Exide DEC200 User's Manual
Contents
1. INDUSTRIAL POWER A Division of EXIDE Technologies DEC200 SERIES INDUSTRIAL BATTERY CHARGER 180 MANUAL TABLE OF CONTENTS TITLE Page 1 Important Operating Instructions 2 2 Introduction 3 3 Receiving Instructions 3 4 Location and Installation of Charger 3 5 Stacking 3 4 6 Electrical Supply 5 8 6 1 Branch Circuit Protection 5 6 2 AC Voltage Connections 8 6 3 Ground Connection 8 7 DC Output 8 8 Fault and Display Codes 8 9 DEC200 Standard Charger Operation 9 10 Charger Functional Description 10 10 1 LED Descriptions 10 10 2 Pause Push Button 10 10 3 Smart Start Stage 10 10 4 Auto Balance 10 10 5 Equalize Stage 10 10 6 Equalize Pushbutton 11 10 7 Low Battery Override Recovery 11 10 8 Incorrect Battery Limits 11 10 9 AC Power Failure 11 11 Maintenance 12 Appendix A Fault Codes 13 Appendix DEC200 Troubleshooting 14 Appendix C Technical Data 15 Appendix D Circuit Diagrams 16 17 Appendix E Cabinet Dimensions 18 Sales e Service e Recycling 1 888 563 6300 DEC200 SERIES INDUSTRIAL BATTERY CHARGERS 1 IMPORTANT OPERATING AND SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS a Before using the battery charger read all the instructions in addition to the CAUTION WARNING and DANGER markings on the charger battery and all the associated equipment b Do not touch un insulated parts of the DC output connector or the battery terminals as there2. For 480V input connect to 480V connections on T1 DRAWING No 4 CMP 2600 01 WD E 4 CMP 2600 01 WD E If any errors are apparent within this diagram please inform CMP EXIDE CMP Batteries Ltd 13 12 02 Pe C000007 B Materials White Polypropylene 60u PP198 Charger Division Unit 2 Pisces 2 Trafford Park 191203 000045 oe Manchester Text As shown Sales e Service e Recycling 1 888 563 6300 16 APPENDIX D Component No DRAWING TITLE CLT6005 GNB UL Single phase wiring diagram Fuse Breakers BLUE For 120V input connect to 120V BLACK connections on T1 BROWN GREY RED WHITE YELLOW GREEN For 208V input connect to 208V connections on T1 For 240V input connect to 240V connections on T1 For 480V input connect to 480V connections on T1 DRAWING No 4 CMP 2600 02 WD E If any errors are apparent within this EXIDE diagram please inform CMP 000007 Materials White Polypropylene 60u PP198 Charger Division V Trev Peacock 17 04 03 Unit 2 Pisces Trev Peacock 000044 Clear Overlaminate 60 20 Mosley Road 51 4 Trafford Park Sales e Service gt Recycling 1 888 563 6300 17 DIMENSION APPENDIX E DIMENSIONS DIMENSION C DIMENSION D DIMENSION E MOUNTING HOLES
3. ic patery Failure matched to battery Check battery condition Contact your local GNB Industrial Power Motive Power representative F10 Second Stage I2 limit not reached within time limit Check battery condition Time Out Contact your local GNB Industrial Power Motive Power representative F11 ie mals Check the mains supply requency Board 12 Failure Contact your local GNB Industrial Power Motive Power representative Temperature F13 Sensor Failure Contact your local GNB Industrial Power Motive Power representative Auto Balance is F17 Stage Time Out Check battery condition F16 Battery Check battery for High Temperature Allow battery to cool Check battery Overheating condition Confirm charger capacity is correctly matched to battery Battery F18 Press the PAUSE button before disconnecting the battery Disconnection F22 Check battery condition Battery Sales e Service e Recycling 1 888 563 6300 14 APPENDIX C TECHNICAL DATA ode be 3 eli D D 9 92 4 aes 0 0 08 40 480 abine gle Phase O O O a a a e b DEC200 24V 40AS1H 330 400 470 24 40 11 4 9 8 4 9 M4 94 8 43 DEC200 24V 75AS1H 625 750 880 24 75 21 3 18 4 9 2 M4 134 61 DEC200 24V 95AS1H 790 950 1120 24 95 27 23 4 11 7 M4 145 66 DEC200 24V 115AS1H 955 1150 1350 24 115 32 6 28 3 14 1 M4 163 74 200 24 135 1125 1350 1590 24 135 38 3 33 2 16 6 4 169 77 DEC200 36V 75AS1H 625 750 88
4. The charger should be located in a clean cool normal ambient room temperature between 32 F 0 C and 104 F 40 C dry and well ventilated area In order to permit free air flow for convection cooling allow four inches minimum between the charger and any wall six inches from other equipment and never store anything beneath or on top of the charger STACKING The following recommendations should be taken into consideration when stacking these units a The base unit should be secured to the floor or a solid base using appropriate bolts and with accordance to local building codes and regulations b These units can be stacked to a maximum 3 high c Ifa lifting sling is used the sling should be placed under the unit where the base plate is located to avoid damage to the units Lifting Sequence is as follows a Secure the base unit to the floor or solid base The bolts can be accessed and secured from the underside of the unit at the front and rear or from inside the unit where the large holes are located directly above mounting holes see appendix G for mounting hole locations When accessing the mounting holes from the inside it is recommended you use a long handle hexagon key or screwdriver with the hexagon key inserted This will allow you to go through the base plate to the bolts which are located on the flange Sales e Service e Recycling 1 888 563 6300 3 b Remove the bolts from the top cover o
5. is a possibility of electric shock c Connect or disconnect the battery plug only when the charger output is off ALWAYS press the PAUSE pushbutton before unplugging the battery to prevent arcing or burning d If the battery is unplugged during charging the charger will indicate F18 To restart the charger plug in the next battery Do not connect the next battery before you see indication or F18 e Only qualified personnel should operate or service this equipment f De energize all AC and DC power connections before servicing this unit If injury does occur apply the prescribed treatment for electrical shock and obtain medical attention immediately g The charger is NOT for outdoor use Do not expose the charger to rain or snow h This charger is factory set to charge lead acid batteries only The operating environment should not contain any materials that may cause corrosion or contamination that would degrade the performance of a charger i Do not operate this unit if it has received a sharp blow been dropped or otherwise damaged Take it to a qualified GNB Industrial Power Motive Power service center j Do not disassemble the charger Have the charger examined by an GNB Industrial Power Motive Power service representative or local qualified service facility Incorrect re assembly of the charger may result in an explosion electric shock or fire k The charger profile is set at the factory for a charg
6. 0 36 75 29 9 25 9 13 4 158 72 DEC200 36V 05ASIH 790 950 1120 36 95 37 9 32 9 16 4 4 163 74 DEC200 36V 115ASIH 955 1150 1350 36 115 45 9 39 8 19 9 M5 216 98 DEC200 36V 135ASIH 1125 1350 1590 36 135 53 9 46 7 23 3 M5 238 108 Three Phase DEC200 24V 75ATIH 625 750 880 24 75 12 11 5 3 M4 134 61 DEC200 24V 95AT1H 790 950 1120 24 95 15 13 6 7 M4 145 66 DEC200 24V 115ATIH 955 1150 1350 24 115 19 16 8 1 M4 145 66 DEC200 24V 135ATIH 1125 1350 1590 24 135 22 19 9 5 M4 180 82 DEC200 36V 75ATIH 625 750 880 36 75 18 16 7 9 M4 180 82 DEC200 36V 95ATIH 790 950 1120 36 95 23 20 10 M4 180 82 DEC200 36V 115ATIH 955 1150 1350 36 115 28 24 12 M4 209 95 DEC200 36V 135ATIH 1125 1350 1590 36 135 33 28 14 5 275 125 DEC200 36V 150ATIH 1250 1500 36 150 36 4 32 16 5 297 135 DEC200 48V 95AT1H 790 950 1120 48 95 30 7 27 13 M5 264 120 DEC200 48V 115ATIH 955 1150 1350 48 115 37 2 32 16 M5 288 130 DEC200 48V 135ATIH 1125 1350 1590 48 135 43 6 38 19 M5 299 136 DC FUSE MUST BE A FAST ACTING FUSE CAPABLE OF PROTECTING SEMICONDUCTORS Sales e Service e Recycling 1 888 563 6300 15 APPENDIX D Component No DRAWING TITLE CLT6006 GNB UL 3phase wiring diagram For 208V input connect to 208V BLUE connections on T1 BLACK BROWN For 240V input connect to 240V GREY RED connections 1 WHITE YELLOW GREEN
7. CB connections must NOT be altered from factory setting 208VAC 60 Hz CONFIGURATION 208 240 480V INPUT PCB Mains Input L Brown Black L1 N Blue Black L2 Black L3 240 60 Hz CONFIGURATION 208 240 480 INPUT Mains Input L Brown Black L1 N Blue Black L2 Black L3 480VAC 60 Hz CONFIGURATION 208 240 480V INPUT 208 240 480 208 240 480 208 240 480 PCB Mains Input L Brown Black L1 Blue Black L2 Black L3 Sales e Service e Recycling 1 888 563 6300 7 6 2 VOLTAGE CONNECTIONS connect the input AC voltage route the AC conduit through the knockout hole provided Continue the AC wiring to the breaker terminals L1 and 12 L single phase input or L1 L2 and L3 three phase input For proper connection torque the screws to approximately 25 inch pounds 6 3 GROUND CONNECTION It is a requirement to ground the chassis while the charger is connected to AC power The charger comes with a threaded M6 hole clearly marked on the chassis To ensure good continuity keep the contact area clean WARNING DO NOT OPERATE THE UNIT WITHOUT PROPER GROUNDING IMPROPER GROUNDING CAN RESULT IN THE RISK OF AN ELECTRIC SHOCK CAUTION USE MINIMUM 75 C WIRING FOR SUPPLY CONNECTIONS GROUND THE CHARGER PROPERLY USING THE THREADED M6 HOLE GND PROVIDED USE COPPER CLAD ALUMINUM ALUMINUM OR COPPER CONDUCTORS ONLY After electrical connection is compl
8. GROUNDED per the local federal Electrical Code Do not allow excessive dust to accumulate on the components inside Blow out with clean compressed air when necessary The chargers are designed with a breaker and fuse for the AC input and DC output respectively Should this fuse fail or breaker trip the cause must be determined before they are corrected or replaced Never replace the fuse or breaker with one of a higher capacity than the one originally fitted Sales e Service e Recycling 1 888 563 6300 12 APPENDIX FAULT CODES coD O STATUS DESCRIPTION Over discharged battery lt 1 90vpc after 30 seconds of charge F02 N Deep discharged battery lt 1 90 after 30 seconds of charge gt 1 90 Sulphated battery F03 N om 0 m NN 11 Incorrect Mains Frequency 12 Control hardware MCU F10 Second stage time out Profile Dependant F13 Thermistor fault F16 Battery overheating if temp probe fitted Auto balance charge time out Battery disconnected without pausing charge di dt termination critical fault gt charge stopped fault code displayed permanently S suspend fault gt charge suspended until criteria fulfilled gt fault code displayed permanently R retry fault gt charge retries after 20 seconds fault code display alternating with standard display N non critical fault gt charge continues gt fault code displ
9. MOUNTING HOLES CABINET DIM A DIM B DIM C DIM D DIM E Size M4 19 69 26 65 16 93 17 54 12 99 Size M5 23 62 26 65 20 87 21 48 16 93 Sales e Service e Recycling 1 888 563 6300 18 INDUSTRIAL POWER A Division of 105 Technologies SALES SERVICE RECYCLING 1 888 563 6300 TOLL FREE GNB Industrial Power A division of Exide Technologies U S A Tel 877 462 4636 GNB Industrial Power A division of Exide Technologies Canada Tel 800 268 2698 V19CIL5200ULD 2004 05 www gn b com
10. VPC is not reached When current is flowing amps will be displayed and the yellow LED will be illuminated When no current is flowing the display will show StSt The FUNCTION button can select charge information The green LED will remain illuminated 10 5 EQUALIZE STAGE Equalize charge consists of 12 hours at 22 of maximum output The following table summarizes the action taken when Equalize is set manually during different charge modes Charge Mode Action During recharge Equalize active after termination After charge termination Equalize active immediately Smart Start termination Equalize active after termination Sales e Service e Recycling 1 888 563 6300 10 10 6 EQUALIZE PUSHBUTTON Equalize charge can be enabled disabled when the FUNCTION button is depressed gt 5 second at anytime whilst a battery is connected Only one equalize charge per recharge cycle is permitted CAUTION DO NOT EQUALIZE MORE OFTEN THAN REQUIRED BY THE CONDITION OF THE BATTERY AS SPECIFIED IN THE BATTERY MAINTENANCE INSTRUCTIONS EXCESSIVE EQUALIZING MAY DAMAGE THE BATTERY 10 7 LOW BATTERY OVERRIDE RECOVORY 10 8 10 9 10 7 1 CONFIGURATION There is the ability to manually override the low Incorrect Battery threshold of 1 70 VPC down to a minimum of 1 00 VPC the level at which the charger will recognize a battery connection This is achieved by holding the FUNCTION push button for 5 seconds when
11. an be changed Follow Figure 1 page 6 for single phase input or Figure 2 page 7 for three phase input transformers A qualified electrical contractor should perform this adjustment 6 1 BRANCH CIRCUIT PROTECTION The charger comes with an internal supplementary protective device rated to accommodate the highest possible current and voltage for that model CAUTION REDUCE THE RISK OF FIRE USE ONLY ON CIRCUITS PROVIDED WITH BRANCH CIRCUIT PROTECTION CONSISTENT WITH THE CURRENT INDICATED ON THE FRONT PANEL RATING LABEL AND ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE ANSI NFPA 70 Sales e Service e Recycling 1 888 563 6300 5 FIGURE 1 SINGLE PHASE INPUT WARNING IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE DAMAGE TO THE CHARGER AND BATTERY NOTE Live connection L Must be connected to the breaker The mains input are the only user configurable connections PCB connections must NOT be altered from factory setting 208 VAC 60Hz CONFIGURATION 208 240 480V INPUT Mains Input Black Black L Mains Input PCB Black N N Blue Black L L Brown 480 VAC 60Hz CONFIGURATION 208 240 480V INPUT Mains Input PCB Black N N Blue L Brown Black Sales e Service e Recycling 1 888 563 6300 6 FIGURE 2 THREE PHASE INPUT WARNING IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE DAMAGE TO THE CHARGER AND BATTERY NOTE P
12. ay alternating with standard display Sales e Service e Recycling 1 888 563 6300 13 APPENDIX DEC200 TROUBLESHOOTING POSSIBLE SYMPTOM CAUSE EXPLANATION ACTION No Display No AC Power Check Input Power Check Breaker Mains fuse on Control Board F01 Battery Voltage less than 1 9 volts per cell initially but rose above this Batter level within the first minute Check battery condition and Equalize Battery less than 1 9 volts per cell after the first minute of charge Check EOE Pyer discharge battery condition and Equalize Make sure your battery gets a full charge every cycle Check battery ay SUPARA Banery condition and Equalize Charger Check Fan for operation on initial power up Ensure adequate F04 A ventilation Contact your local GNB Industrial Power Motive Power 9 representative F05 Mains Failure Electrical Supply failure during charge Power Cut F06 Check DC Fuse SCRs Connection to Battery Current Incorrect Battery Make sure the battery voltage matches the charger voltage 7 Low Voltage Check battery voltage with a voltage meter Make sure battery voltage High Voltage matches charger Battery may require servicing Check battery voltage with a voltage meter Make sure battery voltage matches charger Battery did not reach gassing volts within the time limit Check battery for low voltage Confirm charger capacity is correctly
13. er DC cable length of 9 ft anda battery DC cable length of 25 in If DC cable lengths are adjusted please contact your local GNB Industrial Power Motive Power service representative Sales e Service e Recycling 1 888 563 6300 2 2 INTRODUCTION The GNB DEC200 battery chargers are fan cooled solid state microprocessor controlled SCR regulated chargers designed to make battery charging simple They are designed to charge flooded lead acid batteries The charger has a comprehensive self checking diagnostic program to control all charger functions monitor the quality of charge and check its own safety conditions RECEIVING CHARGER Examine the charger thoroughly before using to make sure that no parts have been loosened or damaged during shipment Check the contents of the package against the delivery slip before disposing of the shipping package If any shipping damage or partial loss is found file a claim with the carrier without delay and take any necessary steps to protect your rights Before installing check that the charger nameplate data corresponds to the packing slip and to the model specified on the original sales order The DEC200 chargers are delivered on skids for easy handling using a forklift truck LOCATION AND INSTALLATION OF CHARGER Proper installation is important in order to achieve good charger performance and long trouble free operation and to prevent damage to the charger and batteries
14. eted the charger is ready for operation 7 DC OUTPUT The DC charging cable has a commonly used battery plug or receptacle The polarity of the charger plug must be the same as the battery connector The BLACK DC cable must be connected to the battery negative terminal and the RED DC cable must be connected to the battery positive terminal The charger will not operate in a reversed polarity condition The DC output fuse is a fast acting fuse used to protect the power semiconductors of a charger NOTE Use only identical replacement fuses available from your GNB Industrial Power Motive Power service representative The DC fuse must be replaced with a fast acting fuse capable of protecting semiconductors See Appendix C and D for correct fuse sizes 8 FAULT AND DISPLAY CODES Refer to Appendix A and B on pages 13 and 14 for a complete list of fault codes Sales e Service e Recycling 1 888 563 6300 8 9 DEC200 STANDARD CHARGER OPERATION DISPLAY DEFAULT TERMINATION FAULT CODE R SETTING EQUALISE EqAL for 5 seconds then default display 27 EQUALISE CHARGE A EqAL Y AUTO BALANCE StSt A SISt V G Lobt CHARGE PERIOD Lobt A Y CHARGE CONDITION FUNCTION BUTTON DISPLAY SELECTION LED Lobt OFF PERIOD Lobt V CRITICAL FAULT CODE NONE CRITICAL FAULT CODE Charge continues R A Output current F Fault code display will alternate with the two codes Ph Phase
15. f the base unit but do not discard these as they will be required to fix the two units together c Use an appropriate lifting sling to lift the second unit on to the base unit inch the second unit over the base unit and align the holes before resting the second unit on top d Secure the two units together using the bolts removed from the top cover of the base unit Use the access between the two units or inside the second unit using the tools as recommended above e If stacking three high use the above procedure for stacking the third unit WARNING THESE PROCEDURES MUST BE FOLLOWED EXACTLY TO AVOID INJURY OR RISK OF ELECTRIC SHOCK WARNING TO REDUCE THE RISK OF FIRE INSTALL BATTERY CHARGER ON A FLOOR OF NON COMBUSTIBLE MATERIAL SUCH AS STONE BRICK CONCRETE OR METAL IF THIS IS NOT AVAILABLE A FLOOR PLATE OF AT LEAST 1 43mm GALVANIZED OR 1 6mm UNCOATED STEEL EXTENDED AT LEAST 150mm BEYOND THE EQUIPMENT ON ALL SIDES MUST BE INSTALLED Sales e Service e Recycling 1 888 563 6300 4 6 AC ELECTRICAL SUPPLY The charger must be connected to either a single phase or three phase 60 Hertz 2 AC power source Three phase chargers cannot be powered with a single phase source The following transformer options are available TABLE 1 INPUT VOLTAGE CHOICES Single phase Three phase 208 240 480VAC 60Hz 208 240 480VAC 60Hz Only the AC input wire configuration for multi input chargers c
16. of charge i e 1 2 and 3 SISt Smart start LoBt low battery override Display will alternate with the two displayed information flashing LED NOTE In LoBt StSt Equalize and Termination charge function display will only be displayed for 10 seconds not permanently 3t Display if due to smart start R Red Fault flashing red is none critical fault Y Yellow Current flowing flashing yellow when lt 2 37VPC G Green charge complete Sales e Service e Recycling 1 888 563 6300 9 10 CHARGER FUNCTIONAL DESCRIPTION 10 1 LED Descriptions Yellow Flashing High Rate Creat Yellow Solid 80 Charged Green Solid Charge Complete Red Fault See page 15 for codes 10 2 PAUSE PUSH BUTTON This PAUSE push button will halt the charge cycle The battery can then be safely unplugged for up to 10 minutes If the battery is still connected after this time the charger will continue with the present charge cycle 10 3 SMART START If the time to gassing voltage 2 40 VPC is less than 30 minutes the normal charge profile will terminate and the unit will charge at constant voltage 2 35VPC until 22 of the maximum current is reached The charger will then proceed to the auto balance stage 10 4 AUTO BALANCE The charger maintains a constant current level of 22 of maximum output that is activated by voltage on at 2 20VPC and off at 2 40VPC with a time limit of 1 hour if 2 40
17. the incorrect battery fault has been detected 10 7 2 OPERATION If Low Battery Override has been enabled and a battery voltage 1 00 VPO is connected to the charger the charger will pass current at 75 of the maximum output current If less than 3 0VPC current will flow for 5 minutes and the charge will be suspended for 5 minutes The cycle is repeated until the battery voltage is greater than 1 70 VPC at the end of the 5 minute rest period If the battery voltage is greater than 1 70 VPC at the end of the 5 minute rest period the battery recovery mode will cease and charge will start from stage 1 with smart start disabled If 3 0 VPC is reached within the 5 minutes of charge the charge will be suspended equal to the on time maximum of 5 minutes During this period the display will show Lobt During the 5 minute off period the display will show the battery volts per cell alternating with Lobt INCORRECT BATTERY LIMITS Incorrect battery detection limits will be 1 70 VPC and 2 25 VPC off charge If the battery voltage comes within this window the charger will automatically commence charging AC POWER FAILURE If the AC power fails during a charge cycle the charger will resume the cycle at the point of termination as soon as AC power is restored Sales e Service e Recycling 1 888 563 6300 11 11 MAINTENANCE The charger requires minimum maintenance ENSURE THE CHASSIS IS SECURELY
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