Home

Service Manual, I.B. 1510 - Industrial Batteries and Chargers

1. 89 Schematics SCHEMATIC D3G GTX 81849978 AMALLVE 318v9 AMALLVE 9 E a 7 0 6898 919392 z TA q or 4 e e 96 x Q fd va 9 ed 9 8 6 11 T w ANNHS THIS 81 238 P nur fez 4 H wl I n 19 621 d 2 ry 9 9 fe Je 59 r9 to zer 3 Y ao ice 495 voas 7 7 ec 4 st tour 6 be y 1 SNOLLO3NNOO 04318 1 335 1A a THZIETPISTST TIVI vi Si 10 100 HOS 90 CONTROL TRANSFORMERS 7 15 ITEM PART NO DESCRIPTION 1 SEE BOM 3PH SUB ASS Y PANEL FOR SCR 2 SEE BOM TERMINAL BOARD 3 SEE BOM TERMINAL BOARD 4 SEE BOM FUSE BLOCK 5 164 8 4 NYLON RIVET 6 036 4 67 BOLT 8 X 1 2 7 074 2 2 8 LOCK WASHER 8 X012 7 24 GROUND LUG 9 103 31 5 BOLT 1 4 20 X 1 HEX HD 10 074 9 3 1 4 FLAT WASHER 11 074 3 10 1 4 LOCK WASHER EXT TOOTH 12 074 2 5 1 4 LOCK WASHER 13 007 3 51 1 4 20 NUT 14 074 7 9 8 FLAT WASHER 15 074 3 18 STAR WASHER Schematics FI Au SEE NOTE 1 NOTE 1 WHEN APPLY
2. the battery L a 1 Y User can press Disconnect the Equalize Battery pushbutton to start an Equalize Time battery Charge cycle remained Y connected Display scrolls msgs BATTERY parameter REF DATE IS Yes a No MEC performed 7 Tunna Charger starts Equalize LED and stops in a lights steady couple seconds Cha 3 outputs current at Finish 3 hour charge Rate curent performed Time spent in Refresh mode No Time specified in Service Level parameter REF TIME 31 Load Hog Control Board RECHARGE CHARACTERISTICS Please follow Recharge Characteristics following as you read through this description When a charge cycle begins constant current is applied to the battery Start Current mode This constant current called Start Rate current is specified in Service Level parameter START AMP When the Gassing Voltage point factory default is 80 charge voltage of 2 38 volts cell is reached the charger stops applying constant current and starts applying constant voltage Constant Voltage mode GASSING VOLTAGE POINT NOT REACHED If the Gassing Voltage point is not reached during the time allotted specified in Service Level parameter MAX STIM which is factory set for 7 hours the Override timer will time out and shut down the charger The charger s display will show a fault code that indicates a defective or mismatched batte
3. 58 USER PARAMETER CONFIGURATION 58 Adjusting Battery Selection 58 Adjusting User 6 59 SERVICE PARAMETER CONFIGURATION 59 Adjusting Service Parameter Settings 59 Default Settings 60 Field Calibration 61 RECHARGE CHARACTERISTICS 62 Gassing Voltage Point Not Reached 62 Gassing Voltage Point Reached 62 Finish Current Mode Not Reached 62 Finish Current Mode Reached 62 Equalize 62 Refresh Mode 62 Checking the Recharge Characteristics 62 ALL CHARGERS TESTING COMPONENTS 63 Transformer 63 SCR Diode 64 Diode Testing ns 65 AC and DC 2 4 22222 2 65 PC Boards 65 Snubber Assembly 66 ID Board Loadhog only 66 Contactor If available 66 Control Transformer If available 67 hne ue eO 67 HOW REPLACE COMPONENTS 67 Introduction 67 Main Transform
4. 4 V6 6 p B5 E a ad 121515 5 9 1521 V e e v s 9 if 1 i 5 3 YOLIINNOI Nid OL c c nt auvog GvO4 10HLNO9 11 De l YOLIINNOI Nid 9 q af eur Si 2 HOLIMS 3NV38N3N AV1dSIQ En 7 4 ed 7 ld SNOILOANNOO 01 31841 33S 87 e aS non Minn SS SUM SUUS SMS SUUS veers pan re ibid set i Lu er u sr zi gt UE 1069 0 Ar AZ coco nove UC 8 a caos s ass 3 f 8 2 3 4 1 j 1 i e 2 9 d 5 9 go xovig v4 Ad3llVa JD gt gt F 318 2 5 2908 a eom 0 z 18 t AMALLVE Na a Le ie HA 8 9 Le gt 0L ce 3 id WaggnNs 1 4 o Yy
5. 4 Release the UP and DOWN pushbuttons 5 All battery profile settings will now be reset to the original default settings FIELD CALIBRATION No field calibration is necessary All control boards are factory calibrated No pots or adjustments are available Return all failed or defective boards to the factory 61 D3G Control Board RECHARGE CHARACTERISTICS When a charge cycle begins constant current is applied to the battery start current mode This constant current is called start rate current When the gassing voltage point 80 charge voltage of 2 38 volts cell is reached the charger stops applying constant current and starts applying constant voltage constant voltage mode GASSING VOLTAGE POINT NOT REACHED If the gassing voltage point is not reached during the time allotted which is factory set for 6 hours the override timer will time out and shut down the charger GASSING VOLTAGE POINT REACHED When the gassing voltage point is reached the override timer resets and timing begins again for constant voltage mode During constant voltage mode the current tapers down to approximately 4 5 amps per 100 AH At this point the charger stops applying constant voltage and returns to applying constant current finish current mode This constant current is called finish rate current FINISH CURRENT MODE NOT REACHED If the finish current mode is not reached during the time allotted the override timer will time out a
6. EQUALIZE COUNTS Total amount of charge cycles that need to occur before an automatic equalize charge cycle will take place 0 indicates that no Equalize charge will occur 0 20 charge cycles 5 charge cycles When Multiple Battery Select is enabled the customer can easily select between 5 completely different battery profiles by simply pressing and holding the Equalize button for 5 seconds Choose the particular battery setting by scrolling the UP or DOWN arrows after the display reads Set Changing the service parameters will apply only to the particular battery that is selected After the particular group of settings are chosen press the START STOP button twice to exit battery select mode When setting service parameters for Multiple Battery Selection DO NOT exceed the charger nameplate cell size or amp hour rating SERVICE PARAMETER CONFIGURATION ADJUST BATTERY SELECTION Choose the particular battery settings to be modified Note that changing the service level parameters for a particular battery selection will not affect the parameters for other battery selections ADJUSTING SERVICE PARAMETER SETTINGS Only while the charger is in idle mode the charger s service parameters may be configured In order to do so press the DOWN and EQUALIZE pushbuttons simultaneously and hold for approximately ten seconds The display will read SEr and is now ready for service parameter configuration When you release the DOWN and
7. Fuse Voltages F5 F8 AC line Voltage volts F8 to F7 10 10 F8 to F6 10 1096 F8 to F5 10 1096 NOTE These values are dependent upon the actual line voltage 6 Measure and verify the voltages of the heatsinks All values should be within 1096 of those in the following table SCR Diode Block Input Voltages Measure between These SCR Diode Blocks Left SCR Diode Block to center SCR Diode Block 2 35 vic AC 10 Left SCR Diode Block to right SCR Diode Block 2 35 vic AC 10 Center SCR Diode Block to right SCR Diode Block 2 35 vic AC 10 NOTE These values are dependent upon the actual line voltage NOTE 2 35 v c AC multiplied by the number of cells total AC voltage 7 If a DC fuse has opened check Battery and charger connector polarity Loose DC assembly Shorted SCR Diode Blocks 22 D3E2 Control Board 8 If an AC fuse has opened check Transformer taps Shorted SCR Diode Blocks SCR Diode Block balance Check balance with a clamp on AC ammeter All currents should be within 1096 of each other If any SCR Diode Block is zero an open component or loose connection may exist 9 Measure and verify the voltages at connector J1 Refer to PCB diagram All values should be within 10 of those in the following table Wires at J1 X1 to X2 10 10 X1 to X4 10 10 X1 to X6 10 10 NOTE These values are dependent upon the actual line voltage 10 Verify that the cell size ju
8. No Check AC power source and AC power cables Yes to charger AC fuse Check heatsink alright Change secondary pad tse connections LED s AC to blink No charger No then turn and board A off OK 7 2 Yes Transforme Double check Yes wired for transformer wiring applied Vac replace bad transformer Fix AC taps Less than 1 Check for bad No SCR Diode Block volt across D Hint remove the bussbars and Ohm out each SCR Diode Block for shorts at Yes bottom of Check fuses lug connector J1 crimps control control fuses wiring connectors within range Trouble is Display scrolls thes messages CONNECT BATTERY DATE IS XX XX XX ROSE R CONNECT BATTERY m d TIME IS XX XX XX Yes Connect battery t charger Voltage at J DC within range Check for at PC SN pin 1 3 10V connections a connector J4 wires Yes 2 3 10V lug crimps and J1 Charger recognize battery connector problems No Y1 amp Y2 voltage across 1 2 17V bussbar Yes Wait 5 seconds No Trouble is Check for bad lead loose connection probably p at shunt bad DC cord or connector iioi battery ce
9. Testing and Replacing Components 4 Be sure that all wires being connected to the terminal strip are bare Make sure insulation is removed from the wires for good connections 5 Avoid placing the A phase primary leads near the top panel s mounting hole ME Be sure to install phase A phase B and phase C wires to their proper terminals in the front of WARNING the charger A is on the left C is on the right WARNING When installing primary leads into the terminal blocks take special precaution in preparing the double wire leads wires 2 and 5 for insertion into the terminal blocks 6 Connect the transformer s control voltage wires to the fuses ME Be sure to install 7A 7B and 7C in proper order A is on the left C is on the right If they are WARNING not connected properly a phase control problem will occur T Connect the secondary leads to the SCR Diode Blocks Again be careful to connect phase A to phase A phase B to phase B etc SCR DIODE BLOCK Specifications for Mounting SCR Diode Blocks on Flat Aluminum Heat Sinks Surface 1 No scratches gouges or burrs allowed in the SCR Diode Block contact area 2 No oil dirt paint adhesive or other foreign substances are permitted in the contact area 3 Apply a light coating of heat sink thermal compound to the flat side of the SCR Diode Block Mounting Instructions 1 Tighten the nut with your fingers as far as possible Then use
10. damage 3 Now verify what you measured at the connector against actual battery voltage 65 Testing and Replacing Components SNUBBER ASSEMBLY Please follow these steps before testing the snubber assembly Disconnect the battery Disconnect the AC power The snubber assembly consists of a series resistor and a capacitor Before taking measurements on the Snubber assembly 1 Verify that the mounting wire is sound properly screwed on and not broken 2 Verify that the Snubber assembly is not burned broken or smoking To test the snubber assembly 1 Disconnect a mounting wire and check for no continuity 2 Replace if your meter reads less than 200k ohms ID BOARD LOAD HOG ONLY Please follow these steps before testing the ID board Disconnect the battery Disconnect the AC power Using the following table test the pins on the ID board If your measurements are different than those in the table replace the ID board Model Pins Ohms Model Pins Ohms Co En BEEN p Wisa _ i Es Measure the resistance across pins 1 and 2 on connector J14 of the PC board You should measure k ohm resistance CONTACTOR IF AVAILABLE First Contactor Test Please follow these steps before testing the contactor Disconnect the battery On Connector J3 on the PC board 1 Short pins 6 and 7 2 The contactor should pull in 3 If it does not check the wiring fr
11. 014 99 25 18 1500 24127 18 1500 22 40 014 99 40 20 40 014 99 40 18 35 014 99 35 18 1600 X127 818 1700J 24 40 X014 99 40 21 40 014 99 40 19 35 014 99 35 18 1700 127 518 1700 25 40 014 99 40 22 40 014 99 40 20 35 X014 99 35 18 2000 X127 818 2000J 30 50 X014 99 50 26 40 014 99 40 24 40 X014 99 40 24 550 X127 S24 681J 11 20 X014 99 20 10 15 X014 99 15 9 15 X014 99 15 24 680 X127 S24 681J 14 25 014 99 25 12 20 X014 99 20 11 20 X014 99 20 24 750 X127 S24 681J 15 25 X014 99 25 13 20 X014 99 20 12 20 X014 99 20 24 850 X127 S24 850J 17 30 014 99 30 15 25 014 99 25 14 25 X014 99 25 24 950 127 524 1050 19 30 2014 99 30 17 30 014 99 30 15 25 014 99 25 24 1000 X127 S24 1050J 20 35 014 99 35 18 30 014 99 30 16 25 X014 99 25 24 1050 X127 S24 1050J 21 35 014 99 35 18 30 014 99 30 17 30 014 99 30 24 1200 X127 S24 1200J 24 40 2 014 99 40 21 35 014 99 35 19 30 014 99 30 24 1500 X127 S24 1500J 30 50 X014 99 50 26 40 014 99 40 24 40 X014 99 40 36 450 X127 S40 550J 14 25 014 99 25 12 20 X014 99 20 11 20 X014 99 20 36 550 X127 S40 550J 17 30 X014 99 30 15 25 014 99 25 13 20 X014 99 20 36 680 X127 S40 680J 20 35 014 99 35 18 30 014 99 30 16 25 X014 99 25 36 750 X127 S36 680J 22 35 014 99 35 20 35 014 99 35 18 30 014 99 30 36 850 X127 S
12. Battery may be defective v c does not rise above 2 38 7 7 7 7 Failed to complete the charge cycle within the allotted time Possible Causes Check Gassing Voltage point and v c at the battery terminals vs the display Extended cable length from original cables This may have been an equalize cycle that was shut off by the maximum time limit Check battery temperature It may be hot Battery AH may be larger than the charger s AH rating 8 8 8 8 Amp hours returned 15096 of charger amp hour rating Check time settings 9 9 9 9 EEPROM write error Occurs at the end of a charge but the charger runs OK Contact service engineering A fault is cleared by disconnecting and reconnecting the battery or by disconnecting the battery and pressing the Stop push button Determine the cause of the fault and correct it before reconnecting the battery and trying to charge it again Battery voltage is lower than what control unit is set for Shorting of pins 1 and 2 of J5 connector or control unit has shorted components AC line input voltage has fallen below 1096 of the AC line Example 480VAC falls below 432VAC FIELD ADJUSTMENTS There are two levels of field adjustments 1 Userlevel 2 Field technician level Setting Parameters To change a number in the display use the Up and Down Arrow pushbuttons in combination with the Refresh Stop and Select pushbuttons Pushbuttons Pressed UP OR DOWN ARROW UP OR DOWN ARROW REFRESH U
13. ENDS Solutions Service Manual SCR Transformer Type Battery Charger INTERIM SERIES DEPTH D3E2 sp3e2 RENEGADE GTS2 rers LOAD HOG L T2 LTC2 SLT2 SLTC2 DEPTH D3G soso RENEGADE GTX rer LB 1510 Rev J 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 Letters volts rms Hz iz D 220 380 440 J 480 550 600 T Comments Applicable to all charger families single or three phase chargers Applicable to all charger families single or three phase chargers Applicable to all charger families single or three phase chargers Use only for special designs single or three phase B D J x Y E S 480 400 E 40 Use only for special designs Contact the plant for further information S SPECIAL VOLTAGES UNSPECIFIED Use only for special designs Contact the plant for further 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 Note refer specialty charger part numbers to the standard models contained in this manual Y Suffix Description Kitpart part C Charger Communication Module
14. non fault at the start of the Finish Phase MESSAGES BATTERY NOT CONNECTED When no battery is connected and AC power is applied to the charger one of the following set of messages will display in rotation on the front panel If Program Level parameter VVR FUNC is off CONNECT BATTERY DATE IS 00 00 00 month date year CONNECT BATTERY TIME IS 00 00 00 hours minutes seconds If Program Level parameter VVR FUNC is on and User Level parameter VVR OPTION is off NORMAL CHARGE DATE IS 00 00 00 month date year CONNECT BATTERY TIME IS 00 00 00 hours minutes seconds If Program Level parameter VVR FUNC is on and User Level parameter VVR OPTION is on VVR CHARGE DATE IS 00 00 00 month date year SET FOR 00 CELLS TIME IS 00 00 00 hours minutes seconds BATTERY CONNECTED When a battery is first connected to a powered up charger the display will show this message STARTING CHARGER 34 Load Hog Control Board Then in 60 seconds if in Automatic mode the charger will start outputting Start Rate current and the messages in the following table will begin to display These values are displayed in rotation for the amount of time specified in Program Level parameter CHG HLD Other messages are added to this scrolling display as needed such as CHG 80 REACHED All messages that can be seen in this scrolling display are listed in the following table Push the Up and Down Arrow push buttons to display the info
15. 2 1 0 2 0 amp 3 0 m Load Hog charger with Contactor and Control cable 35012 20 transformer ONLY ID board and additional 009323 NA PCB power DC cable clamp for 4 0 cable 356 5 16 20 Rivets Latch 164 8 6 N A Refer to item numbers on the following illustrations Parts require a Base kit Determine the appropriate kit number for your charger Each kit includes the base and cross members for heat sink and transformer If 11 inch distance between transformer brackets If 15 inch distance between transformer brackets and if there are three 3 heat sink extrusions X225 99 3 11 X225 99 3 15 73 Replacement Parts Note The illustration below identifies the location of some important components in standard chargers The component P N may vary from charger to charger For a P N refer to the Replacement Parts tables ITEM DESCRIPTION 1 Cabinet Base 2 Cabinet Right side 3 Cabinet Left side 4 Cabinet Top Back 5 Upright 6 Cross Member Main Transformers 7 Main Transformer 8 HeatSink Assembly 9 SCR Diode Blocks 10 Bussbar 11 Cross Member Heat Sink 12 PC Board Fuses F5 F6 F7 F8 13 Shunt 14 DC Fuse F4 15 Terminal Board Primary Main Transformer 15 Terminal Board Primary Main Transformer 16 Panel Sub assembly 17 AC Block Input Fuses F1 F2 F3 8 Door Z O 19 Ground L
16. 9A FROM XFMR 9 TO SHUNT NEG 8A 88 8C FROM XFMR 7C FROM XFMR 7B FROM XFMR TA FROM XFMR 24 22 CTOJIS 15 REF TO J1S FUSE SHUNT POS 83 18 KPOS TO J4 ER TO JM SHUNT NEG D p 14 TG 17 19 Ig FROM BUSS BAR 14 V POS TO J4 TYPICAL X2 17 18 RED TO BATTERY 6 LOCK WASHER 6 SCREW FUSE BLOCK HEAT SINK MOUNTING PANEL BLACK TO BATTERY V NEG TO J4 Schematics n LL LL m TRIPLE EXTRUSION DESCRIPTION HEAT SINK EXTRUSION SCRIDIODE BLOCK 10 LOCK WASHER SUPPRESSOR ASS Y 114 SCREW 1 4 FLAT WASHER 1 4 LOCK WASHER 10 FLAT WASHER 10 LOCK WASHER 10 X 1 25 SCREW FUSE BLOCK 6 LOCK WASHER 5 16 18 X 2 75 BOLT INSULATION WASHER INSULATION BUSHING 5 16 LOCK WASHER 5 16 NUT 5 16 FLAT WASHER BRASS HEAT SINK MTG PANEL TYPICAL X3 SEE BOM 074 2 3 101 41 7 X1106 99 3 2 103 31 5 074 9 3 074 2 5 007 3 51 006 208 1 74 1 17 074 2 3 7015 48 36 4 59 42 1 15 044 2 18 55 1 85 007 3 71 X052 99 3 9 ENERSYS PART R521 99 3 5 TYPICAL X2 ITEM 10 13 14 15 16 17 18 19 20 21 24 a gt ac TYPICAL 74 22 84 a a z a SCRIDIODE BLOCK FROM BUSS BAR BLACK TO BATTERY V NEG a lt m a w 2 m FROM
17. Battery Voltage Gassing Voltage point 80 LED lights Constant Voltage Mode gt Charger begins sending constant voltage to the battery 4 User Press Equal pushbutton to change charge cycle from Equalize to Daily Equalize LED stops blinking or User can Press the Equalize pushbutton to change charge cycle from Daily to Equalize Equalize LED starts blinking Charge current tapers down Termination requirements satisfied Finish LED lights 30 Finish Current mode Charger begins sending constant current Finish Rate current to the battery Load Hog Control Board or starts blinking User can Press the Equal pushbutton to change charge cycle from Equalize to Daily Equalize LED stops blinking Press the Equalize pushbutton to change charge cycle from Daily to Equalize Equalize LED Finish Current mode complete this an Equalize charge Y No Equalize LED lights steady Charging continues for 3 hours Charge Cycle in Automatic Mode con t b Charge cycle Complete Charge cycle is done Charger stops sending current and voltage to Load Hog Control Board
18. Push button Description Daily Equalize Starts or Restarts an Equalize charge cycle can also convert a Daily charge cycle to an Equalize charge cycle or vice versa Equalize also toggles Equalize ON or OFF until locked into Equalize of 3 hr Refresh Starts a Refresh charge or adds a Refresh charge to a completed Daily or Equalize charge cycle Stop Test Interrupts a charge in progress If there is no charge in progress it tests the LEDs and the display by lighting them for as long as the push button is held down LEDs Description Lights and remains on when a charge cycle begins 80 Lights and remains on after the Gassing Voltage point begins 80 charge of 2 38 V C Flooded cell 2 37 VIC Sealed cell Finish Lights and remains on when Finish current mode begins Lights steady when the 3 hour Equalize mode begins Lights steady when the Refresh charge cycle begins Blinks again after the Refresh is complete Fault Lights when a fault occurs The display will show the fault code Fault codes are described in this manual under error messages D3E2 Control Board Description ption Lights steady when AC power is applied to the charger Blinks when a power fault occurs Possible Problems An AC fuse opened A controlled winding opened A bad lug A phase of AC interrupted Wrong transformer code if a new board was installed Low AC line One phase opened The display shows information such as Cycl
19. Recharge Characteristics Sealed Cell VRLA CHARGE PROFILE SEALED SCR 18 0 4 2 600 AMPS 100 16 0 4 2 500 14 0 4 2 400 d 2 LU 2 o e 2300 py 0 0 p x Ww 8 0 L 2 200 o a 2 100 9 12 4 0 2 000 2 0 0 0 L 1 900 3 CHARGE TIME HRS CHARGE CYCLE TERMINATION METHODS There are 5 types of termination methods Proportional Time Voltage Program Level parameter T V TERM AH Return Program Level parameter AHRS TERM DV DT Program Level parameter DVDT TERM and Finish Termination DVDT TERM T V TERM and AHRS TERM can be selected individually or in any combination When a combination of termination methods have been selected the first requirements satisfied will determine termination Proportional termination can only be selected by turning OFF all other methods of termination It cannot be selected in combination with any of the others Proportional termination should only be used when the battery is discharged more than 50 on a daily basis The model LT LTC default setting is DV DT and Time Voltage Termination PROPORTIONAL When the charger is set to Proportional termination the charger remains in Start Current mode Service Level parameter START AMP until the Gassing Voltage point Service Level parameter 8096 V CEL is reached Then control changes to Constant Voltage mode and maintains constant voltage until the output current m
20. Remove the charger cover Connect the charger to AC power First Transformer Test You will be testing the transformer s windings with a good quality meter to check the transformer s voltages Your measurements should be within 1096 of what is listed on the nameplate Second Transformer Test 120V Test Be sure to disconnect the transformer from SCR Diode Block PC board and control transformer primary You will need to have the transformer isolated for this test 1 Use a line cord with a 3 to 5 amp slow blow fuse in an in line fuse holder 2 Power each section separately Power from TB 1 and 6 and jumper leads 3 and 4 63 Testing and Replacing Components 3 If a fuse has opened there might be a winding problem in the transformer Perform all other tests in this section before replacing the transformer SCR DIODE BLOCK K1 CATHODE OR SENSE RED WIRE 2 1 G1 GATE WHITE WIRE 2 1 XFMR SECONDARY LEADS 2 POSITIVE BUS BAR 3 3 NEGATIVE BUS BAR i CONTINUITY TEST GATE AND 2 9 TO 100 OHMS INI SENSE K1 AND 2 0 TO 5 OHMS G1 SCR TEST MUST BE DONE USING A TEST LIGHT K161 POSITIVE OF TEST LIGHT ON TERM 2 R507 18 4 285 A R507 18 3 162 A 507 18 2 104 A WANT Faulty SCR Diode Blocks may cause voltage to be present at the DC cables Physical Test If you do not have a clamp on meter to check for current in the 3 SCR Diode Blocks you can perform the following to locate a fault in the second
21. X014 99 12 6 10 X014 99 10 6 1050 X127 S06 1050D 12 20 014 99 20 7 12 014 99 12 6 10 2014 99 10 12 550 X127 S12 550D 12 20 X014 99 20 7 12 014 99 12 6 10 X014 99 10 12 680 X127 S12 680D 15 25 X014 99 25 9 15 014 99 15 8 12 X014 99 12 12 750 X127 S12 680D 16 25 014 99 25 10 15 014 99 15 8 12 X014 99 12 12 850 X127 S12 850D 19 30 X014 99 30 11 20 X014 99 20 10 15 4014 99 15 12 950 X127 S12 1050D 21 35 X014 99 35 12 20 X014 99 20 11 20 X014 99 20 12 1000 127 512 1050 22 35 X014 99 35 13 20 X014 99 20 11 20 X014 99 20 12 1050 127 512 1050 23 40 X014 99 40 13 20 X014 99 20 12 20 X014 99 20 12 1200 127 512 1200 26 40 014 99 40 15 25 X014 99 25 13 20 X014 99 20 18 550 X127 S18 550D 18 30 X014 99 30 11 20 X014 99 20 9 15 X014 99 15 18 680 X127 S18 680D 22 35 X014 99 35 13 20 X014 99 20 11 20 X014 99 20 18 750 X127 S18 680D 24 40 014 99 40 14 25 X014 99 25 12 20 X014 99 20 18 850 X127 S18 850D 28 45 X014 99 45 16 25 014 99 25 14 25 X014 99 25 18 950 X127 S18 1050D 31 50 014 99 50 18 30 014 99 30 16 25 X014 99 25 18 1000 X127 818 1050L 32 50 014 99 50 19 30 014 99 30 16 25 X014 99 25 18 1050 127 518 1050 34 50 014 99 50 20 35 014 99 35 17 30 2014 99 30 18 1200 X127 S18 1200D 39 60 014 99 60 23 40 X014 99 40 20 35 014 99 35 18 1500 127 518 1500 48 70 014 99 70 2
22. X014 99 90 50 80 X014 99 80 25 40 X014 99 40 18 2000 127 518 2000 68 100 X014 99 10 59 90 X014 99 90 30 50 014 99 50 24 550 127 524 550 25 40 014 99 40 22 35 014 99 35 11 20 X014 99 20 24 680 X127 S24 680B 31 50 014 99 50 27 45 X014 99 45 14 25 X014 99 25 24 750 X127 S24 680B 34 50 014 99 50 30 50 014 99 50 15 25 X014 99 25 24 850 X127 S24 850B 39 60 X014 99 60 34 50 014 99 50 17 30 014 99 30 24 950 X127 S24 1050B 43 70 014 99 70 38 60 X014 99 60 19 35 2014 99 35 24 1000 127 524 1050 46 70 7014 99 70 40 60 X014 99 60 20 35 2014 99 35 24 1050 127 524 1050 48 70 7014 99 70 42 60 2014 99 60 21 35 2014 99 35 24 1200 127 524 1200 55 80 X014 99 80 47 70 X014 99 70 24 40 X014 99 40 24 1500 127 524 1500 68 100 X014 99 10 59 90 X014 99 90 30 50 014 99 50 24 1600 X127 824 1500B 73 100 014 99 10 63 100 X014 99 10d 32 50 7014 99 50 36 450 X127 S40 550B 31 50 014 99 50 27 45 X014 99 45 14 25 X014 99 25 36 550 X127 S40 550B 38 60 2014 99 60 33 50 014 99 50 17 30 7014 99 30 36 680 127 540 680 47 70 X014 99 70 40 60 2014 99 60 20 35 7014 99 35 36 750 X127 S40 750B 51 80 2014 99 80 44 70 X014 99 70 22 35 7014 99 35 36 850 X127 S40 850B 58 90 2014 99 90 50 80 2014 99 80 25 40 2014 99 40 36 1000 127 536 1050 68 100 X014 99 10Qd 59 90 X014 99 90 30 5
23. of data in the Log Data file Each line number contains the data about a different event NOTE Pressing the Up Arrow push button while the most recent entry is displayed will cause the oldest entry in the log to display The Log Data file can store up to 1000 entries When the Log Data file becomes full the new entries will overwrite the oldest entries Once you are done viewing the Log Data file press the Equal push button Press the Equal push button 2 more times to exit from the User level Setting the VVR Parameters To set the VVR parameters please follow these steps 1 Press the Select push button to enter the User level 2 Use the Up and Down Arrow push buttons to scroll through the variables until VVR OPTION displays 3 Press the Select push button if you want to toggle the VVR OPTION off or on Press the Equal push button to return to Display mode After the Select push button is pressed VVR ON or VVR OFF will display a Use the Up and Down Arrow push buttons to scroll through the following options i ON ii VVR OFF b When the option you want is displayed press the Select push button 4 If you selected VVR OFF press the Equal push button twice to return to Display mode 5 To make changes to the VVR parameters VVR CELLS VVR AMPS VVR CHARGE TIME VVR PRINT TIME please follow these steps a Press the Select push button when VVR is in the display b Use the Up and Dow
24. 1000 X127 S06 1050J 5 8 X014 99 8 5 8 X014 99 8 4 7 X014 99 7 6 1050 X127 S06 1050J 6 10 014 99 10 5 8 X014 99 8 5 8 X014 99 8 12 550 X127 S12 550J 6 10 014 99 10 5 8 X014 99 8 5 8 X014 99 8 12 680 X127 S12 680J 7 12 X014 99 12 6 10 X014 99 10 6 10 X014 99 10 12 750 X127 S12 680J 8 12 X014 99 12 7 12 X014 99 12 6 10 X014 99 10 12 850 X127 S12 680J 9 15 X014 99 15 8 12 014 99 12 7 12 X014 99 12 12 950 127 512 1050 10 15 2014 99 15 9 15 X014 99 15 8 12 X014 99 12 12 1000 X127 812 1050J 10 15 014 99 15 9 15 X014 99 15 8 12 X014 99 12 12 1050 X127 812 1050J 11 20 X014 99 20 9 15 X014 99 15 9 15 X014 99 15 12 1200 X127 S12 1200J 12 20 X014 99 20 11 20 X014 99 20 10 15 X014 99 15 18 550 X127 S18 550J 9 15 X014 99 15 8 12 014 99 12 7 12 X014 99 12 18 680 X127 S18 680J 10 15 X014 99 15 9 15 X014 99 15 8 12 X014 99 12 18 750 X127 S18 680J 11 20 X014 99 20 10 15 X014 99 15 9 15 014 99 15 18 850 X127 S18 850J 13 20 2014 99 20 11 20 X014 99 20 10 15 X014 99 15 18 950 X127 818 1050J 14 25 014 99 25 13 20 014 99 20 12 20 X014 99 20 18 1000 X127 818 1050J 15 25 014 99 25 13 20 X014 99 20 12 20 X014 99 20 18 1050 X127 818 1050J 16 25 014 99 25 14 25 X014 99 25 13 20 X014 99 20 18 1200 X127 818 1200J 18 30 014 99 30 16 25 014 99 25 15 25
25. 12 for Delay Start Time The factory setting is 00 00 SET EQUALIZE Equalize Functional when the charger is set to Automatic mode Service Level Day Equalize parameter MANUAL OP Counter Determines when an Equalize charger cycle will automatically occur Equalize Day sets the day of the week that the automatic Equalize charge cycle will be done Equalize counter determines how often an Equalize charge cycle will occur When the Cycle counter Service Level parameter CHG CYCLE Equalize counter an Equalize charge cycle occurs and the Cycle counter is reset to 1 Only Equalize day or Equalize counter will be active not both The last one you modified is the one that is active This parameter is only accessible if Service Level parameter EQUAL FUNC is set to ON The factory setting is Equalize Counter 5 39 Load Hog Control Board Display Contains Variable s Description VVR OPTION Enables or disables a VVR variable voltage rectifier charge A VVR charge is a constant current charge for a specified period of time When the VVR option is ON you can change the 4 VVR parameters VVR CELLS VVR AMPS VVR CHARGE TIME and VVR PRINT TIME See section Setting the VVR Parameters for more information WARNING Contact Technical Support and your battery manufacturer before performing a VVR charge This parameter is only accessible if Program Level parameter VVR FUNC is set to ON The range is ON or OFF The factory setting is O
26. 2 Verify that AC voltage is present at the proper value at the bottom of all three AC input fuses Fuse values are listed in this manual 3 Verify that the transformer AC taps are in their proper positions Refer to the Voltage Conversion section 4 Measure and verify the transformer voltages All values should be within 10 of those in the following tables Readings of the phases should be within 1 5 of each other depending on the line variations For example the value measured between terminals 2 and 3 for Phase A Phase B and Phase C must all be within 1 596 of each other Also measurements between terminals 1 and 2 should be the same as measurements between terminals 4 and 5 measurements between terminals 2 and 3 should be the same as measurements between terminals 5 and 6 etc NOTE If a transformer is replaced make absolutely sure that power wires 9A 9B and 9C and control wires 7A 7B and 7C are connected to the proper locations per the schematic wiring diagram NOTE Steps 4 5 and 6 determine whether the transformer and associated wiring is functioning properly Terminals on each phase 1 2 208 10 4 5 2 3 32 10 5 6 1 3 240 10 4 6 NOTE These values are dependent upon the actual line voltage 5 Measure and verify the voltages at the bottom of fuses F5 F6 F7 F8 These fuses are located in the upper left corner The leftmost fuse is F5 All values should be within 1096 of those in the following table
27. 4 equals voltage across bussbar Yes Check for bad lead loose connection at shunt bad Trouble t DC cord battery cell size probably with x program or PCB reverse polarity 24 Check for loose connections bad lug crimps and J1 connector problems D3E2 Control Board Troubleshooting Flowchart con t Push Start pushbutton to override Dela counter Charger starts Check battery Replace and there any Display contains m 144141 bad fuse SCR Diode Block Yes Display amp LEDs Replace blink bad SCR Diode Y Charger in reset mode current a E 6 amp min Reset current Check Double leads at AC taps Are charger parameters se No properly for this charger and this battery Reset parameters Yes Perform calibration routine Thal or amps or both Charger calibrated properly No Output current stable No Check shunt connections Ap P clean shunts 25 D3E2 Control Board SYMPTOMS SUGGESTIONS AND REMINDERS 1 10 11 12 If the DC fuse is continually opening a One of the SCR Diode Blocks may be defective b The charger may h
28. 6 j LL bd ld SNOLLO3NNOO nies 80431871 33S z 2 00 Hi g 013 64 JS non gt 9 25151519 V z e v 9 ER 18 i zr I 8 Oo 8 PAIE MO193NNOO Nid OF 6 v 8 VOS 10H1NO9 211 ed p MOLO3NNOONId9 q ar er HOLIMS 3NVH8W3IN 471950 SM NOLLO3NNOO T18V1 335 88 Schematics 31 709971 Ad3 LLV8 AH3 LLV8 SCHEMATIC LT2 18 850D 9 9 a gt x o 09 s 0311 T8 3 t 1 4 71 i oo 64 zo 2 8 79 590 v4 T T ego qt gt E za t 4 INNHS 208 goss 52 N A 1 Bet ae kq n o 8 aac 9 9 2 tg 5 r ia 0i CE 8 13 98 1035 3 i ec o e i ole 22 84 SNOLLO3NNOO 01 31871 336 1j m 94 M 99 4 82 0901X zel e9 rje 4 9 294 5 O1O3NNOO Nid OF c e nt auvos 2 quvO8 1081800 11 pA HO193NNOO Nid9 __ q af eur Nul L HOLIMS 3NVd8N3N
29. 94 09 19 43 PASSKEY INSERTED V 038 8 A 000 6 AH 0564 CT 18 08 BC 18 CAH 0850 CC 0002 CHARGER REVISION 3LH V1 1 PASSKEY 65021 Led PATTERN 000 07 28 94 09 19 43 AC POWER ON V 038 8 A 000 6 AH 0564 CT 18 08 BC 18 CAH 0850 CC 0002 CHARGER REVISION 3LH V1 1 PASSKEY 65021 LED PATTERN 000 07 28 94 09 19 42 PERIODIC LOG ENTRY V 038 8 A 000 6 AH 0564 CT 18 08 BC 18 CAH 0850 0002 CHARGER REVISION 3LH V1 1 PASSKEY 65021 LED PATTERN 000 07 28 94 09 06 45 PERIODIC LOG ENTRY V 038 9 A 000 6 AH 0564 CT 18 08 BC 18 CAH 0850 CC 0002 CHARGER REVISION 3LH V1 1 PASSKEY 00000 LED PATTERN 000 07 28 94 08 56 31 FAULT MAX CHG TIME OVER V 039 6 A 038 1 AH 0564 CT 18 08 BC 18 CAH 850 CC 0002 CHARGER REVISION 3LH V1 1 PASSKEY 00000 LED PATTERN 000 07 28 94 08 56 20 STARTING CHARGE V 038 8 A 000 8 AH 0564 CT 18 08 BC 18 CAH 0850 CC 0002 CHARGER REVISION 3LH V1 1 PASSKEY 00000 LED PATTERN 000 PROGRAMMABLE PARAMETERS For security purposes there are 3 levels of programmable parameters User level Service level Program level These levels are described below USER LEVEL The User level is used to do such things as clear faults set the Real Time clock enable delay start set equalize day or equalize count and view the Log Data file No hardware key or password is required to access this level Enter the User level by pressing the Select push button Use the Up and Down Arrow push buttons to scroll through the variables you can modify To exit the
30. A X225 2 0 350 3 0 N A X225 3 0 350 Cable kits above are nine feet 9 long For longer cable two more lengths are available twenty feet 20 and thirty feet 303 Example part numbers X225 2 0 350 20 for twenty feet of cable or X225 2 0 350 30 for thirty feet of cable NOTE Cable kits do not include the connector housing only the contact Select desired connector housing below Connector Housing Part Numbers m CONNECTOR Cable CONNECTOR Cable PART NUMBER DESCRIPTION Size PART NUMBER DESCRIPTION Size 05804 EC CHR HALF 2 2 0 06340 SBX350 GRAY 2 4 0 06316 SB175 3 POLE 2 1 0 06341 SBX350 BLUE 2 4 0 06320 SB350 GRAY 2 4 0 06342 SBX350 RED 2 4 0 06321 SB350 BLUE 2 4 0 06343 SBX350 GREEN 2 4 0 06322 SB350 RED 2 4 0 06359 SBX350 BLACK 2 4 0 06323 SB350 YELLOW 2 4 0 06360 SBX350 YELLOW 2 4 0 06324 SB350 GREEN 2 4 0 06370 SBX175 GRAY 2 1 0 06325 SB175 GRAY 2 1 0 06371 SBX175 BLUE 2 1 0 06326 SB175 BLUE 2 1 0 06372 SBX175 ORANGE 2 1 0 06327 58175 ORANGE 2 1 0 06373 SBX175 YELLOW 2 1 0 06328 SB175 YELLOW 2 1 0 06378 SBX175 RED 2 1 0 06329 SB175 RED 2 1 0 07205 YC RECEPTACLE 2 3 0 06400 SB350 ORANGE 2 4 0 06368 SBX350 ORANGE 2 4 0 When ordering replacement cables 1 Determine cable size and length 9 20 or 30 2 Determine kit part number by conn
31. BUSS BAR 10 a o e a B a TYPICAL X6 Schematics Schematics Schematics 3187099719 AdaLlvg 21gvo 09 v4 d 0 6495 935 o 06 20 gt 5 0 4 1 86 Be 19 9 amp 405 235 N Olt co m x ID N gt 9 3 epo L bpa 3 ed Ip bpo 8 ee L b Le d 9 56 n T Y2 82 21 SNOLLO3NNOO 121 171919 De quvog 1OHLNOO H2S 71519 sir 3191 33 86 Schematics SCHEMATIC LT2 29 5 09 a 91038 1 8 4 56 1 17 z 318 70991 5 ast gt navo ANNHS 2408 sos 0 E Ad3llVg r i4 651 1 e s i 19 5 5 a 1295 038 me Times
32. CONFIGURATION 0 2 This parameter configures the controls to the configuration of the battery cables for the purposes of calculating the battery cable drop compensation 0 Cable drop compensation disabled 1 Standard cable 2 Dual parallel cables ter TERMINATION METHOD 1 5 3 1 DVDT Terminates after no change in voltage is detected in the battery 2 TV Terminates 5 hours after the 80 gassing voltage is reached 3 Both Either DVDT or TV whichever occurs first 4 Proportional 5 Amp Hour set Battery AH BEES NE EXTENDED DVDT 0 hrs EN An extended time period added to DVDT termination for prolonging the charge cycle 4 hrs TA80 TIME AFTER 80 Ohrs 5hrs The maximum amount of time the battery charge cycle will continue after the gassing 10 hrs voltage is reached P Fc PROPORTIONAL FACTOR 0 40 The amount of time the charge cycle remains in taper and finish mode as a percentage of 100 the start mode time Parameter Description Range Default 60 D3G Control Board Fn A FINISH CURRENT 1 38 Finish amps This parameter is automatically derived when setting the battery amp 200A hours and charge profile Can also be set directly ose START CURRENT 1 400 136 Start Amps This parameter is automatically derived when setting the battery amp hours A Can also be set directly Ch P CHARGE PROFILE 1 2 1 Flooded or Sealed Profile 1 IEI Flooded 2 IEIE Seal
33. Chargenet N A 6 of 10AWG AC Cord with 30 AMP Plug X225 77 2 C8 8 of 10AWG AC Cord with 30 AMP 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 CF 12 42 of 8AWG AC Cord with 50 AMP Plug N A CR 6 of 10AWG AC Cord with 30 AMP Plug and 30AMP receptacle X225 TT 1 D Charger with AC Disconnect Switch See page 92 HD3 6 of 10AWG AC Cord with 30 AMP Plug X225 77 2 HD4 6 of 10AWG AC Cord with 30 AMP Plug and Receptacle X225 77 1 113 13 of DC cable See page 82 L15 15 of DC cable See page 82 118 18 of DC cable See page 82 L20 20 of DC cable See page 82 L25 25 of DC cable See page 82 L30 130 of DC cable See page 82 LM 50 Charger with Load Management Control N A O Special configuration of a standard EPROM N A P Parallel DC cables standard size See page 93 PP Charger shipped on a Plastic Pallet N A Q AC input change Quick N A S Series DC cables N A T Block Out Timer switch N A Stacking Hardware Kit 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 TABLE OF CONTENTS AC LINE VOLTAGE CODES 1 IMPORTANT
34. Components 1 Turnthe AC power OFF 2 Unplug the battery 3 Touch your finger to a ground to discharge static 4 To remove the EPROM slip a narrow bladed screwdriver GENTLY between the socket and the EPROM chip 5 Carefully pry up the chip making sure that the legs on both sides of the chip come up at the same time 6 DO NOT bend the legs 7 You may need to use a larger screwdriver once the chip is partially out of the socket 8 Place the removed EPROM into the anti static bag that the replacement EPROM came in Replacement 1 When placing the new EPROM in the socket make sure that the notch on the EPROM and the notch on the socket line up 2 BE CAREFUL when inserting the new EPROM DO NOT bend the legs Make sure that the legs go into the proper holes You may need to change some of the charger s parameters The instructions that came with the replacement EPROM will tell you whether it is necessary When inserting the new EPROM DO NOT bend the legs Verify that the legs go into the proper holes Field adjustment and calibrations may be required Instructions that come with the replacement EPROM will specify whether this is necessary To replace the PCB follow the steps outlined in the PCB section 70 Voltage Conversion 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
35. ON or OFF The factory setting is OFF Set to ON to charge gel cell batteries The following lists the parameters that automatically change when this function is enabled NOTE VRLA TERM must also be set to ON FINISH AMP 2 A 100AH 80 V CEL 2 37 POST 80 06 00 DVDT TERM OFF The range is OFF or ON The factory setting is OFF When ON VVR OPTION is accessible at the User Level The range is OFF or ON The factory setting is OFF When ON AMP HOUR RATING is accessible at the User Level The range is ON or OFF The factory setting is OFF When ON CHGR CELL SIZE is accessible at the User Level The range is ON or OFF The factory setting is OFF When ON CLEAR FAULT is accessible at the User Level The range is ON or OFF The factory setting is ON When ON SET CLOCK is accessible at the User Level The range is ON or OFF The factory setting is ON 46 Load Hog Control Board Description EDIT FUNC Forces the default factory settings to be entered into all parameters To force default data into all the parameters set this function ON remove the hardware passkey and turn the AC power off then on Default data will have been entered in all the parameters and this function will have been set to OFF Note Another way to force default data throughout the system is to turn AC power off press and hold down the SELECT and EQUAL push buttons turn AC power back on and then releasing the push buttons The ran
36. 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 TAP OPTIONAL Quick Tap is a feature to EnerSys chargers that allows the user to change AC input easily and quickly See the heading VOLTAGE CONVERSION FOR MORE INFORMATION NORMAL OPERATION 1 There are no jumper selections pot adjustments or slide switch selections on the D3G GTX control board All parameters are programmed via User or Service level parameters There are no pots for calibration Board calibration is done at the factory only 2 Idle Mode When AC input voltage is applied to the charger and no battery is connected the POWER LED will be lit The message will display in rotation on the front panel display Conn where Bat is the selected battery settings 1 5 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 Amp 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 w
37. TO BATTERY 2 NC T 8 2 G 5 SINGLE SHUNT POS SIDE RED TO BATTERY NOP 2 7 8 _ S LE 16 A 1 I SN X DOG 11 40 15 PARALLEL SHUNT POS SIDE usa TO BATTERY b HEAT SINK SCR Z 2 6 2 f E E 3 2 Y NIN A X L N 4 2 5 D e DC FUSE TYPE ANN NEG TOP DC FUSE TYPE ANN POS 3 FROM HEAT SINK SCR 4 2 oP 22 jud x M rii pi M E 1 9 9 3 E C 5 DC FUSE TYPE FWA NEG TOP DC FUSE TYPE FWA POS IMPORTANT NOTE ITEM PART NUMBER DESCRIPTION THIS NUT MUST BE LOCATED SO THAT THE DC 1 042 7 75 5 16 18 X 2 75 HEX HD BOLT FUSE IS PARALLEL TO THE PANEL WHEN THE 2 074746 5 16 FLAT WASHER ZINC PL HARDWARE IS TIGHTENED BLACK TO BATTERY x 3 044 2 18 INSULATION WASHER 4 085185 INSULATION BUSHING 9 5 074 2 6 5 16 LOCK WASHER 1 2 6 007371 5 16 HEX NUT ZINC PL x x 7 074 4 6 BRASS WASHERS amp BLACK LEAD E Enhi Hg 8 SEEBOM HEATSINK MTG PANEL AN 9 SEEBOM DC FUSE N a 6 10 SEEBOM SHUNT 5 25 11 0062072 SPACER 12 0272 BOLT 5 16 18 X 1 75 13 00733 5 16 JAM NUT ZINC PL DC FUSE ANY TYPE NEG BOTTOM 0427 52 BOLT 5 16 18 X 2 15 0446 BRASS WASHERS amp RED LEAD 16 0427 76 516 18 X 3 50 HE
38. User level press the Equal push button The following table describes the variables you can change at the User level and the following sections describe how to change each variable A parameter will only be accessible at the User level if permission was granted at the Service or Program level NOTE The User level cannot be entered during a charge cycle User Level Functions Display Contains Variable s Description Block Out Time BO START Sets up Block Out periods when charger will not start charging a battery BO END 38 Load Hog Control Board Variable s Description AMP HOUR Charger AH Set to the charger s nameplate rating or to the AH rating of the battery being RATING charged This parameter is the same as Service Level parameter CHGR AHRS Changing this parameter automatically causes adjustments to be made to Service Level parameters START AMP and FINISH AMP This parameter is only accessible if Service Level parameter CHARG FUNC is set to ON The range is 0 to nameplate rating The factory setting is the AH nameplate rating CHGR CELL Charger Cell Set to the charger s nameplate cell rating SIZE Size This is the number of cells in a battery that your charger is designed to be able to charge This parameter is only accessible if Service Level parameter CCELL FUNC is set to ON NOTE If this parameter is set to any other number than 6 9 12 15 18 24 36 or 40 the charger will not perform automatic sizing of the batt
39. are longer than the normal 8 feet a Be aware that this will cause a voltage drop of about 1 2 volts per 10 feet at Start Rate current 52 Load Hog Control Board b Be sure to set Service Level parameter CABLE so that the charger can determine the voltage drop The charger comes with 8 feet of cable 10 feet of positive and 10 feet of negative 13 There is a Charge Override a Shorting together pins 1 and 2 of PC board connector J5 will stop a charge in progress blank the display and turn off the LEDs b When the pins are opened a new charge cycle will begin C No data from the overridden charge cycle will be saved 14 Chargers are specifically built for 50 or 60 Hz not both a A 50 Hz model cannot be converted to a 60 Hz model b A 60 Hz model cannot be converted to a 50 Hz model 53 D3G Control Board D3G CONTROL BOARD COMP B 5 80 CALL SERVICE gt 20 TIME LIMIT BATTERY EXCEEDED DISCONNECT m 10 START STOP up REFRESH DOWN BQUALIZE LED POWER Light on when control board powered CALL SERVICE Light on when serious fault occurs during charge cycle usually requiring field assistance TIME LIMIT EXCEEDED Light on when charger time fault occurs BATTERY DISCONNECTED Light on when battery disconnected during charge cycle before normal termination START STOP Light on during charge cycle Light is off when charger is
40. current to Start Rate current The factory setting is the nameplate rating 1 4 80 V CEL The gassing voltage point In the charge cycle this pint indicates the end of start current mode and the beginning of constant voltage mode The range is 0 100 to 3 150 The factory setting is 2 380 5 FINISH AMP Found by multiplying battery AH by 4 5 In the charge cycle this is the current rate during Finish Current mode FINISH AMP will automatically be changed when Service Level parameter CHGR AHRS or User Level parameter AMP HOUR RATING is changed If this parameter is set to a value lower than Service Level parameter MIN AMPS then MIN AMPS will automatically be reset to FINISH AMP minus 1 The range is 003 0 to Start Rate current Service Level parameter START AMP 6 MIN AMPS The minimum output current in amps that may occur in a charge cycle If the current drops below this level the cycle will terminate because the charger assumes the DC cord is unplugged or the DC fuse is opened If FINISH AMP Service Level parameter is set below this parameter then MIN AMPS will automatically be adjusted to FINISH AMP minus 1 The range is 001 0 to FINISH AMP minus 1 The factory setting is 002 0 7T MAXSTIM Maximum time in Start Current mode If a battery does not reach the Gassing Voltage point within the time specified by this timer the charge cycle will be terminated Note MAX STIM Maximum time in Start Current mode Note A different
41. cycle is to be completed If this 18 hrs time limit is exceeded before the charge cycle completes a fault occurs t rf REFRESH TIME 0 60 20 Amont of time allotted for a refresh charge cycle mins mins 1 REFRESH INTERVAL 2hrs 24hrs Amount of time between when a charge cycle completes and a refresh cycle begins 99 hrs A refresh cycle will occur at the interval until the battery is disconnected from the charger t EU EQUALIZE TIME 6 mins 3 hrs Amount of time that a charged connected battery will remain in an equalize charge cycle 10 hrs GASSING VOLTAGE 80 POINT 1 000 2 370 Battery voltage in Volts Cell that is needed in order to indicate that the gassing voltage 3 000 Volts 80 point is reached and will light the 80 LED BE dt 0mV 20mV Amount of voltage in mV cell that the battery voltage must drop after the gassing voltage 100 is reached in order to give a Hot Batt error Can only occur when the termination method is set to TV or in an equalize cycle mV Up t UP TIME DETECT 0 min 2 mins The programmed time for the battery voltage to stabilize before the charger determines 10 its state of charge mins Cb L BATTERY CABLE LENGTH 1 2400 120 Length of battery cables installed on the charger used in battery cable drop compensation calculations Length is entered in inches Cb t BATTERY CABLE TYPE 3 2 0 cable 1 5 Size of battey cable 4 1 0 cable 1 4 0 cable 5 2 cable 2 3 0 cable Cb C BATTERY CABLE
42. fully discharged Connect the meter to measure the current at the battery load 15 D3E2 Control Board If the charger display contains 01 press the Select pushbutton to activate mode 01 If the charger display does not contain 01 use the Up or Down Arrow pushbuttons until 012 is in the display Then press the Select pushbutton to activate mode 01 UNI Be sure to have a load connected to the charger About 5 or 10 seconds after the Select pushbutton is pressed the charger will begin to output a small amount of current about 2 of the Ampere Hours AH of the charger When the meter reading becomes stable change the value on the charger display to the current reading on the meter Use the Up and Down Arrow pushbuttons to change the value in the display Press the Select pushbutton to save the data and exit this mode Calibrating the High Current Setting Mode 03 _ EMEN D calibrate this mode do not apply all of the cells of a fully charged battery The charger is not capable of delivering start rate current over 2 45 v c In most cases the voltage should be read in the charger at the positive and negative cable Follow these steps before trying to calibrate this mode Connect to the charger a battery that is more than 2096 discharged or to a group of cells that will keep the charger voltage near or below 2 45 v c Connect a meter to measure current at the battery Press the Up or Down Arrow
43. quickly selected for the customer that has multiple battery types and sizes 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 can 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 a least one hour of continuous charging of the battery by the charger Every time the battery completes a charge cycle the charge 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 COMPLETELED will light and the charger will immediately go into the equalize charge cycl
44. the PC board 5 Remove the mounting standoff screws from the PC board NOTE Handle the PC board with care Do NOT place it on top of the battery or other acid contaminated surfaces 6 Place the removed PC board into the anti static bag or foam that the replacement board was in Replacement Please follow these steps to install a PC board 1 Using the screws from the old PC board mount the replacement board on the door 2 Attach the connectors to the replacement board Be careful to insert the connectors properly The connectors should be inserted so that the raised portion of the socket slips under the raised portion of the plug on the PC board 3 NOTES FOR D3E2 GTS2 SERIES CHARGERS ONLY a Verify that the cell size jumpers JP4 are properly set for this type of charger The charger nameplate rating shows what the cell size is b Verify that the shunt element jumpers JP5 are properly set for this type of charger C See shunt chart under section Other Replacement Parts 4 Enter Service Level parameters per the model number of the charger 5 Perform the four calibration steps to ensure that the correct voltages and currents are being read by the control unit EPROM Please follow these steps before removing or replacing an EPROM Disconnect the battery Disconnect the AC power Removal Follow these steps to remove the EPROM Be sure your hands are fairly clean before touching a PC board 69 Testing and Replacing
45. the battery reaches this level the charge cycle is complete To turn on AH termination set Program Level parameter AHRS TERM to ON The range is 0000 to 220 of nameplate The factory setting is 1250 44 20 PROP FACTR 21 PAUSTIME 22 CHG CYCLE 1 2 3 24 CABLE 25 HLD 26 SEL HLD 27 OVERD FUNC 28 RND DEL FUNC 23 RUNS Load Hog Control Board Description When Proportional termination is selected PROP FACTR determines when a charge cycle will terminate This parameter is a percentage The charger uses it to calculate the amount of time that will be spent in Finish Current mode Time in Finish Current mode PROP FACTR times the amount of time spent in Start Current mode Note To select Proportional termination set the following Program Level parameters to OFF DVDT TERM T V TERM AHRS TERM The range is 000 to 100 The factory setting is 040 Specifies how long a charge cycle will pause before automatically restarting A pause is caused by pressing the Start Stop push button while a charge is in progress and leaving the battery connected to the charger Note Service Level parameter MANUAL OP must be set to OFF for PAUSTIME to work The range is 00 00 to 04 00 The factory setting is 01 00 1 hour Increments each time a charge cycle successfully completes If less than 1 hour was spent in Start Current mode then CHG CYCLE will not be incremented If the charger is set for Automatic Equalize Servi
46. the display Use the Up and Down Arrow pushbuttons to change the value in the display Press the Select pushbutton again to save the current setting in the display to return to the User level 11 D3E2 Control Board When the User level adjustments are complete press the Stop pushbutton to exit or continue to the next option by the Up or Down Arrows 03 Automatic Manual Option The Automatic Manual option determines if charge cycles will be performed in Automatic or Manual mode If this option is set to Automatic 1 the charge cycle will begin auto delay as soon as a battery is connected to the charger The following lists what will happen when your charger is operating in Automatic mode Also refer to the Automatic mode flow chart contained in this manual Actual charging will begin after the time specified in Delay Start User level option 01 elapses If the Equalize Counter option User level option 02 is not 0 then an Equalize charge cycle will be performed as specified by that option If the Equalize pushbutton is pressed during a Daily charge cycle it will become an Equalize charge cycle If the Equalize pushbutton is pressed during an Equalize charge cycle but before Equalize mode begins it will become a Daily charge cycle A Refresh charge cycle will occur if the battery is left connected to the charger for longer than the Refresh Wait period after the charge cycle has completed If this option is set to Manu
47. the torque wrench Do not exceed the torques shown in the following table 2 Do not use any other wrench to tighten the nut HE Block Size SCR Diode Block mounting Torque in Ib Buss bar mounting Torque in Ib Bolt Size Max Bolt Size 104 Amp 10 32 x 1 25 162 Amp 10 32 x 1 25 250 Amp 10 32 x 1 25 285 Amp 10 32 x 1 25 Removal The SCR Diode Blocks cannot be removed until the bussbars are removed first These steps explain how to remove the heatsink Remove the DC cable leads Remove the DC control leads red from the PC board Unplug the SCR Diode Blocks gate leads Remove the secondary transformer leads from the input of the SCR Diode Block Unscrew the two bussbars from the SCR Diode Blocks Note on the units where the bussbar is directly attached to the jumper wire leave the bussbar attached to the jumper wire and just move the bussbar away from the SCR Diode Blocks 6 Now you can remove the SCR Diode Block from the heatsink Replacement 1 Remove old silicone heatsink compound from the heatsink 2 Apply silicone heatsink compound i e thermalloy 249 Aavid 1001 etc to the SCR Diode Block and fasten it to the heatsink Use the proper torque See table above Replace the heatsink into the charger case being careful to slide it onto its holder Mount the two bussbars back to the SCR Diode Blocks Connect the secondary transformer leads to the inputs of the SCR Diode Blocks Reconnect the SCR Diode Block g
48. timer and is only used when parameter 13 is setto SEAL The 8 factory setting is 4 00 4 hours Time after Selects the time that the charger runs after the Finish Voltage of 2 53 vpc has been reached Finish This parameter is a termination timer and is only used when parameter 13 is set to SEAL The factory setting is 2 00 2 hours 1 Finish This voltage is factory set to 2 53 volts per cell This parameter is only used when parameter Voltage 13 is set to SEAL Once finish rate is reached battery voltage will climb to this set point Battery voltage will be held constant at 2 53 v c until parameter 16 or 17 above is satisfied 14 D3E2 Control Board TRANSFORMER CODES REFER TO THE FIELD ENHANCEMENT UPGRADE DECAL FOR THE FACTORY SET TRANSFORMER CODE If the transformer is replaced contact the technical support The following table represents a guideline for the reference transformer code CODE NUMBERS CODE NUMBERS J model E model J model D model 1518 1700 s1g 2000 S24 200 4 24550 48 524 680 824850 2 S24950 2 92410500 21 21 23 24 Es 22 19 06 680 12 550 12 680 12 850 S12 1200 S18 550 S18 950 S18 1050 S18 1200 S18 1500 19 18 16 6 EPS 18 18 2 6 18 20 19 17 1200 2 1500 2 FIELD CALIBRATION PROCEDURE The Field calibration procedure MUST BE DONE to calibrate the charger current and volt
49. 0 2014 99 50 36 1050 X127 S36 1050B 72 100 X014 99 10d 62 90 X014 99 90 31 50 014 99 50 40 450 127 540 550 34 50 014 99 50 30 50 014 99 50 15 25 X014 99 25 40 550 127 540 550 42 60 X014 99 60 36 60 X014 99 60 18 30 X014 99 30 40 680 X127 S40 680B 52 80 X014 99 80 45 70 X014 99 70 23 40 X014 99 40 40 750 X127 S40 680B 57 90 2014 99 90 49 70 014 99 70 25 40 2014 99 40 40 850 X127 S40 850B 64 100 X014 99 10 56 90 X014 99 90 28 45 X014 99 45 40 1000 127 540 105 76 N A N A 66 100 X014 99 10d 33 50 014 99 50 40 1050 X127 840 1050B 79 N A N A 69 100 X014 99 10q 35 50 7014 99 50 79 AC FUSES MODEL D 220 380 440 V Replacement Parts FUSES MODEL D Transformer P N 220 Volts 380 Volts 440 Volts AC Value P N AC Value P N AC Value P N 6 550 X127 S06 550D 6 10 014 99 10 4 7 X014 99 7 3 5 X014 99 5 6 680 X127 S06 680D 8 12 X014 99 12 5 8 X014 99 8 4 7 X014 99 7 6 750 X127 S06 680D 8 12 X014 99 12 5 8 X014 99 8 4 7 X014 99 7 6 850 X127 S06 850D 10 15 X014 99 15 6 10 014 99 10 5 8 X014 99 8 6 950 X127 S06 1050D 11 20 X014 99 20 6 10 X014 99 10 6 10 X014 99 10 6 1000 X127 S06 1050D 11 20 X014 99 20 7 12
50. 00 2000 X1060 61 11 24 2500 NOTE Control Board replacement requires set up 76 Replacement Parts OTHER REPLACEMENT PARTS HEAT SINK Heat Sink Extrusion Charger s Assy P N BIk P N Note One heat sink assembly is required per charger which includes everything extrusion SCR Diode block bussbars jumpers and hardware Extrusion J x 42 E O SCR Heat Sink Extrusion Charger s Diode BussBar Jumpers 5 Assy P N P N Bik P N Length amp P N Size PTT TET R507 18 3 T 6 124 1 0W 26 x 24 1200AH R521 99 3 50 R521 99 3 5 160A 090 2 75 11 124 1 0W 11 1 0AWG E 99 3 99 3 R507 18 4 5 74 6 124 2 0W 6 1500AH to 2000 521 99 3 51 090 2 74 117 124 2 0 14 2 0AWG Note Three heat sink assemblies are required per charger and each assembly includes extrusion and SCR Diode block Bussbars jumpers and hardware shall be ordered separate See drawings for hardware 6 inch jumper connects to DC fuse and 11 inch jumper connects to Shunt DC Fuses Charger s DC fuse values ANN Fuse P N FWA Fuse P N NOTE 36 and 40 cell chargers use FWA DC fuse type 77 Replacement Parts SHUNT Models D3E2 and GTS2 Models LT2 and LTC2 JP5 Shunt Shunt Shunt Charger s Shunt P N Value Jumper Charg
51. 20 11 20 X014 99 20 6 10 2014 99 10 12 680 X127 S12 680B 16 25 014 99 25 14 25 014 99 25 7 12 X014 99 12 12 750 X127 S12 680B 17 30 70014 99 30 15 25 X014 99 25 8 12 X014 99 12 12 850 X127 S12 850B 20 35 014 99 35 17 30 X014 99 30 9 15 X014 99 15 12 950 X127 S12 1050B 22 35 2014 99 35 19 30 014 99 30 10 15 X014 99 15 12 1000 X127 S12 1050B 23 40 014 99 40 20 35 X014 99 35 10 15 X014 99 15 12 1050 127 512 105 24 40 X014 99 40 21 35 X014 99 35 11 20 014 99 20 12 1200 X127 812 1200B 28 45 014 99 45 24 40 X014 99 40 12 20 014 99 20 18 550 X127 818 550B 19 30 X014 99 30 17 30 X014 99 30 9 15 014 99 15 18 680 X127 S18 680B 24 40 X014 99 40 20 35 014 99 35 10 15 014 99 15 18 750 2127 18 6808 26 40 014 99 40 22 35 014 99 35 11 20 X014 99 20 18 850 X127 818 850B 29 45 X014 99 45 25 40 014 99 40 13 20 X014 99 20 18 950 X127 818 1050B 33 50 X014 99 50 28 45 X014 99 45 14 25 X014 99 25 18 1000 X127 S18 1050B 34 50 X014 99 50 30 50 X014 99 50 15 25 X014 99 25 18 1050 X127 818 1050B 36 60 X014 99 60 31 50 X014 99 50 16 25 X014 99 25 18 1200 127 518 12006 41 60 X014 99 60 36 60 X014 99 60 18 30 2014 99 30 18 1500 127 518 15006 51 80 2014 99 80 44 70 X014 99 70 22 35 2014 99 35 18 1600 X127 818 1700B 55 80 X014 99 80 47 70 X014 99 70 24 40 X014 99 40 18 1700 X127 818 1700B 58 90
52. 40 850J 25 40 014 99 40 22 35 014 99 35 20 35 014 99 35 36 1000 X127 S40 1050J 30 50 X014 99 50 26 40 014 99 40 24 40 X014 99 40 36 1050 X127 S40 1050J 31 50 X014 99 50 27 45 014 99 45 25 40 X014 99 40 40 450 X127 S40 550J 15 25 014 99 25 13 20 2014 99 20 12 20 X014 99 20 40 550 X127 S40 550J 18 30 X014 99 30 16 25 014 99 25 15 25 X014 99 25 40 680 X127 S40 680J 23 40 014 99 40 20 35 014 99 35 18 30 014 99 30 40 750 X127 S40 680J 25 40 014 99 40 22 35 014 99 35 20 35 014 99 35 40 850 X127 S40 850J 28 45 014 99 45 25 40 014 99 40 23 40 014 99 40 40 1000 X127 S40 1050J 33 50 X014 99 50 29 45 014 99 45 27 45 014 99 45 40 1050 X127 S40 1050J 35 50 X014 99 50 30 50 014 99 50 28 45 014 99 45 SPECIAL MODELS NOTE special charger models might not be listed in these tables However AC input is listed on the charger s nameplate AC fuse values are listed on a decal inside the charger The AC fuse part number would be X014 99 X X AC fuse value 81 Replacement Charger Cables Charger Cable Size Replacement Parts Charger AH Rating Ve Cable 0 775 2 776 1050 1 0 1051 1200 2 0 1201 1500 3 0 1501 1700 4 0 Replacement kits CABLE KIT FOR SB 175 KIT FOR SB 350 GAUGE CONNECTOR CONNECTOR 2 X225 2 175 X225 2 350 1 0 X225 1 0 175 X225 1 0 350 2 0 N
53. 6 1000 X127 840 1050D 64 100 X014 99 10Q 38 60 X014 99 60 32 50 7014 99 50 36 1050 127 540 1050 68 100 X014 99 10 39 60 2014 99 60 34 50 7014 99 50 40 450 X127 S40 550D 32 50 014 99 50 19 30 014 99 30 16 25 014 99 25 40 550 X127 S40 550D 40 60 014 99 60 23 40 X014 99 40 20 35 X014 99 35 40 680 X127 S40 680D 49 70 014 99 70 28 45 X014 99 45 25 40 014 99 40 40 750 X127 S40 680D 54 80 X014 99 80 31 50 014 99 50 27 45 014 99 45 40 850 X127 S40 850D 61 90 X014 99 90 35 50 X014 99 50 31 50 014 99 50 40 1000 X127 S40 1050D 72 N A N A 42 60 X014 99 60 36 60 X014 99 60 40 1050 127 540 1050 75 N A N A 44 70 X014 99 70 38 60 X014 99 60 80 Replacement Parts AC FUSES MODEL J 480 550 600 V MODEL J Transformer P N 480 Volts 550 Volts 600 Volts AC Value P N AC Value P N AC Value P N 6 550 X127 S06 550J 3 5 X014 99 5 3 5 X014 99 5 3 5 X014 99 5 6 680 X127 S06 680J 4 7 X014 99 7 3 5 X014 99 5 3 5 X014 99 5 6 750 X127 S06 680J 4 7 X014 99 7 4 7 X014 99 7 3 5 X014 99 5 6 850 X127 S06 850J 5 8 X014 99 8 4 7 X014 99 7 4 7 X014 99 7 6 950 X127 S06 1050J 5 8 X014 99 8 5 8 X014 99 8 4 7 X014 99 7 6
54. 8 45 X014 99 45 24 40 014 99 40 18 1600 127 518 1700 52 80 X014 99 80 30 50 014 99 50 26 40 014 99 40 18 1700 X127 S18 1700D 55 80 2014 99 80 32 50 014 99 50 28 45 2014 99 45 18 2000 X127 S18 2000D 64 100 X014 99 10 38 60 2014 99 60 32 50 7014 99 50 24 550 X127 S24 550D 24 40 X014 99 40 14 25 X014 99 25 12 20 X014 99 20 24 680 X127 S24 680D 30 50 014 99 50 17 30 014 99 30 15 25 014 99 25 24 750 X127 S24 680D 32 50 014 99 50 19 30 014 99 30 16 25 014 99 25 24 850 X127 S24 850D 37 60 2014 99 60 21 35 014 99 35 19 30 7014 99 30 24 950 X127 S24 1050D 41 60 2014 99 60 24 40 X014 99 40 21 35 014 99 35 24 1000 127 524 1050 43 70 014 99 70 25 40 X014 99 40 22 35 014 99 35 24 1050 2127 24 1050 45 70 014 99 70 26 40 014 99 40 23 40 014 99 40 24 1200 127 524 1200 52 80 2014 99 80 30 50 014 99 50 26 40 014 99 40 24 1500 127 524 1500 64 100 014 99 100 38 60 2014 99 60 32 50 014 99 50 36 450 X127 S40 550D 29 45 X014 99 45 17 30 014 99 30 15 25 014 99 25 36 550 X127 S40 550D 36 60 2014 99 60 21 35 014 99 35 18 30 7014 99 30 36 680 X127 S40 680D 44 70 014 99 70 26 40 014 99 40 22 35 014 99 35 36 750 X127 S36 680D 48 70 014 99 70 28 45 X014 99 45 24 40 2014 99 40 36 850 X127 S40 850D 55 80 X014 99 80 32 50 014 99 50 28 45 014 99 45 3
55. APER FINISH EQUALIZE c E I EXAMPLE OF START TAPER amp FINISH EQUALIZE TIME VOLTAGE Mec TERMINATION 5 HOURS 5 HOURS 3 HOURS EXAMPLE OF START TAPER FINISH EQUALIZE PROPORTIONAL TERMINATION 5 HOURS 2HRS 3 HOURS 5 0 4 2 18 Charge Cycle in Automatic Mode Apply AC power to charger Y LEDs blink Display shows C XX and E XX and AC ON LED lights other LEDs off Attach battery Battery voltage less than 1 6 amp Battery voltage greater than 2 38 v c Battery voltage greater than 1 3 v c Error message displays Disconnect battery Display contains ON and Start LED lights D3E2 Control Board Equalize LED dn to blink Charge cycle starts after a delay of 5 seconds or starts after the time specified in the Delay Time parameter Start Current Mode i Charger sends constant current to the battery at Start Rate current and Display begins to show Charger Current Volts per Cell AH Returned Time on Charge Y User can Press the Equalize pushbutton to change charge cycle from Equalize to Daily Equalize LED stops blinking or User can Press the Equalize pushbutton to change charge cycle from Daily to Equalize Equalize LED starts blinking Battery Volta
56. Bato 2001 03 F2 to A5 F2 to A6 F2 to A6 D4 F3 to B6 D3 F2 to B1 F2 to B1 F2 to Bt ba 3001 Het D4 to BS F3 to B6 F3 to B6 A2 A1 to A4 A1 to A4 A3 to A4 E E s D4 F3 to C1 F3 to 1 F3 to C1 n m A2 A2 to M A2 to M A3 to M db en mes A2 B2 to B4 B2 to 84 B3 to B4 M 0100 61004 B3 to B4 A2 C2 to C4 C2 to C4 C3 to C4 A2 C2 to C5 C3 to C6 C3 to C4 INDICATES TWO JUMPERS 71 Voltage Conversion WIRING CONNECTION CHART 3 PHASE SCR CHARGERS MODEL D WIRING CONNECTION CHART 220 VOLTINPUT 380VOLTINPUT 440 VOLT INPUT 3 WIRE CONNECTION CONNECTION CONNECTION 3 400 VOLT INPUT D2 F1to A1 F1 to A1 Fito A1 WIRE CONNECTION D7 F1 to C6 F1 to C5 F1 to C6 D2 1 1 D3 F2 to A6 F2 to A5 F2 to A6 D7 F1 TO C6 D3 F2 to B1 F2 to B1 F2 to B1 5 10 D4 F3 to B6 F3 to B5 F3 to B6 Di 166 04 731001 731001 731001 04 F3 TO CI A2 A1 to M A2 to A4 A3 to A4 A2 A3 to A6 B2 to B4 B3 to B4 A2 311084 0210 04 C3 to C4 A2 B3 to B6 A2 to A4 A3 to A4 A2 C1 to C4 B2 to B4 B3 to B4 A2 C3 to C6 C2 to C4 C3 to C4 AC INPUT CHANGE WITH QUICK TAP 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 f
57. CR 2 Provide the signal by which the controller monitors the utility voltage How the controller exactly interprets this voltage is dependent on the transformer code which is described later The controller will give an AC fault if any of the 3 phases drops to approximately 90 of the input voltage or if any of the 3 AC fuses clear Each SCR is gated with a DC pulse The red lead of the SCR is tied to control common and the white gate lead is tied to the gate firing circuit on the control circuitry The control will automatically balance SCR currents to within 1096 at the beginning of each charging cycle Refer to later sections of the manual for specific measurements and values that can be expected for normal charger operation D3E2 Control Board OPERATING INSTRUCTIONS Read the specific Operating Instructions for your charger Three types of control boards are available for 3 phase SCR chargers The Operating Instructions are different depending on the control board Settings are referred to Flooded Cell typed batteries unless otherwise defined and marked with Sealed Cell settings Operations of the PCB remain the same for either Flooded or Sealed Cell within each type of control board DEPTH amp rENEGADE CONTROL BOARD D3E2 and FGTS2 are factory set for Flooded And SD3E2 and GTS2 are factory set for Sealed NORMAL CHARGER OPERATION When a battery is connected to the charger the charger control circuitry measures the b
58. Ds Light Emitting Diodes and 5 push buttons Push buttons mE Push button Description Start Stop Starts or restarts a Daily charge cycle when the charger is in Manual mode In Automatic mode it can change an Equalize charge cycle to a Daily charge cycle If the 3 hour Equalize mode has begun the charge cycle cannot be changed to a Daily charge cycle Interrupts a charge in progress The interrupted charge can be manually restarted within 1 hour factory default setting of Program Level parameter PAUSTIME If the battery has remained connected to the charger for 1 hour factory default setting of PAUSTIME the charger will automatically restart If a battery with a voltage outside of the acceptable range 1 6 v c to 2 4 v c is connected pressing this button for more than 5 seconds will start the charger and the charger will attempt to charge the battery If the battery accepts charge current the charge cycle will continue if not the attempted start will be aborted Up Arrow Scrolls through the displayable parameters or menu selections and when modifying a parameter increases the number shown in the display If pressed and held while a charge is in progress causes the value currently in the display to remain displayed The value will continue to display for a few seconds after the push button is released 27 Load Hog Control Board Description Down Arrow Scrolls through the displayable parameters or menu selections and when mo
59. EQUALIZE pushbuttons the display will then read Cell 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 EQUALIZE pushbutton To adjust the service 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 parameter configuration mode and save the parameter setting The display will now read Conn Only the service parameters for the particular battery selection have been modified 59 D3G Control Board DEFAULT SETTINGS Parameter Description Range Default Cell CELL SIZE 1 40 18 This is the number of cells that the charger is designed to charge This parameter should be set to match the cell size rating on the charger nameplate This parameter is important for cable drop compensation C AH CHARGER AMP HOUR RATING 10 850 Nameplate amp hour rating of charger 2500 AH od TIME TO GASSING 1hr 6 hrs Amount of time before gassing voltage is reached If this time limit is exceeded before 12 hrs reaching gassing voltage a fault occurs t Lt TIME LIMIT 2hrs 18hrs Maximum amount of charge cycle time in which a charge
60. FF Charger s Nameplate Rating Battery Cell Range Setting the Date and the Real Time Clock Parameter To change the date or time of the Real Time clock please follow these steps 1 Press the Select push button to enter the User level 2 Use the Up and Down Arrow push buttons to scroll through the variables until SET CLOCK displays 3 Press the Select push button if you want to change the date or time Press the Equal push button to return to Display mode After the Select push button is pressed YEAR will display a Use the Up Down Arrow push buttons to scroll through the following Real Time clock parameters Year Month Date day of the month Day day of the week Hour Minute b When the parameter you want to change is displayed press the Select push button The value of the parameter is now displayed Use the Down Arrow keys to change the value the display d Press the Select push button to save the new value you just entered or press the Equal push button to keep the old value e To change another parameter of the Real Time clock repeat Steps 3a through 3d 4 Once you have completed changing the Real Time clock press the Equal push button SET CLOCK should now be back in the display 5 Press the Equal push button once again to exit the User level Setting the Delay SET DELAY has 2 parameters WAIT and UNTIL WAIT specifies the amount of time the charger will wait before beginning a
61. ING 100A FUSE BLOCK 4 p USE THE CENTER EXTRUSION MOUNTING 9 HOLE FOR BOTTOM ATTACHMENT v df USE 036 99 2 10 32 X 1 3 8 IN THIS APPLICATION ALT 13 1 11 8 AA 91 DISCONNECT SWITCH OPTIONAL 3 J 1 f Ge 2 4 SL 9 gt NOTE SET SCREW Aj 5 6 7 8 TS NA F i HORIZONTAL POSITION NOTE HORIZONTAL POSITION AC INPUT 84 N LEOSITION IS THE SAME FOR N 40A amp 80A SWITCHES 600V BAWG ITEM PART NO DESCRIPTION 1 007 3 21 8 NUT 2 074 2 2 8 LOCK WASHER 3 SEE BOM SUB ASS Y PANEL 4 X002 99 0 45 40A DISCONNECT SWITCH X002 99 0 51 80A DISCONNECT SWITCH 3 5 101 31 7 8 32 X 3 4 SCREW VIEW OF 3PH STAN DARD 6 X002 99 0 47 ROD CUT TO SIZE HARGER 7 PROVIDED SCREW C G 8 PROVIDED FLAT WASHERS 9 SEE BOM DOOR FOR DISCONNECT SWITCH 10 X002 99 0 46 HANDLE 92 PARALLEL CABLES OPTIONAL Auto Start delay is required NOTE DETERMINE NUMBER OF SHUNTS FUSE TYPE amp CABLE SIZE FOR THE CHARGER THEN REFER TO THE APPROPRIATE ILLUSTRATION BLACK RED BLACK TO HEAT SINK yo sur OO xai f ANY SIZE PARALLEL CABLES FROM HEAT SINK SINGLE SHUNT NEG SIDE ANY SIZE PARALLEL CABLES FROM HEAT SINK 3 4 6 2 lt 8 w PARALLEL SHUNT SIDE ants RED TO BATTERY BLACK TO BATTERY FROM HEAT SINK SCR RED
62. M it should read a 7V drop on the diode scale Reverse the wires on the meter The needle should not move on the analog scale measurement of infinity The DVM should not get a reading The SCR Diode Block is shorted if the meter measures zero current for both directions polarities 0 The SCR Diode Block is open if the meter reads infinity for both directions polarities AC AND DC FUSES Please follow these steps before testing the fuses Disconnect the battery Disconnect the AC power You will be testing each fuse to see whether there is continuity across it PON NO GE amp N 1 Using an ohmmeter set to its x1 scale test each fuse 2 If a fuse tests as an open circuit infinity replace it 3 If there is continuity across the fuse less than 1 ohm it is working properly LEDs To test if the LEDs are working 1 Turn AC power off then back on 2 When the power is turned on all the LEDs should blink PC BOARDS ALL Please follow these steps before testing the PC board Disconnect the AC power You will be testing the DC battery voltage on the PC board at connector J4 then verifying that this voltage is the same as the battery s voltage 1 Connect your meter to Pin 1 the square pad of Connector J4 and to the opposite end Pin 4 2 Verify that you have voltage at the board WARNING We have specifically chosen Pins 1 and 4 because shorting battery voltage could cause
63. P OR DOWN ARROW STOP UP OR DOWN ARROW STOP amp REFRESH 10 D3E2 Control Board USER LEVEL ADJUSTMENTS To enter the User level hold down the Display and Daily pushbuttons at the same time After approximately 5 seconds the display will read USEr When this displays release all the pushbuttons The display should contain 01 The User level parameters can now be modified Use the Up and Down Arrow pushbuttons to change the display The User level has three options that can be modified 01 Delay Start Option 02 Equalize Counter Option 03 Automatic Manual Option 01 _ Delay Start Option This option is only functional when the charger is set to Automatic User level 03 1 The Delay Start option makes it possible to delay the start of the charge It can be set from a minimum of 0 minutes 00 00 to a maximum of 18 hours and 12 minutes 18 12 Delay Start immediately begins counting down when a battery is connected to the charger If the Delay Start option is set to 00 00 charging will begin in about 5 seconds after a battery is connected to the charger The range is 00 00 to 18 12 The factory setting is 00 00 Changing Delay Start To change or view the Delay Start option enter the User level and have the display contain 01 Press the Select pushbutton The current setting of Delay Start will appear in the display Use the Up and Down Arrow pushbuttons to change the value in the display Press the Sele
64. S 15 FIELD CALIBRATION PROCEDURE 15 RECHARGE CHARACTERISTICS 17 Gassing Voltage Point Not Reached 17 Gassing Voltage Point Reached 17 Finish Current Mode Not 17 Finish Current Mode Reached 17 Equalize Mode 17 Refresh Mode oni eee 17 Checking the Recharge Characteristics 18 CHARGE CYCLE IN AUTOMATIC 19 BASIC TROUBLESHOOTING PROCEDURE 22 Troubleshooting Flowchart 24 Symptoms Suggestions amp Reminders 26 LOADHOG CONTROL BOARD NORMAL CHARGER OPERATION 27 Front Control 27 Charge Cycle in Automatic Mode 29 RECHARGE CHARACTERISTICS 32 Gassing Voltage Point Not Reached 32 Gassing Voltage Point Reached 32 Finish Current Mode Not 32 Finish Current Mode Reached 32 Equalize 32 Refresh Mode 4 4 32 Checking the Recharge Characteristics 32 Sealed Cell Chargers 33 CHARGE CYCLE TERMINATION METHODS 33 Proportional petendi 33 Time Voltage 34 Amp Hours Retur
65. SAFETY INSTRUCTIONS 3 INSTALLATION 4 Location ene 4 Stacking Multiple Chargers 4 Electrical Connections 4 Connecting Input 5 Branch Circuit Protection 5 Plug Polarity 5 Grounding the Charger 5 THEORY OF 5 Introduction 5 Printed Circuit Boards 6 Control Circuitry 7 D3E2 CONTROL BOARD OPERATING INSTRUCTIONS 8 D3E2 Control 8 Normal Charger 8 Front Control 8 BIETER 9 Error 9 FIELD ADJUSTMENTS 10 Setting Parameters 10 User Level Adjustments 11 Field Technician Level Adjustments 12 Service Level Parameters 12 Charger Parameters 13 TRANSFORMER CODE
66. X HD BOLT 17 0746 6 5 16 DIA X 1 16 COPPER WASHER 18 07463 5 16 DIA X 1 32 COPPER WASHER 93
67. actory setting is 00 00 no cool down time Battery Type Specifies flooded or sealed battery charging FLOd flooded cell SEAL sealed cell Presets the gassing point finish rate current termination method time voltage limit and the charge time limit parameters to the typical configurations of the selected type of battery These configurations are as follows Flooded cell Gassing point 2 38 Finish rate current 4 5 A 100 A H Termination method Time voltage Time voltage limit daily 5 00 hours Charge time limit 6 00 hours equalize Sealed cell Gassing point 2 37 vic Finish rate current 2A 100 A H Termination method Time voltage Time voltage limit daily 6 00 hours Charge time limit 7 30 hours equalize the time spent in start rate This parameter is only used in proportional time termination mode The range is 0 100 13 14 Proportional This parameter adjusts the percentage rate of the proportional time termination mode Time Factor Proportional mode selects the time the charger runs in finish rate based on a percentage of The factory setting is 40 40 T V Time Limit Selects the time that the charger runs after the 8096 point has been reached This parameter is used in time voltage termination mode only The range is 0 00 12 00 The factory setting is 5 00 5 hours 16 Time After Selects the time that the charger runs after the 8096 point has been reached Gassing This parameter is a termination
68. al 2 the charge cycle will not begin after the battery is connected to the charger until either the Daily or Equalize pushbutton is pressed The following lists what to expect when operating the charger in Manual mode Charging will begin as soon as the Daily or Equalize pushbutton is pressed when a battery is connected to the charger If the Equalize pushbutton is pressed during a Daily charge cycle it will become an Equalize charge cycle If the Equalize pushbutton is pressed during an Equalize charge cycle but before Equalize mode begins it will become a Daily charge cycle To begin a Refresh charge cycle when a charge cycle has completed and the display reads OFF press the Refresh pushbutton The Refresh charge cycle will begin immediately The factory setting is 1 Automatic Changing Automatic Manual Option To change or view the Automatic Manual option enter the User level and change the display to contain 03 Press the Select pushbutton the current setting of Automatic Manual will appear in the display Use the Up and Down Arrow pushbuttons to change the Value in the display Press the Select pushbutton again to save the current setting in the display and to return to the User level When you have completed making User level adjustments press the Stop pushbutton to exit FIELD TECHNICIAN LEVEL ADJUSTMENTS NOTE Refer to the Field Enhancement Upgrade decal located on the inside part of the door to see if th
69. are calculated and the charger parameters are automatically updated b Besure that the Start Rate current Service Level parameter START AMP does not exceed the charger s nameplate rating C Finish Rate current Service Level parameter FINISH AMP will need to be adjusted upward for the AH rating of that battery Contact technical support before performing an upward adjustment on the Finish Rate current To stop or pause a charge a Push the Stop push button and then disconnect the battery b Toonly pause the charge leave the battery connected the charge will continue from where it left off when the charger is started again During an AC power failure a Key information concerning the charge cycle is saved electronically When power returns this information is automatically retrieved and if a battery is connected to the charger charging automatically continues from where it was interrupted protecting the battery from being overcharged b NOTE Ifa battery is connected to the charger at the moment power returns the charger assumes that this is the same battery that was connected to it when the power failure occurred If the battery is disconnected during a charge cycle a The CHR will turn itself off and fault message DC FUSE CBL OPEN usually appear on the display To stop an equalize cycle when the Equalize LED is lighting steadily a Push the Stop push button and unplug the battery If you are installing cables that
70. ary phase 1 Start the charger and run it for 5 minutes with a battery connected 2 Then turn off the charger and disconnect the battery 3 Within 1 minute check the temperature of the SCR Diode Blocks If an SCR Diode Block is cold then it is defective Heatsink and SCR Diode Blocks may be very warm Please exercise caution First SCR Diode Block Test Please follow these steps before testing the SCR Diode Blocks Disconnect the battery Disconnect the AC power You will be testing the SCR Diode Blocks to see whether there is continuity or forward leakage current 100k ohms or less 1 Disconnect the gate leads from SCR Diode Blocks 2 Remove the transformer input connection to the SCR Diode Block anode 3 Using an ohmmeter set to its 1k scale check for continuity between each SCR Diode Block anode input connection and bussbar The ohmmeter should read infinity 4 If continuity is shown replace the SCR Diode Block 5 If infinity open is measured in both directions the SCR Diode Block may be open To prove the SCR Diode Block functions properly you need to go to the next test Second SCR Diode Block Test to check the gating operation of the SCR Diode Block Second SCR Diode Block Test Please follow these steps before testing the SCR Diode Block Disconnect the battery Disconnect the AC power You can test a single SCR Diode Block at a time You will need a Flashlight tester or a Contin
71. atches the 33 Load Hog Control Board current of Finish Current mode Service Level parameter FINISH AMP Control then reverts back to Constant Current control The amount of time spent in Finish Current mode is based on the time spent in Start Current mode The amount of time in Finish Current mode is calculated by multiplying Service Level parameter PROP FACTR by the time spent in Start Current mode To select Proportional termination set the other termination s methods OFF Program Level parameters DVDT TERM T V TERM and AHRS TERM TIME VOLTAGE Time Voltage termination Program Level parameter T V TERM follows the same path as described in Proportional except that the amount of time left in the charge cycle after the Gassing Voltage point is reached is specified in Program Level parameter POST 80 AMPHOURS RETURNED AH Returned termination Program Level parameter AHRS TERM follows the same path as described in Proportional except that a charge cycle ends when the accumulated AH returned during the charge cycle equals the value set in Program Level parameter TERM AHS DV DT DV DT termination Program Level parameter TERM follows the same path as described in Proportional except that the charge cycle ends when the change in voltage is acceptable for a specified period of time Program Level parameter DV DT SP FINISH TERMINATION The charger can be set to terminate a charge normally i e
72. ate leads Connect the DC control leads to the PC board Replace the DC cable leads Since you have removed the SCR Diode Block gate leads from the harness take special care in reconnecting the SCR Diode Blocks firing lead connections making sure that ROMA j NN D RW 68 Testing and Replacing Components 1 Phase A is connected to phase A 2 PhaseB to phase B 3 Phase C to phase C CONTACTOR IF AVAILABLE Removal 1 Remove the screws holding the contactor in place 2 Carefully transfer one lead at a time from the old contactor to the replacement contactor Replacement 1 Mount the replacement contactor in the charger using the screws from the old contactor CONTROL TRANSFORMER IF AVAILABLE Removal 1 Remove the screws holding the control transformer in place 2 Carefully transfer one lead at a time from the old control transformer to the replacement contactor Replacement 1 Mount the replacement control transformer in the charger using the screws from the old control transformer PC BOARD Removal Use an anti static wrist strap i e EnerSys part number 174 2 1 when handling removing and CAUTION replacing circuit board assemblies Please follow these steps to remove a PC board Be sure your hands are clean before touching a PC board 1 Turn the AC power OFF 2 Unplug the battery 3 Touch your finger to a ground to remove any static charge 4 Unplug the connectors from
73. attery charger read all instructions cautions and warnings on the battery charger the battery and the product using the battery Read and understand all setup and operating instructions before using the battery charger to prevent damage to the battery and to the charger Do not touch non insulated parts of the output connector or the battery terminals to prevent electrical shock During charge batteries produce 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 space 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 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 Only factory qualified personnel can service this equipment For service contact the nearest EnerSys Battery authorized representative 1 866 443 9433 De energize all AC and DC power connections before servicing the charger The charger is not for outdoor use Do not expose the charger to moisture Operating conditions should be 0 to 104 F 0 to 70 relative humidity Do not operate the charger if it has been dropped received a sharp hit or otherwi
74. attery voltage to determine that the battery is within the charging range The control circuitry begins constant current control by measuring the voltage across the shunt This measurement is used as the current feedback signal for controlling the phase angle at which each of the three SCR Diode Blocks are gated on The higher the feedback signal the more the SCR Diode Blocks are retarded and the shorter the SCR Diode Block gate pulse in order to maintain current Conversely the lower the feedback signal the more the SCR Diode Blocks are advanced and the longer the gate pulse in order to maintain current control Loss of the feedback signals can cause one of several faults described in the Error Messages section A similar operation occurs during constant voltage control When the gassing voltage point is reached constant voltage control begins and the voltage across the battery terminal is measured This measurement will be the new feedback signal which is used to control the phase angle at which each SCR Diode Block is gated on When finish rate current is reached constant current control resumes but at a substantially lower current level SELECT DISPLAY FRONT CONTROL PANEL O DALY There are five push buttons seven LEDs Light Emitting Diodes and a iude EQUALIZE EQUALIZE display screen on the charger s Front Control Panel mew REFRESH FAUT 5 STOPITEST Front Control Panel Push buttons
75. ave loose shunt wires c The charger may have battery polarity reversed d Verify that the shunt element jumpers JP5 are in the proper position e Verify that the start rate current is set properly charger parameter 1 f Worn connectors on DC cables If the charger is faulting 5 5 5 5 6 6 6 6 or 7 7 7 7 and charger parameter 10 charge time limit is set to 6 hours Is the battery gt 125 of nameplate AH Try changing charger parameter 10 to a larger number If every time a charge cycle begins there is a phase loss as the charger tries to start up and then the charger appears to correct itself LEDs blinking indicating a fault detection then a fault correction a The 2 lugs at the bottom of each input fuse may not be secured properly under the screws b The transformer double wires for example wires 2 and 5 may not be properly inserted into the AC terminal blocks To protect from overcharging be sure that a Start rate and finish rate currents are set properly charger parameters 1 and 3 b Gassing voltage point charger parameter 2 is not set too high should be set to 2 38 volts per cell c Time limits charger parameter 10 are set properly d Refresh charger parameter 7 is not too frequent gt 4 to 1 ratio 1 hr charge To protect from undercharging be sure that a Finish rate current charger parameter 3 is not set too low finish rate 4 596 rated capacity of the battery b Start
76. battery from the charger cycle AC fLt Occurs when AC fuse is blown or a phase of Call Service NO Can be reset by disconnecting AC power is interrupted Bar Graph Steady On battery from the charger Disconnect AC power amp check AC source MULTIPLE BATTERY SELECT A total of 5 completely different battery profile selections for both USER and SER parameters can be chosen The default for the charger is to have this feature shut off so that only a single battery selection can be made Multiple battery selection can be enabled in service parameters ADJUSTING SETTINGS USER PARAMETER CONFIGURATION The chargers user parameters may only be configured while the charger is in idle mode Press the EQUALIZE pushbutton and hold for approximately 5 seconds parameters skip the following paragraph ADJUSTING BATTERY SELECTION With Multiple Battery Select Enabled After holding the EQUALIZE pushbutton in for 5 seconds the display will read UsEr and is now ready for battery selection Release the EQUALIZE pushbutton the display now reads Set Use the UP and DOWN arrows to scroll through the battery selection from 1 5 By selecting a different battery an entirely new set of charging parameters can be selected while saving the previous setting Contact your local sales service representative to install alternate battery settings When the correct battery is chosen press the START STOP pushbutton to exit the selection proce
77. c mode The range is ON or OFF The factory setting is OFF 4 T V TERM Enables Time Voltage charge cycle termination This termination method determines the amount of time after the Gassing Voltage point is reached that a charge cycle will take Program Level parameter POST 80 specifies when the charge cycle will terminate The range is OFF or ON The factory setting is ON 1 15 POST 80 For Time Voltage termination specifies the amount of time remaining in a charge cycle after the Gassing Voltage 8096 point is reached To turn on Time Voltage termination set Program Level parameter T V TERM to ON The range is 00 00 to 18 12 16 DVDT TERM Enables DV DT charge cycle termination This termination method is based on the battery voltage desired Program Level parameter DV DT SP is used to determine when the charge cycle will terminate The range is OFF or ON The factory setting is ON 17 DV DT SP Note Consult Technical Support before changing this parameter To turn on DV DT termination set Program Level parameter DVDT TERM to ON The range is 00 01 to 02 00 The factory setting is 00 15 18 AHRS TERM Enables Amphours Returned termination This termination method is based on the number of AH returned to the battery Program Level parameter TERM AHS specifies when the charge cycle will terminate The range is OFF or ON The factory setting is OFF 19 TERM AHS For AH termination specifies the number of AH put back in a battery When
78. ce Level parameter MANUAL OP the charger will automatically perform an Equalize charge cycle when CHG CYCLE equals the Equalize counter User Level parameter After an Equalize charge cycle is performed CHG CYCLE resets to 1 The Equalize counter remains the same The range is 01 to 99 The factory setting is 01 Counts the number of charge cycles started It does NOT count restarts This parameter is resettable The range is 00000 to 32767 The factory setting is 00000 DC cable length in inches used to determine the voltage at the battery The charger calculates the voltage drop across the cable and compensates for it The calculation is based on the CABLE parameter and the assumption that the cable size is the same as the original cable supplied by the factory The range is 0 to 3816 The factory setting is 156 Note The factory setting of 156 includes 8 feet 96 of charger cable and 5 feet 60 of cabling on the battery If the charger or battery cables are different the cable parameter should be changed The display period of each variable during a charge cycle minutes seconds The range is 00 01 to 05 00 the factory setting is 00 02 Display period when the Up or Down Arrow push button is pressed minutes seconds The range is 00 01 to 05 00 The factory setting is 00 04 Allows a user to override a delayed start User Level parameter SET DELAY by pressing the Start push button The range is ON or OFF The factory setting
79. charge cycle UNTIL specifies the exact time of day that the charge cycle will begin Also SET DELAY can be turned ON and OFF To turn SET DELAY on or off or to change WAIT or UNTIL please follow these steps 1 Press the Select push button to enter the User level 2 Use the Up and Down Arrow push buttons to scroll through the variables until SET DELAY displays 3 Press the Select push button if you want to turn SET DELAY on or off or to change WAIT or UNTIL Press the Equal push button to return to Display mode After the Select push button is pressed DELAY OFF or DELAY ON will be displayed 4 Use the Up and Down Arrow push buttons to scroll through these options Delay On Delay Off 5 To turn off Automatic delay put DELAY OFF in the display and press the Select push button DELAY IS OFF will display until you release the push button then DELAY OFF will return to the display This resets the delay settings to their default values Press the Equal push button twice to return to Display mode 6 To turn on Automatic delay or to change WAIT or UNTIL put DELAY ON in the display and press the Select push button DELAY IS ON will display until you release the push button UNTIL will display when you release the push button Use the Up and Down Arrow push buttons to scroll through the Delay parameters Until Wait 40 Load Hog Control Board a When the parameter you want to select or program is displayed p
80. cle 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 24 hours This is a configurable parameter consult your service representative for more information COOL DOWN When a 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 c o o L in section User Parameter Configuration The factory default setting for the Cool Down is 1 hour PARALLEL CHARGING OPTIONAL In parallel charging batteries must have an equal number of cells and must match the charger nameplate s ratings Amp Hour rating of charger must be equal to the Amp Hour of both batteries combined Theoretically charging current is equally divided between both batteries provided that batteries percentage of discharge and ages are equal Make sure both batteries are connected before charge cycle starts The charger must be set for parallel cable and have Auto Cell sizing disabled in the service settings Contact your sales service representative 55 D3G Control Board SERIES CHARGING OPTIONAL In series charging the voltages of both batteries add up and must match charger s nameplate rating Charger s Amp Hour rating must be equal to each of the batteries Amp Hour rating Charge cycle will not start unless both batteries are connected AC DISCONNECT
81. ct pushbutton again to save the current setting in the display and to return to the User level After completing the User level adjustments press the Stop pushbutton to exit or continue to the next option by the Up or Down Arrows 02 Equalize Counter Option This option is only functional when the charger is set to Automatic User level option 03 The Equalize Counter option determines which charge cycle will be an equalize cycle For example if the Equalize Counter option is set to 5 every fifth charge cycle will be an Equalize charge cycle If this option is set to 1 and equalize will automatically occur every charge cycle when the charger is in Automatic mode If this option is set to 0 automatic equalize is disabled In order to begin an equalize charge the Equalize pushbutton must be pressed The cycle counter charger parameter 6 increments each time a charge cycle successfully completes unless the time spent in start current mode is less than 1 hour When the cycle counter and the Equalize Counter option contain the same value an Equalize charge cycle is performed and the cycle counter is reset to 1 The charger display shows the Equalize counter in the format The range is 0 to 20 The factory setting is 5 Changing Equalize Counter To change or view the Equalize Counter option enter the User level and have the display contain 02 Press the Select pushbutton The current setting of Equalize Counter will appear in
82. d protecting the battery from being overcharged There will be a random delay before restart 30 seconds to 10 min If the battery is disconnected during a charge cycle The charger turns off and fault code 1 1 1 1 will usually appear on the display To stop an equalize cycle when the Equalize LED is lighting steadily Push the Stop push button and unplug the battery DC cables that are longer than the 8 feet standard will cause a voltage drop of about 1 2 volts per 10 feet at start rate Use the next larger size of cable for every additional 10 feet of cable used 26 Load Hog Control Board LOAD HOG CONTROL BOARD Two types of control boards are available for 3 phase SCR chargers The Operating Instructions are different depending on the control board In addition settings are referred to Flooded Cell typed batteries unless otherwise defined and marked with Sealed Cell settings Operations of the PCB remain the same for either Flooded or Sealed Cell within each type of control board NORMAL CHARGER OPERATION LT2 and LTC2 are factory set for Flooded And SLT2 and SLTC2 are factory set for Sealed Reference the following flowchart for a Charge Cycle in Automatic Mode When a battery is connected to the charger the charger goes through an examining period and determines the battery cell size to begin normal charging The charger s control circuitry measures the battery s voltage to determine if the battery is within the char
83. d Down Arrow pushbuttons to do this Example The charger nameplate rating is 18 cells The charger is connected to a group of 16 cells The meter reads 34 2V 34 2 divided by 18 equals 1 90 Set the display to 1 90 Press the Select pushbutton to save the data and exit this mode Note the charger will only output current if less than 1 00 volt cell is applied to the charger 16 D3E2 Control Board Calibrating the High Voltage Setting Mode 04 Follow these steps before trying to calibrate this mode Connect a battery or a group of cells that can reach 2 5 v c to the charger NOTE Do NOT use a partially discharged battery The charger will attempt to force the battery to 2 5 by means of a high current Connect your meter to the Positive and Negative terminals in the charger to measure voltage Press the Up or Down Arrow pushbuttons to go to 04 Press the Select pushbutton to activate the mode After the Select pushbutton is pressed the charger will output current and try to bring the battery voltage up to 2 5 v c When the meter reading becomes stable calculate v c This is done by dividing the voltage the meter shows by the number of cells indicated on the charger nameplate Change the value in the display so it contains the v c calculated Use the Up and Down Arrow pushbuttons to do this Press the Select pushbutton to save the data and exit this mode Note The charger will only output current if less than 2 50 volt cell is appl
84. d correct it before resetting the Fault Condition monitor and trying to charge the battery again The Fault code is cleared by pressing the Select push button by disconnecting and re connecting the battery or by using the CLEAR FAULTS select function if that function is enabled Log Data File The Log Data file contains a history of significant charger activity All entries begin with the date and time the event happened The entries include information such as faults charger parameter changes when a charge cycle began etc There are also periodic entries every 15 minutes in the Log Data file when a battery is connected to the charger These periodic entries include date and time of the entry voltage amperage etc The Log Data file can be viewed from the display on the charger s front control panel through User Level parameter LOG DATA or it can be electronically sent to a printer or to a computer through a non isolated RS 232 serial communication link on the PC board Use Service Level parameter PRNT LINE to specify how many lines of the Log Data file you want printed When using the terminal or printer be sure to set the Service Level parameters BAUD RATE COMM FUNC and PRINT FUNC You can configure your charger to automatically output data over the RS 232 port at regular intervals the status of the charger and the charge cycle with Service Level parameter PRINTIME 37 Load Hog Control Board SAMPLE OF LOG DATA FILE 07 28
85. difying a parameter decreases the number shown in the display If pressed and held while a charge is in progress causes the value currently in the display to remain displayed The value will continue to display for a few seconds after the push button is released Select Enters the User Level parameter menu when not in a charge cycle Selects the charge parameter s to be changed It is also used to save the change and exit the Parameter Selection mode Equal Selects or deselects an Equalize charge cycle or converts a Daily charge cycle to an Equalize charge cycle In Manual mode it starts an Equalize charge cycle or changes a previously started Daily charge cycle to an Equalize charge cycle In Automatic mode it can change a Daily charge cycle to an Equalize charge cycle or vice versa If the 3 hour Equalize mode has begun the charge cycle cannot be changed to a Daily charge cycle In Parameter Selection mode it is used to exit Parameter Selection mode without saving the change made to a parameter LEDs LED Description Lights and remains on when a charge cycle begins Lights and remains on when the Gassing Voltage point is reached Lights and remains on when the charger enters Finish Current mode Equalize Blinks if a charge cycle is an Equalize charge cycle Lights steady when the 3 hour Equalize mode begins Lights steady during a Refresh charge cycle Turns off when the Refresh charge cycle is complete Complete Lights w
86. e 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 The charger can also equalize a battery manually Pressing the EQUALIZE pushbutton 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 pushbutton 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 pushbutton during the equalize charge cycle will have no effect on the charger NOTE Since Equalize charging extends the recharge 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 AC POWER FAIL AC power may fail with a battery connected to the charger during a charge cycle When AC power returns with the battery connected the charge cycle will resume the battery charging after a random delay The charger will also detect an AC fuse open resulting in a stopping of the charge and a fault code displayed REFRESH CYCLE If a battery remains connected to the charger for a predetermined amount of time after a charge cy
87. e charger has any custom settings Hold down the Select and the Refresh pushbuttons at the same time After approximately 5 seconds the display will read SErc Release the pushbuttons The display should contain 01 The Charger parameters can now be modified Use the Up and Down Arrow push buttons to access parameters as identified in the table contained in the Standard Settings section of Theory of Operation To access the parameter value indicated on the display press the Select push button To change the parameter value use the Up and Down Arrow push buttons After entering a new parameter value press the Select push button to save the new value and return to the previous level where you can choose another parameter to change NOTE An optional Edit parameter is available to reset the user and service level parameters to a default flooded cell configuration This is accomplished by decreasing the parameter from parameter 1 and setting Edit to 1 This will reset parameters to 18 cell 850 AH flooded cell battery 12 D3E2 Control Board SERVICE LEVEL PARAMETERS The standard charger setting is time voltage termination charger parameter 9 When the charger is set to time voltage termination the charger remains in start rate current charger parameter 1 until the gassing voltage point charger parameter 2 is reached Then control changes to constant voltage and maintains volta
88. e pendant 15 minutes Consulter imm diatement un m decin Seul le personnel d usine qualifi peut entretenir cet quipement Supprimer la tension des connexions lectriques alternatives et continues avant d entretenir le chargeur Le chargeur ne doit pas tre utilis en plein air Ne pas exposer le chargeur l humidit Ne pas utiliser le chargeur s il est tomb s il a recu un coup violent ou s il a t d t rior de toute autre mani re appeler ou exp dier l appareil au centre d entretien autoris EnerSys General Battery le plus proche Pour une protection continue it pour r duire le risque d incendie installer les chargeurs sur le sol ou sur un mat riau non combustible comme la pierre la brique ou du m tal mis la terre Installation INSTALLATION WARNING The shipping pallet must be removed for proper and safe operation LOCATION For maximum trouble free service choose a location that 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 Chargers are not designed to be stacked side by side due to ventilation requirements 1 Position the first charger so tha
89. e counter C XX Equalize Target E XX currents voltages and times Itis also used to change the Charger parameters While the charger is outputting current the display can be set to show the following Charger current Volts per Cell AH Returned Time on charge To see specific values in the display press the Display push button The display will show d X where X is a number between 1 and 5 The following table describes what each number corresponds to Each time the Display push button is pressed X increments Releasing the push button will cause the data corresponding to the X to display If the charger is idle then pressing and holding the Display push button will display the AH returned and time on charge What is Displayed Format Charger current in amps 000 0 Volts per cell v c 0 000 ERROR MESSAGES The charger is constantly monitored for fault conditions If a fault occurs the charge in process is terminated all data for that charge is lost and the charger display shows the fault code Error Messages Fault Code Description No current when expected Possible Causes Open DC fuse or partially melted fuse Loose connection in output string shunt cable lugs etc Battery inter cell problems Loose or missing current feedback connections at pins 1 and 2 of connector J4 No voltage when expected Possible Causes Loose Cell Size jumper JP4 Loose wire or missing connection a
90. e service COMMON TO ALL SCR STANDARD CHARGERS Part H ti Description Part Number Ref Description Number Ref Load Hog charger Door X054 99 3 3 18 kin less th n 70A fuse into 100A X014 17 6 N A D3G GTS Charger Door 05463206 18 fuse tan 40A fuse n 60A X01425 NA D3E 2 charger Door X054 99 3 4 18 Ground Lug X012 7 24 19 Top Panel X052 99 3 12 Back Panel X057 99 3 16 Board Fuses X014 7 28 12 Side Panel Left X057 99 0 5 3 Side Panel Right X057 99 0 6 2 Control Transformer If available for B models X127 61 1 N A Base 3ph Base kit 1 Control Transformer If available for models X127 61 4 N A Cross Member Heat Sink 3ph Base kite 11 Control Transformer If available for D models X127 61 3 N A Cross Member Main Transformers 3ph Base kit 6 Contactor 40 Amp If available X129 62 53 N A Upright X052 99 0 6 5 Contactor 60 Amp 1 available X129 62 54 N A Door Latch X044 1 32 N A Wire Group all SCR chargers PCB X1106 99 21 W 2 Wire Group Primary voltage all SCR chargers Bd Primary G left Main 256 99 12 15 NOTE Two sets are required when the larger X1106 99 23 W 1 ransformer te AC input is greater than 45A 7 LT2 Chargers wire group TAa 256 99 13 15 Load Hog charger ONLY ID board and X1106 99 22 additional PCB power Or LTC2 Chargers wire group DC cable clamp for
91. e to 1 Reconnect all leads exactly as they were removed 2 Replace any heat shrink tubing if any old tubing was removed 3 Retighten all connections 4 Replace covers Preparation Please follow these steps before removing or replacing any component Disconnect the battery Disconnect the AC power MAIN TRANSFORMER Use the wiring diagrams in the back of this manual to help identify wires connected to the transformer Removal To remove the transformer 1 Remove the AC input wires from the 3 terminal input blocks 2 Remove the transformer control voltage wires from the little glass fuse holder 3 Remove the secondary leads from the SCR Diode Blocks 4 In the back compartment of the charger remove the bolts as many as 6 that hold the transformer to the charger frame The transformer is heavy Use appropriate equipment to lift it Replacement To insert a transformer follow these instructions 1 Place the new transformer into the back of the charger taking care of the transformer s pigtail 2 Replace the bolts that secure the transformer to the charger frame 3 Connect the AC input wires onto the 3 terminal input blocks Do this by pre bending the wires and trimming the double leads wires 2 and 5 to the same length The purpose for doing this is so that when you install the double leads into the terminal block they both get properly secured when the screw is tightened down on them 67
92. ector type SB175 or SB350 3 Determine connector housing part number Example A charger requiring twenty feet 20 of 2 0AWG Ga cables and a SB350 RED connector the part numbers to order are 1 X225 2 0 350 20 2 6322 82 Schematics Drawings and schematics HEAT SINKS DESCRIPTION SUPPRESSOR ASSEMBLY FLAT WASHER LOCK WASHER NUT 5 16 X 2 75 BOLT 5 16 FLAT WASHER INSULATION WASHER INSULATION BUSHING 5 16 LOCK WASHER 5 16 NUT 10 X 1 25 SCREW 5 16 FLAT WASHER BRASS ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER R521 99 3 4 HEAT SINK EXTRUSION 11 X1106 99 3 1 SEE BOM SCR DIODE BLOCK 12 PROVIDED 074 2 3 10 LOCK WASHER 13 10427 75 101 41 7 10 SCREW 14 074 7 16 103 32 5 1 4 SCREW 090 2 71 BUSS BAR 15 1044 218 103 21 10 10 SCREW 090 2 73 BUSS BAR 18 055 14 074 9 3 1 4 FLAT WASHER 090 2 71 BUSS BAR 47 107426 074 7 17 10 FLAT WASHER 090 2 73 BUSS BAR 090 2 71 BUSS BAR SEE nez 090 2 73 BUSS BAR SEE BOM 19 036 99 1 074 2 5 1 4 LOCK WASHER 090 2 71 BUSS BAR 20 074 4 6 074 2 3 10 LOCK WASHER 090 2 73 BUSS BAR 21 074 2 1 007 3 51 1 4 NUT 090 2 71 BUSS BAR 22 036 4 59 007 3 41 10 NUT 090 2 73 BUSS BAR 23 015 48 006 208 1 SPACER 24 5 BOM 2 11 9B FROM XFMR 96 FROM XFMR TO DC FUSE POS 8 E G q 2 SINGLE EXTRUSION 15 16 i 15 14 17 18 DC FUSE POS gt 14 FROM BUSS BAR E 6 i zie 2 2 22 14 5 dm 7 11 n
93. ed Note that changing the setting will also change the Finish Current S Fn SEALED FINISH VOLTS 1 00 2 53 VRLA finish voltage 3 00 Vpc S Ft SEALED FINISH TIME 0 12 2 VRLA finish time hrs b AH BATTERY AMP HOURS 0 2500 850 Set battery amp hours for start rate and finish rate determination Also used for amp AH hour termination and for excessive amp hour faults MN BATTERY SELECT ENABLE 0 1 0 Battery Select Disabled must set cell size 1 Battery Select Enabled E rd RANDOM DELAY ENABLE 0 1 1 Enables Disables random delay start after an AC power outage 0 disabled 1 enabled LE DISPLAY ENABLE 0 1 1 Allows modification of Display mode in User parameters 0 disabled 1 enabled DELAY START ENABLE 0 1 1 Allows modification of Delay Start in User parameters 0 disabled 1 enabled E Co COOLDOWN ENABLE 0 1 1 Allows modification of Cooldown time in User parameters 0 disabled 1 enabled E Ec EQUALIZE COUNT ENABLE 0 1 1 Allows modification of Equalize count in User parameters 0 disabled 1 enabled totL TOTAL CHARGES 0 9999 NE Total count of every charge cycle greater than one hour that terminates normally This parameter is not modifiable DEFAULT SETTINGS 1 Remove power to the control board 2 Before applying power to the board hold down the UP and DOWN pushbuttons 3 Reapply power Hold down the UP and DOWN pushbuttons for approximately five seconds until the display reads
94. el whether you remove the hardware key or not Use the Up and Down Arrow push button to scroll through the parameters Press the Select push button when the variable to be changed is displayed Pushing the Select push button causes the present value of the variable to be shown in the display Use the Up and Down Arrow push buttons to change the value in the display Press Select to save the new value or press Equal to keep the old value and exit Variable mode When Equalize is pressed again the charger displays REMOVE PASSKEY if the hardware key was not yet removed 42 Load Hog Control Board Service Level Parameters Function Name Description CHGR AHRS Set to the charger s nameplate rating or to the AH rating of the battery being charged This parameter is the same as User Level parameter AMP HOUR RATING Changing this parameter automatically causes adjustments to be made to Service Level parameters START AMP and FINISH AMP The range is 0 to nameplate rating The factory setting is the AH nameplate rating 2 CHGR CELLS Set to the charger s nameplate cell rating This is the number of cells in a battery that your charger is designed to be able to charge This parameter is the same as User Level parameter CHGR CELL SIZE Note If this parameter is set to any other number than 6 9 12 15 18 24 36 or 40 the charger will not perform automatic sizing of the battery The range is 0 to nameplate rating 1 The range is Finish Rate
95. er 67 SCR Diode 68 Contactor if available 69 Control Transformer if available 69 PGBoald uet RP ies 69 EPROM eene sna Manas 69 VOLTAGE 71 AC Input Change Standard 71 AC FUSES nee e ee 79 AC Input Change with Quick Tap Satin 72 Charger 82 72 DRAWINGS AND SCHEMATICS REPLACEMENT 73 Heat Sink Assembly 83 Common All SCR Standard Chargers 73 Schematic Drawings 85 Replacement Parts by Control Boards 76 Control 91 Other Replacement 77 Sub Assembly Panel amp Wiring 91 Heat Sinks ayu iine etate 77 Disconnect Switch 92 DC 77 Parallel Cables Optional 93 ts u edet Ee 78 2B IMPORTANT SAFETY INSTRUCTIONS This manual contains important safety and operating instructions Before using the b
96. er It is important not to exceed any of these nameplate ratings The charger power circuitry contains a transformer that provides full isolation from the primary utility source to the secondary In the LTC2 with line contactor an AC line contactor controls power to the primary of the main transformer It is under the direct control of the control circuitry and applies power only when current is required for charging a battery In the transformer secondary there is a 3 phase bridge rectifier made up of 3 SCR Diode Blocks which converts AC to DC for charging The AC voltage of the secondary is connected directly to the SCR Diode Blocks For increased reliability there is a snubber assembly connected across each SCR Diode Block to limit the gate firing noise and high voltage spikes Each snubber assembly consists of an MOV Metal Oxide Varistor which is a device used to clamp positive or negative voltage spikes at a given level and a capacitor used to limit DV DT on the SCR in parallel The magnitude of the secondary AC voltage can be measured across the inputs of the SCR Diode Blocks and the values are listed in the troubleshooting section of this manual Each primary input line is individually fused and in some cases the charger may have been provided an optional AC fused disconnect switch This switch when it is on prevents the front door from opening The secondary DC cable is fused on the negative lead Chargers rated at 36 cel
97. er is set properly for your printer 1 Press the Select push button to enter the User level 2 Use the Up and Down Arrow push buttons to scroll through the variables until LOG DATA displays 3 Press the Select push button if you want to view the Log Data file on the display screen or send it to a serial printer Press the Equal push button to return to Display mode After the Select push button is pressed VIEW LOG will display 4 Use the Up and Down Arrow push buttons to scroll through the following Log Data file parameters View Log Print Log 5 To send the Log Data file to a printer put PRINT LOG in the display and press the Select push button LOG PRINT DONE will display when the file has been sent to the printer The number of lines of data that will print is determined by Service Level parameter PRNT LINE Press the Equal push button to stop a printout LOG PRINT ABORTD will display If the display contains LOG PRINT ABORTD or LOG PRINT DONE press the Select push button to reprint the Log Data file Press the Equal push button twice more to return to Display mode 41 Load Hog Control Board 6 To view the Log Data file on the display screen put VIEW LOG in the display and press the Select push button The display will begin to automatically scroll through the data saved during the last event To view the data use the Up and Down Arrow push buttons to access different lines entries
98. er s P N Value location 450AH 750AH X117 8 14 150A 1 0 850AH X117 99 2 150A 850AH 1050AH X117 8 15 300A 2 1000AH 1600AH X117 8 13 300A 1200AH 1700AH X117 8 16 450A 3 18 2000AH 28008 3 SHUNT MODELS D3G AND GTX Ampere hours Value Part Number 0 680 150 X117 99 2 681 1200 300 X117 99 1 1201 amp UP 2X 300 X117 99 1 78 Replacement Parts AC MODEL 208 240 480 Replacement part numbers for chargers with letter codes T X and Y shall be referred to the charger s tables with code letter B Transformer FUSES MODEL B P N 208 Volts 240 Volts 480 Volts I AC Value P N I AC Value P N AC Value P N 6 550 X127 S06 550B 7 12 X014 99 12 6 10 014 99 10 5 X014 99 5 6 680 X127 S06 680B KH 12 X014 99 12 7 12 X014 99 12 4 7 X014 99 7 6 750 X127 S06 680B 9 15 014 99 15 8 12 X014 99 12 4 7 X014 99 7 6 850 X127 S06 850B 10 15 014 99 15 9 15 X014 99 15 5 8 X014 99 8 6 950 X127 S06 1050B 11 20 X014 99 20 10 15 X014 99 15 5 8 X014 99 8 6 1000 X127 S06 1050B 12 20 014 99 20 10 15 X014 99 15 5 8 X014 99 8 6 1050 X127 S06 1050B 12 20 014 99 20 11 20 X014 99 20 6 10 X014 99 10 12 550 X127 S12 550B 13 20 014 99
99. ery and it will not automatically start a charge cycle The range is 0 to nameplate rating 1 The factory setting is the cell size nameplate rating CLEAR FAULTS Clears fault This parameter is only accessible if Service Level parameter CLEAR FUNC is or FAULTS ARE messages set to ON CLEAR LOG DATA Allows you to This parameter is only accessible if Service Level parameters LOG FUNC PRINT view or print and FUNC are set to ON the Log Data file SET CLOCK Real Time clock contains the current date month day of week day of month year and the current time hour minute NOTE The real time clock must be set for the charger to automatically perform equalize and delay functions This parameter is only accessible if Service Level parameter CLOCK FUNC is set to ON SET DELAY Delay Start Functional when the charger is set to Automatic mode Service Level Time Wait parameter manual OP Until Time Determines how long the charger will wait before beginning the charge cycle after the control circuitry determines that a battery is connected See section Setting the Delay for more information This parameter is only accessible if Service Level parameter DELAY FUNC is set to ON NOTE Wait Until Time specifies the exact time a charger will start if a battery is connected If a battery is connected after the time specified in Wait Until Time then the charge will not start The range is 00 00 to 23 59 for Wait Until Time 00 to 13
100. es The output voltage terminals can be checked during constant voltage mode The battery voltage should be steady at 2 37 1 and the charge current should gradually decrease The battery voltage can be checked during finish current mode The battery voltage should measure at least 2 37 at a constant current of 4 596 of the charger nameplate rating 62 D3G Control Board Recharge Characteristics CONSTANT FINISH VOLTAGE CURRENT START CURRENT MODE MODE MODE EQUALIZE MODE pa rr AMPS PER PERCENT OF 100 A H u RECHARGE AMP HOUR RETURNED j VOLTS Y 100 PER CELL CHARGE CURRENT AMPS 90 27 16 16 I 80 14 2 70 d E VOLTS PER CELL 25 12 60 24 10 50 237 23 8 40 6 30 45 21 4 20 2 10 0 0 TIME 0 1 2 3 4 5 6 8 9 10 11 12 13 TIME DEPENDENT ON DEPTH OF DISCHARGE START TAPER FINISH EQUALIZE p I E I EXAMPLE OF START TAPER 4 FINISH EQUALIZE TIME VOLTAGE TERMINATION 5 HOURS 5 HOURS 3 HOURS EXAMPLE OF START TAPER FINISH EQUALIZE PROPORTIONAL TERMINATION 5 HOURS 2HRS 3 HOURS 5 04 2 Testing Components all chargers The following information applies to all chargers types unless otherwise noted TRANSFORMER Please follow these steps before testing the Transformer Disconnect the battery
101. es how the charge cycle will terminate 1 Proportional 2 Time voltage Termination If this parameter is set to 1 charge termination will occur when time spent in finish current mode 40 factory setting of the time spent in start current mode If this parameter is set to 2 charge termination will occur 5 hours factory setting after the gassing voltage point is reached If this is an Equalize cycle the charging time will be the termination time specified above plus 3 hours D3E2 Control Board Display Charger General Information Number Parameter The time in start current mode Factory set to 06 00 6 hours If a battery does not accept normal charge within the time specified by this timer the charge cycle will be terminated 10 Charge Time Limit NOTE Charge Time Limit Maximum time in start current mode NOTE Charge Time Limit divided by two time limit in constant voltage mode NOTE Charge Time Limit multiplied by 2 time limit on total charge cycle The range is 00 00 18 12 The factory setting is 6 hours 11 Transformer See the table following for code numbers If your code is not listed use the default setting 1 Code Number 12 Cool Down Cool down time after the charge cycle has completed but before battery is ready to use Waiting Time NOTE While in cool down the charger cannot be restarted The display will contain COOL during this time period The range is 00 00 18 12 The f
102. function MAX CTIM specifies the time limit on the total charge cycle The range is 00 00 to 18 12 The factory setting is 07 00 43 3 START AMP Start Rate current in amps found by multiplying the battery AH by 16 START AMP will automatically be changed when Service Level parameter CHGR AHRS or User Level parameter AMP HOUR RATING is changed The charger may not be able to reach a Gassing Voltage point above 2 45 vlc at Start Rate current when low line conditions exist Load Hog Control Board Description Charge cycle time limit hours minutes The range is 00 00 to 32 00 The factory setting is 12 00 9 COOLTIME Cool down time after the charge cycle has completed output current has stopped but before the battery is ready to use The Complete LED will light after the cool down time has finished The range is 00 00 to 18 12 The factory setting is 00 00 1 10 REFS FUNC Enables the charger to automatically perform Refresh charge cycles The range is OFF or ON The factory setting is ON 11 REF WAIT Time between the end of a charge cycle and the beginning of a refresh cycle provided that the battery is left connected to the charger The range is 01 00 to 18 12 The factory setting is 12 00 12 REF TIME Time spent doing a Refresh charge The range is 00 00 to 02 30 The factory setting is 00 15 13 MANUAL OP Specifies whether the charger will run in Manual or Automatic mode ON Manual mode OFF Automati
103. ge Fault 5 5 5 5 Parameter 10 equals Gassing Voltage point 19 Charge cycle in Automatic Mode con t 80 LED lights Charger begins sending constant voltage to the battery Y User can Press the Equalize pushbutton to change charge cycle from Equalize to Daily Equalize LED stops blinking or User can Press the Equalize pushbutton to change charge cycle from Daily to Equalize Equalize LED starts blinking Finish Current Mode Charger begins sending constant current finish Rate current to the battery Y User can Press the Equalize pushbutton to change charge cycle from Equalize to Daily Equalize LED stops blinking or Press the Equalize pushbutton to change charge cycle from Daily to Equalize Equalize LED starts blinking Charge current tapers down Battery Fault 6 6 6 6 Parameter 10 2 current equals finish rate current Finish LED lights Finish current mode complete Is this an Equalize ae cycle D3E2 Control Board Fault 7 7 7 7 if total time gt Parameter 10 X 2 Equalize LED lights steady Charger continues sending constant current finish Rate current to the battery for 3 hours 20 Charge cycle in Automatic Mode con t Charge C
104. ge is ON or OFF The factory setting is OFF 4 4 44 BAUD RATE This sets the baud rate for the optional communications board value multiplied by 100 The range is 003 to 192 The factory setting is 096 PRINT FUNC Enables the serial printer The range is ON or OFF The factory setting is OFF 3 5 46 PRINTIME How often the optional printer will print monitoring data Note Service Level PRINT FUNC must be set to ON for this function to operate The range is 00 01 to 18 12 The factory setting is 00 15 15 minutes 47 PRNT LINE Number of lines of the Log Data file to be printed when PRINT LOG of User Level parameter LOG DATA is selected The range is 0001 to 1000 The factory setting is 1000 48 COMM FUNC Set to ON when a communications board is installed in the charger Note This function is not yet implemented The range is ON or OFF The factory setting is OFF a CHRG NETWK Enables the Charge network requires optional communications board and Service Level parameter COMM FUNC ON Note This function is currently not implemented The range is ON or OFF The factory setting is OFF b BAT ID FNC When ON BATT is accessible at the User Level The range is ON or OFF The factory setting is OFF c CHG ID FNC When ON CHGR ID is accessible at the User Level The range is ON or OFF The factory setting is OFF d TRCK ID FNC When ON TRUCK ID is accessible at the User Level The range is ON or OFF The factory setti
105. ge until finish rate current charger parameter 3 is reached Control then reverts back to constant current control It takes a standard period of 5 hours to get from the gassing voltage point to the end of the charge cycle not including Equalize The optional proportional termination method charger parameter 9 follows the same path but records the amount of time in start rate current The amount of time spent in finish rate current is based on the time spent in start rate current The amount of time in finish rate current is calculated by multiplying a standard 0 4 times the start rate time The proportionality is under software control and can be changed from the front panel charger parameter 14 Standard start rate current is 0 16 16 amps 100 times the amp hour rating on the charger nameplate or of the battery whichever is smaller Standard finish rate current is 0 045 4 5 amps 100 times the amp hour rating on the charger nameplate or of the battery Display Charger General Information Number Parameter 1 Start Rate Multiply the AH rating on the charger nameplate by 0 16 WARNING The start rate should never be set above the maximum DC current indicated on the charger nameplate rating Gassing Factory set to 2 38 v c In a cold environment the gassing voltage point will need to be Point higher In the charge cycle this point indicates the end of start current mode and the beginning of constant voltage mode In the c
106. ging range In LTC with line contactor the control circuitry will close the input contactor energizing the main transformer The control circuitry then begins Constant Current control by measuring the voltage across the shunt This measurement is used as the current feedback signal for controlling the phase angle at which each of the 3 SCR Diode Blocks are gated on The higher the feedback signal the more the SCR Diode Blocks are retarded and the shorter the SCR gate pulse in order to maintain current Conversely the lower the feedback signal the more the SCR Diode Blocks are advanced and the longer the gate pulse in order to maintain current control Loss of the feedback signals can cause one of several faults described in section Fault Messages A similar operation occurs during Constant Voltage control When the Gassing Voltage 8096 point is reached Constant Voltage control begins and the voltage across the battery terminal is measured This measurement will be the new feedback signal which is used to control the phase angle at which each SCR is gated on When Finish Rate current is reached Constant Current control resumes but at a lower current level In LTC with line contactor after the charge is completed the AC input contactor will open de energizing the main transformer The PC board will remain powered as long as AC input power is present FRONT CONTROL PANEL The front control panel consists of a 16 digit display 5 LE
107. harge cycle this is the current rate during finish current mode Charger AH Set to the charger nameplate rating or less depending on the battery Rating May effect volts per cell reading Cable compensation has been internally set for the charger nameplate AH rating and 8 ft of battery cable 5 Charger Cell Set to the charger s nameplate cell rating Size Cycle Increments each time a charge cycle successfully completes If less than 1 hour was spent Counter in Start Current mode then the cycle counter will not be incremented The charger s display shows the cycle counter in the format C XX If the charger is set for Automatic Equalize User level options 02 and 03 the charger will automatically perform an equalize charge cycle when the cycle counter equals the equalize counter After the equalize charge cycle is performed the cycle counter is reset to one The equalize counter remains the same Select a number a day of the week Monday 01 thru Sunday 07 The range is C71 to C 99 The factory setting is C71 7 Refresh Wait Usually set to 12 00 12 hours Period Time after a charge has completed and the battery is left connected to the charger before a refresh charge will start The recommended range is 6 00 18 12 The factory setting is 12 hours Refresh Usually set to 00 20 20 minutes Charging Time spent doing a refresh charge Time The range is 00 00 3 00 The factory setting is 20 minutes Method of Specifi
108. he charger stops applying constant voltage and returns to applying constant current finish current mode This constant current called finish rate current is specified in Charger parameter 3 FINISH CURRENT MODE NOT REACHED If the finish current mode is not reached during the time allotted specified by 1 2 of Charger parameter 10 the override timer will time out and shut down the charger The charger display will show a fault code of 6 6 6 6 FINISH CURRENT MODE REACHED If the finish current mode is reached the charger will continue charging until termination time is reached EQUALIZE MODE If this is an Equalize charge cycle the charger will complete the finish current mode and then enter Equalize mode where it will equalize all the cells in the battery It is recommended that every fifth or sixth charge cycle be an equalize cycle check with battery engineering During Equalize mode the charger applies constant current at the same rate as the current in finish current mode The Equalize mode adds 3 hours to a daily charge cycle REFRESH MODE Refresh mode will be entered after the charge cycle has completed if the battery is left connected to the charger for the period of time specified in Charger parameter 7 Refresh Wait period which is factory set for 12 hours A refresh charge assures that the battery is fully charged 17 D3E2 Control Board During Refresh mode the charger applies constant current at finish setting The
109. hen 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 The control board senses voltage Once the battery is connected to the charger the START STOP LED will flash for approximately 5 seconds while the display shows this message Strt Cell THHHE Fid 3 2 1 Strt Charging will begin The START STOP LED will light steadily 5 The LED bar graph will indicate the percent charged status of the battery and the display will now begin to show THHHE Charger output current HHHH Amp hours returned THE HH Charge Time TETHHE Cell Voltage These values are displayed in rotation for about 3 seconds each The 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 be displayed 56 D3G Control Board CAUTION To prevent arcing and 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 When the battery reaches Gassing Voltage the yellow 80 LED will light and the charge current will begin to taper After the current tapers to the finish rate current charging will continue until the battery voltage flattens or the time in taper equals 5 hours If no Equalize charge is to be ap
110. hen the charge cycle has completed there is an equalize or cool down period it will not light until they have completed During a Refresh charge cycle it will continue to stay lit Front Control Panel 28 Charge Cycle in Automatic Mode No battery connected Apply AC power to charger Y LED s blink wt Y Display through these messages CONNECT BATTERY DATE IS XX XX XX CONNECT BATTERY TIME IS XX XX XX Battery voltage less than vic Battery Battery voltage greater y voltage greater than 1 3 v c than 2 4 v c Disconnect Battery Charge cycle starts Display contains STARTING CHARGER and Start LED lights 29 Load Hog Control Board Equalize cycle Equalize LED to blink Charge cycle starts after a delay of 5 seconds or starts after the time specified in the Delay Time parameter Start Current Mode Charger sends constant current to the battery at Start Rate current and display begins to show CHARGE CURRENT VOLTS PER CELL AH RETURNED TIME OF CHARGE l User can Press Equal pushbutton to change charge cycle from Equalize to Daily Equalize LED stops blinking or User can Press the Equalize pushbutton to change charge cycle from Daily to Equalize Equalize LED starts blinking
111. ied to the charger Ending the Calibration Routine Press the Select pushbutton to save the data from the last mode you calibrated Press the Stop pushbutton to exit the Calibration routine Do NOT go back and check any of the settings The system will enter random data rather than what was just entered This random data will cause charger performance to be less than the optimum that can be obtained from a careful calibration RECHARGE CHARACTERISTICS When a charge cycle begins constant current is applied to the battery start current mode This constant current called start rate current is specified in Charger parameter 1 When the gassing voltage point 80 charge voltage of 2 38 volts cell is reached the charger stops applying constant current and starts applying constant voltage constant voltage mode GASSING VOLTAGE POINT NOT REACHED If the gassing voltage point is not reached during the time allotted specified in Charger parameter 10 which is factory set for 6 hours the override timer will time out and shut down the charger The charger s display will show a fault code that indicates a defective or mismatched battery or wrong setting 5 5 5 5 GASSING VOLTAGE POINT REACHED When the gassing voltage point is reached the override timer resets and timing begins again for constant voltage mode During constant voltage mode the current tapers down to approximately 4 5 amps per 100 AH At this point t
112. instructions within this manual for more information SCR Diode Blocks are used to control the output and yield tight regulation over the whole operating curve Line variations of 10 will have almost no effect on the operating curve All chargers are designed for convection cooling with no derating up to an ambient temperature of 40 C 104 F if properly installed per the Installation and Operating Instructions manual All models have an Equalize cycle that can be started manually or automatically Operation While charging the information about the state of charge is provided through the control board s LEDs and display Batteries rated from 64 to 200 of the charger AH rating can be charged without adjustment Batteries outside of this range can be charged when the charger is adjusted When available with the line contactor LTC2 amp SLTC2 the power transformer is only energized as needed Therefore there is a special control transformer providing power to the board before the contactor is energized This control transformer also provides 24V control for the contactor coil Refer to the schematic diagrams in the back of this manual as you read the following description The 3 phase SCR controlled battery chargers are available with several operating voltage ranges and come in 50 or 60 Hz models The voltage current and frequency ratings are specified on the nameplate located on the lower left corner in the front of the charg
113. is OFF When ON causes a random amount of time to be added to the delay time User Level parameter SET DELAY if power was lost when a battery was connected This is useful when you want your chargers to stagger their charge cycles The range is OFF or ON The factory setting is OFF 45 29 EQUAL FUNC 30 DELAY FUNC 31 BLOCK OUT FUNC 32 BLOCK OUT ENABLE 33 BLOCK OUT START 34 BLOCK OUT END 35 LOG FUNC 36 PERIOD LOG FUNC 37 CHRG GELL Load Hog Control Board Description When ON SET EQUALIZE is accessible at the User Level The range is ON or OFF The factory setting is ON When ON SET DELAY is accessible at the User Level The range is ON or OFF The factory setting is ON When ON BLOCK OUT TIME is accessible at the User Level The range is ON or OFF The factory setting is OFF Enables the BLOCK OUT TIME When ON this enables the BLOCK OUT START and BLOCK OUT END timers The range is ON or OFF The factory setting is OFF Selects the time when the BLOCK OUT TIME starts The range is 00 00 to 23 59 The factory setting is 00 00 Selects the time when the BLOCK OUT TIME ends The range is 00 00 to 23 59 The factory setting is 00 00 When ON LOG DATA is accessible at the User Level The range is ON or OFF The factory setting is ON When ON it enables periodic entries every 15 minutes into the Log Data File The Log Data File can be viewed from the charger display computer monitor or printer The range is
114. ll size reverse 50 Load Hog Control Board Troubleshooting con t hx lur Start pushbutton to override Delay Charger starts Is there any current Check battery bad fuse polarity and Display contains DC FUSECRE OREN SCR Diode Block Yes SCR Diode Block CRIDI Bad SCR Diode 7 parameters set properly for this charger and this battery No Reset Parameters Yes i No current stable 7 Yes Y EE No Check shunt match connections clean gt display shunts Yes 51 Load Hog Control Board SYMPTOMS SUGGESTIONS AND REMINDERS 1 10 11 12 If the DC fuse is continually opening a One of the SCR Diode Blocks may be defective b May have loose shunt wires c Verify that the Start Rate current is set properly Service Level parameter START AMP d Worn connectors on DC cables If the charger is faulting START TIME EXCED or MAX CHG TIM OVER and Service Level parameter MAX STIM is set to 6 hours a This may be a hot battery if it is not b Try changing Service Level parameter MAX STIM to 8 hours If every time you begin a charge cycle there is a phase loss as the charger tries to start up and then the charger a
115. llow 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 BRANCH CIRCUIT PROTECTION 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 PLUG POLARITY 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 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 THEORY OF OPERATION INTRODUCTION EnerSys SCR Battery chargers are three phase 50 or 60 Hz and SCR Diode Block controlled D3E2 and GTS2 chargers use the control board known as D3E2 LOAD HOG chargers use the control board known as LT2 D3G and GTX chargers use the control board known as D3G Refer to the control board operation
116. ls and higher will have a different style fuse designed to clear at higher voltages This will typically be a FWA style semiconductor fuse If the charger has been provided with optional parallel DC cables each of the 2 negative leads will be individually fused with a size 1 2 of the rating of a single cabled charger of similar rating PRINTED CIRCUIT BOARDS All charger functions features and controls are handled by 1 printed circuit board PC board under microprocessor control Because of its flexible design this PC board model is capable of being used on an entire range of chargers If changes are required on a board that is already installed then all adjustments calibrations and settings are made through the front panel using the push buttons and the display The specific operation of all adjustments through the front panel are described in detail in later parts of the manual The adjustments are permanently stored in an on board EEPROM Electronically Erasable Programmable Read Only Memory chip If AC power is lost while battery charging is in process data will be saved in RAM This allows the charger to return to where it left off when power is restored NOTE There are no trimming potentiometers located in this charger Operation Caution must be observed when handling or taking measurements on the PC board The control common or ground is tied to the positive battery buss This is especially important to consider when taking meas
117. mpers JP4 in the correct position consistent with the charger s nameplate Refer to the diagram following this section for location of jumpers BACK TRACE SIDE 11 Verify that the shunt size jumpers e CES JP5 are in the correct position position 1 150 amp shunt I I position 2 300 amp shunt and 3 J1 450 amp shunt See the PCB diagram for jumper locations 12 Verify that the battery has the E proper voltage rating and the JP4 12 proper hour AH rating for your charger J4 13 Verify that when a battery is connected full battery voltage appears at PC board connector J4 wires Y4 and Y3 with Y3 positive JP5 14 With the charger running verify that EPROM LOCATION the DC voltage at PCB connector 7 ON OTHER SIDE J4 wires Y1 and Y2 is the same as the DC voltage across the shunt i 10 75 mV depending the DC ow current output J7 m 15 After a charge cycle successfully ends disconnect the battery and measure the voltage across the positive and negative charger terminals This should measure less than 1 v c If it measures a greater voltage a SCR Diode Block may be leaky Test your SCR Diode Blocks as described in the Testing Components section The power circuitry is functioning properly if no problems were found when you went through the above steps If problem is still present after going through these steps look carefully for loose c
118. n Arrow push buttons to scroll through the VVR parameters i VVR CELLS ii VVR PRINT TIME 00 00 to 32 00 hours minutes iii VVR CHARGE TIME 00 00 to 32 00 hours minutes and iv VVR AMPS 000 1 to 136 0 When the parameter you want to change is displayed press the Select push button The value of the parameter is now displayed d Use the Up and Down Arrow keys to change the value in the display e Press the Select push button to save the new value you just entered or press the Equal push button to keep the old value f To change another VVR parameter repeat steps b through e g Once you have completed changing the VVR parameters press the Equal push button h Press the Equal push button 2 more times to return to the User level SERVICE LEVEL PROGRAM PARAMETERS Verify that the control board s part number for S LT2 S LTC2 is X1060 60LT 1 NOTE Refer to the Field Enhancement Upgrade decal located on the inside part of the door to see if the charger has any custom settings This level allows you to change basic charge parameters such as Start Rate current Gassing voltage point Refresh times etc A special hardware key is required to gain access to this level Enter the Service level by inserting the hardware key onto the PC board s connector J10 When the hardware key is in place the display will contain PASS KEY xxxxx You now have access to the Service level functions You will remain in the Service lev
119. n Service Level parameter REF WAIT Refresh Wait Period which is factory set for 12 hours During Refresh mode the charger applies constant current at the same rate as the current in Finish Current mode The time spent in Refresh mode is specified in Service Level parameter REF TIME Refresh Charging Time which is factory set for 15 minutes CHECKING THE RECHARGE CHARACTERISTICS You can monitor the battery voltage during Start Current mode on a discharged battery The battery voltage should gradually increase to 2 38 volts cell v c with the charging current at 16 of the battery and or charger nameplate rating Example If you are using a 550 AH charger the charging current during Start Current mode will be 16 of 550 which is 88 amperes You can monitor the output voltage terminals during Constant Voltage mode The battery voltage should be steady at 2 38 v c 196 and the charge current should gradually decrease You can monitor the battery voltage during Finish Current mode The battery voltage should measure at least 2 38 v c at a constant current of 4 596 of the charger s nameplate rating 32 Load Hog Control Board SEALED CELL CHARGERS NOTE In chargers specially configured to charge sealed cell batteries model number prefix S the following parameters have been set up Start Rate 16 0 Amps 100 A H Finish Rate 2 Amps 100 A H Gassing Point 2 37 Volts Cell Charge Time Limit 15 Hours Termination MethodTime Voltage
120. nd shut down the charger FINISH CURRENT MODE REACHED If the finish current mode is reached the charger will continue charging until termination time is reached EQUALIZE MODE If this is an Equalize charge cycle the charger will complete the finish current mode and then enter Equalize mode where it will equalize all the cells in the battery It is recommended that every fifth or sixth charge cycle be an equalize cycle check with battery engineering During Equalize mode the charger applies constant current at the same rate as the current in finish current mode The Equalize mode adds 3 hours to a daily charge cycle REFRESH MODE Refresh mode will be entered after the charge cycle has completed if the battery is left connected to the charger for the period of time specified Refresh Wait period is factory set for 24 hours A refresh charge assures that the battery is fully charged During Refresh mode the charger applies constant current at finish setting The time spent in Refresh mode is specified Refresh Charging time is factory set for 20 minutes CHECKING THE RECHARGE CHARACTERISTICS You can check the battery voltage during start current mode on a discharged battery The battery voltage should gradually increase to 2 37 volts cell v c with the charging current at 1696 of the charger nameplate rating Example If you are using a 550 AH charger the charging current during start current mode will be 1696 of 550 which is 88 amper
121. ned 34 DVIDT seen tienne 34 MESSAGES 34 Battery Not 34 Battery Connected 34 Fault Messages 36 LOG DATA FILE issir rnc 37 PROGRAMMABLE PARAMETERS 38 User Level Functions 38 SERVICE LEVEL PROGRAM PARAMETERS 42 BASIC TROUBLESHOOTING PROCEDURE 48 Troubleshooting Flowchart 50 Symptoms Suggestions amp Reminders 52 D3G CONTROL BOARD FRONT CONTROL PANEL 54 CHARGER FEATURES 54 Multiple Battery Select 2 55 Auto Start Delayed Start 55 Auto Equalize 55 Manual Equalize Cycle 55 AC Power Fail eene 55 Refresh Cycle 55 Cool DOWN 55 Parallel Charging Optional 55 Series Charging Optional 56 AC Disconnect Optional 56 AC Input Change Quick Tap Optional 56 NORMAL 56 CHARGER
122. ng is OFF 49 VRLA TERM Enables VRLA Sealed Cell termination For Value Regulated Lead Acid or Sealed Cell battery charging NOTE CHRG GELL parameter must also be set to ON The range is ON or OFF The factory setting is OFF 50 FINISH This voltage is factory set to 2 53 volts per cell This parameter is only used when VRLA TERM is set to VOLTAGE ON Once finish rate is reached battery voltage will climb to this set point Battery voltage will be held constant at 2 53 v c until TIME AFTER GAS amp TIME AFTER FIN are satified The range is 0 100 to 3 150 TIME AFTER Selects the time that the charger runs after the 8096 point has been reached GAS This parameter is a termination timer and is only used when VRLA TERM is set to ON The range is 00 01 to 06 00 The factory setting is 4 00 4 hours TIME AFTER FIN Selects the time that the charger runs after the Finish Voltage of 2 53 vpc has been reached This parameter is a termination timer and is only used when VRLA TERM is set to ON The range is 00 01 to 06 00 The factory setting is 2 00 2 hours 53 Finish Selects charge termination at start of finish phase i e at the end of taper phase Termination 47 Load Hog Control Board BASIC TROUBLESHOOTING PROCEDURE NOTE In LTC with line contactor To measure voltages the contactor must be pulled in To do this jumper Pins 6 and 7 of PC board connector J3 1 Visually inspect all connections and components for signs of overhea
123. om Connector J3 to the fuse and to the contactor Second Contactor Test Please follow these steps before testing the contactor Disconnect the battery Disconnect the AC power Disconnect J3 connector from the control board I i gt ERN 66 Testing and Replacing Components You will be testing the contactor to see if it is shorted 1 Measure in ohms the resistance at the coil connections of the contactor 2 If it measures infinity or zero replace the contactor CONTROL TRANSFORMER IF AVAILABLE Please follow these steps before testing the control transformer Disconnect the battery You will be testing the wiring of the control transformer for continuity 1 Lugs 1 through 5 are located at the front of the control transformer with lug 1 at the top 2 Lugs 6 through 10 are located in the back with lug 10 at the top 3 Measure across the lugs specified in the ID Board Previous table 4 J1 on control board Measurement Nominal charger input Vac 1096 ura 28 Vac 10 RCE 11 Vac 10 11 Vac 10 LED D3E2 GTS SERIES With no battery and the AC applied To test the LEDs push the Stop Test push button All the LEDs should light and the display should contain 8888 How to Replace Components Introduction Return all replaced components to your service center The following sections explain how to replace each component After replacing a component be sur
124. onnections If there is still a problem then the trouble is probably in the PCB or program 23 Troubleshooting Flowchart Visually inspect for signs of overheating loose connections improper connections damage Verify cell size jumpers JP4 set properly Verify shunt element jumpers JP5 set properly Y Connect AC power to charger LEDs blink then AC ON amp OFF LEDs light E Push Stop Start pushbutton isplay contains 8888 Connect battery to charger Charger Wait 5 seconds D3E2 Control Board AC present at charger No Check AC power source and AC power cables AC Sos ee alright Change bad fuse check heatsink secondary connections lt Transformer wired for applied VAC AC to charger and board on a check xfmr wiring then replace bad xfmr AC taps OK Fix AC taps Yes at Trouble is bottom of probably with fuses F5 PCB or the F8 within EEPROM range Contact Engineering Check fuses lug crimps control wiring connectors Voltages at PCB connector J1 within range DC voltage at PCB connector J4 wires Y3 amp
125. ound 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 WIRING CONN ILLUSTRATION QUICK TAP SOCKETS 9 9 9 10 6 o pm gt NO MODELB 208 240 480 MODELD 20 380 440 2 MODELJ 480 550 600 2 QUICK PLUG MAINTENANCE 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 upon the environment in which this unit is installed For service contact your sales representative or call 1 866 443 9433 UNITED STATES 1 800 693 9433 or 905 790 1212 CANADA Or visit us at our website www enersysmp com 72 technical support Replacement Parts REPLACEMENT PARTS Check the Field Enhancement Upgrade decal to see if the charger has a TDR or addendum indicating it was specially built If this information is not with this manual contact the factory NOTE When requesting assistance on replacement parts please have the model number part number and serial number ready to ensure a fast and accurat
126. plied to the battery the charger will stop and the display will read done NOTE If the battery is to receive an Auto Equalize charge the charge cycle continues for more hours at finish rate current and then stops with the reading done 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 If cool down is not selected the display will read done when the charge is complete If cool down is selected at the end of charge the display will read Cool dn for the duration of the cool down period After the cool down period has expired the display will read done When the battery is disconnected only the POWER LED remains lit and the display will alternate Conn The charge counter will increment by one for the completed charge cycle 57 CHARGER FAULTS D3G Control Board 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 Description Fault LED Fault Clearing Parameter DC FuSE Occurs when the DC fuse opens or no DC Call service YES Can be reset by disconnecting the output current Bar Graph Flashes battery from the charger Replace fuse or
127. ppears to correct itself LEDs blinking indicating a fault detection then a fault correction a 2 lugs at the bottom of each input fuse may not be secured properly under the screws b The transformer double wires for example wires 2 and 5 may not be properly inserted into the AC terminal blocks To protect from overcharging be sure that a Start Rate and Finish Rate currents are set properly Service Level parameters START AMP and FINISH AMP b Gassing Voltage point Service Level parameter 80 V CEL is not set too high C Time limits are set properly d Refresh Service Level parameter REF WAIT is not too frequent To protect from undercharging be sure that a Finish Rate current Service Level parameter FINISH AMP is not set too low Finish Rate 4 596 rated capacity of the battery b Start Rate current Service Level parameter START AMP is set to your charger s nameplate rating If the AH rating of the battery is smaller than the AH rating of the charger a Finish Rate Service Level parameter FINISH AMP and Start Rate Service Level parameter START AMP currents must be adjusted downward for the AH rating of that battery Finish Rate 4 596 rated capacity of the battery Start Rate 21696 rated capacity of the battery If the AH rating of the battery is greater than the AH rating of the charger a NOTE If the AH parameter is changed new START AMPS 16A 100AH and new FINISH AMPS 4 5A 100AH
128. push buttons to scroll through the following Equalize parameters Day Count b When the parameter you want to change is displayed press the Select push button The value of the parameter is now displayed C Use the Up and Down Arrow keys to change the value in the display d Press the Select push button to save the new value you just entered or press the Equal push button to keep the old value NOTE you set both the Equalize day and the Equalize counter parameters only the last one set will be active 4 Once you have completed changing the Equalize parameters press the Equal push button 5 Press the Equal push button once again to return to exit the User level Setting the Clear Fault Faults Are Clear Parameter To clear a fault or to verify if the fault monitor contains a fault code please follow these steps 1 Press the Select push button to enter the User level 2 Use the Up and Down Arrow push buttons to scroll through the variables until CLEAR FAULTS or FAULTS ARE CLEAR is displayed a If FAULTS ARE CLEAR is displayed then there are no faults in the fault monitor b If CLEAR FAULTS displays press the Select push button to clear the faults Pressing the Equal push button will exit you from the User level but will NOT clear the faults Viewing the Log Data File To look at the Log Data file on the display or to send it to a printer please follow these steps NOTE Verify that the baud rate Service Level paramet
129. pushbuttons to go to 03 Press the Select pushbutton to activate the mode A few seconds after the Select pushbutton is pressed the charger will begin to climb to a high current setting When the meter reading becomes stable set the display to the current reading on the meter To change the value in the display use the Up and Down Arrow pushbuttons If the value in the display requires change more than 10 check all of the shunt connections for tightness or corrosion The values measured at the high current point will be approximately 10 times the values measured at the low current point Press the Select pushbutton to save the data and exit this mode Calibrating the Low Voltage Setting Mode 02 Follow these steps before trying to calibrate Mode 02 Connect a group of cells that equal 1 0 to 2 0 volts per cell v c to the charger Connect a good quality meter to the positive and negative terminals IN THE CHARGER to measure voltage Press the Up or Down Arrow pushbuttons to go to 02 Press the Select pushbutton to activate Mode 02 sure to have the proper load connected to the charger Wait 5 to 10 seconds for the charger to stabilize if the reading is changing When the meter reading stabilizes calculate v c This is done by dividing the voltage the meter shows by the number of cells indicated on the charger nameplate Change the value in the display so it contains the v c calculated Use the Up an
130. rate current charger parameter 1 is set to your charger s nameplate rating or the AH of the battery X 16 whichever is less To protect from overcharging a If the AH rating of the charger is greater than the AH rating of the battery the start rate current charger parameter 1 should be reduced to the proper value for this battery b Finish rate charger parameter 3 and start rate charger parameter 1 currents must be adjusted downward for the AH rating of that battery Finish rate 4 596 rated capacity of the battery start rate 16 rated capacity of the battery If the AH rating of the battery is greater than the AH rating of the charger a Be sure that the start rate current CHR parameter 1 does not exceed the charger s nameplate rating b Finish rate current CHR parameter 3 will need to be adjusted upward for the AH rating of that battery Contact technical support before performing an upward adjustment on the finish rate current To stop or pause a charge Push the Stop push button and then disconnect the battery To only pause the charge leave the battery connected the charge will continue from where it left off when the charger is started again During an AC power failure Key information concerning the charge cycle is saved electronically When power returns this information is automatically retrieved and if a battery is connected to the charger charging automatically continues from where it was interrupte
131. ress the Select push button The value default or last value entered of the parameter is now displayed b Use the Up and Down Arrow keys to change the value in the display C Press the Select push button to save the new value you just entered or press the Equal push button to keep the old value 7 Press the Equal push button 3 times to exit the User level Setting the Equalize Parameter There are 2 Equalize parameters Equalize day and Equalize counter If Equalize day is set an Equalize charge cycle will begin when a charge cycle starts on the day specified in Equalize day If a Daily Charge has completed on a day other than the Equalize Day and the battery remains connected to the charger an Equalize Charge will be applied to the battery when the Equalize Day occurs If Equalize counter is set an Equalize charge cycle will begin when the Cycle counter equals the Equalize counter After an Equalize charge cycle the Cycle counter will be reset to 1 and the Equalize parameter will remain the same To change an Equalize parameter please follow these steps 1 Press the Select push button to enter the User level 2 Use the Up and Down Arrow push buttons to scroll through the variables until SET EQUALIZE displays 3 Press the Select push button if you want to change an Equalize parameter Press the Equal button to return to Display mode After the Select push button is pressed DAY will be displayed a Use the Up and Down Arrow
132. rmation described in the following table This information can be viewed whether or not the charger is in a charge cycle Charge Time Messages i ee a Messages that are always displayed during a charger cycle Message CURRENT 000 0 VOLT CELL 0 000 AH RET D 0000 CHG TIME 00 00 Time spent in the charge cycle hours minutes Messages that are added when an event occurs Message CHG 80 REACHED Begins to display when the Gassing Voltage point has been reached EQUALIZE CYCLE Begins to display when the 3 hour equalize BATT COOL DOWN Displays after CHARGE COMPLETE during a starts CHARGE COMPLETE Displays when a charge has successfully completed CHARGE STOPPED Displays when the Stop push button is pressed while a charge is in progress Additional Information Displays the battery voltage BATT CELLS 00 Displays the cell size of the battery AH RATING 0000 Displays the charger s AH setting TIME IS 00 00 00 Displays the Real Time clock NOTE A 40 cell charger will generally start up and indicate 36 cells After a few minutes of running on a discharged battery the charger will correct itself to 40 cells 35 FAULT MESSAGES Load Hog Control Board The charger s control circuitry constantly monitors for several fault conditions If a fault should occur the charge in progress is interrupted a fault message displays on the front control panel and the fault message is entered into the Log Data file Faul
133. ry GASSING VOLTAGE POINT REACHED When the Gassing Voltage point is reached the Override timer resets and timing begins again for Constant Voltage mode During Constant Voltage mode the current tapers down to approximately 4 5 amps per 100 AH At this point the charger stops applying constant voltage and returns to applying constant current Finish Current mode This constant current called Finish Rate current is specified in Service Level parameter FINISH AMP FINISH CURRENT MODE NOT REACHED If the Finish Current mode is not reached during the time allotted determined by the termination method described in section Termination Method the Override timer will time out and shut down the charger The charger will display a fault code FINISH CURRENT MODE REACHED If the Finish Current mode is reached the charger will continue charging until termination time is reached EQUALIZE MODE Equalize mode is basically the addition of 3 hours of charge If the charger is running and equalize is selected then an additional 3 hours of charge is added to the charge cycle s normal termination point If the charger s Complete LED turns on and then Equalize is selected the charger restarts and runs for 3 hours It will start in Start rate and taper to Finish as needed by the battery REFRESH MODE Refresh mode will be entered after the charge cycle has completed if the battery is left connected to the charger for the period of time specified i
134. s per cell v c NOTE The National Parts Center has meters that are appropriate for performing calibration settings NPC carries a clamp on DC ammeter and 2 types of Fluke hand held meters DVM Digital Volts Meter and DMM Digital Multi Meter The following modes can be calibrated 32012012 Low current 4032032 Hi current 02 02 Low v c 04 04 Hi v c Voltage or current can be calibrated independently Preparation To perform the calibration procedure the following Equipment is required A charged battery A set of jumper cables with alligator clips A good quality meter Verify that the following are set as indicated The AC power is ON The battery is NOT connected Set charge parameters for the charger being calibrated The cell size jumpers JP4 are properly set for this type of charger The shunt element jumpers JP5 are properly set for this type of charger Refer to the section Problem Identification and Troubleshooting for the PCB diagram showing jumper location and shunt element requirements Beginning the Calibration Routine Hold down the Select and the Equalize pushbuttons at the same time After approximately 5 seconds the display will read CALb Release the pushbuttons In Calibration mode the display will contain 01 Calibrating the Low Current Setting Mode 01 Follow these steps before trying to calibrate Mode 01 Connect a good battery to the charger The battery can be in any condition fully charged to
135. se damaged in any way 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 INSTRUCTIONS DE S CURIT IMPORTANTES 12 Ce manuel contient des informations importantes sur la s curit et le fonctionnement Avant d utiliser le chargeur de batterie lire toutes les instructions les pr cautions et les avertissements sur le chargeur de batterie la batterie et le produit utilisant la batterie Lire et comprendre toutes les instructions de configuration et de fonctionnement avant d utiliser le chargeur de batterie pour viter de d t riorer la batterie et le chargeur Ne pas toucher les parties non isol es du connecteur de sortie ou les cosses de la batterie pour viter une lectrocution Pendant la charge les batteries produisent de l hydrog ne qui peut exploser s il est enflamm Ne jamais fumer utiliser une flamme vive ou cr er des tincelles proximit de la batterie Bien a rer si la batterie est dans un lieu clos Ne pas connecter ou d connecter la batterie pendant que la sortie du chargeur est sous tension Cela pourrait d clencher un arc et br ler le connecteur entrainant des d t riorations du chargeur Les batteries plomb acide contiennent de l acide sulfurique qui cause des br lures viter le contact avec les yeux la peau ou les v tements En cas de contact avec les yeux rincer imm diatement l eau clair
136. shown on the charger nameplate DANGER POWER MUST BE DISCONNECTED BEFORE CHANGING AC INPUT CONNECTIONS N N CAUTION RY CHARG CABINET ONLY QUALIFIED PERSONNEL SHOULD ATTEMPT TO ADJUST OR SERVICE THIS BATTERY CHARGER AC INPUT CHANGE STANDARD NOTE Chargers with optional Quick Tap M 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 CAUTION Failure to perform this step may cause the Control Trans Primary fuse to open 2 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 3 Indicate the line voltage change on the decal inside the charger 3PH WIRING CONN CHART WIRING CONNECTION CHART 3 PHASE SCR CHARGERS WIRING CONNECTION CHART 3 PHASE SCR CHARGERS MODEL B MODEL J 208 VOLT INPUT 240VOLTINPUT 480 VOLT INPUT WIRE CONNECTION CONNECTION CONNECTION 480 VOLT INPUT 550 VOLT INPUT 600 VOLT INPUT D2 F1 to A1 F1 to A1 F1 to A1 WIRE CONNECTION CONNECTION CONNECTION D7 F1 to C5 F1 to C6 F1 to C6 D2 F1toA1 F1to A1 F1to A1 D3 F2 to A5 F2 to A6 F2 to A6 D7 F1to C5 F1 to C6 F1 to C6 LE
137. sible Causes Battery does not match AH range on charger s nameplate Charger s AH rating programmed wrong SCR failure during last use 36 Load Hog Control Board Message Description HIGH BATT VOLTS Displays after a battery is connected if the battery with a cell size larger than specified on the chargers nameplate is connected to the charger Displays during a charge cycle when reaches 3 of the battery cell size the charger has selected at that given time Possible Causes Wrong cell size applied to charger Old sulfated batter MAX CHG TIM OVER Failed to complete the charge cycle within the time specified in Service Level parameter MAX CTIM Possible Causes Battery AH rating may be larger than charger AH rating Battery temperature may be too high Bad cells in the battery NO BATT VOLTS No battery voltage when expected Possible Causes Loose V DC control wires START TIME EXCED Displays when the charger remains in Start Rate longer than permitted Possible Causes Battery s AH rating may be larger than the charger s AH rating Battery temperature may be too high Cell failure Failed to reach the Gassing Voltage point within 7 hours factory default setting of the start of charge CHECK SET UP Displays when a battery is connected if the battery is greater than 3 v c Possible Causes Parameters programmed incorrectly for this battery Bad connection at pins 1 and 2 of the ID board Determine the cause of the fault an
138. ss and enter into User parameters The display will now show disp 58 If multiple battery select is disabled default in service ADJUSTING USER SETTINGS With or without Multiple Battery Select Enabled For a list of available user parameters and their definitions see the table below D3G Control Board The display shows diSP You can scroll up through the different parameters by using the EQUALIZE pushbutton To adjust the user 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 Parameters DESCRIPTION Range Default Display mode 3 displays current A H returned charge time and battery voltage 2 displays current and voltage only 1 displays current only 0 displays voltage only 0 3 ad DELAYED START Amount of time delay after a battery is connected to the charger before charging proceeds Increments in 1 minute intervals 0 min 25 hr ERE CooL COOL DOWN TIME Amount of time after a complete charge cycle that a battery needs to cool down before being utilized O hr 12 hr 1 00 hr EU C
139. stopped or charge cycle terminates REFRESH Light on during refresh cycle EQUALIZE Light flashes when an equalize cycle is pending Light on during and after the actual equalize cycle Light is reset when battery is disconnected from charger BAR GRAPH Shows capacity returned to battery during charge cycle Pushbutton eee START STOP Stops a charge in progress or restarts a charge that has been stopped Can also force a charge cycle by pushing and holding for 5 seconds EQUALIZE Will activate the equalize function at any time during the charge cycle The equalize button is also used for programming the charger UP Used to scroll through charge cycle data when charger is idle Also used to scroll up through charger settings in programming mode P Used to scroll through charge cycle data when charger is idle Also used to scroll down through charger settings in programming mode D3G AND GTX CHARGERS The D3G FGTX chargers are factory set for Flooded The GTX SD3G chargers are factory set for Sealed CHARGER FEATURES GENERAL The standard D3G GTX charger has a wide range of charging features for both flooded and sealed cell batteries The D3G and GTX are capable of charging various cell sizes and ampere hour ratings as listed on the charger nameplate Some of the basic features are described below 54 D3G Control Board MULTIPLE BATTERY SELECT A total of 5 completely different battery profile selections can be stored and
140. t DC shunt Current greater than 110 of Start rate Possible Causes AC line surge Battery cell failure SCR Diode Blocks failure during last use Loss of voltage feedback signal at pins 3 and 4 of connector J4 Voltage greater than 3 000 v c Possible Causes Battery that has been sitting for months and is sulfated Finish rate set too high for the battery Wrong cell size applied to charger Cell Size jumper JP4 set incorrectly 2 2 2 2 3 3 3 3 D3E2 Control Board Description 5 5 5 5 Failed to reach the Gassing Voltage point before the Charge Time Limit was reached Possible Causes Check Gassing Voltage point and v c at the battery terminals vs the display Extended cable length from original cables This could indicate a defective or mismatched battery Make sure charger is set to the proper Start Rate not to exceed the AH rating of the charger Battery AH may be larger than the charger s AH rating Check battery temperature It may be hot Battery may have been over discharged 6 6 6 6 Failed to complete the Constant Voltage mode before 1 2 Charge Time Limit 1 2 of parameter 3110 was reached Possible Causes Check Gassing Voltage point and v c at the battery terminals vs the display Extended cable length from original cables Battery AH may be larger than the charger s AH rating Check battery temperature It may be hot Battery may have been over discharged
141. t Messages Message AC POWER FAULT CHECK AC FUSES CURRENT TOO HIGH CURRENT TOO LOW DC FUSE CBL OPEN HIGH APHR RET D Description Displays during a charge cycle when the AC line voltage falls below 1096 of the nominal line voltage Possible Causes Check the complete contactor coil string and associated wiring LTC with line contactor only AC brownout AC failure AC phase loss Bad AC fuse Displays when not in a charge cycle if the AC line voltage falls below 1096 of the nominal line voltage Possible Causes AC failure AC phase loss Bad AC fuse Displays when high DC output current is detected High Current is defined to be current that is 30 above Start Rate current during the beginning of a charge cycle or 3096 above Finish Rate current at the end of a charge cycle Possible Causes Battery problem Displays when low current is detected Low current is defined to be current that is 2096 below Start Rate current during the beginning of a charge cycle or 2096 below Finish Rate current at the end of a charge cycle Possible Causes Loose connection in output string shunt cable lug etc Battery inter cell problem Displays if current falls below the minimum setting Possible Causes The DC cable unplugged during charge DC fuse opened open or defective Loose connection in output string shunt cable lugs etc Battery problem Displays when more than 22096 of the amp hours have been delivered to the battery Pos
142. t a minimum of 6 inches of space is between the charger and any wall and 12 inches between the charger and any other equipment 2 Place the second charger on top of 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 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 4 Repeat steps 2 and 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 LB 104 F 40 C ELECTRICAL CONNECTIONS To prevent failure of the charger be sure it is connected to the correct line voltage ON THREE PHASE UNITS Connect all the charger as follows Phase A to L1 fuse block Phase B to L2 fuse block Phase C to L3 fuse block TWO STACKED CHARGERS RIGHT SIDE VIEW Installation CONNECTING INPUT POWER WARNING Make sure the disconnect is in the OFF position 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 Fo
143. those on the following tables If a DC fuse has opened check a Battery and charger connector polarity b Loose DC assembly C Shorted SCR Diode Block If an AC fuse has opened check a Transformer taps b Shorted SCR Diode Block and C current balance between the 3 SCR Diode Blocks check with a clamp on AC ammeter All currents should be within 1096 of each other If any SCR Diode Block is zero an open component or loose connection may exist Verify that the battery has the proper voltage rating and the proper ampere hour AH rating for your charger s range Verify that when a battery is connected to the charger full battery voltage appears at PC board connector J4 pins 1 and 4 with pin 4 positive With the charger running verify that the DC voltage at PC board connector J4 wires Y1 and Y2 is the same as the DC voltage across the shunt 10 75 mV depending on the DC current output Do not try to measure battery voltage between Pins 3 and 4 of Connector J4 Shorting these pins is the same as shorting the battery terminal After a charge cycle successfully ends disconnect the battery and measure the voltage across the positive and negative charger terminals This should measure less than 5VDC If it is 5VDC or greater an SCR Diode Block may be leaky Test your SCR Diode Blocks as described in the Testing Components section The power circuitry is functioning properly if no problems were found after going
144. through the above steps If a problem is still present after going through these steps look carefully for loose connections there is still a problem then the trouble is probably in the PC board or program 48 Load Hog Control Board Terminals AC Line Voltage volts on each phase 480 Vac 60 Hz 600 Vac 60 Hz 440 Vac 50 Hz 1 4 32 10 25 10 60 10 5 240 10 300 10 220 10 4 NOTE These values are dependent upon the actual line voltage 208 10 275 10 160 10 Connect Bottom of these Fuses AC Line Voltage volts Fuse F8 to Fuse F7 10 10 Wires AC Line Voltage At J2 volts NOTE These values are dependent upon the actual line voltage SCR Diode Block Input Voltages Measure between These SCR Diode Blocks AC Line Voltage Left SCR Diode Block to center SCR Diode Block 2 35 v c AC 10 Left SCR Diode Block to right SCR Diode Block 2 35 vic AC 10 Center SCR Diode Block to right SCR Diode Block 2 35 vic AC 10 NOTE These values are dependent upon the actual line voltage NOTE 2 35 v c AC multiplied by the number of cells total AC voltage J11 Printed Circuit Board JA i J6 PASSKEY J5 J3 49 Load Hog Control Board Troubleshooting Visually inspect for signs of overheating loose connections improper connections damage Connect AC power power present at charger
145. time spent in Refresh mode is specified in Charger parameter 8 Refresh Charging Time which is factory set for 20 minutes CHECKING THE RECHARGE CHARACTERISTICS You can check the battery voltage during start current mode on a discharged battery The battery voltage should gradually increase to 2 38 volts cell v c with the charging current at 16 of the battery and or charger nameplate rating Example If you are using a 550 AH charger the charging current during start current mode will be 16 of 550 which is 88 amperes The output voltage terminals can be checked during constant voltage mode The battery voltage should be steady at 2 38 v c 1 and the charge current should gradually decrease The battery voltage can be checked during finish current mode The battery voltage should measure at least 2 38 v c at a constant current of 4 5 of the charger nameplate rating Recharge Characteristics Flooded Cell CONSTANT FINISH VOLTAGE CURRENT START CURRENT MODE MODE MODE EQUALIZE MODE a Gae e AMPS PER PERCENT OF 100 A H u RECHARGE AMP HOUR RETURNED VOLTS Y 100 PER CELL CHARGE CURRENT AMPS 90 2 7 16 16 80 14 70 VOLTS PER CELL 25 12 60 24 10 50 23876 28 8 40 6 La 21 4 j 20 2 10 0 0 TIME 0 1 2 2 4 2 6 7 8 9 10 Tt 12 13 TIME DEPENDENT ON DEPTH OF DISCHARGE START T
146. ting loose connections improper connections or damage Don t forget the transformer terminal strip connections Verify that the transformer AC taps are in their proper positions Measure and verify the transformer voltages All values should be within 1096 of those in the next 3 tables Readings of the phases should be within 1 596 of each other For example the value measured between terminals 2 and 3 for Phase A Phase B and Phase C must all be within 1 596 of each other Also measurements between terminals 1 and 2 should be the same as measurements between terminals 4 and 5 measurements between terminals 2 and 3 should be the same as measurements between terminals 5 and 6 etc NOTE f a transformer is replaced make absolutely sure that power wires 9B and 9 and control wires 7A 7B and 7C are connected to the proper locations per the schematic wiring diagram NOTE Steps 4 5 and 6 determine whether the transformer and associated wiring is functioning properly 4 10 11 WARNING 12 Measure and verify the voltages at the bottom of fuses F5 F6 F7 and F8 These fuses are located in the upper left corner top row of fuses The leftmost fuse is F5 All values should be within 1096 of those on the following tables Measure and verify the voltages at connector J2 All values should be within 10 of those on the following tables Measure and verify the voltages of the heatsinks All values should be within 1096 of
147. troubleshoot OPEn batt Occurs when a charging battery is Battery Disconnect YES Can be reset by connecting a disconnected from the charger without first Bar Graph Steady On battery to the charger stopping the charge cycle t 1 Err Occurs when the time limit to gassing voltage Time Limit Exceeded Can be reset by disconnecting the is exceeded Bar Graph Steady On battery from the charger t 2 Err Occurs when the overall charge cycle time Time Limit Exceeded Can be reset by disconnecting the limit is exceeded Bar Graph Steady On battery from the charger t 3 Err Occurs when the time limit after gassing is Time Limit Exceeded Can be reset by disconnecting the exceeded Bar Graph Steady On battery from the charger Lo batt Occurs when the battery is first connected Call Service NO Reset if battery voltage is between and the voltage is between 1 0 and 1 8 Bar Graph Steady On 1 8 and 2 4 volts cell volts cell Hi batt Occurs when the battery is first connected Call Service NO Will automatically reset if battery and the voltage is above 2 4 volts cell Bar Graph Steady On voltage is between 1 8 and 2 4 volts cell Hot batt Occurs when there is negative change in Call Service NO Can be reset by disconnecting the battery voltage Bar Graph Steady On battery from the charger High AH Occurs when more than 150 of battery Call Service NO Can be reset by disconnecting Amp Hours are returned during the charge Bar Graph Steady On
148. ug 20 DC output cables and clamp W 1 Wire Group Primary Voltage W 2 Wire Group PC Board W 3 Cable Connect Heat Sink amp Shunt See Heat Sink 74 Replacement Parts by Control Board 75 Replacement Parts by Control Board REPLACEMENT PARTS BY CONTROL BOARD Control Board Fuse F5 F8 X014 7 28 item 12 D3G GTX CONTROL BOARD X1060 04 D3G 1 STANDARD MODELS DEPTH RENEGADE CONTROL BOARD PC BOARD S D3E2 amp F GTS2 X1060 58 1 Standard Models X1060 58 3 All 54 cell X1060 58 4 All 40 cell X1060 58 5 All 60 cell X1060 58 6 64 cell Standard models with 1050558 Opportunity charging DEPTH RENEGADE DISPLAY BOARD X1060 58 10 LOAD HOG CONTROL BOARD Attention LT2 series chargers have a brand new Load Hog PCB part number Old control board will not operate LT2 charger series DESCRIPTION PIN MODEL S LT2 amp S LTC2 PCB X1060 60LT 1 Standard Models X1060 60LT 99 Standard model w Opportunity charging X1060 60LT 3 Discontinued models 12 680 18 550 PCB 3 AUXILIARY X1060 78 1 Only for 36 40 850D PCBID X1060 61 1 0 X1060 61 6 24 1000 X1060 61 10 12 850 10650817 1060 61 3 MTS X1060 61 8 24 1600 X1060 61 4 18 1000 X1060 61 9 24 680 X1060 61 5 18 16
149. uity tester with 2 AA batteries in it to do this Please follow these steps 1 Disconnect the three phase input wires to each of the SCR Diode Blocks 64 Testing and Replacing Components Disconnect the nylon connector from the SCR Diode Block gate drive Connect the negative potential of your tester to the positive bussbar Connect the positive potential of your tester to the input connection of the SCR Diode Block under test Then by using a jumper wire touch the SCR Diode Block gate pin white lead connects there to the SCR Diode Block input connection The tester will light NOTE If your tester lights before connecting to the SCR Diode Block input then the SCR Diode Block is defective Test one SCR Diode Block at a time to find the faulty one s a Disconnect the jumper wire to the SCR Diode Block gate pin The tester should remain lit b The SCR Diode Block is defective if the tester did not remain lit DIODE TEST Please follow these steps before testing the diode Disconnect the battery Disconnect the AC power You will be testing the diode to see if it is shorted Disconnect the three phase input wires to the SCR Diode Blocks Use an analog meter set to its X1 scale or use a DVM set to its diode scale Connect the meter s negative lead to the input connection of the SCR Diode Block Connect the meter s positive lead to the bussbar If you are using an analog meter it should read close to 0 ohms If you are using a DV
150. urements on the board while it is operating Note Load Hog 40 850D models have been specially configured with an auxiliary circuit board to adjust the control sense winding voltage to the proper level for the main control circuit board CONTROL CIRCUITRY The control circuitry measures current via the precision shunt located in the positive lead of the charger DC Voltage is measured by means of a precision resistor circuit ME Under no circumstance should the starting current be adjusted to higher than the charger s WARNING Tu ampere hour nameplate rating times 0 16 or overheating of the charger will occur The control circuitry has three phases of charge cycle But when set for SEALED it has four 1 Constant Current control at the start current setting and at the finish current setting and 2 Constant Voltage control at the Gassing Voltage 8096 point setting 3 Constant current at finish rate 4 Finish voltage will not exceed 2 53VPC SEALED configuration only These modes of operation are determined by the recharge characteristics described in the following sections The control circuitry is connected to 3 small windings off the main transformer through connector J2 The value of these AC voltages can be found in the troubleshooting section of this manual These windings serve several purposes 1 Provide the signals which enable the control circuitry to synchronize and determine the proper phase angle to gate on each S
151. ycle Complete Charge cycle is done Charger stops sending current to the battery Refresh LED begins to blink D3E2 Control Board Y Y User can press the Equalize User i press pushbutton to start the Refresh an Equalize pushbutton to start a Refresh chage cycle charge cycle Equalize previously performed Yes No Time battery remained connected equals time specified in parameter Refresh Wait Period Equalize LED lights steady Charger sends constant current Finish Rate current to the battery for 3 hours Charger will not start NOTE Charge cycle can be terminated at any time by pressing the stop test pushbutton No Press and hold Display pushbutton to obtain AH returned and charge time 21 Refresh LED lights steady k Charger outputs current at Finish Rate current Time spent in Refresh mode equals Time specified in parameter Refresh Charging Time AA 7 Disconnect Battery Display shows C XX and E XX D3E2 Control Board BASIC TROUBLESHOOTING PROCEDURE 1 Visually inspect all connections and components for signs of overheating loose connections improper connections or damage Be sure to include the transformer terminal strip connections

Service Manual, I.B. 1510 - Industrial Batteries and Chargers

Contents

Download Pdf Manuals

Related Search

Related Contents