Legacy Gold Charger Manual
Contents
1. WARNING HIGH VOLTAGES EXIST WITHIN THE CHARGER WHICH CAN CAUSE SEVERE INJURY OR DEATH SERVICE SHOULD BE PERFORMED ONLY BY QUALIFIED SERVICE PERSONNEL IMPROPER SERVICING MAY DAMAGE THE CHARGER 8 1 MONTHLY PREVENTIVE MAINTENANCE 8 1 1 If a battery is being charged terminate the charge by pressing the STOP button 8 1 2 Disconnect the battery from the charger 8 1 3 Remove AC power from the charger 8 1 4 Using compressed air remove any dust from the inner cabinet walls and internal components of the charger 8 1 5 Wipe the exterior of the cabinet and clear any obstructions from the ventilation louvers 8 1 6 Make sure that all bolted or screwed electrical connections are tight 8 1 7 Make sure that the insulation on all cables and wires is in good condition Replace if necessary 8 2 CHARGER ADJUSTMENTS 8 2 1 CHANGING THE AC INPUT LINE VOLTAGE LEGACY AND LEGACY GOLD chargers are designed to operate at different voltage levels Single phase chargers may be ordered fo2. ckckckckckckckckckckck ck k ck KOK K KOK K K K K K 2 WORKING IN THE VICINITY OF A LEAD ACID BATTERY IS DANGEROUS BATTERIES GENERATE EXPLOSIVE GASSES DURING NORMAL BATTERY OPERATION FOR THIS REASON I IS OF THE UTMOST IMPORTANCE THAT EACH TIME BEFORE USING YOUR CHARGER YOU READ AND FOLLOW THE INSTRUCTIONS PROVIDED EXACTLY IL EST DANGEREUX DE TRAVAILLER A PROXIMITE D UNE BATTERIE AU PLOMB LES BATTERIES PRODUISENT DES GAS EXPLOSIFS EN SERVICE NORMAL AUSSI EST IL IMPORTANT DE TOUJOURS RELIRE LES INSTRUCTIONS AVANT D UTILISER LE CHARGEUR ET DE LES SUIVRE A LA LETTRE KCKCkokckckckok ck ckckckckckckckckckckckokckokckck ck ck K K ck KOK K K K K K K K K K K ck k ck KOK KOK K K K K K KOK K 3 TO REDUCE RISK OF BATTERY EXPLOSION FOLLOW THESE INSTRUCTIONS AND THOSE ON THE BATTERY POUR REDUIRE LE RISQUE D EXPLOSION LIRE CES INSTRUCTIONS ET CELLES QUI FIGURENT SUR LA BATTERIE KCKCkokckckckokckckckckckck ck K K K K K K K K ck K KOK K KOK K K K K K K K KOK ck k ck ck ck OK KOK KOK K K K K 4 NEVER SMOKE OR ALLOW AN OPEN SPARK OR FLAME IN THE VICINITY OF THE BATTERY OR ENGINE NE JAMAIS FUMER PRES DE LA BATTERIE OU DU MOTEUR ET EVITER TOUTE ETINCELLE OU FLAMME NUE A PROXIMITE DE CES DERNIERS KOK KOK K K K K K K K K K K K ck k ck ck ck
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5. proper sized ba ES charger 15 and amp hour capacity of the ba charged with the charger rating found on the charger namepla the display will tch behind the front panel at DELAY START thumbwheel switch the switch yields the number of delay hours setting may be checked by pressing ttery is connected ill indicate begin a the Ih data th the display will LED s star will 6 4 namepla th ttery to be number The Once then connection of a good battery show a countdown will be flashing When the co the charging operation lts cell reading is less than 1 7 volts the charge will not begin and the red SHUT battery voltage floats above 1 7 vpc the If the average volts cell is greater than 2 8 the red SHUTDOWN LED will turn on the display will in amperes ON OF CHARGE There are thr Again ly begin a normal charge cycle volts count down from 9 The green CHARGING LED will ways in which the charge may be terminated TERMINAT ON via dv dt di dt slope CHARGE COMPLETED and PROBLEM SHUTI DOWN TERM NATION MANUAL averag to untdown the DOWN LED the display O the charge will not 0 then be They are TERMINAT ON 6
6. 95 3 INPUT POWER CONNECTI ON three high Contact the nearest if stacking is THE LEGACY and LEGACY GOLD chargers are shipped from the factory connected fof located inside If the charger set for servic Refer KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKK the door is to be used at the charger may be adjusted to operate for the different AC to SECTION 8 2 1 CHANGING THE AC VER IFY THE AC ELECTR the input voltage specified on your purchase order indicates the factory set input voltage A STOP label a different AC voltage than is presently WARNING INPUT L NE VOLTAGE KKEKKKKKKKKKKKKKKKKKKKKKKKKKKKKKK CAL SERV CE S D ATTEMPTING TO CONNECT AC POWER TO THE CHARGER x X x lt X X X x k lt k k k k k k k k k k k k k k k k k k k k k lt lt x x lt lt lt k k k k lt lt lt lt lt k k x Ck lt The AC input terminals are identified by a red on white AC located on the base near connected to the proper AC The fuse block s input terminals recommended torque is lis INPUT the fuse block terminals within are rated for 14 rated for 14 awg to 6 awg wire with a recommended A bare wire System ground available green or green with yel connected from the Grounding T
7. DISPLAY IS IN IDLE MODE BUT CHARGER WILL S TERMINATED IMMEDIATELY 1 PROPER BATTERY Verify that the number of cells in the battery to be charged matches the charger Also check the Fault codes section 4 12 2 BATTERY CONDITION Measure the total battery voltage Divide the voltage value measured by the number of battery cells This will yield an average volts per cell value If the average volts per cell value is less than 1 5 volts or greater than 2 8 volts then the battery is bad and should not be used 3 AC amp DC FUSES Disconnect the battery and AC input power from the charger Verify that the fuses are not open Replace any defective fuses and check the following a Make sure that the battery to charger cables are connected with the proper polarity b Verify that the Terminal Block with Jumpers is correctly configured for the AC input voltage currently being used If the jumpers are not correctly configured then go to SECTION 8 2 1 of this manual CHANGING AC INPUT LINE VOLTAGE Verify that AC power and battery have been disconnected from the charger Locate the rectifier diodes on the heatsink Remove the connecting wires from the diodes Test the diodes and replace if faulty d Make sure all connections are tight 4 20 CONTROL TRANSFORMER Apply AC power to tr
8. DOUGLAS BATTERY Connect with a leader LEGACY and LEGACY GOLD DL DLG SERIES Ferroresonant Industrial Battery Charger Installation and Operating Instructions DOUGLAS BATTERY MANUFACTURING COMPANY 500 BATTERY DRIVE WINSTON SALEM NORTH CAROLINA 27107 FM1219 REV F 1 07 PAGE 2 SECTION 3 SECTION 3 SECTION 3 SECTION 6 SECTION 7 SECTION 11 SECTION 12 SECTION 18 SECTION 21 SECTION 10 TABLE CONTENTS SAFETY INSTRUCTIONS RECEIPT AND INSPECI ON OF THE CHARGER DESCRIPT CONTROL FEATURES NSTALLAT ON OPERATING PROCEDURE CHARGER CABINETS ON OF OPERATION MAINTENANCE Input Voltage Changeover TROUBLESHOOTING GUI SCHEMAT DIAGRAMS DE 2 IMPORTANT SAFETY INSTRUCTIONS INSTRUCTIONS IMPORTANTES CONCERNANT LA SECURITE 1 SAVE THESE INSTRUCTIONS THIS MANUAL CONTAINS IMPORTANT SAFETY AND OPERATING INSTRUCTIONS CONSERVER CES INSTRUCTIONS CE MANUEL CONTIENT DES INSTRUCTIONS IMPORTANTES CONCERNANT LA SECURITE ET LE FONCTIONNEMENT
9. the AC power outlet Measur D BUT THE D SPLAY IS NOT ON located at charger 2 CONTROL TRANSFORMER the voltage Locate the Control Transformer Measur Control Transformer primary NG the AC FUSE BLOCK is connected to and verify that AC power is at the If there is circuit the AC input voltage at the no voltage measured repair open 19 Measure the Control Transformer secondary voltage across terminals 5 amp 7 The AC voltage should be approximately 18 to 20 volts rms If no voltage is measured then the Control Transformer is defective and should be replaced If the measured voltage is extremely high or low verify that the AC line input is connected to the proper terminals of the Control Transformer Refer to SECTION 8 2 1 CHANGING THE AC INPUT LINE VOLTAGE 3 MAIN CELL SELECT CONNECTIONS Locate the Main board and Cell Select board on the front panel Verify the proper connection and polarity of the board and cables 4 MAIN BOARD If there is the appropriate voltage level across the Control Transformer disconnect AC power then reapply AC power This action will reset the Micro controller If the display is still not on replace the main and or cell select board 9 2 SYMPTOM POWER IS APPLIED NOT START OR CHARGE STARTS BUT 0
10. verify the AC input is or LEGACY GOLD control measured 2 8 volts per cell tery connected to the charger has the correct number measure the battery If the is between 1 7 and 2 8 the battery on charge was not receiving current t power from the charger fuses are not open Replace Check for continuity 1 Select Board sconnect AC and 0 the bati DC Fuses Repair any bad lifier if faulty the Capacitor Replac t the battery did not reach 80 of full charge within the battery did not reach charge compl lete within six tery and AC input power from the charger Verify that are not open Replac any defective fuses Verify that the charger and battery AMP HR size are matched 21 4 CABLE DISCONNECTION dlSc The CABLE DISCONNECTION indicator will be on whenever the battery cables are disconnected while the battery is charging Always make sure to manually shutdown press the stop button the charge before disconnecting the cables 5 LOW VOLTAGE Lo U Having a flashing red SHUTDOWN LED with Lo U on indicates that the control measured the average volts cell to be less than 1 5 volts The LOW VOLTAGE condition does not lock the charger off since the charger will automatically start charging if the battery s voltage rises about 1 7 volts per cell Verify
11. no battery connected bad battery to and charger mismatch 4 3 Battery voltage and current are continuously monitored and control 4 4 Automatic dv dt di dt charge termination current compensated tomatic five second delayed start upon connection of a proper sized tery voltage sensing determines if there is a proper sized battery This prevents charging if there is a bad battery charger connection or battery voltage led Voltage slope detection is 4 5 Negative battery slope termination to prevent overcharge thermal runaway 4 6 Automatic 12 hour REFRESH charge adds a top off charge to a fully charged battery The charger will start a refresh charge 12 hours after a normal charge complete has been reached assuming that the battery was not disconnected during that time The charger will automatically start charging the battery and will charge until dv dt di dt is reached DLG only Automatic REFRESH may be disabled by removing R35 from the control board assembly 4 7 Automatic Shutdown Lockout will not allow a charge to start after a manual or problem shutdown occurs Automatic Shutdown Lockout is cleared after the Shutdown battery is disconnected This allows a charge to begin upon connection of a good proper sized battery 4 8 Manual STOP switch Will stop the charger from charging The display will indicate OFF until
12. C00 S k ik ko ko HIGH VOLTAGES EXIST WITHIN THE CHARGER WHICH CAN CAUSE SEVERE INJURY OR DEATH SERVICE SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL IMPROPER SERVICING MAY DAMAGE THE CHARGER k X k k k k k lt x lt k amp amp k k k k k k k k k k k k k k k k k k k k k k k lt lt lt k k K lt k k k k lt k k lt K x x k k Each of the Ferroresonant Transformers has multiple taps for the Resonant Capacitor These allow the charger output current to be adjusted to accommodate variations in the AC line voltage Figure 8K is a schematic representation of the Ferroresonant Transformer Resonant Winding Taps and the Resonant Capacitor There are six Resonant Winding Taps numbered 7 through 12 By connecting the Resonant Capacitor to taps 7 and 12 the charger will be set for maximum output current The Resonant Winding can then be reduced in 5 increments down to a maximum reduction of 30 Each Ferroresonant Transformer is factory set for a nominal charging current start rate of 18 for LEGACY GOLD and 15 for legacy models and a finish rate of 5 of the charger s maximum amp hour output rating If it is necessary to change the battery charger s start and finish rate current use the following procedure CAUTION OBTAIN POSITIVE PROO
13. IDENTICALLY k X lt X x lt k KK KK KEK k k k KKK KKK k k k KK KK KKK k k k k k KK KK k k k KKK KKK k k k k k k k k k k FIGURE 8C AC VOLTAGE SELECTOR BLOCKS 240 480 575 VAC S NGLE PHASE AN D 3 TRANSFORMER THREE PHASE MODELS ONLY NOTE FOR 3 PHASE ALL THREE BLOCKS MUST BE SET IDENTICALLY ko E Ck KC k Ck CK L9 IGURE 8D AC VOLTAGE SELECTOR BLOCKS 220 380 440 VAC S INGLE PHASE AND 3 TRANSFORMER THREE PHASE MODELS ONLY NOTE FOR 3 PHASE ALL THREE BLOCKS MUST BE SET IDENTICALLY k X X X x lt k k k k k k k k k k k k k k k k k k k k lt lt lt k k k k K k k k C k lt k x x k k k x F 2 x x x x lt lt lt lt lt k lt x k NOTE FOR IGURE 8E AC VOLTAGE SELECTOR BLOCKS 40 415 VAC SINGLE PHASE MODELS ONLY k k x lt x lt k k x k lt k k k k k lt lt lt lt k lt k k k lt k k k k k C 415 VOLIS Diy ae QD DIO oli llo FIGURE 8F AC VOLTAGE SELECT
14. K KOK K K K KOK 5 USE CHARGER FOR CHARGING A LEAD ACID BATTERY ONLY I IS NOT INTENDED IO SUPPLY POWER TO AN EXTRA LOW VOLTAGE ELECTRICAL SYSTEM OR TO CHARGE DRY CELL BATTERIES CHARGING DRY CELL BATTERIES MAY CAUSE THEM TO BURST AND CAUSE INJURY TO PERSONS AND DAMAGE TO PROPERTY UTILISER LE CHARGEUR POUR CHARGER UNE BATTERIE AU PLOMB UNIQUEMENT CE CHARGEUR N EST PAS CONCU POUR ALIMENTER UN RESEAU ELECTRIQUE TRES BASSE TENSION NI POUR CHARGER DES PILES SECHES LE FAIT D UTILISER LE CHARGEUR POUR CHARGER DES PILES SECHES POURRAIT ENTRAINER L ECLATEMENT DES PILES ET CAUSER DES BLESSURES OU DES COMMAGES K K K K K K K K K KOK k ck KOK KOK ck K K K ck ck ck k ck ckck ck K 6 NEVER CHARGE A FROZEN BATTERY NE JAMAIS CHARGER UNE BATTERIE GELEE KCKCkokckckckokckckckckckckckckckckckckokckokckckckck ck ck ck ck K KOK KOK K K K K K K ck k ck ck ck K KOK K K K ck KOK Ta DO NOT OPERATE CHARGER IN A CLOSED IN AREA OR RESTRICT VENTILATION IN ANY WAY NE PAS FAIRE FONCTIONNER LE CHARGEUR DANS UN ESPACE CLOS ET OU NE PAS GENER LA VENTILATION KCkCkokckckckokckckckckckckckckckckckckokckokckckckokckckckckckckckckckckckckokckckckck K ck k ck ck ck KOK KOK K K K ck ck 8 DANGER RISK OF ELECTRICAL SHOCK DO NOT TOUCH UNINSULATED PORTION OF OUTPUT CONNECTOR OR UNINSULATED BATTERY TERMI
15. that the battery has the same number of cells for which the charger is rated If the battery has the appropriate number of cells measure the battery voltage Divide the measured voltage value by the number of battery cells This value is the average volts per cell of the battery If the average volts per cell of the battery is between 1 7 and 2 8 volts cell then the battery is good if not the battery should not be used SECTION 10 SCHEMATICS See the following pages 22 AC INPUT ae a GROUND COMMON E 0 vi FUSE 240Q 1200 BLOCK aa O O CONTROL TRANSFORMER I VOLTAGE SELECTOR CONNECTION BLOCK 5 amp 6 NOT USED 5 CHARGING 1 TRANSFORMER 78 OR 9 MAIN CONTROL BOARD 10 11 OR 12 RESONANT WINDING V HEATSINK OPTIONAL SURGE SUPPRESSOR ALTERNATE J construction CHARGE CABLES 2225 To BATTERY Ree DC FUSE ius Se ao INO S UN aS LVYS amp 1 JOILVWd3HOS 11 2 X 3 7 t M3SS3Mddfis 39805 w _ NISIV3H e6 6oooooooo Q 540010 Sd Ed Cava 123138 7732 vd v I AL oooo dvo
16. will automatically start charging when the battery voltage is greater than lx b Fault code HI U High volts per cell the battery voltage is greater than 2 8 vpc c Fault code dISC Battery disconnected from charger during charge d Fault code dur Charge time duration exceeded backup timer expired during high rate charge e Fault code Lo I Low charging current charging current less than approximately 3 amps 4 13 LED Indicators Co N CHARGING charger is charging the battery 80 the battery voltage is CHARGE COMPLETE I f f f ashing equalize at the end of ashing on and off the 1 2 second on every 4 sec the charge cycle each second with the CHARGI greater than 2 37 vpc charge cycle has been terminated normal the charger is set to See section 6 7 NG and 80 lys LED s lit continuously then the charger is in the refresh mode 4 SHUTDOWN the unit has shut down for a fault see section 4 12 4 14 LED TEST button 11 LED s and display segments will illuminate when this button is pressed 4 15 Display mode switch LEGACY GOLD ONLY 1 Press once to display AMP HRS RETURNED 2 Press twice to display TOTAL CHARGE TIME 3 Press three tim
17. 4 1 CHARGE COMPLETED TERM NATI charge characteristics an accurate battery voltage control has verified that predetermined value for automatically Once the COMPLETED LED will turn controller will display only 6 4 2 MANUAL TERMINAT ON The LEGACY AND LEGACY GOL The contro util th full charge is completed and and the display will the battery cool down time on the LEGACY GOLD units on charging slope e battery charge s charge while charging ON occurs when a bat D control izes di dt current compensa 9 monitors tery reaches full the battery charge dv dt the charge is terminated terminated measurement lope has reached the tion to obtain Once the the CHARGE be in the STOP push button switch located on the front panel To remove a charging battery from the charger IDLE MODE Ihe is accomplished by pressing the it is important to press the STOP push button switch first before disconnecting the battery from the charger When the charge has been terminated due SHUTDOWN LED will be on continuously OFF 1 display will show 6 4 3 PROBLEM SHUTDOWN Each of the PROBLEM SHUT SHUTDOWN LED and a FAULT code the red SHUTDOWN LED will remain flashing for indicator will remain on until the battery is DOWN terminations ar
18. F THAT THE CHARGER IS GIVING UNSATISFACTORY PERFORMANCE BEFORE ATTEMPTING ANY ADJUSTMENT THE MEASURING EQUIPMENT USED FOR FACTORY ADJUSTMENT IS EXTREMELY ACCURATE FACTORY TEST CONDITIONS ALLOW FOR AN ADJUSTMENT WHICH IS OPTIMAL FOR A GIVEN RATING ALL SYMPTOMS BEFORE PROCEEDING 1 Manually terminate the charging battery by pressing the STOP button Disconnect the battery from the charger 2 Remove AC power from the charger 3 Locate Resonant Winding Taps 7 through 12 on each of the Ferroresonant Transformers Note which taps are connected to the Resonant Capacitor 4 Use FIGURE 8K to determine which of the taps are to be connected for an increase or decrease in the charging current rate Adjustments should be made in 5 increments 9 1 SYMPTOM POWER IS APPLIE 18 5 Verify the proper connection of each Ferroresonant Transformer to its respective Capacitor Each Ferroresonant Transformer should be tapped the same for proper operation 6 Close and secure the charger cabinet 7 Connect the AC input line to the AC source FIGURE 8K FERRORESONANT TRANSFORMER CAPACITOR WIND SECTION 9 IROUBLESHOOTING GUIDE 1 AC POWER CONNECTION Make sure the AC input line
19. NAL DANGER RISQUE DE CHOCS ELECTRIQUES NE PAS LES PARTIES NON ISOLEES DU CONNECTEUR DE SORTIE OU LES BORNES NON ISOLEES DE L ACCUMULATEUR gt gt gt gt ck K K K K K KOK ck K K K KOK K K KOK K K K K ck k ck ck ck K KOK K ck ck ck k ck K 9 CAUTION DISCONNECT SUPPLY BEFORE CHANGING FUSE OR SERVICING CHARGER ATTENTION COUPER L ALIMENTATION AVANT DE REMPLACER LES FUSIBLES CK Ck CC CC C0 CC CC CCS SC KG Kk ko koc x RECEIPT AND SECTION 3 2 ON NSPECT Upon receipt of the Battery Charger should be checked against your order the information on the shipping carton Any discrepancies should be reported to the nearest authorized re
20. OR BLOCKS 415 VAC 3 TRANSFORMER THREE PHASE 3 PHASE ALL THREE BLOCKS MUST BE SET IDENTICALLY X X X x lt k k k k k k k k k k Sk k lt lt lt k lt K k k k k k k k k k k k lt 16 FIGURE 8G VOLTAGE SELECTOR BLOCKS 208 240 480 VAC THREE PHASE 2 TRANSFORMER MODELS ONLY X x lt k k k k k k k k k k k k k amp k k k k k k k k x lt k k k k K k k k lt k x lt k k x 5 ae 2 31091 FIGURE 8H VOLTAGE SELECTOR BLOCKS 220 380 440 VAC THREE PHASE 2 TRANSFORMER MODELS ONLY CK Ck ck k k k k k k K lt k k k lt k k k k k k k k k k k k k k k k k k k k k k k k AG x lt X x lt lt s 218 FIGURE 8 AC VOLTAGE SELECTOR BLOCKS 240 415 VAC THREE PHASE 2 TRANSFORMER MODELS ONLY 17 tr IGURE 807 VOLTAGE SELECTION ON PRIMARY SIDE OF CONTROL TRANSFORMER NOTE OTHER MODELS ARE SIMILAR IN CONFIGURATION 8 2 3 CHARGING CURRENT START amp FINISH RATE ADJUSTMENT CK kk WARNING
21. d XS davog 90 5 19338 9 1133 41 7109 i SDLOVINES INdNT Ov TI B 9 1 8 6 3W3DJSNV2 1 TUMINDO 83504 Ov 5852 608 NUWAD2 4 1 CNNOYD 1ndNI JlVNH3llVv OX CO OX OG COG OO 3804 aBWAOASNYAL n o 3L1VNel 31 IY 380 20880 Du gt N Ul Ove 1 01 8 2 Gt SLVYNAAL IV r vv v 087 OG G NDAWDO P 4 JlVNalllv aban 1088 NOWWO3 4 25 OL 31198 gt S318YI 398NH2 n 40 04 553 125741 AU 4 33 ONIGNIA ONIGNIA 9NIGNIA glo ea INSNUS 34 INYNOS3Y JNYNDS3y qoo SW3HMOASNVML calo az 5 8010 59 a 0 LAY Y zn 532078 EX X s 8 3591 DA Mbi 21 8 61310120 1 LindNL ov O 1 O 1 53504 3V Q LIndNI 3V SCHEMATIC DIAGRAM 3 PHASE 415 VAC MODELS ONLY 3 TRANSFORMER 26 1 AIFI 5 I gt 12 la TAYDE NIV 31 v v Ayes AOvO33 SNDILcD Era NUWWDES
22. d or circled holes on the fuse label 6 Locate the Control transformer Change the primary input connection in accordance with the voltage printed on the transformer Refer to FIGURE 8J 7 Change the voltage level on the STOP label to the new voltage level 8 CHECKLIST a Verify the Terminal Block s with Jumpers is configured correctly Make sure that all Terminal Blocks with Jumpers have been changed properly and connections are tight b Verify the installation of properly rated fuses c Verify that the Control Transformer primary taps have been changed correctly d Verify the STOP label located inside the door has been corrected to the new input voltage level that the charger is set for 9 Close and secure the cabinet 10 Remove the lock and tag 11 Reapply AC power to the charger 14 221 5 o5 ZA SS 3478 6p 201 2 F GURE 8A AC VOLTAGE SELECTOR BLOCKS 120 240 VAC SINGLE PHASE MODELS ONLY CK k ck k k lt k lt lt k k k k lt k K k k k k lt lt k k k k k k k k lt k k k k k k k k k k k k k k k M k lt X x lt FIGURE 8B VOLTAGE SELECTOR BLOCKS 208 240 480 VAC 51 NGLE PHASE AN D 3 TRANSFORMER THREE PHASE MODELS ONLY NOTE FOR 3 PHASE ALL THREE BLOCKS MUST BE SET
23. e section 4 12 AND LEGACY GOLD SERIES charger 6 5 REFRESH CHARGE When a battery remains connected Failure to do this may damage the charger to MANUAL TERM NAT until the battery is removed After one hour ON the red The indicated by a flashing red the battery is removed The display disconnected from the LEGACY to the charger for 12 hours after the charge has been completed the control will restart another charge cycle The charge rate of the battery will be monitored with dv dt di dt termination occurring typically within 35 minutes When the charger is in REFRESH mode the charge amps will be displayed the CHARGING LED and 80 CHARGE LED will be on and the CHARGE COMPLETE LED will be blinking A two day weekend will have from three to five REFRESH cycles Automatic REFRESH may be disabled by removing R35 from the control board assembly 6 6 LED TEST LEGACY GOLI D ONLY Ihe LED TEST button may be pushed to illuminate all LED s and display segments to ensure that all are functional 10 6 7 THREE HOUR EQUALIZE CYCLE 6 7 1 A 3 hour AUTOMATIC EQUALIZATION cycle will occur every 5 charging cycle when this feature is enabled cycle is counted only if 1 hour or more time is required to reach 80 charged from charge start To enable set DIP Sw 5 to OFF DLG or
24. erminal within The Grounding Terminal is Ground Terminal Label on the charger base the charger frame must be accordance with National and Local electrical codes tight terminal connections are important ted on the fuse block itself SCONNECTED AT THE SOURCE BEFORE INPUT sticker The AC input cable is to be the charger cabinet awg to 2 awg wire The ground lug is torque of 12 in lbs The llow stripe grounding wire is to be the charger cabinet to the identified by a green on white If system ground is not connected to a driven ground rod in Proper application and in avoiding future problems 5 4 OUTPUT POWER CONNECTI ON The charger is normally furnished with an ou Verify chat Verify connected cha 5 5 D PS W ICH Settings t when connected the positive polarity to the positive terminal of the bat LEGACY GOLD ONLY The switch is located on the component side of the control board tery red tput charge plug or receptacle the connectors on both the battery and the charger are correct of the charger is The factory default setting is all switches in the ON position except for units designed for 50 Hz applications SWITCH NUMBER ON OFF 1 Single di dt compensation Double di dt compensation 2 Normal dv dt termination Tr
25. es to display average BATTERY VOLTAGE CELL The display will show the above function for approximately 10 seconds and then return to display charge current or the sequencing dash 4 16 DIGITAL DISPLAY Readout will display the following information 1 Charging current 2 Fault codes 3 Delay start time 4 Equalize mode 5 Amp Hours returned for this charge cycle LEGACY GOLD ONLY 6 Charging time the length of time the charger was charging LEGACY GOLD ONLY 7 Volts per Cell the average battery cell voltage LEGACY GOLD ONLY 8 Cool down time the amount of time since the charger stopped charging LEGACY GOLD ONLY 9 Watering cycle LEGACY GOLD ONLY 4 17 A Watering Signal is provided at connector pin P3 3 LEGACY GOLD ONLY This low current signal is normally logic level lo and goes hi at End of every Charge cycle watering mode When in the watering mode the signal pulses on for 15 sec and off for 15 sec for a total of 20 repetitions OR on continuously for 5 min DIP Sw selectable To prevent over watering in wa Wi tering the will this signal less than 5 min from start of charging interface with an external display shows number of cycles remaining befor Charge is selected This signal not occur if the charge reaches 80 in is meant to circuit for operating a watering valve th During thout a battery connected pressing the Eq
26. iple dv dt termination 3 60 Hz operation 50 Hz operation 4 Display cool down time Do not display cool down time 5 Auto Equalize Disabled Auto equalize enabled 6 Normal current display Double current display 7 Water signal is pulsed Water signal is continuous 8 80 point 2 37 80 point 2 45 vpc SECTION 6 OPERATING PROCEDURE 6 1 PRELIMINARY SETUP With all power removed from previous tables befor the charger set the attemp Once power has been applied D ting to charge a battery to the charger the display on the front panel This MODE awaiting a battery connection 6 2 IMMEDIATE DELAY START indicates the charger is in the I IPswitches per the a dash will sequence across DLE Ihe control may be programmed to delay the start of the charge from one to nine hours as well as an immediate start to charger connection Note mediate start battery set for in If a power fai lure occurs charger LEGACY GOLD will override any immediate start of the charge delay start will delayed start 5 second delay no damage will occur to the batt If a battery is still connected when power returns setting and ini of the charge upon all units are shipped from the factory 0 hour delay tery or the the LEGACY AND tialize an Once the charge has been te
27. ol Transformer ld be approxima Cont sho the If connected S3 1 If ul SYMPTOM CHARGE H secondary the voltage meas tely 24 voli terminals 8 ts rms secondary TERMINATES EARLY IGH VOLTS CELL HI U this indica the average vol tor is 5 1 on then the LEGACY to be greater than a Verify that the Bati of cells b If the battery has the appropria voltage Divide the measured voli cells This value is the average average volts per cell of the battery volts cell then the battery is good 2 LOW CURRENT Lo If this indicator is on a Disconnect the battery and AC input b Check the AC and DC Fuses Verify any faulty fuses c Verify the Magnetic Amplifier is not an open between the Magnetic Amplifier and Cel connections Replace the Magnetic Amp d Verify the AC Resonant Capacitor is not an open if defective 3 CHARGE TIME EXCEEDED dur This indicates tha nine hours or that hours from 8 Di the te number of cells tage value by the number of battery volts per cell of the battery that th the charger and measure the AC voltage across the and 9 The secondary voltage If there is no voltage measured at the Control Transformer is defective and should be replaced ured is extremely high or low to the proper Control Transformer terminals
28. presentative Whenever possible move the charger to the installation site before uncrating All chargers can be handled with a lift truck by inserting the forks under the bottom of Remove the carton damage Check the charger th nameplat discrepancies should be reported immediately representative and inspect the charger for damage save the carton for inspection and notify the carrier immediately amp labels against your order amp specifications If there is any Any to the nearest authorized SECTION 3 DESCRIPTION OF OPERATION LEGACY AND LEGACY GOLD Industrial Battery Chargers are full wave silicon rectified ferroresonant chargers Charging current is regulated by the ferroresonant transformer s The to its state of discharge A solid state charge termination microcomputer incorporates built battery connection and smooth operation tomatically when the control determines that au based on dv dt di dt pre programmed microcomputer provides preventing both undercharging and overcharging in fault detec SECTION transformers allow the battery to determine its own charge rate with respect total control of The tion to ensure correct The charge is terminated the battery is fully charged 4 CONTROL FEATURES 4 1 Au good battery 4 2 Bat connected to the charger
29. r 120 240 volts 208 240 480 volts or 240 480 575 60 Hz electric services depending on the charger Three phase chargers may be ordered for 208 240 480 240 480 575 volts 60 Hz electric services only They may also be ordered set for 220 380 440 or 240 415 50 Hz If the charger is to be operated on a different rated input voltage than the ordered value follow the voltage changeover instructions described in section 8 2 2 13 NOTE THREE PHASE UNITS WILL CONTAIN EITHER TWO OR THREE TRANSFORMERS BE SURE TO MATCH THE CORRECT SCHEMATIC WITH THE TRANSFORMER CONFIGURATION OF YOUR PARTICULAR UNIT 8 2 2 VOLTAGE CHANGEOVER INSTRUCTIONS 1 Manually terminate the charging battery by pressing the STOP button and disconnect battery from charger if charger was in charge mode 2 Remove AC power from the charger 3 Locate the Terminal Block 5 with Jumpers one Terminal Block per phase and the label describing the various voltage jumper configurations Refer to FIGURES 8A 8F The Terminal Block s with Jumpers are located on the Ferroresonant Transformer s 4 Change the jumpers in accordance with the Jumper label located within the charger cabinet for the voltage input configuration desired 5 Locate the AC fuses and fuse label Change the fuses to the appropriate value as indicated by the punche
30. remove W1 DL 6 7 2 The manual Equalize button when pushed will provide a timed three hour charge extension after dv dt di dt termination has been reached It will not reset the automatic equalize counter if Auto Equalize is enabled 6 8 PROBLEM SHUTDOWN Each of the PROBLEM SHUTDOWN terminations are indicated by a flashing red SHUTDOWN LED and a FAULT code section 4 12 After the battery is removed the red SHUTDOWN LED will remain flashing The fault code will remain until the battery is disconnected from the charger 11 SECTION 7 CHARGER CABINETS 0 o oooo o 0 0 N SINGLE PHASE IHREE PHASE 12 SECTION 8 MAINTENANCE ko ko sk Ck sk IMPORTANT S ke CK BEFORE PERFORMING ANY MAINTENANCE ON THE CHARGER A If a battery is being charged terminate the charge by pressing the STOP button B Disconnect the battery from the charger C Remove AC power from the charger D Lock and tag unit out of service
31. rminated the function normally thereafter 6 2 1 Remove AC power from the charger 6 2 2 Open the charger cabinet door 6 2 3 Locate the the bottom of the control board Adjust the DELAY START thumbwheel swi D N until desired the NUMBER CATOR on 6 2 4 Close and secure the cabinet door 6 2 5 Apply AC 6 2 6 Without a battery connected th utton D LEGACY GOLD SERIES charger charge is initiated and the control and holding the to the LEGACY AN time befor power stop b th amount of countdown to charge CHARGI 6 3 NG THE BATTERY Compare the number of cel of cells in amp hour ratings the battery volts cell of 6 3 1 If the c between 1 charge initiali the battery to be charged MUST match th tch for timely charging of the battery n determined to match the charger The control will measur should also ma to be charged has b connect the battery to the charger the connected battery ontrol has verified 7 and 2 8 volts cell zation and the reaches zero 6 3 2 If display shows will be flashin charger will automaticall 6 3 3 shows begin HI m uU 6 3 4 Once the charge begins show the output charging current on the control the average vol SEO U g the to the LEGACY AND LEGACY GOLD SER When a good
32. the battery is disconnected When pressed with no battery connected displays the delay start setting When pressed during watering mode LEGACY GOLD only will terminate watering but allow refreshes if battery remains connected 4 9 One to nine hours programmable delayed start thumbwheel switch This rotary switch can be set from 0 to 9 hours to delay the start of charge 4 10 Optional Automatic Equalization cycle every 5 cycle This option can be enabled by DIPswitch DLG or removal of Wl DL For a charge cycle to be counted the battery must be on charge at less than 80 for 1 hour or more from start of charge 4 11 Equalize switch LEGACY GOLD ONLY The switch when depressed will turn on and off the three hour additional manual equalizing charge When the equalize function is turned on an E will be displayed in the left most digit of the display The E will flash during the actual equalize charge cycle manual and automatic If auto equalize has been selected pressing this switch prior to connecting the battery will allow the number of charge cycles before auto equalize cycle to be displayed 4 12 Automatic shutdown occurs for any of five failure conditions The SHUTDOWN LED will be flashing a Fault code Lo U Low volts per cell the battery voltage is less than 1 7 vpc The charger will not be locked off The charger
33. ualize Switch will display the next auto equalize If Equalize watering occurs immediately after the Equalize cycle 5 1 PHYSICAL LOCATI ON Charging areas should be clean and dry room should be periods of ambien materials charging area k lt lt lt lt lt ko k lt k k k lt lt x lt lt lt k k x x C lt A BATTERY ON CHARGE W TO PREVENT GAS ACCUMULATI tween 32 F 0 C t temperature as high as 104 F Open flames and smoking should not be permitted near or in the SECTION 5 NSTALLAT ON and 77 F 25 C WARNING The temperature of the charging with occasional and brief 40 Combustible kek ke qk CK Ck CK LL EMIT EXPLOS VE GAS VENT LATE THE ON CHARGING AREA A se ko se KKK KK KKKKKKKKKKKKKKKKKKKK KKK KKK KKK KKK KKK KKK KKK KKK KKK 5 2 MOUNTI NG The LEGACY AND LEGACY GOL constructed from non combustible material brick D charger cabinets must be mounted on a surface Such as stone concrete or metal Mounting holes are provided in the frame for securing the charger Most chargers can be stacked up to authorized representative for specific instructions necessary
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