CUMMINS 305-0812, 305-0815, 305-0813, 305-0814 Operation Manual

Operator’s

Redistribution or publication of this document by any means, is strictly prohibited.

12

and

Battery Charger

24

Volt

Manual

Printed

in

USA.

901-0102

5-2001

Safety

Redistribution or publication of this document by any means, is strictly prohibited.

This

manual includes

Precautions

the

following symbols to indicate potentially dangerous conditions to the operator or equipment. Read the manuai carefully and know when these conditions exist. Then take

and

protect personnel

or

sonal injury

death.

liE33GI

severe personal

llSGEi3

personal injury

IMPORTANT

1.

Save these instructions.

the

This symbol warns of immediate

hazards that wi/lresuit in severeper-

This symbol refers

unsafe practice that can resuit in

injury

or

This symbol refers to a hazard or

unsafe praciice that can resuit

or

product

SAFETY

the

necessary steps to

equipment

to

a hazard or

death.

or

property damage.

INSTRUCTIONS

This

manual contains

in

i~po~ant safety and operating instructions.

2.

Work~tig

Batteries generate explosive gasses battery operation. For

importance

harger,

markings

in

the vicinity

that each

you

read

of

a battery

this

reason,

time

before

all

instructions and cautionary

on the battery charger,

is

dangerous.

during

it

is

of

using

the

battery, and the

normal

utmost battery

~ene~at~r set.

3.

To

reduce ~ns~r~~~~on§ manufacturer and the manufacturer ment and follow

battery charger Other can

the

risk

and those published

that

is

used

all

-

To

Pjpes

of

batteries (such

burst,

causing personal

of b~ttery ~xplosion,

in

the

vicinity

of

follow

by

the battery

of

any equip-

the battery. Review

ca~tionary markings on

reduce

ta

risk

of

injury,

only

charge rechargeable batteries.

as

dry

cell batteries)

injury

and property

these

use the

damage.

5.

Never smoke or allow an open spark, arcing equip-

in

ment or flame

set

tor

6.

Do

not expose the battery charger to rain, snow or

sther

pr~cipit~t~on.

thevicini~of

the

batteryorgenera-

7.

Never charge a frozen battery.

8.

Use

of

an attachment

not

recommended

or

the battery charger manufacturer can result of fire, electric shock, or personal

9.

Do

not operate the battery charger

10.

a sharp

in

Do

blow,

been dropped, or otherwise damaged

any way; take

it

to

a qualified 5e~i~e technician.

not disassemble the battery charger; take

qualified service technician when

is

required. Incorrectiy reassembly

risk

of

electric shock or fire.

11.

To

the

ing

trols does

12.

If

reduce the

battery charger from

any

it

is

necessary

risk

of

electrical shock, disconnect

AC

maintenance or cleaning.

NOT

reduce

this

to

remove the battery

generator set battery tray

the

grounded (-)terminal from the battery

sure that

panel are

13.

Study

all

switches on

off

in

order

to

prevent an arc.

all battery manufacturer’s specific precau-

tions, such as removing or

while

14.

Do

charging

not

use the battery charger unless the battery

and

r~~o~mended rates

to

the

injury.

if

it

has received

s

power before perform-

Turning

risk.

charge, always remove

first,

generator set control

not

removing

of

voltage matches the output voltage rating

charger. Refer

ual

to

determine the ~~ltage

15.

Never place the charger directly a~ove or battery; gases or and damage the charger. Locate away from the battery

16.

Do

not operate the battery charger

area or restrict ventilation

17.

Grounding Instructions: be connected to agrounded,

to

the generator

fluids

from the battery can corrade

as

set

the

practical.

operator’s man-

charger as far

in a closed-in

in

any

way.

This

battery

metal,

permanent

n

~quipment-~~ounding conductor

with

circuit ~on~~c~ors and con-

nected to an equipment-grounding terminal or lead on the battery charger. ~onn~~~i charger

comply with

all

local codes

must

ordinances.

sold

in

a

risk

it

to

off

con-

from

Make

cell

caps

charge.

of

below

wlr-

and

by

t

a

the

Table

Redistribution or publication of this document by any means, is strictly prohibited.

of

Contents

c

9

TITLE

SAFETY

INTRODUCTION

OPERATION

TROUBLESHOOTING

PRECAUTIONS

.......................................................................

Operator's Manual.. Model Identification..

.........................................................................

Description

Battery Charging Adjustments

........................................................................

...................................................................

.......................................................................

INCORRECTSERVICE SEVEREPERSONAL INJURY, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL

MUST

...............................................

.................................................................

...............................................................

................................................................

OR

REPLACEMENT OF PARTS CAN RESULT IN DEATH,

BE QUALIFIED TO PREFORM ANY SERVICE.

Inside

PAGE

Front Cover

1

2

3

5

i

Redistribution or publication of this document by any means, is strictly prohibited.

Operator's Manual

Redistribution or publication of this document by any means, is strictly prohibited.

12 and 24 Volt Battery Charger

Printed in U.S.A.

Models

305–0812, 305–0813, 305–0814, 305–0815

901–0102 5-2001

Operation

Redistribution or publication of this document by any means, is strictly prohibited.

DESCRl

All

controls, meters, indicators and fuses areaccessible from the front panel of the battery charger (Figure addition to these external components, three sets of alarm relay contacts are also available.

If the battery voltage rises above an adjustable maximum voltage level or drops below an adjustable minimum voltage level for (High Bat. ponding set

If the AC input voltage fails, a red AC Failure LED and a corresponding set of form C relay contacts is activated.

or

Low Bat.) red alarm LED is lit and a corres-

of

form C relay contacts is activated.

PTlON

90

seconds, a corresponding

1).

In

is

lit

Controls

Power

circuits.

On/Offswifch:Controls both AC and

Equalize Charge Timer:

charger’s

able level) until the timer expires (up this timer, turn the indicator past desired time.

DC

output voltage is increased (to an adjust-

When this timer is set, the

to

2

and then set the

DC

12

hours). To use

power

Equalize Voltage adjustment potentiometer:

adjust the (factory-set) equalize voltage. The equalize

of

the

two

voltage is the higher

Float Voltage adjustment potentiometer:

the (factory-set) float voltage. The float voltage

two

lower of the

High Alarm adjustment potentiometer:

the (factory-set) maximum battery (High Bat.) alarm voltage.

Low

Alarm adjustment potentiometer:

the (factory-set) minimum battery (Low Bat.) alarm voltage.

The high and low alarm and float and equalize voltage adjustments are set at the factory. Adjustment procedures are described under

charge voltages.

Adjustments.

Used to

Used to adjust

is

the

Used to adjust

Meters

DC

Ammeter:

normal for the ammeter indicator to jump between 0 and

2

amperes when the battery is at its float voltage.

DC

Volbneter:

Indicates the charger output current It

Indicates the voltage at the battery.

is

Q

VOLTMETER

AMMETER

\

\ \

\

ZAC

DC

FUSE

FUSES

FIGURE

1.

BATTERY

2

CHARGER

EQUALIZER

CHARGE

TIMER

G1119

LED

Redistribution or publication of this document by any means, is strictly prohibited.

Indicator Lamps

Power

AC

High

>

4

tage has exceeded a pre-set maximum level. Low

age has fallen below a pre-set minimum level. AC

AC power to the charger.

If

section. Fuses

DC

AC input fuses:

KTK)

ponding fuse holder. When replacing blownfuses, besureto useafuseofthe

same rating and type. Do not use fuses with a higher rating.

Alarm

Three sets of (form C) alarm relay contacts (corresponding to the three red fault LEDs) are also available. These contacts can be wired by the installer to activate other audible

Under normal operating conditions, the Low Bat and Fail relays are energized and the High Bat relay is deenergized. In response to a tion, the appropriate normally energized relay (Low Bat

or

tion, the normally de-energized High Bat relay is energized.

The alarm contacts are rated for

or

This battery charger is intended for use wired, industrial application. Installation and serviceare to be performed only bytechnically qualified personnel.

Power On

to charge the connected battery to thefloat voltage. The charger's electronic sensor checks the battery voltage. If the battery voltage is below the reference level, the

a

charger supplies charging current to the battery. As the battery approaches a ing current automatically tapers to zero.

On

L€D:This green LED indicates that there is

power to the charger.

Bat

LED: This red

Bat

L€D:This red

Failure

a red LED is illuminated, refer to the

output

AC

30

L€D:This red

fuse:

15

The AC fuse rating and type

is indicated on the front panel, next to the corres-

Contacts

or

visual alarms.

Fail) drops out In response to a High Bat condi-

VDC.

BATTERY

-Float

LED

indicates that battery vol-

LED

indicates that battery volt-

LED

indicates that there is no

Troubleshooting

Amp

AGC

Low

Bat or AC Fail condi-

4

amperes at

120

CHARGING

in

a

permanently

Cbarge:Turn the power switch to

pre-set full

chargevoltage, charg-

(FNQ

VAC

or

AC

ON

The charger can be powered on a continuous basis to

maintain the battery in a fully charged condition.

Equalize Charge Timer:For

ize the battery's cells, a higher charging voltage is

by

obtained Turning on the timer raises the charger output voltage for the selected time interval (up to

of

the timed charging period, the charger automatically

switches back to the float voltage. To use this timer, turn the indicator past

the desired time.

Most equalize charging each month. Use the equalize charge timer to equalize float charged lead-acid batteries at

intervals recommended by the battery manufacturer.

Nickel-cadmium batteries do not require equalize

charging.

switching on the equalize charge timer.

lead-acid battery manufacturers recommend

faster charging or to equal-

12

hours).

At

the end

2

and then set

ADJUSTMENTS

Battery

The float and equalize voltages are set at the correct

valuesat the factory and should not requireadjustment

However, if the battery shows signs of being overcharged or undercharged, these voltages can be adjusted. and specific gravity indicates a low charge voltage.

To

hydrometer, a small screwdriver, and an accurate volt-

meter

procedures to adjust the float voltage:

1.

2

Charger Float and Equalize Voltages

A

high specific gravity, bubbling

loss

of

water indicate a high charge voltage. A low

change the float voltage, a fully charged battery, a

(0.5%

accuracy) are needed. Use the following

Turn the battery charger power switch to the operation selector for the generator set to STOP and disconnect thestarting battery (negative first). The selector switch is located on the generator set control panel.

Ignition

lZEEl

sonaliniuty. or flame while servicing batteries.

Connect the fully charged battery to the charger (negative

tion with the hydrometer. A fully charged lead-acid

battery will have a specific gravity of (25OC).

E3

AWARNING

to tbe skin. Wear goggles, rubber gloves

protective apron when working

[-I

gases

Do

not

smoke

lead 1ast)and verify the charge condi-

Battery electdyte can cause severe eye damage

of

can

or

cause any spark, arc,

of

electrolyte,

Off.

Turn

[-I

lead

explosive battery

cause severe per-

1260

at

77OF

and

burns

and

with

batteries.

a

3

3.

Redistribution or publication of this document by any means, is strictly prohibited.

Connect the voltmeter directly to the battery terminals. Turn the charger power switch to

On,

measure the voltage.

4.

Compare the voltage reading with the float value

1.

shown in Table

If the voltage is above or below the

recommended float voltage, adjust as specified in

5.

If

step

the voltage

TABLE

1.

is

correct, proceed to step

FLOAT/EQUALIZE

VOLTAGES

I

Battery

Voltage

12

24

Nickd-Cadmium Batteries

Float

Example:

battery

*Voltages shown are for ambient temperatures of

(10°C)

to

85'F

9°F (5°C)

.every

by

1% for every

tage

*Float Equaliie

Voltage Voltage

1

3.3

26.6

Voltage Charge

Float charge for

should

be 13.8 to 14.5 volts.

(30°C).

Reduce

above 85°F

9"F(5"C)

Per

Cell

10

float

voltage

(29°C).

lncreaseiloatvol-

below

50°F

cell

1

4.4

28.8

by

(10°C).

1%

50°F

for

and

6.

9.

When adjustments are complete, turn the charger power switch to

10.

Disconnect the voltmeter from the battery terminals

Off

and replace the plastic

plugs.

and disconnect the test battery from the charger

[-]

(negative

lead first).

c

Ignition of explosive battery

IBI

sonalinjury.

or

flame while servicing batteries.

11.

Reconnect the generator set starting battery (nega-

[-I

tive

lead last) and place the operation selector

gases can cause severe

Do

not smoke

or

cause any spark, arc,

per-

b

switch in the Remote position. Turn the charger power switch to

On

and reset the equalizer timer to

zero for float charging.

Alarm

If

Relay

Settings

the battery voltage rises above the High alarm setting or drops below the Low alarm setting for 90seconds, the corresponding (High or Low) battery alarm LED is litand

C

a corresponding (optional) set of form

relay contacts

is activated. The high and

low

alarm adjustments are set at the fac-

tory. The ranges and factory settings are:

5.

Remove the plastic plug that covers the float adjustment potentiometer. Use a small screwdriver to turn the float adjustment potentiometer.counterclockwise to decrease the float voltage and clockwise to increase the float voltage. Adjust in small steps and wait five minutes for the voltage to stabilize before making additional adjustments.

6.

After the float adjustment is completed, set the equalize timer to equalize charge the battery and

5

wait until the charger current falls below

7.

Compare the voltage reading with the equalize value shown in Table

1.

If

the voltage is above or

amperes.

below the recommended equalize voltage, adjust as specified in step

the voltage

is

correct, proceed

8.

If

to step 9.

8.

Remove the plastic plug that covers the equalize

Use

adjustment potentiometer.

a small screwdriver

to turn the equalize adjustment potentiometer coun-

to

terclockwise

clockwise

in

small

stepsand

stabilize

decrease the equalize voltage and

to

increase the equalize voltage. Adjust

wait

before

five minutes

making additional adjustments.

for

the voltage

to

12-volt

24-vult

charger-

9

VDC to

Factory Setting:

14

Factory Setting:

VDC

13

VDC

(Low

12.5

to

19

VDC (High Alarm)

14.5

Alarm)

VDC

charger-

18

VDC to

Factory Setting:

27

VDC to

Factory Setting:

1.

Remove the plastic plugs that cover the adjustment

25

VDC (Low Alarm)

25

VDC

36

VDC (High Alarm)

29

VDC

potentiometers.

2.

Use a small screwdriver to turn the High Alarm or Low Alarm adjustment potentiometers

charger panel counterclockwise to decrease the alarm voltage and clockwise to increase the alarm voltage.

on

The graduations

the adjustment potentiometers

are approximate.

3.

When finished, replace the piastic plugs.

on

the

0

v

Troubleshooting

Redistribution or publication of this document by any means, is strictly prohibited.

2)

J

The following procedures (Table nary troubleshooting checks.

a service representative.

If

describe prelimi-

the trouble persists,

call

‘

before servicing.

1-1

TROUBLE

No

DC Output

Low DC Output

Voltages witbin the charging system present an electrical shock hazard that

personal injury or death. Disconnect all sources of

of

Ignition

spark, arc,

explosive battery gases

or

flame while servicing batteries.

TABLE

2.

TROUBLESHOOTING PROCEDURES

1.

Blown DC fuse.

2.

Blown AC fuse(s). (AC Failure LED will be lit)

3.

No

AC input (AC Failure

LED will be lit)

4.

Charger failure.

LED may be

can

cause severe personalinjury.

POSSIBLE CAUSE

.

lit)

AC

and

DC

power from the battery charger

Do

notsmoke or cause any

CORRECTIVE ACTION

1.

Correct possible overload and replace

of

same type and rating.

2.

Replace fuse(s) - use fuse@)

of same type and rating.

3.

Call a service representative.

4.

Call a service representative.

fuse - use fuse

can

cause severe

High DC Output

Float or Equalize Charge Rate Only.

.

‘A

Battery

l2@EHI

not smoke or cause any spark, arc, or flame while

servicing batteries.

1.

Replacement

Ignition can cause severe persona/iniury.

Turn the battery charger power switch to the operation selector for the generator set to and disconnect the starting battery (negative

2.

Faulty battery. (Low LED may be

3.

Charger failure. LED may be lit)

1.

Incorrectly set float

equalize voltages. (High

LED may be

2.

Charger failure. (High LED may be lit)

1.

Defective equalize timer.

2.

Defective Regulator.

of

explosive battery gases

Off.

Do

Turn

STOP

[-3

lead

lit)

(Low

5

Bat

or

Bat

first). Theselector switch is located on the generator set control panel.

2.

Connect the replacement starting battery (negative

[-I

lead last) and place the operation selector switch

in the Remote position. Turn

switch to On.

equalize charging is not required, set the equalizer

timer to zero for float charging.

2.

Replace battery - procedure is

described

3.

Call a service representative.

1.

Refer to voltage adjustment

procedures.

2.

Call a service representative.

I.

Call

2.

Call a service representative.

If

the battery is fully charged and

below.

a

service representative.

the

charger power

I

Redistribution or publication of this document by any means, is strictly prohibited.

.

Redistribution or publication of this document by any means, is strictly prohibited.

Cummins Power Generation

Redistribution or publication of this document by any means, is strictly prohibited.

1400 73rd Avenue N.E. Minneapolis, MN 55432 1-800-888-6266 763-574-5000 International Use Fax: 763-528-7229

Cummins is a registered trademark of Cummins Inc.