Legacy Platinum SCR Single Phase Charger
Contents
1. E 7 4 LOCATION AND 5 1 1111 8 4 1 Horizontal DIU m 8 4 2 eine pei 9 20255520 11 5 1 Pic Eee m 12 5 2 AC Voltage Jumper POSITIONS necne ecrire era Leer eaae erase Leurs aene Lua ianao dom ran na ner casn ela Dr cun rai 12 Wy ielJllnc S 12 5 4 Initial AG Power U p p 12 6 DOOR WITH SWITCHES AND AC CONTACTOR OPTIONAL 13 Hes DG OUTPUT sckssexesexiseestesenek nevaze vu secastveunedsasdusvasdvenacdne ddvectsusdentcavedexedevedextsensieinstenees 13 8 PROPER CARE OF DEEP CYCLE MOTIVE POWER BATTERIES 13 9 1 Personal Safety Precautions nanenane aeeoe aea on anna aera 14 9 CHARGER OPERATION eve vevax exo saca xava saevus eene vun eve necs kexenacuxes x 15 9 1 Multi Voltage Charging 5 rire tienen ceret Un edi 16 9 2 User Interface oorr naci deca dedo road va dva2. 121 1 1 29 www douglasbattery com 3 of 30 User s Manual 1 2 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important safety and operating instructions Before using battery charger read all instructions and cautionary markings on battery charger battery and product using battery IT MEANS ALERT YOUR SAFETY IS INVOLVED F YOU DO LOOK FOR THIS SYMBOL POINT OUT SAFETY PRECAUTIONS 10 11 12 13 NOT FOLLOW THESE SAFETY INSTRUCTIONS INJURY OR PROPERTY DAMAGE CAN OCCUR DANGER TO REDUCE THE RISK OF FIRE OR ELECTRIC SHOCK CAREFULLY READ AND FOLLOW THESE IMPORTANT SAFETY AND OPERATING INSTRUCTIONS BEFORE INSTALLING OR OPERATING THE CHARGER INSTRUCTIONS IMPORTANTES CONCERNANT LA SECURIT Awarnine TO REDUCE THE RISK OF FIRE INSTALL THIS BATTERY CHARGER ON A SURFACE OF NON COMBUSTIBLE MATERIAL SUCH AS BRICK CONCRETE OR METAL RISK OF ELECTRIC SHOCK DISCONNECT CHARGER FROM BATTERY AND POWER BEFORE SERVICING TURNING OFF THE CHARGER DOES NOT REDUCE THIS RISK DANGER RISK OF ELECTRIC SHOCK DO NOT TOUCH UNINSULATED PORTION OF AC OR DC CONNECTORS OR UNINSULATED BATTERY TERMINAL DANGER RISQUE DE CHOCKS LECTRIQUES NE PAS TOUCHER LES PARTIES NON ISOLEES DU CONNECTEUR DE SORTI OU LES BORNES NON ISOLEES DE L ACCUMULATEUR Acaution CHARGE ONLY LEAD ACID BATTERIES OTHER TYPES OF BATTERIES MAY B
3. AWG Model Number Min 6 450B Wire Size AWG Min Wire Size AWG Min 6 550B 6 680B 12 380B 12 550B 12 680B 12 850B 18 600B 18 800B 24 600B Figure 5 1 AC Input Specifications www douglasbattery com 11 of 30 User s Manual 5 1 AC Voltage Connections THE CHARGER DC OUTPUT SHOULD NOT BE CONNECTED TO A BATTERY DURING INSTALLATION OF THE AC INPUT POWER CONNECTIONS AND DURING INITIAL AC POWER UP To connect the input AC voltage route the AC supply wiring in conduit through the conduit hole in the floor of the charger case Route the AC wiring to the terminal lugs of the fuse holder located below the AC fuses labeled F1 and F2 single phase or above the AC fuses labeled F1 F2 and F3 three phase For proper connections torque the terminal lug screws to the Terminal Lug Torque shown in Figure 5 1 1 below Charger Type Fuse Holder Size Terminal Lug Size Terminal Lug Torque Single phase 30 amp or less 1 4 28 screws 25 inch pounds Single phase 35 amp or larger 3 8 24 screws 38 inch pounds Figure 5 1 1 AC Input Torque Specifications Awarnine IMPROPERLY CONNECTED AC VOLTAGE CONDUCTORS CAN CAUSE AN ELECTRICAL FIRE Connect the AC ground to the terminal lug located below the AC fuses on the base floor single phase Awarnine DO NOT OPERATE THE CHARGER WITHOUT PROPER GROUNDING IMPROPER GROUNDING CAN RESULT IN
4. but some permanent loss should be expected 7 Cold batteries require more time to fully charge When the temperature falls below 65 F the batteries should be placed on charge as soon after use as possible 8 The tops of batteries and battery hold downs must be kept clean and dry at all times to prevent excessive self discharge and the flow of current between the battery posts and frame Electrolyte spilled on batteries never dries or evaporates 9 All connections to batteries must be maintained clean and tight Due to heating and discharge rates bolted connections loosen over time Re tighten the connections twice yearly to the torques specified by the battery manufacturers 10 Follow all operating instructions cautions and warnings as specified in this manual on the charger in the battery manuals and in the vehicle manuals 8 1 Personal Safety Precautions 1 Have someone within the range of your voice and close enough to quickly come to your aid when you work near a lead acid battery 2 Ensure that ample fresh water and soap are nearby in case battery acid contacts your skin clothing or eyes 3 Wear complete eye and clothing protection Avoid touching your eyes while working near a battery 4 If battery acid contacts your skin or clothing wash immediately with soap and water If acid enters your eye immediately flush your eye with running cold water for at least 10 minutes and get medical attention immediately 5 NEVER s
5. Last Chrg displays the parameters of the last charge cycle The third entry in the History menu Select History enables the user to select from the 95 archived charge Cycles previous to the record available through Last Chrg Figure 9 3 4 2 lists the available parameters and their descriptions available through Last Chrg and Select History The Select History menu will not display the Date Time T1 T2 or T3 values Parameter Description Date Time Start date and time Last Chrg only T1 Time elapsed from start to knee 1 Last Chrg only T2 Time elapsed from knee 1 to knee 2 Last Chrg only T3 Time elapsed from knee 2 to termination Last Chrg only Cycle Charge cycle number Profile Battery profile used Chrg Time Charge time Term Termination method used AH Rtrnd Amp Hours returned Init V Initial battery voltage Final V Final battery voltage E B Equalize balance charge cycle Y N Figure 9 3 4 2 Archived Charge Cycle Parameters The Up and Down buttons on the navigation pad can be used to scroll through the archived charge cycle parameters Because of its length the value of the Date Time parameter is only displayed after pressing the Select button on the navigation pad The Left button can be used to navigate back up the menu system 21 of 30 User s Manual 9 3 5 System Info The fifth entry in the menu system System Info enables the user to view select information reg
6. THE RISK OF AN ELECTRIC SHOCK 5 2 AC Voltage Jumper Positions The charger is factory wired for the AC input voltage AC VOLTS listed on the ratings label Contact your charger dealer to have the AC voltage jumper positions changed for a different AC input voltage DOCUMENT ANY CHANGES ON THE RATINGS LABEL ON THE FRONT OF THE CHARGER OR ON AN ADDITIONAL LABEL OR TAG 5 3 AC Fuses The correct fuses for the factory wired AC input voltage were installed at the factory If the AC input voltage is changed it may be necessary to change the AC input fuses Contact your charger dealer to have the AC voltage wiring changed and obtain the proper fuses USE ONLY THE CORRECT SIZE IDENTICAL TYPE REPLACEMENT FUSES FUSES ARE AVAILABLE FROM YOUR DEALER S QUALIFIED SERVICE TECHNICIAN 5 4 Initial AC Power Up The charger DC output should not be connected to a battery during initial AC power up After applying AC power to the charger it will execute a test routine The routine takes approximately 15 seconds to complete Do not connect the charger DC output to a battery until this routine is complete If the routine executes successfully the Voltage and Battery Type String for example 24VW will be shown on the main display indicating that the charger is ready to be connected to a battery see Section 9 2 2 for additional information regarding the Voltage and Battery Type String If the routine detects an issue one 1 of the codes listed in Fig
7. a clear airflow space at the rear of the charger This space should not be reduced or obstructed in any way Awarnine IF CHARGER IS DROPPED OR SEVERELY BUMPED DURING HANDLING DO NOT OPERATE CHARGER POSSIBLE DAMAGE OR UNSAFE OPERATING CONDITIONS MAY OCCUR CONTACT YOUR DEALER S QUALIFIED SERVICE TECHNICIAN www douglasbattery com 9 of 30 User s Manual 6 450 Single Phase 180 82 900 410 6 550B Single Phase 190 86 950 430 6 680 Single Phase 193 88 965 440 12 380B Single Phase 200 91 1000 455 12 550 Single Phase 223 101 1115 505 12 680B Single Phase 225 102 1125 510 12 850B Single Phase 260 118 1300 590 18 600B Single Phase 248 113 1240 565 18 800B Single Phase 290 132 1450 660 24 600B Single Phase 290 132 1450 660 Awarnine DO NOT STACK CHARGERS WHEN USING WALL MOUNTING BRACKETS BRACKETS ARE DESIGNED TO SUPPORT ONE CHARGER ONLY Single Phase Cabinet Dimensions 19 0 W x 27 0 H x 17 5 D Figure 4 2 1 Wall Anchor Design Load Table Figure 4 2 1 shows the weight that the set of mounting bolts and their anchoring structure must withstand for the various charger types The Design Load shows the Charger Weight times a safety factor of five 5 certain that both the mounting structure and the bolts will at a minimum support the Design Load Drywall or plaster will not be strong enough on its own without pr
8. by the solid 80 Charged LED 7 For a balance charge cycle the charge profile transition to the balance phase is indicated by both the blinking Charge Complete LED and the solid Equalizing LED 8 For an equalize charge cycle the completion of the equalize phase is indicated by the solid Equalizing LED 9 The charger automatically terminates the charge cycle when the battery reaches full charge The necessary charge time is affected by numerous factors The major factors affecting the required charge time are the amp hour capacity depth of discharge temperature and age usage of the battery Completion of the charge cycle is indicated by the solid Charge Complete LED and both the Charging and 80 Charged LEDs turning off 10 Disconnect the charger DC output connector from the battery connector by grasping both connectors and pulling them straight apart 9 1 Multi Voltage Charging Legacy Platinum SCR chargers are multi voltage and capable of charging batteries with standard cell counts and DC voltages up to the maximums listed on the ratings label on the front of the charger For example a 24 cell 48 volt charger is capable of charging 24 cell 48 volt 18 cell 36 volt 12 cell 24 volt and 6 cell 12 volt batteries They automatically sense the DC voltage of the connected battery and adjust the DC output voltage accordingly This feature eliminates the need to purchase multiple chargers for multi voltage charging An individual amp hour setti
9. cleaning and watering of non sealed batteries is very important Logging the water usage of non sealed batteries is useful As a battery ages it will use more water 11 TROUBLESHOOTING AND SERVICE Awarnine USE EXTREME CAUTION WHEN WORKING INSIDE THE CHARGER OR WITH THE CHARGING SYSTEM DO NOT ATTEMPT TO WORK INSIDE THE CHARGER UNLESS YOU ARE A QUALIFIED SERVICE TECHNICIAN OR ELECTRICIAN HIGH VOLTAGES APPEAR AT SEVERAL POINTS INSIDE THE BATTERY CHARGER DISCONNECT AND LOCK OUT BOTH AC AND DC POWER FROM THE CHARGER BEFORE REMOVING ANY COMPONENT CONTACT WITH LIVE COMPONENTS WITHIN THE CHARGER COULD CAUSE ELECTRICAL SHOCK SERIOUS INJURY OR DEATH The charger was fully tested and calibrated before leaving the factory It was delivered ready to charge with user specified factory configured amp hour settings and battery profiles If properly installed the charger should require very little attention If improper charger operation occurs it will require repair by your dealer s Qualified Service Technician CONTACT YOUR CHARGER DEALER FOR TROUBLESHOOTING AND SERVICE www douglasbattery com 29 of 30 User s Manual NOTES Represented By 3 8 4 9 4 38494A www douglasbattery com 30 of 30 User s Manual
10. duration of time before Post Charge is automatically terminated if Post Charge is enabled in the battery profile Unit Minutes Range 0 1440 AH RATING AH RATING defines the amp hour rating of the battery pack This is used to calculate proper start and finish current ratings for the charger Unit Amp hours Range 100 Charger Maximum 10 MAINTENANCE Awarnine DISCONNECT BOTH AC AND DC POWER FROM THE CHARGER BEFORE ENTERING THE ENCLOSURE CONTACT WITH LIVE COMPONENTS WITHIN THE CHARGER COULD CAUSE ELECTRICAL SHOCK SERIOUS INJURY OR DEATH CAUTION KEEP CHARGER CLEAN AND DRY INSIDE AND OUT FAILURE TO DO SO MAY CAUSE DAMAGE OR FAILURE OF CHARGER The charger requires minimal maintenance It should be kept clean and all connections tight BE CERTAIN THAT THE CHASSIS IS SECURELY GROUNDED Twice a year or as often as the cleanliness of the area may dictate the louvers should be vacuumed and the interior thoroughly blown clean with dry compressed air The components of the charger are cooled by natural convection If dust and debris are allowed to build up they will restrict airflow and could cause components to overheat Moisture may cause electrical shorting and or corrosion It may also combine with dust and debris making them more difficult to remove Do not use liquids to clean the charger Liquids could cause damage Compressed air should be used to clean dust and debris from the charger and its com
11. enabled and the type of equalize balance mode If automatic equalize balance mode is enabled system settings EB CHRGS and EB DAY define which charge cycles will automatically be equalize balance cycles Units Disabled Charge Cycles Day of Week Range Off Num Day EB CHRGS EB CHRGS defines the number of charge cycles between automatic equalize balance cycles if E B ACT is NUM enabled Units Charge Cycles Range 1 100 EB DAY EB DAY defines the day of week when all charge cycles will automatically be equalize balance cycles if E B ACT is DAY enabled Units Day of Week Range Sunday Saturday www douglasbattery com 25 of 30 User s Manual SRT DLY SRT DLY ACT defines if a delay exists between the connection of valid battery to the charger and the automatic start of a charge cycle If SRT DLY ACT is enabled system setting STRT DELAY defines the duration of the delay Units Enabled Disabled Range Ena Dis STRT DELAY STRT DELAY defines the duration of the delay between the connection of valid battery to the charger and the automatic start of a charge cycle if SRT DLY ACT is enabled Units Minutes Range 0 1500 BLCKOUT ACT BLCKOUT ACT defines if a blackout time period exists when a charge cycle will not automatically start if a valid battery is connected to the charger If BLCKOUT ACT is enabled system settings B OUT STRT and
12. navigation pad selects the current character and advances the cursor to the next position in the password The Left and Right buttons on the navigation pad can be used to move the cursor between positions Pressing the Select button on the navigation pad enters the password If an incorrect password is entered two times in a row the menu system is automatically exited Two menu items are available under Change Settings System and Battery Profile System settings apply to all battery profiles Battery Profile settings apply to a specific battery profile When the user selects the Battery Profile menu up to four battery profiles will be available depending on the maximum battery cell count voltage of the charger and the configuration at the time of charger order The Up and Down buttons on the navigation pad can be used to scroll through the charger settings Pressing the Select button or the Right button on the navigation pad selects the current charger setting After selecting a charger setting the Up and Down buttons on the navigation pad can be used to increment decrement or change the value After selecting the desired value for a charger setting pressing the Select button on the navigation pad enters the current value and modifies the setting The Left button on the navigation pad can be used to move back up the menu system without modifying the setting The user modifiable System settings are detailed in Section 9 6 The user modifiabl
13. that were specified at the time of order CBL LEN CBL LEN should reflect the length of DC cable used on the charger This value is used for calibration purposes Units Feet Range 1 50 CBL GAUGE CBL GAUGE should reflect the gauge of DC cable used on the charger This value is used for calibration purposes Units American Wire Gauge AWG Range 16 000 STORAGE ACT STORAGE ACT defines if storage refresh mode is enabled and the type of storage mode If storage mode is enabled system settings T STORAGE and V STORAGE define when a storage refresh charge cycle starts and system settings TERM STORAGE STOR MIN V MAX T STORAGE and MAX AH STORAGE define the termination conditions for storage mode Disabled Hours Volts Hours amp Volts Units Hours or Volts Range Off Hours Volts Hrs amp V Hrs or V T STORAGE T STORAGE defines the delay between the end of a charge cycle and the automatic start of a storage refresh charge cycle if the battery is not disconnected from the charger if STORAGE ACT is enabled for Hours Hrs amp V or Hrs or V Units Hours Range 24 168 V STORAGE V STORAGE defines the battery voltage at which a storage refresh charge cycle will automatically start if a battery is not disconnected from the charger after the end of a charge cycle if STORAGE ACT is enabled for Volts Hrs amp V or Hrs or V Units Volts per Cell
14. valid battery is connected if STRT T ACT is enabled Units 24 Hour Time Range 00 00 23 59 SULF MIN SULF MIN defines the minimum duration of time that the charger will remain in start current regardless of battery voltage to break down sulfated batteries for WET type batteries only 9 7 Battery Profile Settings Units Minutes Range 0 10 The charger was factory configured with the Battery Profile Settings that were specified at the time of order STRT C STRT C defines the start current Unit Amps Range 0 1 Charger Maximum FIN C FIN C defines the finish current Unit Amps Range 0 1 5096 of STRT C T PST KNEE T PST KNEE defines the duration of time after the first knee or 8096 point before the charge cycle is automatically terminated if Time Past Knee termination is enabled in the battery profile Unit Minutes Range 30 600 www douglasbattery com 27 of 30 User s Manual MX CHRG T MX CHRG T defines the maximum charge cycle duration before automatic termination Unit Minutes Range 30 1440 RTRN RTRN defines the percent of amp hour return to occur before the charge cycle is automatically terminated if Percent Amp Hour Return termination is enabled in the battery profile This is a percentage above 100 Example 10 110 Unit Percent Range 0 50 PCCT PCC T defines the maximum
15. 2 View Settings The second entry in the menu system View Settings enables the user to view the charger settings that define the charge profile s The View Settings menu is only accessible when a charge cycle is not active Two menu items are available under View Settings System and Battery Profile System settings apply to all battery profiles Battery Profile settings apply to a specific battery profile When the user selects the Battery Profile menu up to four battery profiles will be available depending on the maximum battery cell count voltage of the charger and the configuration at the time of charger order The Up and Down buttons on the navigation pad can be used to scroll through the charger settings Pressing the Select button or the Right button on the Navigation pad selects the current charger setting The Left button can be used to navigate back up the menu system 9 3 3 Change Settings Acaution IMPROPER SETTING OF THE CHARGER PARAMETERS CAN CAUSE DAMAGE TO THE CHARGER OR BATTERIES The third entry in the menu system Change Settings enables the user to change select charger settings The Change Settings menu is only accessible when a charge cycle is not active For security purposes a password is required to enter the Change Settings menu If you do not know your password please contact your dealer The Up and Down buttons on the navigation pad can be used to scroll through the characters Pressing the Right button on the
16. ATTERY CONNECTOR CHARGERWILLSTARTAUTOMATICALLY 0 80 Charged Fault 2 CHARGER WILL TURN OFF AT END OF CHARGE TO TERMINATE EARLY PRESS STOP BUTTON 3 LEDs INDICATE CHARGE CYCLE PROGRESS X 4 BLINKING EQUALIZING LED INDICATES EQUALIZE CHARGE CYCLE Equalizing 5 IF FAULTLEDLIGHTS CONSULT USER MANUAL WARNING DO NOT DISCONNECT CHARGER PLUG FROM BATTERY CONNECTOR WHEN CHARGER IS ON THE RESULTING ARCING D AND BURNING WILL DAMAGE THE CONNECTORS AND COULI Charge Complete AC Applied CAUSE THE BATTERY TO EXPLODE TURN CHARGER OFF FIRST Figure 9 2 1 User Interface 9 2 1 Control Panel To interact with the user the user interface includes a control panel with 4 buttons 8 LEDs light emitting diodes and a 4 digit alphanumeric display with high visibility 1 characters Figure 9 2 1 1 and Figure 9 2 1 2 describe the button and the LED functions respectively Button Description Converts a daily charge cycle to an equalize balance charge cycle Converts an equalize balance charge cycle to a daily charge cycle Equalize Daily Stop Start Stops a charge cycle that is in progress Manually starts a new charge cycle Scroll Scrolls through the real time charge cycle parameters on the 4 digit alphanumeric display Initiates a full factory self diagnostic test of the charger See Section 9 5 for Self Test details Figure 9 2 1 1 Control Panel Buttons When a charge cycle is in progress the Se
17. B OUT END define the start and end of the blackout time period respectively Enabled Disabled B OUT STRT B OUT STRT defines the beginning of the blackout time period when a charge cycle will not automatically start if a valid battery is connected to the charger and BLCKOUT ACT is enabled Units 24 Hour Time Range 00 00 23 59 B OUT END B OUT END defines the end of the blackout time period when a charge cycle will not automatically start if a valid battery is connected to the charger and BLCKOUT ACT is enabled Units 24 Hour Time Range 00 00 23 59 COOL DN ACT COOL DN ACT defines if a cool down period will occur at the end of a charge cycle If COOL DN ACT is enabled system setting COOL T defines the duration of the cool down period Units Enabled Disabled Range Ena Dis COOL T COOL T defines the duration of the cool down period if COOL DN ACT is enabled Units Minutes Range 0 1200 www douglasbattery com 26 of 30 User s Manual STRT T ACT STRT T ACT defines if a charge cycle will only start if a valid battery is connected to the charger after a specified time If STRT T ACT is enabled system setting STRT T defines the time at which a charge cycle will automatically start if a valid battery is connected Units Enabled Disabled Range Ena Dis STRT T STRT T defines the time at which a charge cycle will automatically start when a
18. CR charger It was factory configured to charge wet flooded or sealed deep cycle lead acid batteries The charger has an I E I profile which is high rate constant current start bulk region constant voltage plateau absorption region and low rate constant current finish region It is controlled by an advanced microprocessor controller Figure 1 1 lists the features of the controller including automatic multi voltage charging individual amp hour setting battery profile per DC voltage level field programmability and a real time clock The charger can also be configured for opportunity charging 2 line LCD display and navigation pad Plain English menu system Opportunity charging support Figure 1 1 Legacy Platinum SCR Controller Features www douglasbattery com 6 of 30 User s Manual Figure 1 2 provides specifications for the Legacy Platinum SCR product line Model AC SiG Cell Count Amp Hour Rating DC Amps AC Amps Approx Shipping Number Phase Max d Max C5 Max 8 Hrs Max 208V 240V 480V Weight Lbs 6 180 4 5 5 5 12 380B 12 680B 12 850B 18 600B 36 18 600 96 35 31 15 248 18 800B 36 18 800 128 45 38 19 290 1 1 1 1 12 550 1 1 1 1 1 24 600B 48 24 600 96 45 5 40 20 290 Figure 1 2 Legacy Platinum SCR Product Line Specifications 2 RECEIVING THE CHARGER Unpack the charger and examine it for shipping damage In the event that shipping damage i
19. E CYCLE MUST BE INTERRUPTED PRESS AND HOLD THE STOP START BUTTON TO TERMINATE THE CHARGE CYCLE BEFORE DISCONNECTING THE DC OUTPUT CORD FROM THE BATTERIES KEEP SPARKS FLAME AND SMOKING MATERIALS AWAY FROM BATTERIES WARNING ALWAYS SHIELD EYES WHEN WORKING NEAR BATTERIES DO NOT PUT WRENCHES OR OTHER METAL OBJECTS ACROSS BATTERY TERMINAL OR BATTERY ARCING OR EXPLOSION OF THE BATTERY CAN RESULT CAUTION AVOID DAMAGE TO THE CHARGER CORD AND BATTERY CONNECTOR DISCONNECT BY GRASPING THE PLUG HANDLE OR BODY AND PULLING IT STRAIGHT OUT OF THE BATTERY CONNECTOR DO NOT PULL ON THE CHARGER CORD DO NOT TWIST ROCK OR PULL THE PLUG SIDEWAYS Legacy Platinum SCR chargers can be ordered and factory configured with highly customized system settings and battery profiles The system settings and battery profiles completely define the charging process from start to termination to equalization or balancing The chargers can also be programmed in the field see section 9 3 3 Thus the typical operation explained below may not apply to a particular unit Please contact your dealer with questions The charger was factory configured to charge wet flooded or sealed deep cycle lead acid batteries The charger has an charge profile which is high rate constant current start bulk phase constant voltage plateau absorption phase and low rate constant current finish phase If it is configured for opportunity charging it will
20. Legacy Platinum SCR Chargers By Douglas Battery Single Phase SCR Battery Chargers USER S MANUAL Important Safety Installation Operation and Maintenance Instructions www douglasbattery com CHARGER RATINGS LABEL The charger ratings label see example below provides the MODEL and SERIAL number identification for the factory configuration of the charger that was ordered This information will be required if service parts are needed The factory wired AC input information is provided on the rating label AC VOLTS AC AMPS PHASE and HERTZ This information will be required for charger installation The DC output specifications CELLS DC VOLTS DC AMPS and AMP HRS are the maximum nominal charger ratings The charger is capable of being configured for lower DC AMPS AMP HRS and was factory configured for the output specified at the time of order which means that the actual DC AMPS and AMP HRS output may be configured to be lower than the maximums listed on the ratings label TYPE indicates the factory configured battery type This charger is capable of multi voltage output multiple battery profiles and capable of automatically charging batteries with CELLS and DC VOLTS up to the maximums listed on the ratings label Each CELLS DC VOLTS level requires configuration at the time of order to be active Each CELLS DC VOLTS level uses a unique battery profile that is specified at the time of order so the DC AMPS AMP HRS and TYPE lis
21. Range 2 00 2 50 TERM STORAGE TERM STORAGE defines the maximum number of storage refresh charge cycles before storage mode automatically terminates if STORAGE ACT is enabled for Hours Volts Hrs amp V or Hrs or V Units Charge Cycles Range 0 100 www douglasbattery com 24 of 30 User s Manual STOR STOR MIN V defines the battery voltage below which storage refresh charge cycle will automatically restart if one of the following is not meet set voltage is not reached TERM STORAGE value is not reached or if a battery is not disconnected from the charger after the end of a charge cycle if STORAGE ACT is enabled Units Volts per Cell Range 2 00 3 00 MAX T STORAGE MAX T STORAGE defines the maximum elapsed time of a storage refresh charge cycle before automatically terminating if STORAGE ACT is enabled for Hours Volts Hrs amp V or Hrs or V If a charge cycle reaches this value it will terminate with a fault condition Units Minutes Range 30 1440 MAX AH STORAGE MAX AH STORAGE defines the maximum amp hours returned of a storage refresh charge cycle before automatically terminating if STORAGE ACT is enabled for Hours Volts Hrs amp V Hrs or V If a charge cycle reaches this value it will terminate with a fault condition Units Amp Hours Range 1 25 000 E B ACT E B ACT defines if automatic equalize balance mode is
22. UPPORTING THE DESIGN LOAD SHOWN IN FIGURE 4 2 1 USE APPROPRIATE FASTENERS FOR THE WALL CONSTRUCTION THE USE OF FOUR MACHINE BOLTS IS REQUIRED TO SECURE THE LOAD NOTIFY YOUR DEALER S QUALIFIED SERVICE TECHNICIAN IF YOU HAVE ANY QUESTIONS OR PROBLEMS OCCUR Acaution ALLOW 4 102mm MINIMUM CLEARANCE BETWEEN THE CHARGER AND ANY WALL 6 152mm FROM OTHER EQUIPMENT TO ALLOW FOR PROPER VENTILATION Acaution TO ENSURE THE STRUCTURAL INTEGRITY OF THE WALL MOUNTING BRACKETS USE 8 3 8 DIAMETER BOLTS NOT PROVIDED TO ATTACH BRACKETS TO A WALL STRUCTURE AVIOD USING LAG BOLTS To install the wall mounting brackets this procedure must be followed in sequence The brackets are to be used as shown in Figure 4 2 2 1 Locate the holes for the fasteners according to the dimensions in the illustrations Note Where applicable connect fasteners directly to studs in the wall 2 Use level to ensure proper mounting 3 Use each bracket as a template and mark where the mounting holes should be located When locating the brackets bracket flanges should face towards the inside Do not use the slots for mounting the bracket to the wall Acaution THE CHARGER MUST BE SUPPORTED UNTIL IT IS SECURED TO THE BRACKETS 4 Secure charger to brackets using the hardware provided with the wall mounting kit Refer to the appropriate illustration for placement instructions 5 When the charger wall brackets are mounted on the wall there will be
23. URST CAUSING PERSONAL INJURY AND DAMAGE BEFORE CHARGING ANY OTHER TYPE OF RECHARGEABLE BATTERY CHANGE THE CHARGER SETTINGS AS RECOMMENDED BY THAT BATTERY MANUFACTURER ATTENTION UTILISER POUR CHARGER UNIQUEMENT LES ACCUMULATEURS AU PLOMB ELECTROLYTE LIQUIDE D AUTRES TYPES D ACCUMULATEURS POURRAIENT ECLATER ET CAUSER DES A CAUTION DO NOT EXPOSE TO RAIN INDOOR USE ONLY ATTENTION NE PAS EXPOSER LA PLUIE WARNING DO NOT DISCONNECT THE CHARGER PLUG FROM THE BATTERY CONNECTOR WHEN THE CHARGER IS ON THE RESULTING ARCING AND BURNING WILL DAMAGE THE CONNECTORS AND COULD CAUSE THE BATTERIES TO EXPLODE TURN CHARGER OFF FIRST www douglasbattery com 4 of 30 User s Manual 14 15 16 17 18 19 20 21 22 23 DANGER TO PREVENT ELECTRICAL SHOCK DO NOT TOUCH EITHER AC OR DC UNINSULATED PARTS MAKE SURE ALL ELECTRICAL CONNECTORS ARE IN GOOD WORKING CONDITION DO NOT USE CONNECTORS THAT ARE CRACKED CORRODED OR DO NOT MAKE ADEQUATE ELECTRICAL CONTACT USE OF A DAMAGED OR DEFECTIVE CONNECTOR MAY RESULT IN A RISK OF OVERHEATING OR ELECTRIC SHOCK WARNING HAZARD OF ELECTRIC SHOCK WARNING Lead acid batteries generate explosive gases To prevent arcing or burning near batteries do not disconnect DC charging cord from batteries when the charger is operating Push and hold the STOP START Button until charger turns OFF Keep sparks flame and smoking materials away from batterie
24. a specialized I E charge profile for daily cycles and a specialized charge profile for equalization cycles 1 With AC power properly applied to the charger which will be indicated by the solid AC Applied LED connect the charger DC output connector to the battery connector by firmly grasping both connectors and plugging them straight together The charger will start automatically after a short delay which is indicated by the solid Charging LED 2 equalize balance charge cycle is indicated by a blinking Equalizing LED 3 If the charger must be disconnected from a battery pack while a charge cycle is in progress press the Stop Start button on the user interface to stop the charge cycle before disconnecting the DC output connector from the battery Do not disconnect the DC output connector from a battery pack while a charge cycle is in progress The resulting arcing and burning of the connectors could cause the battery to explode 4 The display s can be used to monitor the charge status See sections 9 2 2 and 9 3 5 Ifthe charger is configured for multi voltage charging approximately 11 minutes after the start of a charge www douglasbattery com 15 of 30 User s Manual cycle the main display will show REST for approximately 3 minutes while the DC output is shut off as part of the voltage detection routine 6 The charge profile transition from the start bulk phase to the plateau absorption phase is indicated
25. arding the charger Figure 9 3 5 1 lists the available parameters and their descriptions Parameter Description Board SN Control board serial number Input Phases Input phase Phase Detect Phase detect number Input Volts Charger factory input voltage wiring Output Volts Charger maximum output voltage configuration System SN Charger serial number Num Profiles Number of battery profiles Model Charger controller type Ethernet Ethernet option present Y N Mx AH Rt Charger maximum battery pack amp hour configuration Mx C Rt Charger maximum output current configuration Figure 9 3 5 1 System Info Parameters The Up and Down buttons on the navigation pad can then be used to scroll through the System Info parameters Pressing the Select button or the Right button on the navigation pad selects the current parameter The Left button can be used to navigate back up the menu system 9 3 6 Clock The sixth entry in the menu system Clock enables the user to both view and set the real time clock The first entry in the Clock menu View Clock displays the current day date and time of the real time clock The second entry in the Clock menu Set Clock enables the user to set the Day Hour Minute Date Month and Year settings of the real time clock The Up and Down buttons on the navigation pad can be used to scroll through the real time clock settings Pressing the Select button or the Right bu
26. ct it before starting a new charge cycle It may be necessary to observe charger displays and function to determine the cause 9 5 Self Diagnostic The Self Test button should be used when it is suspected that the charger is not functioning properly Pressing the Self Test button initiates a full self diagnostic much like the final test performed in the factory at the end of the production line The self diagnostic will not execute if a battery is connected to the charger Internally a test load is connected to the DC output of the charger which ensures that a faulty battery does not affect the self diagnostic The Self Test LED is illuminated while the self diagnostic executes Figure 9 5 1 lists the self diagnostic error codes In the event that the self diagnostic returns an error code contact your charger dealer and provide them with the error code Error Code Description E1 Control board failure E2 Control board failure E3 Control board failure E4 Control board failure E5 Control board failure E6 PCB temperature sensor error E7 N A E8 Battery connected remove and re test 9 SCR 1 error E10 SCR 2 error E11 SCR 3 error E12 General SCR error E13 AC path error AC contactor AC fuses etc Figure 9 5 1 Self Diagnostic Error Codes www douglasbattery com 23 of 30 User s Manual 9 6 System Settings The charger was factory configured with the System Settings
27. e Battery Profile settings are detailed in Section 9 7 www douglasbattery com 20 of 30 User s Manual 9 3 4 History The fourth entry the menu system History enables the user to review both the history of the charger and specific parameters from the previous 96 archived charge cycles The first entry in the History menu Charge Info provides a history of the charger Figure 9 3 4 1 lists the available parameters and their descriptions www douglasbattery com Parameter Description Cycles Total number of charge cycles Cycles P1 Number of charge cycles using battery profile 1 Cycles P2 Number of charge cycles using battery profile 2 Cycles P3 Number of charge cycles using battery profile 3 Cycles P4 Number of charge cycles using battery profile 4 L Eq P1 Last equalize balance cycle using battery profile 1 L Eq P2 Last equalize balance cycle using battery profile 2 L Eq P3 Last equalize balance cycle using battery profile 3 L Eq P4 Last equalize balance cycle using battery profile 4 Hist Cnt Total number of charge cycle history records Figure 9 3 4 1 Charge Info Parameters The Up and Down buttons on the navigation pad can be used to scroll through the Charge Info parameters Pressing the Select button or the Right button on the navigation pad selects the current parameter The Left button can be used to navigate back up the menu system The second entry in the History menu
28. e battery connector The BLACK DC cable must be connected to the battery negative and the RED DC cable must be connected to the battery positive The charger will not operate if the polarity is reversed The DC output fuse F3 single phase is a fast acting fuse used to protect the SCRs USE ONLY THE CORRECT SIZE IDENTICAL TYPE REPLACEMENT FUSES FUSES ARE AVAILABLE FROM YOUR DEALER S QUALIFIED SERVICE TECHNICIAN This charger is capable of charging batteries with cell counts and DC voltages up to the maximums listed on the ratings label as configured at time of charger order Do NOT charge batteries with cell counts and DC voltages greater than those listed on the charger ratings label 8 PROPER CARE OF DEEP CYCLE MOTIVE POWER BATTERIES Motive power batteries are subjected to severe deep cycle duty on a daily basis Although these batteries are designed to withstand such duty the following precautions must be observed to obtain good performance and maximum cycle life CAUTION ALWAYS WEAR PROTECTIVE EYE SHIELDS AND CLOTHING WHEN WORKING WITH BATTERIES BATTERIES CONTAIN ACIDS WHICH CAN CAUSE BODILY HARM DO NOT PUT WRENCHES OR OTHER METAL OBJECTS ACROSS THE BATTERY TERMINAL OR BATTERY TOP ARCING OR EXPLOSION OF THE BATTERY CAN RESULT 1 When installing new batteries be sure the polarity of each battery and the overall battery pack is correct Otherwise battery and or charger damage can result 2 New batteries should be giv
29. en a full charge before their first use because it is difficult to know how long the batteries have been stored 3 New batteries and older batteries that have been in storage are not capable of their rated output until they have been discharged and charged a number of times 4 DO NOT EXCESSIVELY DISCHARGE THE BATTERIES Excessive discharge can cause polarity reversal of individual cells resulting in complete failure shortly thereafter 5 Maintain the proper electrolyte level of wet flooded batteries by adding water when necessary Distilled or deionized water is best for battery life Never allow the electrolyte level to fall below the top of the battery plates Electrolyte levels lower during discharge and rise during charge Therefore to prevent the overflow of electrolyte when charging it is mandatory that water be added to cells AFTER they have been www douglasbattery com 13 of 30 User s Manual fully charged do not overfill Old batteries require more frequent additions of water than new batteries 6 Hard crystalline sulfates form when batteries in storage not maintained in a charged active state Internal self discharge can bring about the start of this condition in as little as three days in warm temperatures Batteries not maintained and allowed to sit in storage will self discharge sulfate and lose capacity Repeated charging without using the batteries between charges can recover some of the lost power range and life
30. led RDY A battery is connected but AC power is not yet available to the main transformer so the charge cycle cannot be started If this message is constantly displayed an issue exists in the AC path AC contactor AC fuses etc Figure 9 2 2 1 4 Digit Display Information Voltage and Battery Type String The profile voltage and battery type information will be used to create a display string The format will follow xxVb Where xx voltage 12 24 36 or 48 or M for multiple voltage V indicates VOLTS b battery type where W wet S sealed O opportunity charge or M more then one battery type exists among the multiple battery profiles Examples 1 24VW is 24 Volt wet 2 MVW is multiple voltages wet 3 MVM is multiple voltages and multiple battery types 9 3 LCD Display and Navigation Pad User Interface www douglasbattery com 18 of 30 User s Manual charger user interface includes 2 line 32 character LCD display and navigation pad These features enable the user to view the charger status and extended charge cycle parameters view and change charger settings and reviewing the charge cycle history by navigating the menu system diagramed in Figure 9 3 1 Amportant CHARGER WILL NOT START CHARGE CYCLE UNLESS LCD DISPLAY SHOWS THE MAIN MENU MENU SYSTEM Status Messages Automatically Displayed View Status See Section 9 3 1 View Settings See Section 9 3 2 Change Set
31. lf Test button is not functional and the Equalize Daily Stop Start and Scroll buttons must be held for a short amount of time before the charger will acknowledge the button press This delay will guard against accidental button presses while a charge cycle is in progress LED Description Lights when a charge cycle begins Turns off when the charge cycle completes Charging Blinks during the REST period of the multi voltage charging voltage detection routine Lights when the 80 point gassing voltage is reached during a charge cycle 8096 Charged Turns off when the charge cycle completes Eg alizin Blinks when an equalize balance charge cycle begins Turns solid when the q 9 equalize mode completes or turns solid when the balance mode begins Charge Lights when a charge cycle completes successfully Blinks when balance or post Complete charge mode is occurring Manual Stop Lights when the Stop Start button is pressed while a charge cycle is in progress to manually stop charging Lights when a fault occurs The display s will show the fault code Fault codes Fault are described in Section 9 4 www douglasbattery com 17 of 30 User s Manual Lights when AC power is applied to the charger Turns off when AC power is AG Applied removed from the charger Self Test Lights when a self diagnostic test begins Turns off when the self diagnostic test completes See Section 9 5 for de
32. moke or allow a spark or flame to be in the vicinity of a battery 6 Be extra cautious to reduce the risk of dropping a metal tool onto a battery It could spark or short circuit the battery or other electrical components that could cause an explosion 7 Remove personal metal items such as rings bracelets necklaces and watches when working with a battery A battery can produce a short circuit current that is high enough to cause a severe burn 8 NEVER charge a frozen battery www douglasbattery com 14 of 30 User s Manual 9 CHARGER OPERATION Acaution MAKE SURE THE BATTERY IS A RECHARGEABLE DEEP CYCLE BATTERY WITH THE PROPER RATED VOLTAGE FOR THIS CHARGER DANGER TO PREVENT ELECTRICAL SHOCK DO NOT TOUCH UNINSULATED PARTS OF THE CHARGER DC OUTPUT CONNECTOR BATTERY CONNECTOR OR BATTERY TERMINALS MAKE SURE ALL ELECTRICAL CONNECTORS ARE IN GOOD WORKING CONDITION DO NOT USE CONNECTORS THAT ARE CRACKED CORRODED OR DO NOT MAKE ADEQUATE ELECTRICAL CONTACT USE OF A DAMAGED OR DEFECTIVE CONNECTOR MAY RESULT IN A RISK OF OVERHEATING OR ELECTRIC SHOCK Awarnine CHARGER IS TO BE USED WHILE THE BATTERY POWERED EQUIPMENT IS OPERATING Ne pas utiliser le charger pendant que l equipment est en marche WARNING LEAD ACID BATTERIES GENERATE GASES WHICH CAN BE EXPLOSIVE TO PREVENT ARCING OR BURNING NEAR BATTERIES DO NOT DISCONNECT DC CHARGING CORD FROM BATTERIES WHEN THE CHARGER IS OPERATING IF THE CHARG
33. nches 152mm from other equipment and never store anything beneath the charger Do not obstruct the airflow space around and beneath the charger Allow 36 inches 914mm minimum clearance in front of the charger for ease of operation maintenance and service Install the charger an area where the temperatures will remain within the range of 32 F to 105 F 0 C to 40 and the relative humidity will remain below 95 percent Exceeding these ranges will reduce the current capacity and possibly the service life of the charger If the charger will be operated outside of these ranges contact the dealer to verify if it will withstand these conditions and perform at the needed capacity 4 1 Horizontal Mounting To bolt to the horizontal mounting surface the mounting bolts will attach through the four mounting bolt slots in the bottom surface of the charger legs that are nearest the corners of the charger The charger itself can be used as a template to mark the locations of the holes to be made in the mounting surface or the bottom mounting hole dimensions in Figure 4 1 1 can be used to measure the locations of the mounting bolt holes i Figure 4 1 1 Bottom Mounting Hole Dimensions Single Phase www douglasbattery com 8 of 30 User s Manual 4 2 Wall Mounting Optional Awarnine THE CHARGER IS NOT TO BE POSITIONED ON OR MOUNTED OVER ANY FLAMMABLE SUBSTANCE Awaarnine THE WALL AND THE FASTENERS USED MUST BE CAPABLE OF S
34. ng and battery profile must be specified at the time of order for each supported battery cell count DC voltage Please contact your dealer to inquire about multi voltage charging using non standard battery cell counts and DC voltages other than 24 cell 48 volt 18 cell 36 volt 12 cell 24 volt and 6 cell 12 volt When a charger is configured for multi voltage charging a voltage detection routine takes place at the beginning of a charge cycle As part of this routine approximately 11 minutes after the start of a charge cycle the main display will show REST for approximately 3 minutes while the DC output is shut off as part of the routine During this REST period the Charging LED will blink 9 2 User Interface The charger user interface includes a 4 digit alphanumeric display with extra large 1 characters that are readable from a significant distance 8 LEDs for indicators and 4 buttons for operating the charger Additionally the user interface includes a large 2 line LCD display and navigation pad for accessing and modifying charger settings viewing charge cycle parameters and reviewing charge cycle history The LCD displays plain English parameters messages and menus that are easy to understand and navigate www douglasbattery com 16 of 30 User s Manual A IITE Equalize Stop Scroll a doD Start Charging Manual Stop READ USER MANUAL BEFORE OPERATION NORMAL OPERATION 1 CONNECT CHARGER PLUG TO B
35. oper structural reinforcement 4 Wall Fasteners 9 Not supplied with 17 wall mounting kit 8 Required Figure 4 2 2 Single Phase Charger Wall Mounting Bracket Installation www douglasbattery com 10 of 30 User s Manual 5 AC INPUT POWER CONNECTIONS MUST BE INSTALLED BY A LICENSED ELECTRICIAN THE CHARGER DC OUTPUT SHOULD NOT BE CONNECTED TO A BATTERY DURING INSTALLATION OF THE AC INPUT POWER CONNECTIONS AND DURING INITIAL AC POWER UP The charger must be connected to the proper single phase or three phase AC power source as specified on the ratings label on the front of the charger The AC frequency must be 60Hz 3 unless the charger ratings label reads HERTZ 50 60 and then it may be operated at either 50Hz 3 or 60Hz 3 Check the ratings label on the front of the charger to determine the proper AC power source The charger is pre wired and fused at the factory for an AC input of 208 240 or 480 V 410 as indicated on the charger ratings label The AC input voltage wiring of the charger can be changed in the field by your dealers Qualified Service Technician The minimum AC input wire size for each charger model and AC input voltage can be determined from Figure 5 1 Any changes must be documented on the charger ratings label on the front of the charger or on an additional label or tag see second label on page 2 of this manual 208V AC Input 240V AC Input 480V AC Input Wire Size
36. ponents It may be necessary to remove the top panel and or back panel from the charger cabinet to allow access to internal components for cleaning Always be careful not to bump wiring or components This could cause loose connections and failures 10 1 Check Charger Area The area around the charger must remain clean cool dry and well ventilated Check for obstructions to airflow clearances or other violations of the requirements in Section 4 www douglasbattery com 28 of 30 User s Manual 10 2 Visual Inspections Check the charger for any physical failures such as loose contacts or hardware excess wear or damage Darkened or hot terminals should be tightened or replaced 10 3 Battery Conditions Batteries must be well maintained for the charging system to operate properly Follow battery manufacturer instructions for battery maintenance Check for loose connections or corrosion Acaution CHECK THE DC CONNECTIONS FROM THE CHARGER TO THE BATTERY AND MAKE SURE THEY ARE TIGHT AND CLEAN TIGHTEN AND OR CLEAN IF NEEDED FAILURE TO DO SO COULD CAUSE MALFUNCTION FIRE OR EXPLOSION DC connections may become corroded over time If the connections become corroded they should be cleaned as recommended by the battery manufacturer After the connections have been cleaned a battery connection treatment should be applied to help prevent corrosion from reoccurring Contact the battery manufacturer for their recommendations Periodic
37. s WARNING Always shield eyes when working near batteries Do not put wrenches or other metal objects across battery terminal or battery top Arcing or explosion of the battery can result WARNING Batteries produce hydrogen gas which can explode if ignited Never smoke use an open flame or create sparks near the battery Ventilate the area when the battery is charging in an enclosed place WARNING Lead acid batteries contain sulfuric acid which may cause burns Do not get acid in eyes on skin or clothing If contact with the eyes occurs flush immediately with clean water for 15 minutes and obtain medical attention WARNING Only your dealer s Qualified Service Technicians should program or service this equipment CAUTION Do not operate the charger if it has received a sharp blow been dropped or otherwise damaged Have your dealer s Qualified Service Technician examine and repair as needed WARNING Do not disassemble the charger Have the charger examined by your dealer s Qualified Service Technician Incorrect re assembly of the charger may result in an explosion electric shock or fire CAUTION Make sure the battery system has the properly rated voltage amp hours and type Wet Sealed etc for this charging system SAVE THESE INSTRUCTIONS www douglasbattery com 5 of 30 User s Manual 1 INTRODUCTION This Legacy Platinum SCR battery charger is an advanced silicon controlled rectifier S
38. s found the preferred course of action is for the recipient to refuse delivery from the freight company After refusing delivery of the charger please contact your dealer to inform them of the refused delivery If the shipping damage is not discovered until after the item has been accepted from the freight company please report it as a claim to the carrier 3 STORAGE When the charger is stored prior to being installed and powered up it must be stored indoors in a clean and dry environment where the temperatures will remain within the range of 32 F to 120 F 0 C to 49 C The charger should be stored upright bolted to the shipping pallet and covered by the plastic wrap and shipping carton that it was shipped in This will help protect the charger from dust and abrasion It should be stored in an area where it is not likely to be damaged Do not stack anything on top of the charger www douglasbattery com 7 of 30 User s Manual 4 LOCATION AND INSTALLATION Awarnine DO NOT INSTALL THE CHARGER ON OR NEAR FLAMMABLE MATERIALS POSITION THE CHARGER ON A FOUNDATION OF STONE BRICK CONCRETE OR GROUNDED METAL Proper installation of the charger is important in order to achieve good performance and to prevent damage to the charger and batteries The charger should be located in a clean cool dry and well ventilated area To permit free air flow for convection cooling allow 4 inches 102mm minimum between the charger and any wall 6 i
39. tails Figure 9 2 1 2 Control Panel LEDs 9 2 2 Main Display The main display is a 4 digit alphanumeric display that communicates status information charge cycle parameters and fault codes to the user With extra large 1 inch characters the display can be read from a significant distance During a charge cycle the user can press the Scroll button to select which real time charge cycle parameter is shown on the display Available parameters are current in amps XXXA voltage in volts XX XV amp hours returned XXXX and time on charge in hours and minutes XX XX By default the display toggles between the current amps and voltage in volts When charge cycle is not in progress the Voltage and Battery Type String is displayed Displays Description xxVb Waiting for a battery to be connected to start a charge cycle See Voltage and Battery Type String information below DONE Charge cycle completed successfully TIME Waiting for a programmed delay time of day or blackout start time before starting charge STOP Manual stop was pressed to stop the charge cycle COOL Charger is in the programmed cool down time after a completed charge cycle REST Charger DC output is shut off for approximately 3 minutes as part of the multi voltage charging voltage detection routine The output will start again automatically TEST Self test is being performed PASS The self test passed FAIL The self test fai
40. ted on the ratings label may not apply to all CELLS DC VOLTS levels Please fill in the blank label that is provided below with the information from the ratings label on the front of your charger for future reference ET LLL LESTER ELECTRICAL 536R SERIAL 625 West A Street MODEL C Lincoln NE 68522 USA C US Industrial Battery Charger AC VOLTS AC AMPS HERTZ LISTED DC VOLTS DC AMPS AMP HRS TYPE CELLS AH Document any configuration or settings changes that are made by marking the ratings label on the front of your charger or on an additional label or tag on the front of your charger SAVE THIS MANUAL Keep it in a location where it is available to anyone who may operate the charger www douglasbattery com 2 of 30 User s Manual TABLE OF CONTENTS CHARGER RATINGS 5 2 TABLE OF CONTEN TS inta Did pinta Dt DN DM DN DN LC E d UE 3 IMPORTANT SAFETY INSTRUCTIONS 355555532 25252 3 525 in 4 2 lt 25 6 2 RECEIVING THE 22 5 7 3 STORAGE
41. tings See Section 9 3 3 History See Section 9 3 4 System Info See Section 9 3 5 Clock See Section 9 3 6 Figure 9 3 1 Menu System Status messages are automatically displayed on the LCD When a charge cycle is active the first entry in the menu system View Status is automatically selected and the menu system is locked When a charge cycle is not active the Up and Down buttons on the navigation pad can be used to scroll through the menu items An asterisk denotes which menu item is currently active Pressing the Select button or the Right button on the navigation pad opens the active menu item The Left button on the navigation pad can be used to move back up the menu system Figure 9 3 2 shows the navigation pad with the buttons labeled Figure 9 3 2 Navigation Pad www douglasbattery com 19 of 30 User s Manual 9 3 1 View Status The first entry in the menu system View Status enables the user to view the charger status and charge cycle parameters When a charge cycle is not active the View Status menu provides the charger status When a charge cycle is active the View Status menu is automatically selected and the menu system is locked Real time charge cycle parameters are displayed in an easy to read format The user can press the scroll button on the control panel to scroll through the following charge cycle parameters voltage in volts current in amps amp hours returned and time on charge in minutes 9 3
42. tton on the navigation pad selects the current setting After selecting a setting the Up and Down buttons on the navigation pad can be used to increment decrement or change the value After selecting the desired value for a setting pressing the Select button on the navigation pad enters the current value and modifies the setting The Left button on the navigation pad can be used to move back up the menu system without modifying the setting 9 4 Fault Monitoring The charger is constantly monitored for fault conditions If a fault occurs the charge in progress is terminated The main 4 digit display alternates between showing the fault code and the characters FLT The LCD display also shows the fault code with a description Figure 9 4 1 lists the fault codes and their descriptions Fault Code Description Mx V Maximum voltage reached MxAH Maximum amp hours reached Mn V Minimum voltage not reached TEMP Temperature too high EPRM Control board failure ERR Maximum time reached for an individual charge cycle phase bulk etc or the complete charge cycle ThRy The output current began to significantly increase during a constant voltage charge cycle phase Figure 9 4 1 Fault Codes www douglasbattery com 22 of 30 User s Manual fault is cleared by disconnecting the battery from the charger or removing AC power from the charger The user should determine the cause of the fault and corre
43. ure 5 4 1 below will be shown on the main display Figure 5 4 1 also provides instructions for correcting each potential issue www douglasbattery com 12 of 30 User s Manual Code Issue Solution XFMR The control transformer primary is Contact your dealer s Qualified Service Technician to mis wired correct the control transformer primary wiring PWRA The control board has AC power Contact your dealer s Qualified Service Technician available but the charger is unable The issue likely lies in the charger AC path AC to produce DC output power contactor AC fuses etc Figure 5 4 1 AC Power Up Faults 6 DOOR WITH SWITCHES AND AC CONTACTOR OPTIONAL Chargers that were purchased with the AC contactor option are equipped with internal lockout switches on the front door When the door is opened the switches are opened and AC control power is removed from the controller and the AC contactor de energizing both This removes AC power from some internal components of the charger AC POWER IS STILL ENERGIZED AT THE AC INPUT CONNECTIONS AC FUSES AND CONTROL TRANSFORMER INSIDE THE CHARGER The controller will also open the AC contactor when a charge cycle is not active This both conserves electricity and extends the lifetime of charger components which reduces operating costs 7 DC OUTPUT The DC output cable includes a commonly used connector The polarity of the charger connector must be the same as th
44. voutevsauvues scdurswaaeucsuaniecewnuatevesuueusersnad ieaus 16 9 2 1 Coritrol Panel uni me d ird ree tt ai gi Hd nv ve Ea dad 17 9 2 2 MainiDisplay ed t a oes He Rh le E ned 18 9 3 LCD Display and Navigation Pad User Interface 18 JaA View SiS a EI 20 ROPA TESTO 20 9 3 3 Change Settings RET 20 9 3 4 MILD 21 953 5 System INTO Mi nna eE ENE oe desde ce ap av as ul ax 22 953 6 ClOGK v 22 9 4 Fault Monitoring ccsscseecesessesenseeesensccensnseneesensnsesenscneesusencesenseneseeseneeseusnceesesensesenaeesaneneesanenessenaenerenseneeseneneesenses 22 ERDEDDDDONMED DID Rr C aasa 23 9 6 System Settings 24 9 7 Battery Profile 2 2 2 P 27 10 Q 28 10 1 Check Charger 20 204000 G iaia 28 10 2 Inspections 29 10 3 2 020 29 11 TROUBLESHOOTING AND
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