Alpha Spectra Series User Manual
Important Safety,
Installation,
Operation andration and
Maintenance Instructions
Maintenance Instructions
Installation and Operation Manual
Spectra Series Battery Charger
Effective: March 2006
Preliminary Operating Instructions 2 of 62 AIP SERVICE NUMBER 1-800-863-3364
HOW TO READ THE ST MODEL NUMBER CONFIGURATION
The model number describes the options on the charger. Write the model number from the charger ratings specification label
in the spaces provided below. The descriptions shown below will confirm your charger’s configuration. If the charger options
are changed in the field, please make sure to tag the charger with a detailed description of the changes.
ST
A
If a space has no option selected, a zero must be inserted.
Box ST Description
A
B
C
D
E
F
Note:
* 130 Vdc; 50 Adc is not available in 120 Vac.
SAVE THIS MANUAL: Keep it in a location where it is available to anyone who may operate
B C D E F G H I J K
Box ST Description
1 1 Phase
Nominal DC Output Voltage
024 24 Vdc
048 48 Vdc
130 130 Vdc
Nominal DC Output Current
006 6 Adc
012 12 Adc
020 20 Adc
025 25 Adc
050 50 Adc *
Input Voltage
1 120
2 208 (not UL listed)
3 240
Filtering
0 Unfiltered
1 Filtered / Eliminator
Relays
0 No Relays
1 Individual Alarm Relay Contact
Board
or service the charger.
G
H
I
J
K
Remote Sensing
0 Not Supplied
1 Remote Control Panel
2 Remote Temperature Compensation
3 Remote DC Voltage Sensing
4 Lines 1 & 2
5 Lines 1 & 3
6 Lines 2 & 3
7 Lines 1, 2 & 3
Lightning Arrester
0 Not Supplied
1 Included
Charging
0 Not Supplied
1 Parallel Charging
2 Series Charging (Consult Factory)
Special Treatments
0 None
1 Fungus Proofing
2 Conformal Seal On Electronic PC
Board
3 Lines 1 & 2
Other Options
0 None
1 Lockable enclosure door
2 NEMA 4 enclosure
3 NEMA 12 enclosure
4 19” Rack flanges @ 6.0” from front
5 23” Rack flanges @ 6.0” from front
6 Lines 1 & 4
7 Lines 1 & 5
Preliminary Operating Instructions 3 of 62 AIP SERVICE NUMBER 1-800-863-3364
TABLE OF CONTENTS
HOW TO READ THE ST MODEL NUMBER CONFIGURATION ....................................................................... 3
TABLE OF CONTENTS....................................................................................................................................... 4
IMPORTANT SAFETY INSTRUCTIONS............................................................................................................. 7
1. INTRODUCTION .............................................................................................................................................. 9
2. RECEIVING CHARGER................................................................................................................................... 9
3. STORING CHARGER...................................................................................................................................... 9
4. LOCATION FOR CHARGER INSTALLATION................................................................................................ 9
FIGURE 4.0: TABLE OF CHARGER ENCLOSURE SIZES.............................................................. 10
5. INSTALLATION OF CHARGER.................................................................................................................... 10
5.1 SHELF, COUNTERTOP OR FLOOR MOUNTING ............................................................................... 10
FIGURE 5.1: BOTTOM MOUNTING HOLE DIMENSIONS............................................................... 11
5.2 WALL MOUNTING ................................................................................................................................ 11
FIGURE 5.2-1: KEYHOLE DIMENSIONS.......................................................................................... 11
FIGURE 5.2-2: CHARGER WALL MOUNTING HOLES................................................................... 11
FIGURE 5.2-3: WALL ANCHOR DESIGN LOADS TABLE.............................................................. 12
5.3 RACK MOUNTING ................................................................................................................................ 12
FIGURE 5.3: ATTACHING RACK-MOUNTING BRACKETS............................................................ 12
6. AC ELECTRICAL SUPPLY ........................................................................................................................... 13
6.1 AC INPUT CONNECTIONS................................................................................................................... 13
FIGURE 6.1-1: RATINGS AND BREAKERS TABLE........................................................................ 13
FIGURE 6.1-2: AC AND DC WIRE HOOK UP................................................................................... 15
FIGURE 6.1-3: GROUND WIRE HOOK UP....................................................................................... 15
6.2 AC VOLTAGE JUMPER SETTINGS..................................................................................................... 15
FIGURE 6.2: AC VOLTAGE JUMPER POSITIONS.......................................................................... 16
6.3 AC AND DC CONNECTION LOCATIONS ........................................................................................... 16
FIGURE 6.3-1: S1 ENCLOSURE...................................................................................................... 16
FIGURE 6.3-2: S2 ENCLOSURE...................................................................................................... 17
FIGURE 6.3-3: S3 ENCLOSURE...................................................................................................... 18
7. DC OUTPUT................................................................................................................................................... 19
7.1 DC OUTPUT CONNECTIONS............................................................................................................... 19
FIGURE 7.1: VOLTAGE DROP PER 1 FT (305MM) OF WIRE TABLE ........................................... 19
8. REMOTE AND ALARM I/O RELAY OPTIONS............................................................................................. 19
8.1 REMOTE DC VOLTAGE SENSING...................................................................................................... 19
8.1.1 WIRING THE REMOTE DC VOLTAGE CABLE............................................................................. 20
FIGURE 8.1.1: CHARGER VOLTAGE SENSING WIRING DIAGRAM ............................................ 20
8.1.2 REMOVING REMOTE VOLTAGE SENSING CABLE.................................................................... 20
8.2 REMOTE TEMPERATURE SENSING CABLE..................................................................................... 20
8.2.1 REMOTE TEMPERATURE SENSING CABLE INSTALLATION................................................... 21
8.2.2 REMOVING TEMPERATURE SENSING CABLE.......................................................................... 21
8.3 OPTIONAL REMOTE CONTROL PANEL............................................................................................ 21
8.3.1 REMOTE CONTROL PANEL INSTALLATION.............................................................................. 21
8.4 ALARM I/O RELAY BOARD OUTPUT................................................................................................. 22
8.4.1 ALARM I/O RELAY BOARD OPERATION.................................................................................... 22
8.4.2 ALARM I/O FIELD INSTALLATION INSTRUCTIONS................................................................... 23
Preliminary Operating Instructions 4 of 62 AIP SERVICE NUMBER 1-800-863-3364
8.4.3 WIRING THE ALARM I/O BOARD TO EXTERNAL CIRCUITS..................................................... 23
8.4.4 TESTING THE ALARM I/O RELAY BOARD AND EXTERNAL CIRCUITS .................................. 23
FIGURE 8.4.4-1: ALARM I/O RELAY BOARD MOUNTING............................................................. 24
FIGURE 8.4.4-2: ALARM I/O RELAY BOARD OUTPUT CONNECTIONS...................................... 24
9. CHARGER START UP SEQUENCE............................................................................................................. 25
9.1 CHECK DISPLAY AND LEDS .............................................................................................................. 25
9.2 CHARGER SETTINGS.......................................................................................................................... 25
9.3 AC & DC POWER UP............................................................................................................................ 25
9.4 RECONNECT DC & RE-CHECK........................................................................................................... 25
10. CIRCUIT BOARDS....................................................................................................................................... 25
10.1 SCR DRIVER BOARD......................................................................................................................... 25
FIGURE 10.1: SCR DRIVER BOARD................................................................................................ 26
10.1.1 BACKUP CHARGER POWER...................................................................................................... 26
10.1.2 SUMMARY ALARM BUZZER AND RELAY CONTACT CONNECTIONS.................................. 26
10.1.3 GFI JUMPER................................................................................................................................. 27
10.1.4 INTERNAL TEMPERATURE SENSOR........................................................................................ 27
10.1.5 OPTIONAL REMOTE TEMPERATURE SENSOR CONNECTOR............................................... 27
10.2 CONTROL BOARD FEATURES......................................................................................................... 27
FIGURE 10.2: CONTROL BOARD .................................................................................................... 27
10.2.1 LIQUID CRYSTAL DISPLAY (LCD)............................................................................................. 28
10.2.2 “HOLD TO EQUALIZE” BUTTON (LARGE SQUARE BUTTON)............................................... 28
10.2.3 ARROW BUTTONS....................................................................................................................... 28
10.2.4 GREEN “AC ON” LED.................................................................................................................. 28
10.2.5 GREEN “DC ON” LED.................................................................................................................. 28
10.2.6 YELLOW “FLOAT” LED............................................................................................................... 28
10.2.7 RED “EQUALIZE” LED ................................................................................................................ 28
10.2.8 BUTTON LOCKOUT JUMPER CONNECTOR............................................................................. 28
10.2.9 BEEPER ........................................................................................................................................ 28
11. CONTROL BOARD OPERATION ............................................................................................................... 28
11.1 DEFAULT DISPLAY MODES.............................................................................................................. 28
11.2 HOW TO VIEW OR CHANGE INFORMATION................................................................................... 29
11.3 CHARGER INFORMATION AND MENU DESCRIPTIONS................................................................ 30
11.3.1 DC VOLTAGE AND DC CURRENT.............................................................................................. 30
11.3.2 FAULT CODES AND FAULT LEDS............................................................................................. 30
11.3.3 DC SETTINGS............................................................................................................................... 32
11.3.4 ALARM SETTINGS....................................................................................................................... 33
11.3.5 EQLZ SETTINGS (EQUALIZE SETTINGS).................................................................................. 35
11.3.6 HRS RUN (HOURS RUN) ............................................................................................................. 36
11.3.7 INTEMP (INTERNAL TEMPERATURE)....................................................................................... 36
11.3.8 EXTEMP (EXTERNAL TEMPERATURE)..................................................................................... 36
11.3.9 CURRENT TIME............................................................................................................................ 36
11.3.10 PAUSE (CHARGER PAUSE) ..................................................................................................... 36
11.3.11 NEXT EQLZ (NEXT EQUALIZE CYCLE)................................................................................... 36
12. SPECIAL MENUS........................................................................................................................................ 36
12.1 SECURITY MENU ............................................................................................................................... 36
12.2 TECH MENU........................................................................................................................................ 37
12.2.1 RELAY START.............................................................................................................................. 37
12.2.2 LEDS ARE OFF............................................................................................................................. 37
12.2.3 DISP (DISPLAY VOLTAGE MODE)............................................................................................. 37
Preliminary Operating Instructions 5 of 62 AIP SERVICE NUMBER 1-800-863-3364
13. CHARGER CONTROL BOARD QUICK GUIDE ......................................................................................... 37
14. MAINTENANCE........................................................................................................................................... 39
14.1 FUNCTIONAL TESTS......................................................................................................................... 39
14.2 PHYSICAL CLEANING....................................................................................................................... 39
14.3 CHECK AREA AROUND CHARGER................................................................................................. 40
14.4 VISUAL INSPECTION......................................................................................................................... 40
14.5 BATTERY CONDITION....................................................................................................................... 40
15. SERVICING THE CHARGER ...................................................................................................................... 40
15.1 TROUBLESHOOTING......................................................................................................................... 42
15.2 TESTING SCRS................................................................................................................................... 48
15.2.1 SCR1 SHORTED OR LEAKY....................................................................................................... 48
15.2.2 SCR1 OPEN .................................................................................................................................. 48
FIGURE 15.2.2-1: SCR1 TERMINAL DIAGRAM .............................................................................. 49
FIGURE 15.2.2-2: SCR1 TERMINAL DIAGRAM FOR 50A CHARGER........................................... 49
15.3 TRANSFORMER TESTING................................................................................................................. 50
FIGURE 15.3: TRANSFORMER AC VOLTAGES TABLE................................................................ 50
15.4 CHARGER ID TESTING...................................................................................................................... 51
FIGURE 15.4: TS1 ID TERMINAL STRIP RESISTORS TABLE....................................................... 51
16. ORDERING REPLACEMENT PARTS......................................................................................................... 51
17. FACTORY REPLACEMENT PARTS........................................................................................................... 52
18. CHARGER SCHEMATIC............................................................................................................................. 57
19. CHARGER SPECIFICATIONS .................................................................................................................... 58
Preliminary Operating Instructions 6 of 62 AIP SERVICE NUMBER 1-800-863-3364
IMPORTANT SAFETY INSTRUCTIONS
1. SAVE THESE INSTRUCTIONS – This manual contains important safety and operating
instructions.
2. Before using battery charger, read all instructions and cautionary markings on battery
charger, battery, and product using battery.
LOOK FOR THIS SYMBOL TO POINT OUT SAFETY
PRECAUTIONS. IT MEANS: BE ALERT—YOUR SAFETY IS
3.
4.
5.
6.
7.
8.
9.
10.
11.
CAUTION: This charger is factory set to charge only lead-acid type rechargeable
batteries. Other types of batteries may burst causing personal injury and damage.
Before charging any other type of rechargeable battery, change the charger settings as
recommended by that battery manufacturer.
DANGER: TO REDUCE THE RISK OF FIRE OR ELECTRIC SHOCK, CAREFULLY READ
AND FOLLOW THESE IMPORTANT SAFETY AND OPERATING INSTRUCTIONS BEFORE
INSTALLING OR OPERATING THE CHARGER.
INSTRUCTIONS IMPORTANTES CONCERNANT LA SECURITÉ.
DANGER: RISK OF ELECTRIC SHOCK. CAPACITORS STORE HAZARDOUS ENERGY.
DO NOT OPEN DOOR OR REMOVE PANELS UNTIL 5 MINUTES AFTER DISCONNECTING
ALL AC AND DC SUPPLY. THE CAPACITORS WILL HOLD A CHARGE FOR UP TO 5
MINUTES AND CAN CAUSE A SHOCK EVEN IF THE POWER HAS BEEN DISCONNECTED.
DANGER: TURN OFF EXTERNAL AC POWER AND DISCONNECT EXTERNAL DC
VOLTAGE BEFORE SERVICING CHARGER OR BEFORE CONNECTING OR
DISCONNECTING THE BATTERY TO PREVENT ARCING OR BURNING.
DANGER: RISK OF ELECTRIC SHOCK. DO NOT TOUCH UNINSULATED ELECTRICAL
PARTS, EITHER AC OR DC, WHILE THE POWER IS CONNECTED.
DANGER: RISQUE DE CHOCKS ÉLECTRIQUES. NE PAS TOUCHER LES PARTIES
NON ISOLÉES DU CONNECTEUR DE SORTI OU LES BORNES NON ISOLÉES DE
L’ACCUMULATEUR.
DANGER: TO PREVENT ELECTRICAL SHOCK, DO NOT TOUCH EITHER AC OR DC
UNINSULATED PARTS. MAKE SURE ALL ELECTRICAL CONNECTORS ARE IN GOOD
WORKING CONDITION. DO NOT USE CONNECTORS THAT ARE CRACKED, CORRODED
OR DO NOT MAKE ADEQUATE ELECTRICAL CONTACT. USE OF A DAMAGED OR
DEFECTIVE CONNECTOR MAY RESULT IN A RISK OF OVERHEATING OR ELECTRIC
SHOCK.
WARNING: HAZARD OF ELECTRIC SHOCK.
INVOLVED. IF YOU DO NOT FOLLOW THESE SAFETY
INSTRUCTIONS, INJURY OR PROPERTY DAMAGE CAN OCCUR.
Preliminary Operating Instructions 7 of 62 AIP SERVICE NUMBER 1-800-863-3364
12. Lead-acid batteries generate explosive gases. To prevent arcing or burning near
batteries, do not disconnect DC charging cord from batteries when the charger is
operating. Switch the AC breaker and the DC breaker to the “off” position before
disconnecting the DC output cord from the batteries. Keep sparks, flame, and smoking
materials away from batteries.
13. Always shield eyes when working near batteries. Do not put wrenches or other metal
objects across battery terminal or battery top. Arcing or explosion of the battery can
result.
14. Batteries produce hydrogen gas, which can explode if ignited. Never smoke, use an open
flame, or create sparks near the battery. Ventilate the area when the battery is charging
in an enclosed place.
15. Lead-acid batteries contain sulfuric acid, which may cause burns. Do not get acid in
eyes, on skin, or clothing. If contact with the eyes occurs, flush immediately with clean
water for 15 minutes and obtain medical attention.
16. Only qualified personnel should program or service this equipment.
17. De-energize all AC and DC power connections before servicing this unit. If injury does
occur, apply standard treatment for electric shock and, if necessary, consult with a
physician.
18.
19.
20.
21. This charger is factory set to charge lead-acid batteries.
22. Do not operate the charger if it has received a sharp blow, been dropped, or otherwise
23. Do not disassemble the charger. Have the charger examined by a factory authorized
24. Make sure the battery system has the properly rated voltage for this charging system.
CAUTION: FOR INDOOR USE ONLY. THIS CHARGER IS NOT DESIGNED FOR
OUTDOOR USE. DO NOT EXPOSE THE CHARGER TO RAIN OR SNOW.
ATTENTION: NE PAS EXPOSER À LA PLUIE.
ATTENTION: UTILISER POUR CHARGER UNIQUEMENT LES ACCUMULATEURS AU
PLOMB À ELECTROLYTE LIQUIDE. D’AUTRES TYPES D’ACCUMULATEURS
POURRAIENT ÉCLATER ET CAUSER DES BLESSURES OU DOMMAGES. LES
CCUMULATEURS AU PLOMB À BOÎTIER ÉTANCHE, Y COMPRISE LES BATTERIES À
ÉLECTROLYTE GÉLIFÎE.
damaged. Have a factory authorized service technician examine and repair as needed.
service technician. Incorrect re-assembly of the charger may result in an explosion,
electric shock, or fire.
SAVE THESE INSTRUCTIONS
Preliminary Operating Instructions 8 of 62 AIP SERVICE NUMBER 1-800-863-3364
1. INTRODUCTION
This single-phase battery charger is convection cooled, microprocessor controlled, and SCR regulated. The
charger has an “l-E” profile, which is high rate constant current (start region), and constant voltage (plateau
region). The plateau region is defined by one voltage point (knee) where the start region changes into the
plateau region. This plateau voltage point is called the “Float Voltage” and it is factory set at 2.25 volts per cell
for charging lead acid batteries.
The charger has an equalize feature used to perform an equalize charge of the battery. An equalize charge is
periodically used to change the voltage set point above the normal float voltage. This increases the gassing to
mix the electrolyte in a battery and charge all of the cells to a uniform level. The equalize charge voltage is
factory set to 2.32 volts per cell. Contact your battery manufacturer’s authorized service technician for
information on how often your batteries should be equalized.
CAUTION: This charger is factory set to charge only lead-acid type rechargeable batteries. Other
types of batteries may burst causing personal injury and damage. Before charging any other type of
rechargeable battery, change the charger settings as recommended by that battery manufacturer.
The charger settings can be changed by following the instructions in SECTION 11, “CONTROL BOARD
OPERATION”, of this manual.
2. RECEIVING CHARGER
Unpack the charger and examine it for possible shipping damage. If any damage is found, report it
immediately as a claim to the carrier.
3. STORING CHARGER
When the charger is stored prior to being installed and powered up, it should be stored upright, bolted to the
shipping pallet, and covered by the plastic wrap and shipping carton it was shipped in. This will help protect it
from dust and abrasion. It should be stored in an area where it is not likely to be damaged. Do not stack
anything on top of the charger.
It must be stored indoors in a clean and dry environment where the temperatures will not exceed a range of
32º F to 120ºF (0°C to 49°C).
The charger should not be stored more than two years before it is powered up. If the charger capacitors are
not powered up, they will lose their effectiveness over time and may need to be replaced.
4. LOCATION FOR CHARGER INSTALLATION
WARNING: DO NOT INSTALL THE CHARGER ON OR NEAR COMBUSTIBLES OR EXPLOSIVES.
INSTALL THE CHARGER ON A FIRE RESISTANT FOUNDATION OF STONE, BRICK, CONCRETE OR
GROUNDED METAL.
The charger should be located in a clean, cool, dry and well-ventilated area. To permit ample airflow for
convection cooling, allow 4” (102mm) minimum clearance on both the right and left sides of the charger. Allow
more space for cooling and convenience of service and maintenance if possible. Do not obstruct the airflow
space provided behind and underneath the charger.
Allow 36” (914mm) minimum clear space in front of the charger for ease of operation, maintenance and
service.
WARNING: DO NOT INSTALL THE CHARGER ABOVE OR NEAR THE BATTERIES. The batteries give
off hydrogen gas, which rises upward and can be explosive and also produce acid fumes, which may harm the
charger.
Do not install the charger in an area where conditions may be below freezing, above 105° Fahrenheit (40°C) or
above 95% relative humidity. These extreme temperatures will reduce the current capacity and possibly the
Preliminary Operating Instructions 9 of 62 AIP SERVICE NUMBER 1-800-863-3364
service life of the charger. If the charger is to be operated at any of these temperature extremes, contact the
manufacturer to verify it will withstand these conditions, and perform at the needed capacity.
The overall outer dimensions of the S1, S2, and S3 charger enclosures are shown in FIGURE 4.0.
FIGURE 4.0: TABLE OF CHARGER ENCLOSURE SIZES
Overall
Enclosure
sizes
height in
modular
units
Overall height
in inches (mm)
Overall width
in inches (mm)
Overall depth in
inches (mm)
S1 10 U* 17.50 (445) 19.00 (483) 16.75 (425)
S2 15 U* 26.25 (667) 19.00 (483) 16.75 (425)
S3 20 U* 35.00 (889) 19.00 (483) 16.75 (425)
* A modular unit (U) is 1.75” (44mm) as defined by the
ELECTRONIC INDUSTRIES ASSOCIATION (EIA).
** Overall width is from the outer edges of mounting flanges, to correspond to a 19” (483mm) rack width.
5. INSTALLATION OF CHARGER
Proper installation is important to achieve good charger performance and to prevent damage to the charger
and batteries.
The S1, S2, and S3 enclosure sizes of the charger can be mounted on a shelf, countertop, floor, wall, or relay
rack.
Be sure to plan a clear routing for the conduit connections prior to mounting the charger. Looking at the front
of the charger, the conduit knockouts are provided on the right side, left side and bottom of the enclosure. See
SECTION 6.3. The AC input connections should enter at the left and the DC output connections at the right.
The alarm relay wiring, sensor wiring, and remote control wiring should enter at the right side through a
separate conduit knockout from the DC connections. The AC and DC wiring should be separated from each
other and from the other optional types of wiring, this is a UL requirement.
5.1 SHELF, COUNTERTOP OR FLOOR MOUNTING
The S1, S2 and S3 cabinets of the charger are shipped standard with a kit to install four cushioned feet.
These are designed to prevent marring of the mounting surface and to absorb vibration. The kit can be
found inside the charger cabinet in a small plastic bag. The kit consists of four round black rubber feet
and four mounting screws.
To install the feet, carefully lay the charger on its back onto a protective surface such as the shipping
carton collapsed flat. The four small .16” (4mm) diameter mounting holes can be found on the bottom
surface of the charger legs near the four corners of the charger. Place the mounting screw through the
recessed end of the foot. The screw head will be within the recess and the screw point will engage into
the mounting hole in the bottom of the charger. The screw is self-threading into the mounting hole.
Tighten each screw until it is snug but do not over compress the rubber.
Now, the charger can be rotated back to its upright position standing on the rubber feet. Be careful to lift
(do not slide) the charger into position.
Next, to avoid placing strain on the conduit and wiring, anchor the charger so it does not become
displaced. This can be done in either of two ways. The charger can be bolted down to the horizontalmounting surface that it is resting on or it can be bolted to the wall behind it.
To bolt to the horizontal mounting surface, the mounting bolts will attach through the four ½” (13mm)
diameter mounting bolt holes in the bottom surface of the charger legs that are nearest the corners of
the charger. The charger itself can be used as a template to mark the locations of the holes to be made
in the mounting surface or the bottom mounting hole dimensions in FIGURE 5.1 can be used to measure
the locations of the mounting bolt holes.
Preliminary Operating Instructions 10 of 62 AIP SERVICE NUMBER 1-800-863-3364
FIGURE 5.1: BOTTOM MOUNTING HOLE DIMENSIONS
5.2 WALL MOUNTING
The S1, S2 and S3 cabinets have built-in wall mounting flanges at the rear. When these flanges are
mounted flush against the wall, they provide for a clear airflow space at the rear of the charger. This
space should not be reduced or obstructed in any way.
The mounting flanges each have a series of keyhole slots. These are designed to conveniently engage
a ¼” (6mm) diameter bolt. The mounting flange bolt hole patterns are shown in FIGURES 5.2-1 and
5.2-2.
FIGURE 5.2-1: KEYHOLE DIMENSIONS
FIGURE 5.2-2: CHARGER WALL MOUNTING HOLES
Preliminary Operating Instructions 11 of 62 AIP SERVICE NUMBER 1-800-863-3364
FIGURE 5.2-3: WALL ANCHOR DESIGN LOADS TABLE
Charger Type Enclosure size
Charger weight
lbs. (Kg)
Design load
lbs. (Kg)
24VDC 6A S1 70 (32) 350 (159)
24VDC 12A S1 75 (34) 375 (170)
24VDC 18A S1 85 (39) 425 (193)
24VDC 20A S1 85 (39) 425 (193)
24VDC 25A S1 90 (41) 450 (204)
24VDC 50A S3 190 (86) 950 (432)
48VDC 6A S1 75 (34) 375 (170)
48VDC 12A S1 90 (41) 450 (204)
48VDC 18A S1 110 (50) 550 (249)
48VDC 20A S1 110 (50) 550 (249)
48VDC 25A S1 115 (52) 575 (261)
48VDC 50A S3 222 (100) 1110 (500)
130VDC 6A S1 100 (45) 500 (227)
130VDC 12A S1 130 (59) 650 (295)
130VDC 18A S2 175 (79) 875 (397)
130VDC 20A S2 175 (79) 875 (397)
130VDC 25A S2 190 (86) 950 (432)
130VDC 50A S3 340 (154) 1700 (771)
FIGURE 5.2-3 shows the weight that the set of mounting bolts and their anchoring structure must
withstand for the various charger types. The “DESIGN LOAD” shows the “CHARGER WEIGHT” times a
safety factor of five (5). Be certain that both
the mounting structure and the bolts will, at a minimum,
support the “DESIGN LOAD”. Drywall or plaster will not be strong enough on its own, without proper
structural reinforcement.
5.3 RACK MOUNTING
The S1, S2 and S3 cabinets can be mounted to a standard EIA 19” (483mm) rack system using the
fasteners provided by the rack manufacturer. The rear mounting flanges are configured for an EIA 19”
(483mm) rack for a forward mounting arrangement. For a recessed mounting arrangement, optional
mounting brackets can be attached to the charger sides to fit either an EIA 19” (483mm) or a 23”
(584mm) rack. See FIGURE 5.3.
FIGURE 5.3: ATTACHING RACK-MOUNTING BRACKETS
CAUTION: TO ENSURE THE STRUCTURAL INTEGRITY OF THE RACK MOUNTING
BRACKETS, USE THE SIXTEEN #10 SELF-THREADING SCREWS PROVIDED IN THE KIT. USE
EIGHT SCREWS PER BRACKET AND TIGHTEN THEM UNTIL SNUG. DO NOT STRIP THE
THREADS.
Preliminary Operating Instructions 12 of 62 AIP SERVICE NUMBER 1-800-863-3364
6. AC ELECTRICAL SUPPLY
The charger must be connected to a single-phase power source. All models can operate on an AC power
source input frequency of 50 or 60 +
3% Hertz. Check the label on the front of the charger or contact the
manufacturer for proper AC power source. The AC input voltage is pre-wired at the factory to 120, 208 or 240
(+10% / -12%) VAC and should not be changed.
NOTE: Field alteration of input voltage voids the charger’s UL Listing.
The AC input wiring must be sized and installed in compliance with the National Electric Code and all
applicable state and local codes and requirements. A qualified electrician must install the AC input wiring
system.
CAUTION: TO REDUCE THE RISK OF FIRE, USE ONLY CIRCUITS PROVIDED WITH BRANCH
CIRCUIT PROTECTION IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE, ANSI/NFPA 70.
6.1 AC INPUT CONNECTIONS
The standard charger is shipped with conduit knockouts and no AC power supply cord. A qualified
electrician must perform this AC input wiring work.
FIGURE 6.1-1: RATINGS AND BREAKERS TABLE
DC Output AC Input
Optional
Rated
DC
Volts
24 6 10 15 14 120 only 5 60 or 50 10
24 6 10 15 14 208 only 3 60 or 50 10
24 6 10 15 14 240 only 3 60 or 50 10
24 12 20 30 12 120 only 7 60 or 50 10
24 12 20 30 12 208 only 5 60 or 50 10
24 12 20 30 12 240 only 5 60 or 50 10
24 18 35 40 8 120 only 10 60 or 50 15
24 18 35 40 8 208 only 6 60 or 50 10
24 18 35 40 8 240 only 6 60 or 50 10
24 20 35 40 8 120 only 12 60 or 50 15
24 20 35 40 8 208 only 7 60 or 50 10
24 20 35 40 8 240 only 7 60 or 50 10
24 25 40 60 8 120 only 14 60 or 50 20
24 25 40 60 8 208 only 8 60 or 50 10
24 25 40 60 8 240 only 8 60 or 50 10
24 50 80 90 6 120 only 24 60 or 50 30
24 50 80 90 6 208 only 15 60 or 50 20
24 50 80 90 6 240 only 15 60 or 50 20
Notes: All input AC circuit breakers are of the “high inrush” type to prevent nuisance tripping during power-up.
Rated
DC
Amps
Rms.
DC
Amps
DC
Circuit
Breaker
Amps
Cable
Size
AWG
(Continued on next page)
Rated
AC Input
Volts
Rated
AC
Amps
AC
Frequency
Hz
AC
Circuit
Breaker
Amps
Preliminary Operating Instructions 13 of 62 AIP SERVICE NUMBER 1-800-863-3364
FIGURE 6.1-1: RATINGS AND BREAKERS TABLE
DC output AC input
Rated
DC
Volts
48 6 10 15 14 120 only 7 60 or 50 10
48 6 10 15 14 208 only 5 60 or 50 10
48 6 10 15 14 240 only 5 60 or 50 10
48 12 20 30 12 120 only 14 60 or 50 20
48 12 20 30 12 208 only 8 60 or 50 15
48 12 20 30 12 240 only 7 60 or 50 10
48 18 35 50 8 120 only 17 60 or 50 30
48 18 35 50 8 208 only 11 60 or 50 15
48 18 35 50 8 240 only 10 60 or 50 15
48 20 35 50 8 120 only 18 60 or 50 30
48 20 35 50 8 208 only 12 60 or 50 15
48 20 35 50 8 240 only 10 60 or 50 15
48 25 40 60 8 120 only 28 60 or 50 30
48 25 40 60 8 208 only 14 60 or 50 20
48 25 40 60 8 240 only 13 60 or 50 20
48 50 80 90 6 120 only 45 60 or 50 60
48 50 80 90 6 208 only 25 60 or 50 40
48 50 80 90 6 240 only 23 60 or 50 40
130 6 10 15 14 120 only 14 60 or 50 20
130 6 10 15 14 208 only 9 60 or 50 15
130 6 10 15 14 240 only 8 60 or 50 15
130 12 20 25 12 120 only 27 60 or 50 40
130 12 20 25 12 208 only 17 60 or 50 30
130 12 20 25 12 240 only 15 60 or 50 25
130 18 35 40 8 120 only 45 60 or 50 60
130 18 35 40 8 208 only 24 60 or 50 40
130 18 35 40 8 240 only 21 60 or 50 30
130 20 35 40 8 120 only 45 60 or 50 60
130 20 35 40 8 208 only 24 60 or 50 40
130 20 35 40 8 240 only 22 60 or 50 30
130 25 40 60 8 120 only 63 60 or 50 70
130 25 40 60 8 208 only 32 60 or 50 40
130 25 40 60 8 240 only 32 60 or 50 40
130 50 80 90 4 208 only 70 60 or 50 90
130 50 80 90 4 240 only 60 60 or 50 70
Notes: All input AC circuit breakers are of the “high inrush” type to prevent nuisance tripping during power-up.
Rated
DC
Amps
Rms.
DC
Amps
DC
Circuit
Breaker
Amps
Wiring and connections must meet the requirements of the National Electric Code, state and local codes
and requirements, and the requirements in this manual.
To connect the input AC voltage, route the AC conduit through the appropriate knockout hole. See
SECTION 6.3. Route the AC wiring to terminal lugs AC1 and AC2 located above the AC breaker as
shown in FIGURE 6.1-2. For proper connection, torque the AC1 and AC2 terminal strip screws to
18 inch pounds (2Nm), and the ground lug screw to 35 inch pounds (4Nm), see FIGURES 6.1-2
and 6.1-3.
Optional
Cable
Size
AWG
Rated
AC Input
Volts
Rated
AC
Amps
AC
Frequency
Hz
AC Circuit
Breaker
Amps
Preliminary Operating Instructions 14 of 62 AIP SERVICE NUMBER 1-800-863-3364
WARNING: ALL AC AND DC CIRCUIT BREAKERS MUST BE IN THE “OFF” POSITION WH ILE
MAKING THE AC AND DC CONNECTIONS TO THE CHARGER.
FIGURE 6.1-2: AC AND DC WIRE HOOK UP
WARNING: IMPROPERLY CONNECTED WIRING CAN CAUSE AN ELECTRICAL FIRE.
Connect the AC ground to the terminal lug located to the right of the AC breaker on the charger floor as
shown in FIGURE 6.1-3. In some models the AC ground lug is above the AC terminal strip on the innerpanel. See SECTION 6.3. For proper connection torque the screw to 35 inch pounds (4Nm).
FIGURE 6.1-3: GROUND WIRE HOOK UP
(Located on charger floor (S1,S2) or above terminal strip (S3))
WARNING: DO NOT OPERATE THE CHARGER WITHOUT PROPER GROUNDING.
IMPROPER GROUNDING MAY CAUSE AN ELECTRIC SHOCK, WHICH COULD RESULT IN INJURY
OR DEATH.
6.2 AC VOLTAGE JUMPER SETTINGS
Check the “AC VOLTS” box on the charger rating specification label to determine its AC Voltage setting.
The AC Voltage jumper settings and the AC Input Voltage of the charger cannot be changed. See
FIGURE 6.2 for AC Voltage Jumper Settings.
NOTE: Field alteration of AC voltage jumper settings voids charger’s UL listing.
WARNING: IMPROPER AC VOLTAGE JUMPER CONNECTION MAY CAUSE SEVERE
DAMAGE TO THE CHARGER AND BATTERY.
Preliminary Operating Instructions 15 of 62 AIP SERVICE NUMBER 1-800-863-3364
FIGURE 6.2: AC VOLTAGE JUMPER POSITIONS
6.3 AC AND DC CONNECTION LOCATIONS
FIGURE 6.3-1: S1 ENCLOSURE
Preliminary Operating Instructions 16 of 62 AIP SERVICE NUMBER 1-800-863-3364
FIGURE 6.3-2: S2 ENCLOSURE
Preliminary Operating Instructions 17 of 62 AIP SERVICE NUMBER 1-800-863-3364
FIGURE 6.3-3: S3 ENCLOSURE
Preliminary Operating Instructions 18 of 62 AIP SERVICE NUMBER 1-800-863-3364
7. DC OUTPUT
It is recommended that a DC disconnect switch or circuit breaker be used between the charger and the DC
bus. This device should have lockout capability to allow the charger to be disconnected from the DC bus when
connecting the charger during installation and maintenance.
7.1 DC OUTPUT CONNECTIONS
The standard charger is shipped with conduit knockouts and no DC output cable. Determine which
charger knockout to route the DC output cable through. See Section 6.3. Make sure to keep the DC
output cable isolated from the AC input cables and any other optional wiring.
To help in determining the proper size of cable to use for the DC output, FIGURE 7.1 lists the DC voltage
drop per one foot (305mm) of cable for the various Rated DC currents of the chargers and various wire
sizes. Take the appropriate number from FIGURE 7.1, and multiply it by the cable length needed to get
the approximate voltage drop from the charger to the battery or DC bus. FIGURE 7.1 values are
approximate values, the exact value can be measured after installation.
NOTE: If the total voltage drop of the DC output cable is greater than 1% of the charger voltage ( 0.24
VDC for a 24 VDC system, 0.48 VDC for a 48 VDC system, 1.3 VDC for a 130 VDC system) it is
recommended that the optional Remote DC Voltage Sensing cable be used.
To connect the DC output cable, route the conduit through the appropriate knockout hole. Route the DC
positive wire to terminal lug labeled DC POSITIVE and the DC negative wire to terminal lug labeled DC
NEGATIVE located above the DC breaker as shown in FIGURE 6.1-2. For proper connection, torque
the terminal strip screws to 18 inch pounds (2Nm). The charger will not operate in a reversed polarity
condition. The DC output circuit breaker is used to protect the silicon-controlled rectifiers (SCRs).
NOTE: DC circuit breaker may trip when switched on until capacitors are charged.
FIGURE 7.1: VOLTAGE DROP PER 1 FT (305mm) OF WIRE TABLE
For stranded copper wire at 68°F (20°C)
WIRE
SIZE
(AWG.)
16 0.0450 0.0900
14 0.0270 0.0540
12 0.0180 0.0360
10 0.0110 0.0220
8 0.0070 0.0140
6 0.0045 0.0090
4 0.0025 0.0050
2 0.0018 0.0036
1 0.0015 0.0030
0 0.0011 0.0022
6A 12A
RATED DC CURRENT, AMPERES
18A
0.1440
0.0864
0.0576
0.0352
0.0224
0.0144
0.0080
0.0058
0.0048
0.0035
20A 25A 50A
- - -
0.0945 - -
0.0630 0.0720 -
0.0385 0.0440 0.0880
0.0245 0.0280 0.0560
0.0158 0.0180 0.0360
0.0088 0.0100 0.0200
0.0063 0.0072 0.0144
0.0053 0.0060 0.0120
0.0039 0.0044 0.0088
8. REMOTE AND ALARM I/O RELAY OPTIONS
The Remote option allows the charger to be controlled and monitored remotely. The ALARM I/O relay board
allows the user to connect other devices to it to monitor various faults. The following sections go over function
and installation of these optional parts.
8.1 REMOTE DC VOLTAGE SENSING
This option will compensate for the voltage drop across the DC output cable due to the resistance and
current flowing through it. The remote voltage sensing cable can measure the DC voltage of batteries or
DC bus up to 30 ft. (9m) with the standard cable length. This can be extended with a longer cable. This
gives the charger display a more accurate voltage display. In order for the charger to function, the
connection to the DC bus must be secure and reliable.
Preliminary Operating Instructions 19 of 62 AIP SERVICE NUMBER 1-800-863-3364
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