pull in voltage As a result a momentary RESET switch SW3 must be activated to open the relays returning them to the ready condition Schematic EJ0086 shows the circuit diagram of this method The panel lamps shown a user option that 15 available for front panel indication The relay coil voltages and series resistances will depend on the output voltage of the battery charger 14 2 AC POWER FAILURE ALARM RELAY 0085 WITH OPTIONAL INDICATOR LIGHT Purpose The purpose of this alarm is to notify the user that the AC input power to the battery charger has been interrupted A front panel FAILURE lamp is optional for local indication Relay contacts are provided for remote monitoring Description The principle of operation utilizes the normally closed contacts of an AC relay K1 K1 is powered from the AC line at the primary of the transformer T1 when energized holds the normally closed contacts open disabling the alarm indication When the AC line fails or the AC circuit breaker is opened for any reason the alarm contacts will close activating the alarm indicator EJ0085 shows the circuit with the optional panel indicator lamp and external relay connections for remote indication The indicator lamp must operate from the battery power since the AC line power is not available in an alarm state As a result the indicator light operating voltage must match t
82. rn SW1 to FLOAT turn the timer manually to zero The charger will indicate zero or little output current until the float voltage is reached At this point the current should increase slowly to the system load value the battery is now floating across the line with approximately equal input and output currents c When operating normally the current limit control will limit the maximum charger output current to approximately 110 of the rated charge current In case of a high DC current demand the current limit control will keep the charger output within safe values without tripping the DC circuit breaker or the AC breaker 9 DESCRIPTION OF OPERATION There are four major sections of the SCR single phase charger which work together to produce stable regulated filtered output The functions of these four sections may be described as follows a The Power Transformer T1 This section includes T1 and its associated input protection Its purpose is basically to supply an AC voltage of the proper magnitude and capacity to the rectifier section It also supplies various other voltages used by the control unit and accessories It is connected to an AC source by means of a circuit breaker b The Rectifier Section This section consists mainly of the voltage regulating silicon controlled rectifiers and the power rectifier diodes It accepts the AC voltage from the transformer rectifies this voltage to DC and controls the voltage s magnitude so
83. rtain the charger leads are connected to the battery and that the panel voltmeter indicates the proper polarity Switch the DC breaker CB2 to ON and AC breaker CB1 to ON The AC ON indicating light DS1 should illuminate indicating power has been applied With the charger in float mode a float voltage charge should be indicated on the panel voltmeter and the ammeter should show either a charge current or practically none at all depending on the state of battery charge 1 If the batteries are in a discharged condition switching to the equalize mode will cause the charger to automatically go into a current limit condition If however the batteries are fully charged they probably will not draw current in the current limit range In order to cause this condition it will be necessary to connect additional load to the battery charger or battery bank This can be resistive elements or turning on the normal load of the installation When current limiting is encountered observe that the charger voltage will be reduced below its set value by the current limit feedback signal Observe that as the current limit condition continues the voltage will slowly increase as the batteries take on a charge Eventually the current will begin to decrease below the current limit value and continue to decrease to a value less than 100 of rated output current As the current decreases below 100 of rated output current the voltage will become constant at the equ
84. ry Leader GNB Flooded m ABSOeLYTE 7ZlaSSic MARATHON LITHIUM POWER GNB Industrial Power a division of Exide Technologies is a global leader in network power applications including com munication data networks UPS systems for computers and control systems electrical power generation and distribution Systems as well as a wide range of other industrial standby power applications With a strong manufacturing base in both North America and Europe and a truly global reach operations in more than 80 countries in sales and service GNB Industrial Power is best positioned to satisfy your backup power needs locally as well as all over the world GNB Industrial Power USA Tel 888 898 4462 Canada Tel 800 268 2698 www gnb com Section 93 20 2011 11 P Sprin Based on over 100 years of technological innovation the Network Power group leads the industry with the most recognized glo bal brands such as ABSOLYTE GNB FLOODED CLASSIC MARATHON ONYX RELAY GEL SONNENSCHEIN and SPRINTER They have come to symbolize quality reliability per formance and excellence in all markets served RELAY GEL Sonnenschein GNB Industrial Power takes pride in its commitment to a bet ter environment Its Total Battery Management program an integrated approach to manufacturing distributing and recy cling of lead acid batteries has been developed to ensure a safe and responsible life cycle for a
85. s are tight The open circuit voltage should be about 8 to 10 below the rated float voltage c The charger can now be energized by first closing the DC breaker to supply voltage for the control circuits then closing the AC breaker Set the charger to float AC power ON pilot light should light and the ammeter should indicate charger output current It is to be expected that the meter may show up to 110 current rating of the charger the 110 being the factory setting of the current limit control d The factory preset float voltage adjustment is shown on page ii and when this value is reached the charger ammeter should show a slow decrease in current eventually down to a stabilized value Please note that whenever a charger is in a current limit condition the output voltage is automatically reduced to a value below the set float or equalize voltage The voltage will not increase to normal value until the battery s state of charge increases causing the charger current to decrease to a value equal to or less than the rated current e The factory adjustment of the equalizing charge voltage is also shown on page ii and assuming this is as desired the Float Equalize switch may be switched to Equalize to check the charger performance at this voltage value If a manual Equalize Timer option has been included turn it clockwise to activate the equalize charger mode The charger ammeter may again go up to current limit until the equali
86. shorted an ohmmeter check will indicate continuity When the suppressor shows an infinite resistance in both directions measured with it disconnected from the charger and has a normal appearance it can be presumed to be in good operating condition e Rectifier Diodes SCR1 SCR2 also see Section 2 f 1 These diodes are a part of an SCR diode module s in which the SCRs and diodes are contained in a module s mounted by an electrically insulated heat sink plate Three connections plus one SCR gate terminal are available for checking The diode portions should be checked by disconnecting one terminal and measuring their forward amp reverse resistance in either of two ways In using an ohmmeter use the R x 1 scale for the forward resistance and this should show approximately 5 to 10 Ohms The reverse resistance should be up in the thousands of ohms probably 50 000 or more measured with a higher scale of the meter The diodes may also be checked by connecting them in series with a 6 or 12 Volt lamp across a DC source of the same voltage The lamp must require at least one quarter Ampere The lamp should light with nearly full brilliance with current flowing in the forward direction and not at all in reverse If it lights in both directions the diode is shorted If in neither direction the diode is open 2 Note that semiconductors usually short in pairs in bridge circuits seldom as single units and it is rare that all four semiconductors
87. sistor Voltage Dropping Resistor Positive Ground Detection Indicator Light Negative Ground Detection Indicator Light Positive Ground Detection Indicator Light Negative Ground Detection Indicator Light Voltage Dropping Resistor Voltage Dropping Resistor Positive Ground Detection Indicator Light Negative Ground Detection Indicator Light Voltage Dropping Resistor Voltage Dropping Resistor Test Switch Float Equalize Switch Float Indicator Light Equalize Indicator Light Ground Detection Ouput Switch Ground Detection Positive Negative Switch Single Phase AC Voltmeter 24 Option Number EJ0096 EJ0097 EJ0120 EJ0121 10123 EJ0127 EJ0131 10133 EJ0134 EJ0135 10137 10138 EJ0141 w o Buzzer Ref Circuit Spare Page Symbol Note 1 Component Description TM3 B 0 72 Hour Manual Timer DS5 B Float Indicator Light 056 B Equalize Indicator Light TM3 0 72 Hour Manual Timer Battery Discharging Alarm PC Board w Relay Socket for A5 DC Current Shunt Battery Discharging Indicator Light 3 Position DC Output Terminal Block batt load load bat Voltage Dropping Resistor Voltage Dropping Resistor M4 Three Phase AC Voltmeter SW5 Phase Selector Switch 40 AUI Common Alarm Buzzer SWI13 Buzzer ON OFF Switch Voltage Dropping Resistor Charger Failure Alarm PC Board w Relay Socket for A3 Voltage Dropping Resistor Voltage Dropping Resistor Charger Failure Indicator Light AC Failur
88. st two pages of this manual refer to the cover artwork only DOCUMENT INFORMATION Document Number 5035 00 Revision Level 2 Engineering Change Number 20053 Electronic Filename JA5035 00 pdf Last Date Saved 12 27 2005 3 39 PM Last Date Printed 12 27 2005 3 39 PM ON LINE AVAILABILITY Electronic versions of this SCR SCRF Series Battery Charger manual saved in Adobe Acrobat Portable Document Format PDF are readily available online for downloading and printing Please contact your sales representative for document availability or visit the manufacturer s web site listed on the back cover of this manual STANDARD DRAWINGS Standard drawings for the SCR SCRF Series Battery Charger saved in Adobe Acrobat Portable Document Format are readily available online for downloading and printing Please contact your sales representative for standard drawing availability or visit the manufacturer s web site listed on the back cover of this manual PARTS DATA PACKAGE Any job specific custom Parts Data Package supplied with this battery charger and or this manual supercede the standard parts listed on pages 53 61 CUSTOM DRAWINGS A customized record drawing package is available for your SCR SCRF Series battery charger featuring itemized internal component layout electrical schematic with component ratings and a full connection diagram If the standard drawings featured in this manual are not sufficient please c
89. t of nq Rc0012 00 RC0012 00 0014 00 RC0014 00 part of 2 TERMINAL BLOCK pane 20006 00 0006 00 RG0012 01 0012 01 0014 01 014 01 8031300 wO panel PARTS COMMON TO ALL SINGLE PHASE SCR SCRF SERIES CHARGERS PART NO DESCRIPTION PART NO DESCRIPTION GK0058 81 CONTROL MODULE PC BOARD UNFILTERED R4 RJ0003 84 VOLTAGE DIVIDER RESISTOR GK0058 82 CONTROL MODULE PC BOARD FILTERED ELIMINATOR RJ0014 06 EQUALIZE ADJUSTMENT POTENTIOMETER RD0001 00 MANUAL FLOAT EQUALIZE SWITCH RA0001 05 AC ON INDICATOR EJ0616 00 PC BOARD HOLDERS RJ0014 06 FLOAT ADJUSTMENT POTENTIOMETER 0068 00 FILTER CAPACITOR BRACKET RP0046 12 SUPPRESSION CAPACITOR 260 VDC R5 RP0043 20 SUPPRESSION CAPACITOR 24 48 130 VDC 501 0617 00 PLUG FOR PC BOARD SW1 TO ORDER PARTS PLEASE CONTACT YOUR SALES REPRESENTATIVE PLEASE ORDER BY QUANTITY PART NUMBER AND CIRCUIT SYMBOL FROM TABLES ABOVE HAVE YOUR BATTERY CHARGER MODEL NUMBER AND SERIAL NUMBER AVAILABLE 54 ELECTRICAL RATINGS AND REPLACEMENT PARTS SCR SCRF Series Battery Charger Single Phase Mainframe PLEASE CONTACT YOUR SALES REPRESENTATIVE FOR DATA ON MODELS NOT LISTED i20Vac 19 22 50 58 81 115 28 AG 240Vac 95 16 21 25 29 40 57 14 480Vac 48 78 10 5 13 15 20 29 74 SYMBOL DESCRIPTION MANUFACTURER S PART No 1 2 FILTER CAPACITOR RP0019 03 RP0019 05 SNUBBER CAPACITOR RP002
90. tal time base set at 5MS CM Compare the waveforms observed with those shown in FIGURE 2 on page 31 for the various test points indicated 4 Check waveform at test point C and compare with FIGURE 2 If waveform is improper check CRI2 and CR13 Check amplified inverted waveform at test point D If it is not present replace IC2 5 Check ramp pattern at test point E If not proper replace Q1 only with its own type Motorola 5 55 Do not substitute 6 Check the ramp with floating DC reference at test point F If it is not present replace IC2 7 Check the short pulse at point G If not present check uni junction transistor Q3 8 Check waveform at point H Note that at both points G and H there may be multiple pulses instead of only one pulse per 8 33 ms period This is normal particularly if the unit is calling for maximum output voltage If no pulse waveform is present replace transistor Q2 9 Check the battery charger rectified waveform by connecting the oscilloscope across the bleeder resistor and readjusting the input sensitivity to 20 V CM If the unit is turned half on the waveform will look approximately like the waveform of I of FIGURE 2 h Current Sensing Resistor SH1 1 In light current chargers the current sensing signal is taken directly across the DC ammeter In chargers with 50 Amp or higher output current the sensing resistor is a meter shunt which also serves as the shunt for the panel ammeter Use a portab
91. te iui 62 SECTION INSTALLATION AND OPERATION 1 SAFETY NOTICE CAUTION READ IMPORTANT SAFETY INSTRUCTIONS ON PAGE i There are dangerous voltages within the battery charger cabinet a Only qualified personnel should attempt to adjust or service this equipment b Refer to instruction manual for service procedures and CAUTION notes 2 APPLICATION Specifications The silicon controlled rectifier is designed to maintain a system voltage within or 0 596 of the set value without exceeding its rated output current It will maintain or 0 5 with input voltage variations 10 above or below the rated input AC voltage and with 5 frequency variations The charger is designed primarily to operate only when connected to a battery load It can be operated as a battery eliminator into a resistive load up to full rated output at increased ripple Filtered type chargers will have a ripple content less than 30 mV RMS under steady state conditions with the charger connected to a battery having an 8 hour Amp Hour rating of at least 4 times the full load current rating of the charger Other connected loads such as DC to DC power supplies or inverters may put ripple on the battery appreciably above 30 mV Unfiltered chargers should not be used with critical loads such as communication systems amplifiers and instrumentation systems but should only be used for non critical applications such as engine cranking This charger can be used on any nu
92. tions 1PH 3PH BATTERY CHARGER NOMINAL OUTPUT 12 Vdc 24 Vdc 48 Vdc 130 Vdc 260 Vdc EJ0837 Em Combined Alarm Status Monitor 1 Form C Control PC Board 2 Form C 0014 83 0014 83 0014 83 0014 83 0014 83 Exe m Les acre namie ea at is 0 R657 eee Les EJ0895 6 16 Adc RB0025 10 20 40 Adc 0025 12 Digital DC Ammeter 50 125 Adc 0025 14 150 250 Adc RB0025 16 300 600 Adc RB0025 19 6 16 Adc RB0008 17 20 40 Adc RB0008 00 SH1 DC Ammeter Shunt 50 125 Adc RB0008 03 RB0008 05 RB0008 18 150 250 Adc 300 600 Adc EJ0967 DS43 Common Alarm Buzzer for CASM EJ0837 0004 00 SW13 Buzzer Control Switch RD0001 00 TO ORDER PARTS PLEASE CONTACT YOUR SALES REPRESENTATIVE PLEASE ORDER BY QUANTITY PART NUMBER AND CIRCUIT SYMBOL FROM TABLES ABOVE HAVE YOUR BATTERY CHARGER MODEL NUMBER AND SERIAL NUMBER AVAILABLE 6 k SECTION X MANUAL SPECIFICATIONS DOCUMENT NUMBER The internal text and graphics contained within this manual are controlled by the battery charger manufacturer s internal part number JA5035 00 Revision level and dates for this part are listed below These controls supercede all other available dates first two and last two pages of this manual are reserved for company specific front and back cover artwork Any document numbers revision levels or revision dates featured on the first two or la
93. trol the control trigger PC Board 1 to determine if it has any effect on the high output current reading This control is the potentiometer labeled R11 on single phase control PC boards GK0058 and R65 on three phase control PC boards GK0048 If it does have an effect make the adjustment for 110 rated current for a current limit setting as described in paragraph IV 2 a 2 above 2 If no effect is noted IC1 on the control trigger PC board A1 may be defective If so replace 3 Check the voltage generated across the ammeter M1 or ammeter shunt SH1 to determine that sufficient voltage is available at rated current to activate the current limit feedback amplifier See Section 2 h Use a sensitive DC voltmeter and measure the voltage across the ammeter M1 or ammeter shunt SH1 Measure the voltage from the current limit pin to the control circuit reference pin the plug 501 of the control trigger PC board 1 These pins are respectively pins 1 and 10 on single phase control boards GK0058 and pins 6 and 9 on three phase control boards GK0048 If the sense voltage is not present at the control trigger PC board 1 check the wiring If the wiring is satisfactory proceed with the check sequence listed in Table A trouble shooting chart on page 27 13 SECTION V SCR SCRF SERIES BATTERY CHARGER CUSTOMER OPTIONS The following pages describe customer options available in SCR SCRF Series battery chargers
94. uns LINDYID 9d uav dug LINDYID OV HJ NHOJSNVH 1 V SANIT 89 Alddluy HEI 32 LON S3OG v 3ALLO3HJ3NI ADVLIOA INauufno HEI INa3uuHfio HO SNIddild 1 udMxVdda OV LON 590 27 L18d 00 9 065 1 JAVNd 113 00 9 063 ON SIN 11 25 1 0 ON N2d 00 94053 Ada SSINVAF DL S3HONI NI Zeg SNOTSNAWIO 03103 3SIMB3HID 559 Mi ON 3SVHd 3 DONIS JIIVW3HOS 3WVadNIVW d39dVH 4991198 S3IS3S 4425 428 sunu AIW nnvan NOIL VNSIS 3AIIVO3N ONY 3AILISUd A3311V8 903 1 104 NOTLIANNOD NV SV SI SI S81 Ova 3ATIv93N NI 031 Vd 0317995 LON SI 285 JI SI 282 33 WNIWON 20 05 31va 59299 2 NI Q3I dd NUWAD2 OL LISNNOD ANN JOIS 3AILV93N 22 ONY 12 3dAL 3 382328 20 30 BDOIVNIWIT3 a3 O3S SI ZI 3dAL 3895 LAdLNO 20 30 9NIS3I SI 24 3514 20 ONOIAS V Av3a8 1119412 20 1 01190 S SI IHS 5 IVN331X3 1 J30 1515 09 22 ONY 19 08160 13 NIHIL IN3WISTICOV Cl3TiVa
95. urrent limit the alarm will be automatically reset 16 CABINET HEATER STRIPS EJ0145 Purpose and Description This option provides a method of maintaining a dry charger interior in high humidity environments Strip heaters R68x placed inside the charger cabinet are physically shielded to prevent accidental human contact A customer supplied 120 Volt single phase source provides power for this option and is separate from the charger circuit This customer power source protected by circuit breaker CB6 is connected to terminal block TB6 located inside the charger enclosure The cabinet heaters are ON OFF type and are controlled by a fixed thermostat TH1 The thermostat opens on a rise to approximately 80 F and resets re closes at approximately 70 F 17 HIGH LOW AC VOLTAGE ALARM RELAYS WITH INDICATOR LIGHTS EJ0155 Purpose The HLAC Alarm relay provides an indication whenever the AC input voltage deviates beyond preset limits The factory set limits are 11596 high alarm and 85 low alarm of the nominal AC input voltage Indicator lights on the battery charger front panel are provided for each condition Description The HLAC Alarm relay operates similarly to the High Low DC voltage alarm relay An AC Detector PC Board assembly A11B converts AC voltage to DC voltage An Alarm PC Board assembly A11A measures this filtered signal from A11B If the measured signal is not within an acceptable range an alarm condition is pro
96. vd NI O3123NNUJ IW 917389 D Ld LNO LIWI XX 850020 035 12 ONY 21 SILON ALON S 3 0 91 9 581 9 310N 0CBl 1 20 IV ASSV 10 1 03 11105915 WLI lIWI 1 33v80333 W31SAS LSnrav 321 EC 3101 310 NES va 2 Do isnrav 17074 310 22078 1 2323016 WNIWASL L 72078 WNIWSSL 045 190 HOLIMS 3ZI fil 193108 9 801551049 3981 1 O3NNUDS31INI IV NMLHS LON Sa3IJIL238 09771084105 10a 1 INL AJMO 33 3130 EN 190 LUN 25117 20 LINJ 833358 dv 113 3 2011 5 CWNOILdO d INI CWNOTLdO el V 881 NIV 14142530 1050 33S 28 SCR SCRF Series Battery Charger a ASMHERH IO d Y 12vu4 O3 OUddv aivo navya _ 59397 ae L2 w ono ee picem SE baie sa
97. vided at terminals 38 39 amp 40 High ACV and 41 42 amp 43 Low ACV of TB3 Corresponding indicator lamps DS18 DS17 are lighted on the instrument panel has a built in delay to prevent line voltage surges and sags from causing erroneous alarm indications When the AC line returns to within acceptable limits the alarm indications will be reset 18 OVER TEMPERATURE ALARM RELAY EJ0439 WITH BUZZER OR INDICATOR LIGHT Purpose The Over Temperature Alarm provides an alarm indication whenever the battery charger internal components become overheated for any reason This feature is standard on all battery chargers rated over 300 ADC Description A built in audible alarm DS19 is furnished along with alarm contacts at TB3 terminals 47 48 amp 49 A normally open thermostat TH2 is mounted on one or more of the heat sensitive components of the charger If an over temperature condition occurs the thermostat closes the circuit to DS19 and the alarm relay K18 The audible alarm may be turned off with a switch SW17 mounted inside the charger enclosure When the internal component temperature returns to an acceptable value the alarm relay is automatically reset SW17 should then be returned to the normal position 20 19 COMBINED ALARM STATUS MONITOR CASM PC BOARD ASSEMBLY EJ0837 Note Refer to the Drawing EJ0837 XX on page 49 for additional information Purpose The Combined Alarm Status Monitor CASM provides a compre
98. x 3VA Im 092 8 END T xnv ZA SX IX ix el EX IX 5X cX DEIF SNUILJ3NNQJ ASVUND23S INON JOA ogr SH IH nm wa SNUILJ3NNQJ E GX SX IX A3v0ND33S 021 SILON a3dwnr JVA 10810 AN ino xnv SX IX JOA indino SNOT LIANNOI AaVONOIAS INON 08v SH IH AaivWIad 021 ND SNUILJ3NND3 SH SX ABVONO23S zH 08 05 Sx ex JVA 092 el EX IX SX cX DIr JOA ASHI SNOT LISNNOI 1 10 355 802 SH IH Ovc OEc SH vH 2H 022 SH IH EH IH GH H 061 011 SH IH IVA NIT SANDT OM T vH ABVONO23S ER TERMINAL NUMBERS 15 TERMINAL NUMBERS HIGH DC VOLTAGE ALARM HIGH DC VOLTAGE ALARM LOW DC VOLTAGE ALARM LOW DC VOLTAGE ALARM POSITIVE NEGATIVE GND DET ALARM POSITIVE GND DET ALARM GND DET ALARM NEGATIVE HIGH LOW AC V
99. zero Once charged they will take several minutes to discharge if bleeder resistor is open If DC circuit breaker CB2 is not provided remove the DC fuses F1 F2 in order to isolate the charger from the battery AFTER LOCATING THE CHARGER PROBLEM ALWAYS DE ENERGIZE ALL AC AND DC CHARGER INPUTS AT THE POWER SOURCE BEFORE SERVICING 2 TROUBLESHOOTING PROCEDURE a When a charger is not operating properly the cause must be determined by checking various components until the fault is located b The major components are not checked in the order as listed in Section 9 since a charger may exhibit a number of difficulties each with different symptoms In many cases failure of one component may cause another component or part to fail Therefore the following paragraphs treat major components functional circuits and parts individually or by symptom Together with serviceability measurements and tests the faulty part or component should be located c Most of the following checks can be performed with an oscilloscope a VoltOhmmeter similar to a Simpson Model 260 and an SCR tester d Consult the trouble shooting chart in Table A on page 27 When using the table first locate the fault symptom observed in the left hand column then follow the sequence for checking components in the numerical order listed 1 2 3 etc for that particular symptom Follow this sequence until the trouble is located After correcting the trouble chec
100. zing charger voltage is reached The length of time required to reach this level depends on the state of charge of the battery and the ampere rating of the charger versus the battery rating f With the charger operating at the desired float and equalizing voltage values the system can be considered installed and ready for service 5 ADJUSTMENTS OF FLOAT amp EQUALIZING CHARGE also see Section IV 1 a Each adjustment is made by means of a potentiometer with a slotted shaft for a screwdriver The potentiometers are front panel mounted and appropriately marked A lock nut on each potentiometer is provided and should be tightened after the proper adjustment is completed This prevents any accidental mis adjustments of the settings The voltage response may be slow if a rise in voltage adjustment is desired because the battery state of charger and connected load must be considered Turning the shaft clockwise will raise the voltage and turning counter clockwise will lower the voltage b Since accuracy of measurement is important when setting float and equalizing voltages a precision portable VoltOhmmeter with at least 1 accuracy is recommended for these DC measurements conventional VoltOhmmeter or analyzer such as the Simpson Model 260 is also satisfactory but is not as accurate c Any setting of the float voltage or equalizing charger voltage should not be considered final until the ammeter shows less than charger rated current and volt

GSCR Charger I&O Manual Single Phase

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GSCR Charger I&amp;O Manual Single Phase

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GSCR Charger I&O Manual Single Phase