P45 Series Battery Charger
Contents
1. or other OK Exit Alarms Active message described in this manual A B C D Each Key corresponds to a function Fixed charger mode Display unit Adjustable values are displayed on the higher row of the LCD i e number of relays alarm ON OFF voltage level Key functions are displayed on the lower row depending of the menu context When an alarm is active on the charger exact failure message is appears and the red LED blinks to warn the user In case of multiple alarm the P45 display unit show sequentially all the warning messages There is also an AC sector detection LED green LED The user is able to save his parameters individually LCD power save feature shuts down the display unit after 5 minutes of keyboard inactivity When the P45 enters power save mode it saves the latest values entered Upon wake up P45 returns to main menu The display accuracy is 296 1 digit P45CHARGER SCR Accessing menu via keypad overview On power up the following reading appears on the screen example 131 4V i e Equalize A B c D From that point if you press any key A to D only once you reach the menu screen MODE FLT 5 Eq OK Exit A B C D Press A OK to access tthe Float Equalize menu Press D Exit to step back to the menu screen From the menu you may reach the different functions by pressing B J MODE FLT lt gt A2. RUSSIA Tel 7 495 916 1854 Fax 7 495 916 1349 Alphatec Baltics S Konarskio G 48 Vilnius 2009 LITHUANIA Tel 370 5 213 8822 Fax 370 5 213 7799 Alpha Technologies 9 impasse Sans Souci 92140 Clamart France FRANCE Tel 33 1 41 90 07 07 Fax 33 1 41 90 93 12 Due to continuing product improvements Alpha reserves the right to change specifications without notice Copyright 2007 Alpha Technologies Inc All rights reserved Alpha is a registered trademark of Alpha Technologies PASCHARGER SCR
3. By C D P45CHARGER SCR 13 after one touch of the B key you get the first function Adjust ADJUST Continuing pressing B gt will make the screen successively scroll through the following functions gt Reset Alarm present only in case of alarm gt Adjust J Reading gt Relay test 2 Contrast LCD Pressing C 4 times will make the screen scroll in the opposite direction back to the initial menu screen MODE FLT lt gt OK A B CJ D Each function has many sub functions represented by the following tree structure 14 P45CHARGER SCR Menu structure quick overview some of the menu items may be not applicable for your order From the previous menu screen press B B gt Reset Alarm visible only in case of alarm B Adjust A Ok Enter Password B AC password for fixed charger only NC WARNING Modifications to the following settings affect output voltage and output current of the charger and should be done only by qualified technician Control A Ok Float 124 9 for example B Lim 23 3A Eq 131 5 On TEQ 08 H LVEQ 106 1V On t TALimEq 05mn On AC Eq On a T Float 30 D N available only if Eq is On B Alarm A Ok Talarm 10 S for example B gt HVAL 138 1V On wih HVSH 90 2V Off L VAL 100 0V On L Vdis 61 5V On GNDF 5 0mA Off GNDF 5 0mA Off AC Fail On LCD latch Off Com Al latch Off In
4. Y PRESS ACTION DEFAULT VALUE Vnom x 1 09 LM kor AgustGurrent Um t 1 ime Or Adjust Equalization Voltage Vnom x 1 12 or Adjust Equalization Tme Hou SET Toggle On Oft AC Equalization on P45CHARGER SCR Alarms Use gt or keys to scroll the Alarm sub menus SET to enter menu EXIT to return to previous menu DISPLAY PRESS ACTION DEFAULT VALUE Talarm or Adjust alarm Timing sec 10 sec HVAL or Adjust High Voltage alarm level V Veq x 1 05 NEXT Go to Relays selection toggle menu NEXT On Off Toggle On Off High Voltage alarm On relay xxx NEXT or Select relays number 1 to 7 No 2 HVSH or Adjust High Voltage Shutdown level V Veq x 1 1 NEXT Go to Relays selection toggle menu NEXT On Off Toggle High voltage shutdown Off relay xxx NEXT or Select relays number 1 to 7 No 8 LVAL or Adjust Low Voltage alarm level V 0 8 x Vfloat NEXT Go to Relays selection toggle menu NEXT On Off Toggle On Off Low Voltage alarm On relay xxx NEXT or Select relays number 1 to 7 No 3 LVDis or Adjust Low Voltage Disconnect level V NEXT Go to Relays selection toggle menu relay xxx NEXT On Off Toggle Low voltage Disconnect y NEXT or Select relays number 1 to 7 No 4 GNDF m Adjust Negative Ground Fault level 5 mA mA NEXT Go to Relays selection toggle menu relay xxx NEXT On Off yS 99 On Toggle Negative Gro
5. alue seting vala 0 2 rR Lim sting value tetova n 2 WR __V ph1 setting value settng value 12 J 2 rR Vpr setting value se ngvau B 2 R Oves mw 4 o im Gemwe 5 o img getingvale 1 Mh E NNNM M NN NU UNE MUN ON TIL TT Tr Table 1 N N NIN N eo l DIDIT N P45CHARGER SCR 23 RAM memory map continued w P Alam low vet wg M Alam neg ground Gau f Alarm pos ground seu aR WamAcfan w 2X Alarm HV ShutDown Sau em 3 Alam Low Volt dese Gu w 1 R iaimAGtigh vok au EM 3 Wamacowwt Gu za 1 Alam High external temperature status 3 Ro Alarm low extemal temperature sau a R o Alarm High temperature of card taw a 1 B iam Battery Discharging Gau 1 R Alam 1Lim________ E 1 Alam Equalize wa 25 1 B Alan cutfuse cawg m 1 P Password 30 2 Table 1 continued NOTE v s the value FF ex at any Status Alarm address means that this alarm has not been ordered with your charger 1 1 Format for voltage and current values Voltage and current values are coded on 2 bytes Example Vout 651 3V 6513 decimal 1971 hex so the coded value will be 19 hex 71 hex 19 MSB 71 LSB or 6513 in decimal 65 MSB 13 LSB MSB mos
6. aptas P45 Series Battery Charger Technical Manual Effective February 2007 Power P45 Series Charger Technical Manual P45CHARGER SCR Effective Date February 2007 Copyright 2007 Alpha Technologies Inc member of The akin Group J NOTE The specifications in this document are subject to change without notice NOTE SA reos contained in this manual are for illustrative purposes only These photographs may not match your installation NOTE v oo is cautioned to review the drawings and illustrations contained in this manual before proceeding If there are questions regarding the safe operation of this powering system please contact Alpha Technologies or your nearest Alpha representative J NOTE Alpha shall not be held liable for any damage or injury involving its enclosures power supplies generators batteries or other hardware if used or operated in any manner or subject to any condition not consistent with its intended purpose or is installed or operated in an unapproved manner or improperly maintained Contacting Alpha Technologies www alpha com or For general product information and customer service 7 AM to 5 PM Pacific Time call 1 800 863 3930 For complete technical support call 1 800 863 3364 7 AM to 5 PM Pacific Time and 24 7 emergency support P45CHARGER SCR TABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS sss naa ka nera l le ke ul d e k a e e
7. attery and AC supply should be disconnected before replacing any component FAULT RECOMMENDATION No output Verify that the AC breaker is closed ON Verify that the AC supply is of correct voltage and frequency Verify the DC output fuse Verify the output and input connections Replace control board PC20 Replace thyristor modules Abnormal noise Verify thyristors Replace control board PC20 If trouble persists please call 1 800 863 3364 7 AM to 5 PM Pacific Time and 24 7 emergency support P45CHARGER SCR 27 28 Regular preventive maintenance Regular maintenance is required to ensure reliable operation of your system COMPONENT ACTION FREQUENCY Battery Measure and record the voltage across each Monthly battery cell and across the entire battery Battery Verify and record the electrolyte level Monthly of each battery cell If necessary top off with distilled water Battery Verify and record the specific gravity of each battery cell Monthly Verify the operation of all indicators Monthly Battery Charger Use a vacuum cleaner equipped with a small brush and re Yearly move any accumulated dust especially around ventilation openings Battery Charger Visually verify the condition of all components Battery Charger Verify all connections If necessary retorque to manufacturers Yearly specifications Battery Clean and re grease all battery connections Battery Wash battery using distille
8. ble in case of alarm only uiEEe 19 er ue 19 Gelato EET N E 19 ASI S sn e ecel Aya eel eyba keyan l aye ee ceder Pme ben deste Tenet te ie e rcd cn yaaa kay 20 Level 2 SMC lov rone T 22 ai lelercm m E S E S T A E ny 23 MODBUS OPTIONAL moissonner aans aea aE ve key GE Y SeA ee Ehe E kev dwa 24 MATERIAL CONFIGURATION iocos rfe eet datar denti Fre deka dett nd EE to e ERE Meck 24 PAM MEMORY MMAB et onere ddr etre etel ke oret ductu edema W kewena kn bana aE bale gr ey a N 24 1 1 Format for voltage and current values a sa auanl ul rai aaya nik n aabee lika sanan n kan nad za 25 1 2 Logie oralinio c r TEE 26 To FO EGUAN c yal ey alay n yan yete y Sal Wa yan xes k z xal n neta kad en y 26 D ais M m 27 Jie Bsigze leegicem ED 28 REGULAR PREVENTIVE MAINTENANCE i ddklaksd d n n dika herk n kya ay adi yene k dera kel k terrenis nnne rennes 29 CONTROL BOARD PC ADJUSTMENT PROCEDURE 4 keke kek kk kk kK kk AK A KARIR 30 zelda 30 giis cse p 31 ALARMS ADJUSTMENT PROCEDURE eeessssseseseeeeeeen aana aa eaaa aa kski awe etin nannten 32 qelc a naa A mann 32 naine Dl ND EUER 32 P45CHARGER SCR Safety Notes Review the drawings and illustrations contain
9. censed electrician is required to install permanently wired equipment Input voltages can range up to 240 VAC Ensure that utility power is disabled before beginning installation or removal Ensure no liquids or wet clothes contact internal components Hazardous electrically live parts inside this unit are energized from batteries even when the AC input power is disconnected AC and DC currents are present in this system even with the indicators and circuit breakers in the OFF position Mechanical Safety Keep hands and tools clear of fans Fans are thermostatically controlled and will turn on automatically Power supplies can reach extreme temperatures under load Use caution around sheet metal components and sharp edges P45CHARGER SCR Battery Safety Notes a Lead acid batteries contain dangerous voltages currents and corrosive material Battery installation maintenance service and replacement must be performed only by authorized personnel Chemical Hazards Any gelled or liquid emissions from a valve regulated lead acid VRLA battery contain dilute sulfuric acid which is harmful to the skin and eyes Emissions are electrolytic and are electrically conductive and corrosive To avoid injury Servicing and connection of batteries shall be performed by or under the direct supervision of personnel knowledgeable of batteries and the required safety precautions Always wear eye protection rubber gloves and a protective v
10. d Al latch Off Audio Alarm Off Mesg latch Off Rct fail On Htemp Off H Ext T 100C Off L Ext T 00C Off ACHV 160 0V Off ACLV 0 0V Off Fuse Off Hi ripple Off lim Alarm Off Eq Alarm Off Bat disch Off P45CHARGER SCR Pressing C repetitively will make you scroll back in the menu Pressing D Exit will make you step one level back in the hierarchy of the tree menu B Level2 A Ok NO WARNING Enter Password B A C password for fixed charger only Modifications to the following settings should be done by qualified technician Display Off Off for example B gt Default value kah Nom Volt 150V Nom AMP 25 A DCV cal 132 0V DCA cal 0 0A AC display Off ACV cal 78 4V ACA cal 539 5A VMIN 0 0V VMAX 160 0V IMAX 02 2A Remote V sens Off Load sharing Off Tcomp Off LCD Pwr save Off Remote EQ Off AH display Off li Batt capa 100AH affect menu option in Reading submenu if set to ON Pressing C repetitively will make you scroll back in the menu Pressing D Exit will make you step one level back in the hierarchy of the tree menu B Reading A Ok Frequency B gt AC display AH meter i not yet available must be set ON in Level2 menu to be visible here Be Relay test A OK A Yes D No B gt Contrast LCD Press A OK A Set D No 16 P45CHARGER SCR MENU DETAILED FUNCTIONS some of the menu items may be not applicable
11. d ende s l dla da ke nen 5 INTRODUCTION Pm 9 INSTALLATION c 10 PLACEMENT 4 ase b wa dekan KA 10 VENTILATION AND GOOLIN G iue xaka ea ee tuc a Xana eate ai Don eset mae yaya k n an Seva k n yana k 10 ELECTRICAL CONNECTION AND WIRING nennen nes H s nnns enne 11 POWER UP ce M 11 SYS TEM POWER OFF PROCEDURE 2 1 2 023 av kab wan pr tee inier Receta ne Wek dede PE bane ge AZ 11 THEORY OF OPERATION 5 disene sa lndilan a d da kek d k een parte o er vs d k lane oe eerta u d dek uan dekene desa bad la TEES 12 DISPLAY SGREEN AND KEY PAD 5 tertia lb kaka kk dek o inte dela k d Ny n ka d ken dek bek gu cek b g eden a Dade Wan 13 DISPEAY SCREEN s s e sar Ke bi nen ke kw kene as nun di aze Ole ade ca bke ce banan de MI IE MED dek 13 KEV E e E 13 FIXED Fetat tio giot oro zt 13 Bore UD er H EX 13 ACCESSING MENU VIA KEYPAD OVERVIEW sssssesseeeneneneenenn kk ek kk kek K k kk AKA KAK AK KA KAK nene 14 MENU STRUCTURE QUICK OVERVIEW sess enn nennen nnnrnen nennen nennen nnne nennen 15 MENU DETAILED FUNGTIGONS 12 rire ete eet tec rc ya k da aa lad a zaqe a aka d w dakan 18 MAIN MENU orei gt gt ee oggxggxgxggowzwwwg__z_mm 18 BIB N E AE A EEE EP 18 LCD Contrast T PDT 18 Reset alarms and relays availa
12. d water only For systems supplied with lead acid batteries a partial discharge of the battery is recommended on an annual basis to verify battery and charger performance For systems supplied with nickel cadmium batteries we recommend a complete discharge and decommissioning charge on a bi annual basis Alpha Technologies provides both these services P45CHARGER SCR Control board PC Adjustment Procedure Required tools DC voltmeter DC ammeter or clamp meter DC load bank or dummy load to simulate a load Use the test report of the unit included in the user s manual and refer to the following data DC output float voltage Vf DC output equalize voltage if required Ve DC output maximum current im Example 18Ni Cd cell system for your specific Ni Cd or lead acid please use the information provided by the battery supplier Constant voltage Float voltage 1 42 volt cell e Equalize voltage 21 55 volt cell Number of cells 18 Current limit Adjust the current limit to the test report value Nickel cadmium battery A B C Float voltage V Number of cells x 1 42 v cell 25 6 v Equalize voltage V Number of cells x 1 55 v cell 27 9v Auto equalize level Vs V x 0 85 21 76 v Maximum charging current I s 5 Amp P45CHARGER SCR 29 30 Control board PC Adjustment Procedure continued Adjustment Procedure 1 Switch the AC breaker off 2 Switch the DC breaker off
13. ed connections Verify battery terminals and or exposed connection hardware is not within 2 inches of a conductive surface Reposition batteries as necessary to maintain adequate clearance Clean up any electrolyte battery emission in accordance with all federal state and local regulations or codes Proper venting of the enclosure is recommended Follow the battery manufacturer s approved transportation and storage instructions Always replace batteries with those of an identical type and rating Never install old or untested batteries Do not charge batteries in a sealed container Each individual battery should have at least 0 5 inches of space between it and all surrounding surfaces to allow for convection cooling All battery compartments must have adequate ventilation to prevent an accumulation of potentially dangerous gas Recycling and Disposal Instructions Spent or damaged batteries are considered environmentally unsafe Always recycle used batteries or dispose of the batteries in accordance with all federal state and local regulations Electrical Safety Lethal voltages are present within the power supply and electrical boxes Never assume that an electrical connection or conductor is not energized Check the circuit with a volt meter with respect to the grounded portion of the enclosure both AC and DC prior to any installation or removal procedure Always use the buddy system when working under hazardous conditions A li
14. ed in this manual before proceeding If there are any questions regarding the safe installation or operation of the system contact Alpha Technologies or the nearest Alpha representative Save this document for future reference To reduce the risk of injury or death and to ensure the continued safe operation of this product the following symbols have been placed throughout this manual Where these symbols appear use extra care and attention ATTENTION The use of ATTENTION indicates specific regulatory code requirements that may affect the placement of equipment and or installation procedures J NOTE A NOTE provides additional information to help complete a specific task or procedure CAUTION The use of CAUTION indicates safety information intended to PREVENT DAMAGE to material or equipment NC WARNING A WARNING presents safety information to PREVENT INJURY OR DEATH to the technician or user Safety Precautions Only qualified personnel may service the system Verify the voltage requirements of the equipment to be protected load the AC input voltage to the power supply line and the output voltage of the system prior to installation Verify the utility service panel is equipped with a properly rated circuit breaker for use with this system When connecting the load DO NOT exceed the output rating of the power supply If batteries are being stored prior to installation charge at least once every three months
15. est when working near batteries Remove all metallic objects from hands and neck Batteries produce explosive gases Keep all open flames and sparks away from batteries Use tools with insulated handles do not rest any tools on top of batteries Batteries contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Battery post terminals and related accessories contain lead and lead compounds Wash hands after handling California Proposition 65 Wear protective clothing insulated gloves eye protection etc whenever installing maintaining servicing or replacing batteries If any battery emission contacts the skin wash immediately and thoroughly with water Follow your company s approved chemical exposure procedures Neutralize any spilled battery emission with the special solution contained in an approved spill kit or with a solution of one pound Bicarbonate of soda to one gallon of water Report chemical spill using your company s spill reporting structure and seek medical attention if necessary Always replace batteries with those of an identical type and rating Never install old or untested batteries Do not charge batteries in a sealed container Each individual battery should have at least 0 5 inches of space between it and all surrounding surfaces to allow for convection cooling All battery compartments must have adequate ventilation to prevent an accumulation of potentia
16. f this equipment Installation Placement FOR INSTALLATION PLEASE REFER TO NATIONAL AND LOCAL ELECTRICAL CODES The system is very heavy equipment To prevent personal injury or equipment damage use lifts and extreme care when handling Ventilation and cooling The rectifier charger is rated to better perform within 18 F 10 C and 122 F 50 C temperature range To calculate the required air displacement exchange volume please use the following equation V BTU x e 0 125 x H x TK To Tr Tk V air flow cubic meter hour BTU Total dissipated heat Tr Maximum allowed room temperature K i e 50 C 323 Tk Temperature of input cooling air To 273 H Altitude km Avoid placing the system in direct sunlight NOTE v gt ensure adequate ventilation and safe access make sure that the following clearances are respected e Sin 10 cm on the sides and top 3 feet 1 meter in front of the unit Should seismic conditions require a more secure installation the unit may be bolted to the floor Four 4 holes are provided for this purpose P45CHARGER SCR Installation continued VA NOTE Electrical connection and wiring Before Connecting the P45 battery charger verify the following The battery is disconnected if applicable e The circuit breakers are OFF The relays fuses and circuit boards are installed The unit is wired in accordance with the instructions refer to the wiring co
17. for your order Definition of the 4 keys functions Display field explains the key function shown on the LCD lower row depending on sub menu context ACTION DISPLAY NOTE Enter the displayed OK Key sub menu or Set key for sub function Return to previous menu Ed Return last selection Go UP next Main menu Use or keys to scroll the level 0 sub menus SET to enter menu Equalize DISPLAY PRESS ACTION Float Equalize Exit Float Set float mode Equalize Set Equalize mode Exit Return to main menu DISPLAY PRESS ACTION LCD Contrast DISPLAY PRESS ACTION Contrast LCD SET Access contrast control Contrast High Contrast Low P45CHARGER SCR Reset alarms and relays available in case of alarm only DISPLAY PRESS ACTION Reset relays Yes Reset all the relays No Go to Reset alarm Reset Alarm msg Yes Clear all alarms messages not displayed No Go to Relay test Relay Test Yes Test all relays not displayed No Go back one level Adjust Use gt or keys to scroll the sub menus SET to enter menu EXIT to return to previous menu DISPLAY PRESS ACTION PASSWORD B A C Push in order Enter Level 1 EXIT Return to previous menu Password must be valid to access Control Alarms and reading sub menu Go to Contro adjustments Go to alarm adjustments Control Use gt or keys to scroll to the Control sub menus SET to enter menu EXIT to return to previous menu DISPLA
18. if provided 3 Disconnect batteries from charger 4 Connect resistive load 5 Connect DC voltmeter across DC output terminal see wiring diagram 6 Switch the AC breaker on Use gt or keys to scroll the Control sub menus SET to enter menu EXIT to return to previous menu DISPLAY PRESS ACTION VALUE Float Or Adjust Float Voltage V 25 6V LIM Or Adjust Current Limit A 5 0A Eq SET Toggle On Off Equalization Voltage On Or Adjust Equalization Voltage V 27 9 V T eq Or Adjust Equalization Time Hour L VEQ Or Adjust Low Equalization Voltage V 21 76 V TI LIM E Or Adjust Time Current limit Equalization 5 min Minute AC Eq SET Toggle On Off AC Equalization On Tfloat 0r Adjust Float Timing Days 28 Days P45CHARGER SCR Alarms Adjustment Procedure Required tools DC voltmeter DC ammeter or clamp meter DC load bank or dummy load to simulate a load Use the test report of the unit included in the user s manual to have the following data handy DC output float voltage Vf DC output equalize voltage if required Ve DC output maximum current Im Example 18Ni Cd cell system for your specific Ni Cd or lead acid please use the information provided by the battery supplier Constant voltage e Float voltage 71 42 Volt cell Equalize voltage 1 55 volt cell Number of cells 18 Nickel cadmium battery f NOTE Fl
19. l temperature level relay xxx Alarm NEXT or Select relays number 1 to 7 or Adjust High AC Voltage level alarm ACVH j NEXT Go to Relays selection toggle menu NEXT On Off Toggle High AC Voltage Level Alarm relay xxx Off NEXT or Select relays number 1 to 7 Or Adjust Low AC Voltage level alarm ACVL NEXT Go to Relays selection toggle menu NEXT On Off Toggle Low AC Voltage Level Alarm relay XXX Off NEXT or Select relays number 1 to 7 SET Toggle On Off Fuse alarm DC Fuse or Select relays number 1 to 7 SET Toggle On Off High Ripple alarm Hi ripple Off or Select relays number 1 to 7 SET Toggle On Off Current Limit alarm llim Alarm or Select relays number 1 to 7 SET Toggle On Off Equalize alarm Off Eq Alarm or Select relays number 1 to 7 No 4 SET Bat disch Toggle On Off Battery Discharge alarm Off or Select relays number 1 to 7 Batt Current O P current P45CHARGER SCR Level 2 strict level Use gt or keys to scroll the level 2 sub menus SET to enter menu EXIT to return to previous menu DISPLAY ACTION Default Value PASSWORD Contact MTI Enters Level 2 EXIT Return to previous menu Password must be valid to access Control Alarms and reading sub menu Value default SET Toggle On Off Select factory value On Off Display Off SET Toggle On Off When Off all values are displayed When On only value
20. lly dangerous gas Prior to handling the batteries touch a grounded metal object to dissipate any static charge that may have developed on your body Never use uninsulated tools or other conductive materials when installing maintaining servicing or replacing batteries Use special caution when connecting or adjusting battery cabling An improperly connected battery cable or an unconnected battery cable can make contact with an unintended surface that can result in arcing fire or possible explosion A battery showing signs of cracking leaking or swelling should be replaced immediately by authorized personnel using a battery of identical type and rating Never charge a frozen battery P45CHARGER SCR General Safety Precautions To avoid injury This enclosure and its associated hardware must be serviced only by authorized personnel Enclosure must remain locked at all times except when authorized service personnel are present Remove all conductive jewelry or personal equipment prior to servicing equipment parts connectors wiring or batteries Read and follow all installation equipment grounding usage and service instructions included in this manual Use proper lifting techniques whenever handling enclosure equipment parts or batteries Batteries contain dangerous voltages currents and corrosive material Battery installation maintenance service and replacement must be performed by authorized personnel only Neve
21. nnections and electrical diagram Wire size is very important The nameplate provides the essential information regarding the input and output voltages and currents Refer to your Local or National Electrical Code NEC for WIRE GAUGE and GROUNDING instructions Wire ampere capacity must be sized to the maximal correspondent current Correct voltage and polarity are of critical importance Check all connections for tightness and polarity Connect battery if applicable to the output terminals observing its polarity Power up After all wire installation has been completed and double checked the unit may be powered up as follows Before connecting the load to the charger compare the critical characteristics of the load with the critical characteristics of the charger i e measure line neutral tension positive neutral tension e Keep a log of manipulations i e Vr oar and Vequatize values entered alarm messages alarm and SCR blinking LEDs All input and output breakers must be in OFF position Apply power to the equipment from the source panel e Turn on AC breaker ON position e Turn on DC breaker if supplied ON position e Green LED must turn ON e Wait 5 seconds until the indication screen LCD indicates the system output voltage and status The system soft starts by increasing the output current and the voltage If readings or calibration of the unit is necessary refer to the field programming secti
22. oat and equalize voltage provided by the battery manufacturer Alarms Adjustment Procedure 1 Switch the AC breaker off 2 Switch the DC breaker off if provided 3 Disconnect batteries from charger 4 Connect resistive load 5 Connect DC voltmeter across DC output terminal see wiring diagram 6 Switch the AC breaker on P45CHARGER SCR A B C Float voltage V Number of cells x 1 42 v cell 25 6 v Equalize voltage V Number of cells x 1 55 v cell 27 9v High volts alarm V V x 1 03 28 7 v Low volts alarm V V x 0 8 20 4 v 31 32 Alarms Adjustment Procedure continued Use gt or keys to scroll the Level 2 sub menus SET to enter menu EXIT to return to previous menu DISPLAY PRESS ACTION DEFAULT VALUE Talarm Or Adjust alarm Timing sec 10 sec HVAL or Adjust High Voltage alarm level V 28 7 V NEXT Go to Relays selection toggle menu relay xxx NEXT On Off Toggle On Off High Voltage alarm On NEXT or Select relays number 1 to 7 No 2 LVAL or Adjust Low Voltage alarm level V 20 4 V NEXT Go to Relays selection toggle menu relay xxx NEXT On Off Toggle On Off Low Voltage alarm On NEXT or Select relays number 1 to 7 No 3 GNDF or Adjust Negative Ground Fault level 5 mA NEXT mA relay xxx NEXT On Off Go to Relays selection toggle menu On NEXT or Toggle Negative Ground Fault No 4 Select relays number 1 to 7 GNDF or Adjust Po
23. on for more information System power Off procedure Open the AC breaker OFF position Open the DC breaker if supplied OFF position Open the source panel s AC breaker OFF position e f work inside the unit has to be performed wait 5 minutes to discharge the filter capacitors or use bleeding resistors of the correct rating to discharge the capacitors Now the system can be considered de energized P45CHARGER SCR Theory of operation CONTROL BOARD PC20 T1 SCR L1 SHUNT F1 T1 The AC supply is transformed and isolated SCR The transformer secondary voltage is rectified by a full wave half controlled bridge L1 C1 optional The rectified DC voltage is smoothed by IC filter section Shunt Current and voltage reading sent to the control board F1 A fuse protects the SCRs and diodes Control Board The PC20 series control board provides automatic charge control precise voltage regulation alarm status annunciation and display P45CHARGER SCR 11 Display Screen and Keypad Display Screen The P45 series provides a very flexible and friendly user interface The display supplied with the standard unit s features a high visibility back light LCD display Keypad The P4500 uses four 4 long life membrane switches Equalize mode or other message described in this To Choose manual AC On 5 MODE FLT lt gt Eq ec Float mode a O A
24. r its equipment match the voltage requirements of the connected equipment load Prior to installation verify that the enclosure s utility service panel is equipped with a properly rated circuit breaker for use with the equipment inside Refer to manufacturer s recommendations Review and upgrade utility service panel circuit breaker requirements whenever the equipment within the enclosure is changed Prior to installation contact local utilities local building maintenance departments and cable piping locator services to ensure that installation does not interfere with existing utility or building cables piping Do not exceed the output rating of equipment Verify load requirements prior and during connection process Prior to handling the batteries touch a grounded metal object to dissipate any static charge that may have developed in your body The charger contains electrostatically sensitive equipment Use proper electroststic discharge ESD procedures to prevent any severe damage to the electronic components P45CHARGER SCR Introduction Thank you for having chosen Alpha Industrial Power The P45 series battery charger is designed to provide quality DC power for many years This user s manual contains important technical instructions to be followed by qualified personnel responsible for the installation start up and maintenance of this unit We recommend that this manual be read closely to ensure safe and reliable operation o
25. r use uninsulated tools or other conductive materials when installing maintaining servicing or replacing batteries Use special caution when connecting or adjusting battery cabling An improperly connected battery cable or an unconnected battery cable can result in arcing a fire or possible explosion A battery that shows signs of cracking leaking or swelling must be replaced immediately by authorized personnel using a battery of identical type and rating Avoid any contact with gelled or liquid emissions from a valve regulated lead acid VRLA battery Emissions contain dilute sulfuric acid which is harmful to the skin and eyes Emissions are electrolytic which are electrically conductive and are corrosive Follow the Chemical Hazards notes if contact occurs Do not smoke or introduce sparks in the vicinity of a battery Under certain overcharging conditions lead acid batteries can vent a mixture of hydrogen gas that is explosive Proper venting of the enclosure is required Follow the battery manufacturer s approved transportation and storage instructions Never energize a pysically damaged charger CAUTION Enclosure equipment or parts may be damaged or cause damage if used or installed improperly To avoid damage Prior to installation verify that the AC input voltage to the enclosure and its equipment match with respect to voltage and frequency Prior to installation verify that the output voltage from the enclosure o
26. s that are set to On are displayed NomVolt or Adjust the Nominal Voltage displayed Factory preset Once values is set Nominal Voltage is not displayed NomAmp or Adjust the Nominal Ampere displayed Factory preset Once values is set Nominal Ampere is not displayed DCV cal Or Adjust the DC Voltage calibration offset XXX NEXT or Adjust the DC Voltage offset DCA cal Or Adjust the DC Current calibration offset XXX NEXT or Adjust the DC Current offset AC display SET Toggle On Off AC display Off ACV cal Or Adjust the AC Voltage calibration ACA cal Adjust the AC Current calibration VMIN Or Adjust the Minimum Output Voltage Default value is 0 VMAX OF Adjust the Maximum Output Voltage IMAX Or Adjust the Maximum Output Current Remote V sens SET Toggle On Off the Remote Voltage Sensing Off P45CHARGER SCR Level 2 strict level continued Use or keys to scroll the Level 2 sub menus SET to enter menu EXIT to return to previous menu DISPLAY PRESS ACTION DEFAULT VALUE Load sharing SET Toggle On Off the Load Sharing Off Negative slope regulation Tcomp SET Toggle On Off Temperature Off Compensation LCD pwr save SET Toggle On Off LCD power save Off After 5 min of inaction on LCD goes on power save Remote Eq SET Toggle On Off Remote Equalization Off AH display SET Toggle On Off Ampere Hour display Off Bat cap Or Adjust the Ampere Hour capacity of Bat
27. sitive Ground Fault level mA 5 mA NEXT Go to Relays selection toggle menu relay xxx NEXT On Off Toggle Positive Ground Fault On NEXT or Select relays number 1 to 7 No 4 AC Fail Or Select relays number 1 to 7 NEXT Go to Relays selection toggle menu NEXT On Off Toggle On Off AC Failure Alarm On NEXT or Select relays number 1 to 7 No 5 Rectifier Fail Or Select relays number 1 to 7 NEXT Go to Relays selection toggle menu NEXT On Off Toggle On Off AC Failure Alarm On NEXT or Select relays number 1 to 7 No 1 P45CHARGER SCR Alpha Technologies ul nr Alpha Industrial Power Inc 1075 Satellite Blvd Suite 400 Suwanee GA 30024 USA Tel 1 678 475 3995 Fax 1 678 584 9259 Alpha Technologies 3767 Alpha Way Bellingham WA 98226 USA Tel 1 360 647 2360 Fax 1 360 671 4936 Web www alpha com Alpha Technologies Ltd 4084 McConnell Court Burnaby BC V5A 3N7 CANADA Tel 1 604 430 1476 Fax 1 604 430 8908 Alpha Technologies Europe Ltd Twyford House Thorley Bishop s Stortford Hertfordshire CM22 7PA UNITED KINGDOM Tel 44 1279 501110 Fax 44 1279 659870 Alpha Technologies GmbH Hansastrasse 8 D 91126 Schwabach GERMANY Tel 49 9122 79889 0 Fax 49 9122 79889 21 Alphatec Ltd P O Box 56468 Limassol Cyprus CYPRUS Tel 357 25 375675 Fax 357 25 359595 AlphaTEK ooo Khokhlovskiy Pereulok 16 Stroenie 1 Office 403 109028 Moscow
28. t significant byte LSB less significant byte 24 P45CHARGER SCR 1 2 Logic of Alarms Address value fF 9 i Table 2 1 3 Float Equalize The command equalize float is coded on 2 bytes The least significant byte LSB indicates the state of operation of the charger Reading mode 0 indicates that the charger is in float mode 1 indicates that the charger is in equalize mode see Table 3 The most significant byte MSB allows the changing of the state of the charger writing mode when it s possible meaning correct pass word and mode remote RS232 1 see Table 4 The equalize mode is authorized i e remote RS232 1 To change the operation mode Float or equalize of the charger refer to Table 3 If the value 0 is sent to address 28 the charger is forced to float mode If the value sent to address 28 is 1 the charger is forced to equalize mode Writing NODE ADDRESS 28 float 0000 equalize 0001 Table 3 Reading MODE ADDRESS 28 float 0000 equalize 0001 Table 4 P45CHARGER SCR 26 1 4 Reset Alarm To deactivate an alarm just send the value 1 at the address 29 in writing mode tee wp Alarm Reset 0001 Table 5 P45CHARGER SCR Troubleshooting Field programming Should trouble occur with your P4500 rectifier please read the following E Maie Only qualified personnel should service this unit The b
29. tery Readings Use or keys to scroll the Readings sub menus SET to enter menu EXIT to return to previous menu DISPLAY PRESS ACTION DEFAULT VALUE Frequency Actual frequency Active AC display L Display AC voltage Off N Display AC current Off AH meter Display Ampere Hour in percent Off Display Ampere hour Off NOTE v FIXED CHARGER mode is in the OFF position then no alarms float equalize modes are accessible i e software exits set up mode after having chosen variable current or and voltage 22 P45CHARGER SCR Modbus optional Material configuration The RS 232 communication operate in slave modbus with 8 bits 1 start and 1 stop bit The speed of the transmission is configured on the communication card PCOM1 The available speed are 300 1200 4800 9600 default and 19200 bauds The address of the PCOM 1 card is on board configurable from address 1 to 255 The default address is 1 RAM memory map The following map show the structure RAM of the PCOM 1 card R means readable and W means writable ADDRESS DEC STATUS Xa TT Dn 2 VajWe gemgvane 0 2 WR eae seting vatuey 28 WR vol iow equaize esting vatvey oa 2 Volt low alarm setting setting value BEE E NEKE Vot low aarm disconnect eting value 5 Vott high alarm seting value 06 f 2 GNbe ooa 2 2 2 zn a UT E C Tout seting v
30. to ensure optimum performance and maximum battery service life The battery pack which provides backup power contains dangerous voltages Only qualified personnel should inspect or replace batteries In the event of a short circuit batteries present a risk of electrical shock and burns from high current Observe proper safety precautions Always wear protective clothing insulated gloves and eye protection i e safety glasses or a face shield whenever working with batteries Always carry a supply of water such as a water jug to wash the eyes or skin in the event of exposure to battery electrolyte P45CHARGER SCR Battery Maintenance Guidelines The battery maintenance instructions listed below are for reference only Battery manufacturer s instructions for transportation installation storage or maintenance take precedence over these instructions To prevent damage inspect batteries every 3 months for Signs of battery cracking leaking or swelling The battery should be replaced immediately by authorized personnel using a battery of the identical type and rating Signs of battery cable damage Battery cable should be replaced immediately by authorized personnel using replacement parts specified by vendor Loose battery connection hardware Refer to battery manufacturer s documentation for the correct torque and connection hardware for the application Apply battery manufacturer s specified antioxidant compound on all expos
31. und Fault NEXT or No 4 Select relays number 1 to 7 GNDF or Adjust Positive Ground Fault level mA 5 mA NEXT Go to Relays selection toggle menu relay xxx NEXT On Off Toggle Positive Ground Fault On NEXT or Select relays number 1 to 7 No 4 or Select relays number 1 to 7 AC Fail NEXT Go to Relays selection toggle menu NEXT On Off Toggle On Off AC Failure Alarm On NEXT or Select relays number 1 to 7 No 5 Mesg latch SET Toggle On Off Alarm Message Latch On LCD latch Not available CAL latch SET Toggle On Off Common Alarm Latch Off Ind alm latch SET Toggle On Off Individual Alarm Latch On Audio latch SET Toggle On Off Audio Alarm Latch Off Mesg latch SET Toggle On Off Alarm Display Latch On P45CHARGER SCR 20 Alarms continued DISPLAY ACTION DEFAULT VALUE Rct fail or Select relays number 1 to 7 On NEXT Go to Relays selection toggle menu relay xxx NEXT On Off Toggle On Off Rectifier Failure alarm y NEXT or Select relays number 1 to 7 No 1 SET Toggle On Off High Temperature alarm Hemp or Select relays number 1 to 7 en H ext T or Adjust High External temperature level Alarm NEXT Go to Relays selection toggle menu relay xxx NEXT On Off Toggle High External temperature level Alarm NEXT or Select relays number 1 to 7 or Adjust Low External temperature level L ext T Alarm NEXT Go to Relays selection toggle menu NEXT On Off Toggle Low Externa
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