Legacy Gold Charger Manual - Models LG1 and
Contents
1. Gold Series Owner s Manual 1 8 1592 Charger Faults The charger control circuitry constantly monitors for several fault conditions If a fault should occur the charge in progress is interrupted and a fault message is displayed on the front panel A list of the faults and their descriptions follow Displayed Fault Description Fault LED Fault Clearing Occurs when the DC fuse opens Can be reset by because of an excess of current disconnecting the battery dC FuSE Call Service YES from the charger Bar Graph Flashes Replace Fuse Occurs when a charging battery Can be reset by is disconnected from the charger connecting a battery to OPEn batt without first stopping the charge Call Service NO the charger cycle Bar Graph Steady On Occurs when the time limit to Can be reset by t 1 Err gassing voltage is exceeded Call Service NO disconnecting the battery Bar Graph Steady from the charger Occurs when the overall charge Can be reset by t 2 Err cycle time limit is exceeded Call Service NO disconnecting the battery Bar Graph Steady On from the charger Occurs when the battery is first Can be reset if battery connected and the voltage is Call Service NO voltage is between 1 8 Lo batt between 1 0 1 8 Volts cell Bar Graph Steady On and 2 4 Volts cell when the battery is first Can be reset if battery connected and the voltage is Call Ser2. 30 999 277 v0148670 60 55 x014 0 5 56550 ass sos v01486 70 108 a a aa X014 99 20 Shunt 1PH amp 3PH Ampere hours Value Part Number 0 1050 300 117 99 1 24775 14 95 60 24865 335 xo14 99 60 29 0 xo14 99 60 1051 1700 2x150 117 99 2 322 014 99 60 24 1050 40 7 14 99 00 20 0149520 DC fuse 1PH 8 Ampere hours Value Number Eos riesen 225 80 _ 1 014114 380 450 150 X014 11 3 550 600 200 14 11 9 775 s 250 X014 11 16 960 1050 300 014 11 17 1200 2506 400 X014 11 14 1700 2x250 014 11 16 16 Legacye Gold Series Owner s Manual 1592 AC Input amp Fuses Multi Shift 3PH Volt Model D 220 380 440 V 3PH Volt Model J 480 550 600 V A Maier D 3 Phase Model J AC FUSES Value PIN Value P N Value P N Value P N 29 6550 2s 20 4 4 18 4 xo14994 32 6600 25 22 4 20 4 14994 41 675 6 28 6 xot4 20 6 26 6 46 6865 32 X014 99 6 X014 99 6 a 61
3. L 31 31 3 4 10 m 12 SHUNT RED TOBATT 35 BLACK TO BATT 1 T 1 LINE 1 if Tf 40 7 8 r n J2 TO CONTROL BOARD 11 18 12 44 e END Loe 47 48 LINE3 TE 3 3 480V CONFIGURATION 550V CONFIGURATION 620V CONFIGURATION 2 CONTACTOR COLS cout 40 COLT RED TO BLACK TO 42 TO CONTROL BOARD 23 Gold Series Owner s Manual 1592 1 1 1 16 UNE1 Hon 40 40 40 9 10 11 12 8 3 SHUNT y RED TO BATT a 4 4 y BLACK TO BATT AC INPUT 45 45 45 46 49 49 ER is 42 TO CONTROL BOARD 120V CONFIGURATION 208V CONFIGURATION 240V CONFIGURATION COL2 CONTACTOR COILS OIL 1 240V F9 208V 120V COL 1 F CONTROL TRANSFORMER F gt M TO CONTROL BOARD 24 Gold Series Owner s Manual 1592 MAINTENANCE LOG 1 Modifications to Factory Settings Date Change SewieTechniian 2 Service 25
4. ems i 30 35 FUSES 208 Volts 240 Volts 480 Volts 559 53 6 25 Goo ss 12 fous 5 57 75 16 1 01 99 5 65 12 099 5665 15 xoreeors 75 5 0 9515 5014555 64050 2 20 019920 20 301 9520 4417 xore0e 715 12 orosz 52 osos 110 20 se 20 xoesezo 48 10 6149910 esso 019950 155 25 30 9525 35 0699 69 0 108 35 171 3019550 6 15 01699 ers 225 1 019940 155 xovesoss 20 0149920 sos 24 6 5 5 642001 349 019970 562 019980 151 014995 ass x014 00 00 Shunt amp Fuses 494 100 101455 100 28 14 40 61499 40 X014 99 15 X014 99 20 2800 201 40 x014 99 40 ssf e ass 5 xoussao so 1 6569 sos x0r4 0 60 262 xouseso 25 46525 148 rouen herr so 36 99570 sse xouseso 160
5. 1PH Standard Wiring SUB ASSEMBLY PANEL 49 48 47 45 45 44 43 42 41 40 HA A a 04 SEE MODEL CHARTS FOR THESE CONNECTIONS r N L F BLACK 8 J pus F1 P LNET 5 22 Le E j 5 gt 272 LUF d unes S ORANGE F6 E L F BLACK RED 13 5 WHITE 120 V ONLY um BLUEORRED T rg oO FA mu raso ES BROWN OR RED um VIOLET VIOLET JE 220 380 440 MODEL D E CREE BYPASSED ON 120 VOLT COIL 20 BLACK HIRING THIS MUST BE THE NEUTRAL CONDUCTOR 3PH Standard Wiring NOTE For T3 see wiring connection cha
6. If available CAUTION CONNECTOR IS KEYED AND PINS ARE FRAGILE 1 Change AC fuses to the value of the desired line voltage available for this charger AC fuse values can be found on the decal inside the charger 2 Change Quick Tap plug to the desired line voltage as marked under the sockets 3 Indicate the line voltage change on the decal inside the charger 1PH and 3PH Wiring Conn Illustration MODEL B MODELD MODEL J MODELA QUICK TAP SOCKETS 208 220 480 120 240 380 550 208 480 440 240 QUICK PLUG Quick Tap Wire Assembly Part Numbers Voltage Model 1Ph QT Part Number 3Ph QT Part Number X1106 99 F1B X1106 99 F3B X1106 99 F1D X1106 99 F3D X1106 99 F1J X1106 99 F3J X1106 99 F1A N A MAINTENANCE amp SERVICE The charger requires a minimum of maintenance Connections and terminals should be kept clean and tight The unit should be periodically cleaned with an air hose to prevent any excessive dirt build up on components Care should be taken not to bump or move any adjustments during cleaning Make sure that both the AC lines and the battery are disconnected before cleaning The frequency of this type of maintenance depends on the environment in which this unit is installed
7. To be automatically connected to your closest Service Center call us toll free at 1 800 DOUGLAS 1 800 368 4527 Or visit us at http www douglas com 12 Gold Series Owner s Manual 1 8 1592 REPLACEMENT PARTS CIRCUIT BOARDS Gold Series X1060 99 DGF 1 BASE KITS KIT DESCRIPTION 1PH 3PH 10 BETWEEN XMR BRACKETS X225 99 1 10 X225 99 3 10 12 BETWEEN XFMR BRACKETS X225 99 1 12 X225 99 3 12 SINGLE PHASE PARTS DESCRIPTION PART NUMBER DESCRIPTION PART NUMBER DOOR X054 99 1 6B TOP BACK X057 99 1 1B CAPACITOR PANEL X052 99 1 2 TERMINAL BOARD E 256 99 8 TERMINAL BOARD 256 99 11 TERMINAL BOARD 256 99 5 CONTROL X127 99 1A CAPACITOR TRANSFORMER MODEL A THREE PHASE PARTS DESCRIPTION PART NUMBER DESCRIPTION PART NUMBER DOOR X054 99 3 17B TOP X052 99 3 12B BACK X057 99 3 16B CAPACITOR PANEL X052 99 3 7 TERMINAL BOARD 256 99 3 TERMINAL BOARD 256 99 4 TERMINAL BOARD 256 99 6 TERMINAL BOARD D 256 99 7 CAPACITOR CAPACITOR TERMINAL BOARD 256 99 9 TERMINAL BOARD QT 256 99 10 DC CABLE CLAMP 4 0 356 5 16 PARTS COMMON SINGLE AND THREE PHASE DESCRIPTION PART NUMBER DESCRIPTION PART NUMBER LEFT SIDE X057 99 0 7B RIGHT SIDE X057 99 0 6B UPRIGHT X052 99
8. voos ere esl 5 2 5 24 50 ous 4993 137 5 0149925 eso 181 5 xums 105 20 2014992 90 2 Moe 5 655 262 50 151 30 X0149930 131 5 04 HAC pes o povoa na le nas ee 23 87 5 62 Dousa foo re secos 0 mese peters pests paor EE 160 52 0 9529 so 5 2019918 massi poem 6 peus o pousa k 2 014980 1606 ee ira ss 01499 5 101 20 57 20 50149520 a X X Xi 12550 x014 99 60 201 40 50145940 Volt Model 220 380 440V 1 Phase D 18 Gold Series Owner s Manual 1592 OUTPUT CABLE REPLACEMENT Charger Cable Size Charger AH Rating Standard Cable Gauge 0 775 2 776 1050 1 0 1051 1200 2 0 1201 1500 3 0 NOTE Cable Kits do not include the connector housing only the contact the cable grommet and cable lugs These standard kits are nine feet 9 long Replacement Cable Kits Cable Gauge Kit for SB 175 Connector Kit for SB 350 Connector 2
9. 225 2 175 225 2 350 1 0 225 1 0 175 225 1 0 350 2 0 225 2 0 350 3 0 225 3 0 350 NOTE Cable Kits do not include the connector housing only the contact Connector Housing Part Numbers CONNECTOR DESCRIPTION CABLE SIZE CONNECTOR DESCRIPTION CABLE PART NUMBER PART NUMBER SIZE 5804 EC 2 2 0 6340 SBX350 GRAY 2 4 0 6316 583 2 1 0 6341 SBX350 BLUE 2 4 0 6320 SB350 GRAY 2 40 6342 SBX350 RED 2 4 0 6321 SB350 BLUE 2 40 6343 SBX350 GREEN 2 40 6322 SB350 RED 2 4 0 6359 SBX350 BLACK 2 40 6323 58350 YELLOW 2 40 6360 SBX350 YELLOW 4 amp 2 4 0 6324 SB350 GREEN 2 4 0 6370 SBX175 GRAY 2 1 0 6325 SB175 GRAY 2 1 0 6371 SBX175 BLUE 2 1 0 6326 SB175 BLUE 2 1 0 6372 SBX175 ORANGE 82 1 0 6327 SB175ORANGE 2 1 0 6373 SBX175 YELLOW s2 1 0 6328 SB175 YELLOW 2 1 0 6378 SBX175 RED 2 1 0 6329 58175 RED 2 1 0 7205 2 3 0 When ordering replacement cables 1 Determine cable size and length 113 L15 118 L20 125 L30 2 Determine kit part number by connector type SB175 or SB350 3 Determine connector housing part number Example For a charger requiring twenty feet 20 2 0AWG gauge cables and 58350 RED connector the two part numbers to order are 1 X225 2 0 350 L20 2 6322 19 Legacye Gold Series Owner s Manual 1592
10. 25 14 99 25 36 380 014 99 15 X014 99 15 36 450 14 99 20 9 1 20 X014 99 20 36 550 12 014 99 25 11 1 20 014 99 20 36 600 14 99 25 121 25 014 99 25 17 Gold Series Owner s Manual 1592 Volt Model J 480 550 600 V 1 Phase Model J AC FUSES 480 Volts 550 Volts 600 Volts Ex Jm 13 ze 6 Domos 24 6469 22174 os 5 ronse es 26 roue 6 600 44 014 99 8 3 8 014 99 8 3 5 014 99 8 625 26 8 21 4 4954 18 4 4994 eseo Prose 0465 so esos 675 0 Donsol 10 0 0 5 5 orev Em ups peespe 5 pes e ee p e 680 z1 15 41 8 4998 36 91498 20 ss 6695 0 s 10 44 492 km premo so 5 zo 13 posse 1 m pes amma e en te a 1225 71 5 ous owes romes 821 5 ETT os ie 845 20 se 5 rosse ve 5 mesul pa Des pos ET os 20 a 2 Dowel 55 25 1275 26 45 mws 42 25 5
11. 3 Change provided jumpers on the main transformer primary tap location as shown on the decal inside the door of the charger or on the following charts Jumpers not being used are stored in the manual s envelope inside the charger 4 Indicate the line voltage change on the decal inside the charger 1PH Wiring Conn Chart 3PH Wiring Conn Chart PERMANENT WIRING PERMANENT WIRING D4 ORANGE T1 to 40 D5 RED T1 to 40 D2 BLACK T2 to 31 MOVABLE JUMPERS MODEL B 208 VOLT INPUT 240 VOLT INPUT 480 VOLT INPUT MODEL B WIRE COLOR CONNECTION CONNECTION CONNECTION LTINPUT 240 VOLT INPUT 480 VOLT INPUT BLUE 40 to 45 40 to 45 4410 45 77 LITE ae Mick NOT USED WIRE COLOR CONNECTION CONNECTION CONNECTION 131048 131049 131049 31 to 34 31 to 34 441045 208V To 240V To 480V A2 BLACK 32 to 35 33 to 36 33 to 34 MOD EL D A3 BLUE 40 to 45 40 to 45 NOT USED NOT USED MOVABLE JUMPERS A3 BLUE 41 to 46 421047 220 VOLT INPUT 380 VOLT INPUT 440 VOLT INPUT M ORANGE 43 to 48 44 to 49 N
12. Fuse 15 DC Output Cables amp DC Cable Clamp 16 Panel Sub assembly 17 Panel Capacitor 18 Cross Member Heat Sink 19 Cabinet Base 20 Cabinet Right side 21 Cabinet Top Back 22 Door 23 Cabinet Left side 24 Main Transformer Teaser 25 Main Transformer Primary 26 Cross Member Main Transformers 27 Upright 28 Ground Lug 29 Brackets Capacitors W 1 Wire Group Primary Voltage W 2 Wire Group Capacitors W 3 Wire Group PC Board W 4 Cable Connecting Heat Sink amp Shunt 14 Legacye Gold Series Owner s Manual 1592 15 Legacye Gold Series Owner s Manual 1592 Replacement part numbers for chargers with letter codes X and shall be referred to the charger s tables with code letter B AC Input amp Fuses 1PH Volt Model B 208 240 480 V 3PH Volt Model B 208 240 480 V 1 Phase Model B 3 Phase Model B AC FUSES 208 Volts 240 Volts 480 Volts Dn T bas ss s 5s s 15 5 12 55 28 50455 669 75 15 roses ess 20 6 5 99 ves 1360 896 87 5599 114 20 0 5 9 20 10
13. be displayed Legacye Gold Series Owner s Manual 1592 prevent arcing burning at the connector and possible battery explosion press the START STOP pushbutton first to stop the charge cycle before removing a battery that is currently on charge 5 When the battery reaches Gassing Voltage the yellow 80 LED will light 6 When the battery is fully charged the green CHARGE COMPLETE LED will light the START STOP LED will extinguish and the charger will shut off At this time the battery is at full capacity and ready for use Charger Features Auto Start Delayed Start Auto Start enables the battery charger to start the charge cycle automatically after the battery is connected to the charger A programmable delay can be programmed so that Auto Start will begin after a set time period This delay can be set through the front panel display refer to d St in section User Parameter Configuration Auto start be delayed anywhere from 0 up to 25 hours in one minute intervals Auto Equalize Cycle An Equalize Cycle adds a predetermined amount of time to extend the battery s charge cycle This charger is equipped with an Auto Equalize function This is a configurable parameter consult your service representative for more information The factory default setting for the Auto Equalize cycle is 3 hours of charge time for every fifth charge cycle A charge cycle consists of at least one hour of continuous
14. charging of the battery by the charger Every time the battery completes a charge cycle the charge counter is incremented When the charge counter reaches the programmed Equalize count value an equalize cycle will occur immediately after the battery completes its normal charge cycle When an equalize charge cycle is pending the EQUALIZE LED will flash The equalize button can be pressed at any time during the normal charge cycle to stop the pending equalize cycle Once the battery has completed a successful charge cycle the Charge Complete LED will light and the charger will immediately go into the equalize charge cycle The EQUALIZE LED will then light steadily Pressing the EQUALIZE button during the equalize charge cycle will have no effect on the charger Manual Equalize Cycle With this charger the battery can also be equalized manually Pressing the EQUALIZE button at any time during the charge cycle will activate the equalize function Once pressed the EQUALIZE LED will begin to flash indicating that an equalize cycle will occur once the battery has completed a successful charge cycle The EQUALIZE button can again be pressed at any time during the normal charge cycle to stop the pending equalize cycle The CHARGE counter is reset every time the battery completes a successful Equalize charge cycle Pressing the EQUALIZE button during the Equalize charge cycle will have no effect on the charger NOTE Since Equalize charging extends the rechar
15. is applied to the charger and no battery is connected the POWER LED will be lit This message will display in rotation on the front panel display Conn Bati 3 During Idle Mode toggling the UP or DOWN pushbuttons will display the previous charge cycle parameters Toggle the UP or DOWN to display the total charge time ampere hours delivered highest voltage during the previous charge cycle the number of charge cycles since the last equalize and the equalize count Only the charge count and equalize count remains in non volatile memory These values will be saved even when AC power is removed The other values will remain in volatile memory until the next charge cycle begins or if AC power is removed 4 Plug the battery connector into the charger connector Once the battery is connected to the charger the START STOP LED will flash for approximately 5 seconds while the display shows this message 51 Cells The contactor will engage and charging will begin The START STOP LED will light steadily the LED bar graph will indicate the percent charged status of the battery and the display will now begin to show Charger output current returned Time Voltage These values are displayed in rotation for about 2 seconds each display can be changed so that current or voltage or current and voltage or all the above will be displayed The default setting is for all the above to
16. is designed to charge flooded lead acid storage batteries only of the cell and ampere hour rating as marked on the nameplate Beginning the Charging When battery is connected to the charger the control board senses voltage and after 5 second delay the charger energizes During this delay the CHARGING LED flashes NOTE For Deluxe type of chargers a programmable Auto Start delay can be set anywhere from 0 up to 25 hours Read more about each type of charger under the heading OPERATING INSTRUCTIONS Charging Charging current is determined by the battery voltage and interaction of the ferroresonant charger Charging current tapers automatically as battery voltage rises during the charge As the battery charges the LED bar graph will display the percentage of battery capacity Power Diodes The power diodes rectify the output of the ferroresonant transformer AC Power Fail The charger will not detect an AC power fault or AC fuse open If the AC power fails with a battery connected to the charger during a charge cycle the charger will reset and start a new charge cycle when power is restored Legacye Gold Series Owner s Manual 1592 Parallel Charging Optional Available for Deluxe chargers only Auto Start delay is required In parallel charging batteries must have an equal number of cells and must match the charger nameplate s ratings Ampere Hour rating of charger must be equal to the ampere hour of both batteries combined The
17. must be supplied with the part number on any correspondence or discussion PHASE regarding this charger OUTPUT Battery Type D C VOLTS The chemical content construction of the battery this unit is designed to d charge is given in this part of the nameplate L A Flooded Lead Acid D C AMPS MAX Ampere Hours The information supplied here is the ampere hour battery capacity which this unit has been factory adjusted to recharge Charging batteries of ampere hour capacities not specified here might cause the charger to deviate from the specifications Cells This portion of the nameplate gives the number of cells this unit will charge This number must match exactly with any battery connected to the charger output Input AC Volts The nameplate shows the input voltage s accommodated by this charger IMPORTANT The charger will operate only on nominal line voltages stamped on the nameplate Failure to select the correct voltage will result in damage to the charger and or the battery The Voltage Conversion section of this manual provides jumper settings for a specific input voltage Input AC Amps The external fusing and or the line disconnect circuit breaker should be as specified in the National Electrical Code AC fuse values can be found on the decal inside the charger Hz This gives the frequency in cycles per second of the AC input voltage Under no conditions operate charger at a different frequency or from a generator with unst
18. 0 6 DOOR LATCH X044 1 32 LATCH RIVETS 164 8 6 DC CABLE CLAMP 22 356 5 15 1 0 2 0 3 0 TERMINAL BOARD 256 99 1 TERMINAL BOARD 3AG 256 99 16 FUSE REDUCER 70A X014 17 6 FUSE REDUCER 40A X014 17 5 W 100A FUSE BLOCK W 60A FUSE BLOCK GROUND LUG X012 7 24 CAPACITOR BRACKET 029 99 B CONTROL X127 99 2B CONTROL X127 99 3D TRANSFORMER MODEL TRANSFORMER MODEL B D CONTROL X127 99 4J FUSE X014 34 5 TRANSFORMER MODEL TERMINAL BOARD J MODEL B AND D FUSE 014 34 7 FUSE F6 F7 F8 X014 7 28 TERMINAL BOARD TERMINAL BOARD MODEL J CONTACTOR 40A X129 62 53 CONTACTOR 60 X129 62 54 13 Gold Series Owner s Manual 1592 Note The illustration below identifies the location of some important components in 1ph 3ph Standard Chargers The component P N may vary from charger to charger For a P N refer to the Replacement Parts tables is DESCRIPTION 1 Control transformer 2 PC Board Fuses 3 Contactor 4 Primary fuse Control transformer 5 Terminal Board Primary Main Transformer 6 AC Block Input Fuses 7 Terminal Board Primary Main Transformer 8 Capacitor 9 Terminal Board Secondary Main Trans 10 Terminal Board Secondary Main Trans 11 Capacitor 12 Heat Sink Rectifier Assembly 13 Shunt 14 DC
19. 050 44 8 38 8 014 99 8 35 8 01499 8 55 0 12 550 40 3014954 014998 12680 72 014 99 15 12400 8 014998 014996 2 775 14 82 014 99 15 71 15 12 680 X014 99 10 46 8 X014998 E 12 775 014 99 10 52 10 014 99 10 EE 12 865 014 99 12 X014 99 12 Tm 12 960 xo14 99 15 64 12 014 99 12 37 12 1050 01499 20 3014 99 15 70 15 14 99 15 12 1200 014 99 20 14 99 20 15 014 99 15 16 80 4 X014 99 10 14 99 8 014998 18 450 57 10 014 99 10 xo14 99 10 45 18 50 69 15 014 99 15 014 99 12 55 10 014 99 10 18 600 76 15 xo1499 15 14 99 12 12 14 99 12 18 680 014 99 15 X014 99 12 18 775 X014 99 15 X014 99 15 18 865 X014 99 20 X014 99 20 18 960 3014 96 20 97 20 014 99 20 18 1050 14 99 25 10 6 20 X014 99 20 18 1200 14 99 25 121 25 014 99 25 y PTS 18 1500 X014 99 30 X014 99 30 18 1700 214 40 X014 99 35 X014 99 30 xogos 62 15 0149515 24 50 76 15 FERE 3014 99 12 60 12 014 99 12 70 24550 92 20 014 99 20 15 14 9 15 74 15 014 99 15 24 600 x01499 20 88 20 14 99 20 X014 99 15 24 680 X014 99 20 X014 99 20 X014 99 20 24 775 014 99 25 014 99 20 X014 99 20 24 865 X014 99 25 X014 99 25 24960 164 0149930 xo14 99 25 129 25 014 99 25 24 1050 176 35 014 99 35 14 99 30 141
20. 1 4B0V 240V 208V F10 COLT F6 CONTROL TRANSFORMER F J1 TO CONTROL BOARD F8 2 2 2 rk 7 16 ES ES 2 2 31 31 9 4 32 10 __ 11 2 SHUNT a RED TO BATT BLACK TO 1 1 T 40 7 16 AC INPUT 8 9 k 4 42 TO CONTROL BOARD pe ei 22 18 Te 31 8 y 4 45 4 LINE 3 13 T3 3 3 3 208V CONFIGURATION 240V CONFIGURATION 480V CONFIGURATION cou 2 CONTACTOR COILS 1 0 F10 F5 COIL 1 F6 gt TO CONTROL BOARD 21 Legacye Gold Series Owner s Manual 1592 AC INPUT ACINPUT LINE 1 LINE 3 SCHEMATIC 1 PHASE VOLT MODEL D 18 AH 6 1 1 1 7 Cc 7 40 40 40 9 10 12 43 4 45 45 45 48 49 49 F3 13 3 3 3 220V CONFIGURATION 380V CONFIGURATION 440V CONFIGURATION COIL 2 CONTACTOR COILS OIL 1 4407 22V F10 COLT CONTROL TRANSFORMER F7 J TO CONTROL BOARD 6 2 2 2 uNE2 dvo 3t 7 ay 10 11 2 E S 1 1 1 LINE t TI 40
21. 4 40 7 E f 9 D 11 2 44 45 45 48 49 49 8 m 3 3 3 220V CONFIGURATION 380V CONFIGURATION 440V CONFIGURATION COL2 CONTACTOR COLS COL 1 COL 1 7 CONTROL TRANSFORMER gt J TO CONTROL BOARD RED TO DCF SE BLACK TO J2 TO CONTROL BOARD SHUNT RED 5 TRE BLACK TO BATT J2 TO CONTROL BOARD 22 Legacye Gold Series Owner s Manual 1 8 1592 yr SCHEMATIC 1 PHASE VOLT MODEL J CONTROL TRANSFORMER F7 gt J1 TO CONTROL BOARD m 1 1 1 7 16 LINE T Fi s 40 40 40 9 EH 10 11 12 DC FUSE AC INPUT Ss 48 49 LINE 3 F3 B 3 3 480V CONFIGURATION 550V CONFIGURATION 600V CONFIGURATION COIL 2 CONTACTOR COILS COLL 1 600 550V COIL 1 CONTROL TRANSFORMER F J1 TO CONTROL BOARD F8 2 2 2 H y UNE2
22. L nee AC INPUT CHANGE QUICK TAP OPTIONAL OPERATING INSTRUCTIONS to NN NO O1 En O1 CONTROL BOARD NORMAL OPERATION CHARGER FEATURES Auto Start Delayed Start Auto Equalize Cycle Manual Equalize Cycle Refresh Cycle Cool DOW a EE NE USER PARAMETER 4 42 2 2 22 0 0000000808000000 000000000000 a a dns serre ern nnns Adjusting Parameter Settings DEFAULT SETTINGS CHARGER FAULTS 10 VOLTAGE CONVERSION 10 AC INPUT CHANGE STANDARD 2 10 3PH Wiring Conn Chart bi Wiring Conn Chart 4 11 AC INPUT CHANGE WITH QUICK 2412 Wiring Conn Illustration 2 12 MAINTENANCE amp SERVICE 12 COMMON REPLACEMENT PARTS 13 SHUNT 8 DC FUSES 216 Shunt 8 16 DC Fuse 8 16 AC INPUT amp FUSES 16 3PH Volt Model B 208 240 480 V 2222 16 TPH Volt Model B 208 240 480 V droves 16 Volt model D 220 380 440 SPH Volt model J 480 550 600 V Volt model D 220 380 440 V
23. Models LG1 8 1 Legacy Gold Series Battery Charger Owner s Manual 1592 REV A To be automatically connected to your closest Service Center call us toll free at 1 800 DOUGLAS 1 800 368 4527 Or visit us at Model S N AC Input Voltage Installed by Date IMPORTANT Read and understand your user s manual before installing operating or servicing this product DO NOT DESTROY THIS BOOK Legacye Gold Series Owner s Manual 1592 AC LINE VOLTAGE LETTER CODES The following table describes the code letters to be used in new charger part numbers to indicate the AC line voltage s and AC line frequency at which the charger can be operated Code Voltage s Line Frequency volts rms Hz Comments 60 208 240 480 Applicable to all charger families single or three phase chargers 120 208 240 Applicable to all charger families single phase chargers only 220 380 440 Applicable to all charger families single or three phase chargers 480 550 600 Applicable to all charger families single or three phase chargers 60 T 28 60 Use or special designs single or tee phase 060 Use ony or special designs single or three phase 20480 60 o 240 480 Use only for special designs single or three phase Use only for special designs single or three phase SPECIAL VOLTAGES UNSPECIFIED Use only for special designs Contact the plant for furt
24. OT USED WIRE COLOR CONNECTION CONNECTION CONNECTION A6 BROWN 35 to 46 36 to 47 36 to 45 BLUE 40 to 45 4310 45 44 to 45 D3 BLUE 131048 73 to 49 T3 to 49 D1 GRAY 131049 131048 131049 220V 380V 440V MOVABLE JUMPERS MODEL D MODEL J 220 VOLT INPUT 380 VOLT INPUT 440 VOLT INPUT MOVABLE JUMPERS WIRE COLOR CONNECTION CONNECTION CONNECTION 480 VOLT INPUT 550 VOLT INPUT 600 VOLT INPUT A2 BLACK 31 to 34 33 34 33 to 34 WIRE COLOR CONNECTION CONNECTION CONNECTION A2 BLACK 33 to 36 43 to 45 44 to 45 BLUE NOT USED NOT USED NOT USED BLUE 40 to 45 NOT USED NOT USED BLUE NOT USED NOT USED NOT USED BLUE 42 to 47 NOT USED NOT USED Dh E EST Eid A4 ORANGE 44 to 49 NOT USED NOT USED A6 BROWN 36 to 47 35 to 45 36 to 45 RED 10448 D3 BLUE 131049 T3 to 48 T3 1049 To 220V To 380V To 440V MOVABLE JUMPERS MODEL 120 VOLT INPUT 208 VOLT INPUT 240 VOLT INPUT MODEL J WIRE COLOR CONNECTION CONNECTION CONNECTION MOVABLE JUMPERS a WIRE COLOR CONNECTUN CONNECTION BLUE 44 to 49 NOT USED NOT USED 7 01 GRAY T3 to 49 T3 to 48 T3 to 49 REL BROW 20038 30109 TIT m NV uN D3 BLUE T3 1047 T3 to 48 T3 to 49 Liv RED To 480V To 550V To 600V T VIOLET ACROSS F3 NOT USED NOT USED 11 Legacye Gold Series Owner s Manual 1592 AC Input Change with Quick
25. QUALIZE pushbutton In order to adjust the parameters press the UP or DOWN pushbuttons If you press and hold the UP or DOWN pushbuttons for 3 seconds when adjusting the parameters the options will scroll through at a rapid pace Release the pushbutton to return to normal scrolling mode When finished adjusting parameters press the START STOP pushbutton to exit the user parameter configuration mode and save the parameter settings The display will now read CONN BATT Parameter Description Range Default Display mode 3 displays current ampere hours returned charge time and battery diSP voltage 0 3 3 2 displays current and voltage only 1 displays current only 0 displays voltage only Delayed start d St Amount of time delay after a battery is connected to the charger 0 min 00 before charging proceeds Increments in 1 minute intervals 25 hr Cool Down Time CooL Amount of time after a complete charge cycle that a battery needs to 0 hr 12 1 00 hr cool down before being utilized hr Equalize Count EU C Total amount of charge cycles that need to occur before an automatic 0 20 5 charge equalize charge cycle will take place charge cycles 0 indicates that no Equalize charge will occur cycles Default Settings Resetting default parameters is not recommended and could seriously affect charger battery performance Consult your local service representative for further information on charger settings
26. Volt model 480 550 600 V Volt model A 120 208 240 V es OUTPUT CABLE REPLACEMENT 19 STANDARD WIRING 20 3PH STANDARD WIRING 20 SCHEMATIC 1 VOLT MODEL 21 SCHEMATIC 3 VOLT MODEL 21 SCHEMATIC 1 VOLT MODEL D niinc 22 SCHEMATIC 3 PH VOLT MODEL 22 SCHEMATIC 1 VOLT MODEL 9 SCHEMATIC 3 VOLT MODEL 9 m SCHEMATIC 1 VOLT MODEL 24 MAINTENANCE LOG Legacye Gold Series Owner s Manual 1592 IMPORTANT SAFETY INSTRUCTIONS 1 This manual contains important safety and operating instructions Before using the battery charger read all instructions cautions and warnings on the battery charger the battery and the product using the battery 2 These chargers are designed to charge industrial flooded lead acid batteries 3 Read and understand all setup and operating instructions before using the battery charger to prevent damage to the battery and to the charger 4 Do not touch non insulated parts of the output connector or the battery terminals to prevent electrical shock 5 During charge batteries product hydrogen gas which can explode if ignited Never smoke use an open flame or create sparks in the vicinity of the battery Ventilate well when the battery is in an enclosed
27. able frequency Phase e Number 1 indicates a Single Phase Charger e Number 3 indicates a Three Phase Charger A single phase charger can be operated from a single phase line or from two lines of a three phase line provided that the line voltage is correct DC Volts This gives the nominal DC output voltage of the system Rated DC Amps This is the nominal DC value of current that this unit will deliver to a battery that is 100 discharged Legacye Gold Series Owner s Manual 1592 INSTALLATION WARNING The shipping pallet must be removed for proper and safe operation Location For maximum trouble free service choose a location which is free of excess moisture dust and corrosive fumes Also avoid locations where temperatures are high or where liquids will drip on the charger Allow six 6 inches of clearance at rear and sides of the charger for air circulation Do not obstruct the ventilating openings or the space under the charger Stacking Multiple Chargers These chargers can be stacked up to a maximum of 3 units high 18 63 Chargers not designed to be stacked side by side due to ventilation requirements 1 1 88 9 Single Phase chargers require holes drilled on the top Use drawing template for drills 0156 1 Position the first charger so that a minimum of 6 inches space is between the charger and any wall and 12 inches between the charger
28. and any other equipment 56 17 25 2 Place the second charger on top the first Align the bolt holes on each charger 3 Fasten both charger cabinets together securely using 3 8 bolts and nuts NOTE the two bolts toward the back of the charger may be al T omitted if an after market metal strap about 8 inches is used to secure both chargers Remove existing 1 4 screws of the chargers sides and attach strap with screws Refer to picture Hardware kit X225 99 0 2 be ordered to attach two chargers p Tj 4 Repeat steps 2 and 3 for the third charger 5 Stacked chargers must be fastened to the wall using devices suitable for the wall construction and the bolt holes at the top of the highest charger NOTE Ambient temperature at all levels cannot exceed N 104 40 C __ Electrical Connections To prevent failure of the charger be sure it is connected to the correct line voltage Single phase units Connect power to the charger as follows Phase A to L1 fuse block Phase C to L2 fuse block TWO STACKED CHARGERS RIGHT SIDE VIEW Three phase units Connect all the chargers as follows Phase A to L1 fuse block Phase B to L2 fuse block Phase C to L3 fuse block Gold Series Owner s Manual 1592 Connecting Input Power WARNING sure the disconnect is in the OFF position
29. and the battery is disconnected before connecting the input power to the terminals of the charger Connect the input power to the appropriate terminals including ground Follow your local electrical or National Electric Code in making these connections The figure that follows shows both the top and right side installation options for routing the incoming power cable IMPORTANT When the AC Disconnect Switch is factory installed connect the input power to the Switch instead the AC fuse block AC Disconnect The user must provide suitable branch circuit protection and a disconnect method from the AC power supply to the charger to allow for safe servicing Even if the charger has an optional factory installed Disconnect Switch HARGE ARGE Plug Polarity LOOKING INSIDE The charging cable is connected to the DC output of the charger with the positive lead marked RED The output polarity of the charger must be strictly observed when connecting to the battery read warning above Improper connection will open the DC fuse Grounding the Charger DANGER FAILURE TO GROUND THE CHARGER COULD LEAD TO FATAL ELECTRIC SHOCK Follow local codes or National Electric Code for ground wire sizing Connect a grounding conductor to the lug provided on the horizontal support panel This lug is marked as shown DESCRIPTION OF OPERATION General This battery charger
30. ge time it is best to do this when additional cooling time is available example on a weekend Consult your factory representative to determine Equalize intervals that meet your needs Refresh Cycle If a battery remains connected to the charger for a predetermined amount of time after a charge cycle has been completed a Refresh charge cycle will be given to the battery The factory default setting for the Refresh Cycle is to refresh for 20 minutes every 12 hours This is a configurable parameter consult your service representative for more information Cool Down When battery completes a charge cycle without error it ideally should cool down before being used This is a configurable parameter that can be set through the front panel display refer to cooL in section User Parameter Configuration The factory default setting for the Cool Down is 1 hour Gold Series Owner s Manual 1592 User Parameter Configuration Adjusting Parameter Settings The charger s user parameters may be configured only while the charger is in idle mode In order to do so press the EQUALIZE pushbutton and hold for approximately five seconds The display will read USEr and is now ready for user parameter configuration When you release the EQUALIZE pushbutton the display will then read diSP For a list of available user parameters and their definitions see the table below You can scroll up through the different parameters by using the E
31. hargeur et la batterie 2 chargeur a t con u pour la charge des batteries industrielles de type plomb acide dites ouverte il ne peut pas tre adapt pour les batteries tanches 3 Lisez toutes les consignes d installation et d utilisation avant d employer le chargeur de batteries afin de pr venir tout dommage envers la batterie et ou le chargeur 4 Ne pas se mettre en contact avec les pi ces sous tension non isol es tels que la prise de charge ou les l ments de connexion de la batterie pour emp cher tout choc lectrique 5 Pendant la charge le d gagement d hydrog ne rend l emploi de feu strictement interdit risque d explosion jamais fumer employer une flamme nue ou cr er d tincelles proximit de la batterie Ventiler suffisamment le local de charge pour viter toute condensation de gaz dans un espace restreint 6 Ne brancher ou d brancher la batterie que si le chargeur est l arr t Proc der ainsi permet d viter d endommager la prise de charge et de causer des dommages au chargeur ou l explosion de la batterie 7 Les batteries d acide que plomb contiennent de l acide sulfurique pouvant causer des br lures Eviter le contact avec les yeux la peau ou les v tements Dans le cas d un contact avec les yeux rincer aussit t avec de l eau propre pendant 15 minutes et consulter un m decin imm diatement 8 Seulle personnel qualifi par l usine peut entretenir cet quipement 9 Avantto
32. her information Replacement part numbers for chargers with such letter codes shall be referred to the charger s tables with code letter B SPECIALTY CHARGER OPTIONS LIST Check items included v Y Suffix Description Kit part 6 of 10AWG AC Cord with 30 8ph X225 77 2 1ph X225 77 4 of 10AWG AC Cord with 30 Plug N A C10 10 of 10AWG AC Cord with 30 AMP Plug N A C12 12 of 10AWG AC Cord with 30 AMP Plug N A CF 10 of 8AWG AC Cord with 50 AMP Plug N A CF12 12 of 8AWG AC Cord with 50 AMP Plug N A CR 10AWG AC Cord with 30 AMP Plug and 30AMP receptacle X225 77 1 1ph 225 77 3 D Charger with AC Disconnect Switch 6 of 10AWG AC Cord with 30 8ph X225 77 2 1ph X225 77 4 4 16 of 10AWG AC Cord with 30 AMP Plug and Receptacle 225 77 1 1ph X225 77 3 13 13 of DC cable See OUTPUT CABLE L15 15 of DC cable See OUTPUT CABLE 118 18 of DC cable See OUTPUT CABLE 120 20 of DC cable See OUTPUT CABLE 125 25 of DC cable See OUTPUT CABLE 130 130 of DC cable See OUTPUT CABLE P Parallel DC cables standard size N A PP Charger shipped on a Plastic Pallet N A input change Quick Tap N A S Series DC cables N A T Block Out Timer switch WF Ferro Charger with WaterGenius P N 1003 position front WFB Ferro Cha
33. oretically charging current is equally divided between both batteries provided that batteries 96 of discharge and ages are equal Make sure both batteries are connected before charge cycle starts Series Charging Optional In series charging the voltages of both batteries add up and must match charger s nameplate rating Chargers ampere hour rating must be equal to each of the batteries ampere hour rating Charge cycle will not start unless both batteries are connected AC Disconnect Optional When an AC disconnect is installed access to the charger through the front door is denied unless the AC disconnect is switched off When the AC disconnect is in the off position power is only present at the disconnect switch input terminals Make sure that main breaker is switched off before working on the charger AC Input Change Quick Optional Quick Tap is a feature to Douglas chargers that allows the user to change input easily and quickly See the heading VOLTAGE CONVERSION for more information OPERATING INSTRUCTIONS Read operating Instructions for the type of control board that matches your charger CONTROL BOARD Normal Operation 1 Make sure that the battery is properly matched for the particular charger For charger characteristics refer to the nameplate label located on the front panel of the charger Failure to properly match charger and battery can result in damage to both 2 Idle Mode When AC input voltage
34. rger with WaterGenius P N 1003 position front DC cables through bottom WR Ferro Charger with WaterGenius P N 1006 position right Ferro Charger with WaterGenius P N 1006 position front door Stacking Hardware X225 99 0 2 Wall Mounting Brackets X225 99 0 1 When AC cord is installed at the factory only one input voltage is marked on the charger Accessories Note refer specialty charger part numbers to the standard models contained in this manual Legacye Gold Series Owner s Manual 1592 TABLE OF CONTENTS AC LINE VOLTAGE LETTER CODES wie isccs acess ccxcsocdsecescetexstvccsccaccevesecscesssesescnduvessscssssatsasiveddsssnesusestuueaietsnscstuccanceiscacsazexscciceasessstysesnieeceres SPECIALTY CHARGER OPTIONS LIST IMPORTANT SAFETY INSTRUCTIONS TECHNICAL INFORMATION INSTALLATION iiec erroe Stacking Multiple Chargers ELECTRICAL CONNECTIONS On single phase units On three phase units Connecting Input Power AC Disconnect Pl g AREE E Grounding the Charger DESCRIPTION OF OPERATION POWER DIODES AC POWER PARALLEL CHARGING OPTIONAL SERIES CHARGING OPTIONAL DISCONNECT OPTIONA
35. rts SUB ASS Y PANEL 111111 0 E A 256 25649 4 CONTROL TRANSFORMER SEE MODEL CHARTS FOR THESE CONNECTIONS g E M FUSE BLOGY UF BLACK GE 5 x d Mb 5 5 BLACK A J 017 5 a8 388 sinks YJ 5 ORANGE L3IF5 WHITE m RED 8 BLUE ORRED Amm t ja H 5 m ind 5 VIOLET mi 9 BLACK 208 240 480 MODELB 480 550 600 MODELJ 220 380 40 MODELD 20 Legacye Gold Series Owner s Manual 1592 SCHEMATIC 1 PHASE VOLT MODEL B 1 1 1 7 OH 24 40 9 1 10 12 SHUNT RED 4 4 t BLACK TO ACINPUT 45 45 4 LES m J TO CONTROL BOARD 3 3 3 208V CONFIGURATION 240V CONFIGURATION 480V CONFIGURATION cou 2 CONTACTOR COILS COIL
36. space 6 Do not connect or disconnect the battery plug while the charger is on Doing so will cause arcing and burning of the connector resulting in charger damage or battery explosion 7 Lead acid batteries contain sulfuric acid which causes burns Do not get in eyes on skin or on clothing In cases of contact with eyes flush immediately with clean water for 15 minutes Seek medical attention immediately 8 Only factory qualified personnel can service this equipment For service contact the nearest Douglas Battery authorized representative at 1 866 443 9433 9 De energize all AC and DC power connections before servicing the charger 10 This charger is not for outdoor use 11 Do not expose the charger to moisture Operating conditions should be 0 to 104 F 0 to 70 relative humidity 12 Do not operate the charger if it has been dropped received a sharp hit or otherwise damaged in any way 13 For continued protection and to reduce the risk of fire install chargers on a floor of non combustible material such as stone brick or grounded metal WARNING The shipping pallet must be removed for proper and safe operation INSTRUCTIONS DE S CURIT IMPORTANTES 1 Cemanuel contient des informations et des consignes importantes pour l installation et l utilisation du chargeur de batteries industrielles Avant tout emploi il est fortement conseill de lire l ensemble des instructions recommandations et avertissements concernant le c
37. ute intervention d entretien ou de r paration il est imp ratif de s assurer que le chargeur est hors tension ainsi que la batterie d connect e du chargeur 10 Le chargeur n est pas congu pour fonctionner en usage ext rieur 11 Ne pas exposez le chargeur l humidit Les conditions de fonctionnement doit tre comprise entre 15 et 40 avec une humidit relative de 0 de 70 12 Ne pas mettre en fonctionnement le chargeur s il a re u un choc m canique ou tout autre dommage de quelque fa on 13 Pour une protection permanente et pour r duire le risque du feu installez les chargeurs sur un plancher un mat riel non combustible tel qu un mur plein en b ton en brique ou l acier Legacye Gold Series Owner s Manual 1592 The nameplate located on the outside the charger should be used to check this application before installation Part Number SALES NO pd This number specifies in general the characteristics of this particular charger and for this reason it is required in any discussion or correspondence MODEL NO gt regarding this unit PART NO 0000 SER NO Model type BATTERY TYPE PC Board type AMP HOURS dos NO CELLS ell capacity Ampere hour 3 4 digits CHARGE TIME Volt code Option s Ac VOLTS 1 CT Serial Number This number indicates complete information about the specific charger It HEATZ
38. vice NO voltage is between 1 8 Hi batt above Bar Graph Steady On and 2 4 Volts cell 2 4 Volts cell Occurs when there is negative Can be reset by change in battery voltage Call Service NO disconnecting the battery Hot batt Bar Graph Steady On from the charger battery voltage is below 1 0 Volt cell the charger will not recognize that a battery has been connected The display will continue to read Conn Batt VOLTAGE CONVERSION The charger is designed to operate from nominal line voltages as marked on the nameplate The line voltage to which the charger is to be converted must be one of the voltages shown on the charger nameplate DANGER POWER MUST BE DISCONNECTED BEFORE CHANGING AC INPUT CONNECTIONS THERE ARE DANGEROUS VOLTAGES WITHIN THE BATTERY CHARGER ABINET ONLY QUALIFIED PERSONNEL SHOULD ATTEMPT TO ADJUST OR SERVICE THIS BATTERY CHARGER AC Input change Standard NOTE Chargers with optional Quick please refer to AC Input Change With Quick Tap 1 Change AC fuses to the value of the desired line voltage available for this charger AC fuse values can be found on the decal inside the charger 2 Change jumper L1 V red wire at terminals of the Control Transformer s Primary fuse to desired line voltage CAUTION Failure to perform this step may cause the Control Trans Primary fuse to open 10 Legacye Gold Series Owner s Manual 1 8 1592
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