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Page 1

DEC200 SERIES

INDUSTRIAL BATTERY

CHARGER I&O MANUAL

Page 2

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. AC 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 B DEC200 Troubleshooting 14 Appendix C Technical Data 15 Appendix D Circuit Diagrams 16-17 Appendix E Cabinet Dimensions 18

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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 there 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 charger DC cabl e length of 9 ft and a

battery DC cable length of 25 in. If DC cable lengths are adjusted, please

contact your local GNB Industrial Power Motive Power service representative.

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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.

3. 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.

4. LOCATION AND INSTALLATION OF CHARGE R

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. The charger should be located in a clean, cool, normal ambient room temperature (between +32

F/0oC and 104oF/40oC), 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.

5. 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) If a 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.

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b) Remove the bolts from the top cover of 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.

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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 can 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: TO REDUCE THE RISK OF FIRE, USE ONLY ON CIRCUITS PROVID ED

WITH BRANCH CIRCUIT PROTECTION CONSISTENT WITH THE CURRENT INDICATED ON THE FRONT PANEL-RATING LABEL AND IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE, ANSI/NFPA 70.

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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)

Mains Input

(Black)

N L

240 VAC 60Hz CONFIGURATION (208/240/480V INPUT)

N L

480 VAC 60Hz CONFIGURATION (208/240/480V INPUT)

208

240

480

PCB

(Blue)

N L

(Brown)

PCB

(Blue)

(Brown)

208

Mains Input

(Black)

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240

480

PCB (Blue)

(Brown)

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FIGURE 2: THREE-PHASE INPUT

WARNING: IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE

SEVERE DAMAGE TO THE CHARGER AND BATTERY

NOTE: PCB connections must NOT be altered from factory setting.

208VAC 60 Hz CONFIGURATION (208/240/480V INPUT)

Mains Input

(Black)

(Black) (Black)

Mains Input

(Black) (Black)

(Black)

208

240

480

240VAC 60 Hz CONFIGURATION (208/240/480V INPUT)

208

240

480

480VAC 60 Hz CONFIGURATION (208/240/480V INPUT)

208 208

480

240240

480

PCB (Brown)

(Blue)

240240

480

PCB

(Brown)

(Blue)

208

240

480

208 208

Mains Input (Black)

(Black) (Black)

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480

240240

480

PCB

(Brown)

(Blue)

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6.2. AC VOLTAGE CONNECTIONS To connect the input AC voltage, route the AC conduit through the knockout hole

provided. Continue the AC wiring to the breaker terminals L1 (N) and L2 (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 completed, 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.

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9. DEC200 STANDARD CHARGER OPERATION

CHARGE CONDITION

CHARGING A A, Ph Y

TERMINATION rEdy G

TERMINATION/ FAULT CODE rEdy / F R*, G

DISPLAY

DEFAULT

FUNCTION BUTTON DISPLAY SELECTION LED

SETTING EQUALISE EqAL for 5 seconds then default display

EQUALISE CHARGE A / EqAL G*, Y

AUTO BALANCE StSt / A StSt / V G

Lobt CHARGE PERIOD Lobt / A Y*

Lobt OFF PERIOD Lobt / V

CRITICAL FAULT CODE F R

NONE CRITICAL FAULT CODE F Charge continues R*

Charge

stage

A = Output current F = Fault code, display will alternate with the two codes Ph = Phase of charge i.e. 1, 2 and 3 StSt = 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.

# Display if due to smart start.

R: Red = Fault, flashing red is a none critical fault. Y: Yellow = Current flowing, flashing yellow when < 2.37VPC. G: Green = charge complete.

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10. CHARGER FUNCTIONAL DESCRIPTION

10.1. LED Descriptions

LED Description

Yellow Flashing High Rate Current

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 autobalance 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

2.40VPC 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

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10.6 EQUALIZE PUSHBUTTON Equalize charge can be enabled/disabled, when the FUNCTION button is depressed

> 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

10.7.1 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 the incorrect battery fault has been detected.

10.7.2 OPERATION If ‘Low Battery Override’ has been enabled and a battery (voltage > 1.00

VPC) 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’.

10.8 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.

10.9 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.

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11 MAINTENANCE

The charger requires minimum maintenance. ENSURE THE CHASSIS IS SECURELY 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.

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APPENDIX A – FAULT CODES

CODE STATUS DESCRIPTION

F01 F02 F03 F04 F05 F06 F07

F07 (+Y led on)

F09 F10 F11 F12

N N N S

S R C C C C

C C

Over discharged battery (<1.90vpc after 30 seconds of charge)

Deep discharged battery (<1.90vpc after 30 seconds of charge > 1.90vpc)

Sulphated battery

Charger over heating

Mains failed during charge

No output current Incorrect battery < 1.70 Incorrect battery > 2.25

Bulk charge time-out

Second stage time-out (Profile Dependant)

Incorrect Mains Frequency

Control hardware (MCU) F13 F16 F17 F18 F22

Key: C = critical fault Ö charge stopped Ö fault code displayed permanently S = suspend fault Ö charge suspended until criteria fulfilled Ö fault code displayed permanently R = retry fault Ö charge retries after 20 seconds Ö fault code display alternating with standard

display

N = non-critical fault Ö charge continues Ö fault code display alternating with standard display

S S C C C

Battery overheating (if temp probe fitted)

Auto balance charge time-out

Battery disconnected without pausing charge

Thermistor fault

di/dt termination

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APPENDIX B – DEC200 TROUBLESHOOTING

SYMPTOM

No Display No AC Power Check Input Power. Check Breaker. Mains fuse on Control Board

POSSIBLE

CAUSE

EXPLANATION / ACTION

Deeply

F01

F02 Over discharge

F03 Sulphated Battery

F04

F05 Mains Failure Electrical Supply failure during charge. (Power Cut)

F06

F07

F09 Battery Failure

F10

Discharged

Battery

Charger

Overheating

No Output

Current

Incorrect Battery Make sure the battery voltage matches the charger voltage.

Low Voltage

High Voltage

Second Stage

Time-Out

Battery Voltage less than 1.9 volts per cell initially but rose above this 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 battery condition and Equalize

Make sure your battery gets a full charge every cycle. Check battery condition and Equalize.

Check Fan for operation on initial power up. Ensure adequate ventilation. Contact your local GNB Industrial Power Motive Power representative.

Check DC Fuse, SCRs. Connection to Battery.

Check battery voltage with a voltage meter. Make sure battery 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 matched to battery. Check battery condition. Contact your local GNB Industrial Power Motive Power representative.

I2 limit not reached within time limit. Check battery condition. Contact your local GNB Industrial Power Motive Power representative.

F11

F12

F13

F17

F16

F18

F22

Incorrect Mains

Frequency

Board

Failure

Temperature

Sensor Failure

Auto Balance

Stage Time Out

Battery

Overheating

Battery

Disconnection

Overheated

Battery

Check the mains supply.

Contact your local GNB Industrial Power Motive Power representative.

Check battery condition. Check battery for High Temperature. Allow battery to cool. Check battery

condition. Confirm charger capacity is correctly matched to battery Press the PAUSE button before disconnecting the battery.

Check battery condition.

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APPENDIX C –TECHNICAL DATA

AC AMPS (RMS) @ AC

VOLTS @ 2.4 VPC

208

Vac

240 Vac

480 Vac

Cabinet

Size

Model Numbers

Single Phase

DEC200-24V-40AS1H DEC200-24V-75AS1H

DEC200-24V-95AS1H DEC200-24V-115AS1H DEC200-24V-135AS1H

DEC200-36V-75AS1H

DEC200-36V-95AS1H DEC200-36V-115AS1H DEC200-36V-135AS1H

Three Phase

DEC200-24V-75AT1H

DEC200-24V-95AT1H DEC200-24V-115AT1H DEC200-24V-135AT1H

DEC200-36V-75AT1H

DEC200-36V-95AT1H DEC200-36V-115AT1H DEC200-36V-135AT1H DEC200-36V-150AT1H

DEC200-48V-95AT1H DEC200-48V-115AT1H DEC200-48V-135AT1H

Amp-Hour Rating

Hour

Volt

Amps

330 400 470 24 40 11.4 9.8 4.9 M4 94.8 43 625 750 880 24 75 21.3 18.4 9.2 M4 134 61 790 950 1120 24 95 27 23.4 11.7 M4 145 66 955 1150 1350 24 115 32.6 28.3 14.1 M4 163 74

1125 1350 1590 24 135 38.3 33.2 16.6 M4 169 77

625 750 880 36 75 29.9 25.9 13 M4 158 72 790 950 1120 36 95 37.9 32.9 16.4 M4 163 74 955 1150 1350 36 115 45.9 39.8 19.9 M5 216 98

1125 1350 1590 36 135 53.9 46.7 23.3 M5 238 108

625 750 880 24 75 12 11 5.3 M4 134 61 790 950 1120 24 95 15 13 6.7 M4 145 66 955 1150 1350 24 115 19 16 8.1 M4 145 66

1125 1350 1590 24 135 22 19 9.5 M4 180 82

625 750 880 36 75 18 16 7.9 M4 180 82 790 950 1120 36 95 23 20 10 M4 180 82

955 1150 1350 36 115 28 24 12 M4 209 95 1125 1350 1590 36 135 33 28 14 M5 275 125 1250 1500 36 150 36.4 32 16 M5 297 135

790 950 1120 48 95 30.7 27 13 M5 264 120

955 1150 1350 48 115 37.2 32 16 M5 288 130 1125 1350 1590 48 135 43.6 38 19 M5 299 136

*DC FUSE MUST BE A FAST ACTING FUSE CAPABLE OF PROTECTING SEMICONDUCTORS.

SHIPPING DATA

WEIGHT

Lbs KG

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Component No: CLT6006

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

APPENDIX D

DRAWING TITLE: GNB [UL] 3phase wiring diagram

bl BLUE bk BLACK br BROWN gy GREY rd RED wh WHITE YL/G YELLOW / GREEN

L2 L3

KEY

L2 L3

YL/G

L2 L3

blgybl

CON1

wh '0'

1234

FS1

12345678

PCB1

bl '2'

wh '1'

wh '2'

9101112131415

CON 5

bl '1'

bl '0'

wh '2' bl '2'

wh '1' bl '1'

wh '0'

bl '0'

Shunt

FS2

DRAWING No: 4 - CMP - 2600 - 01 - WD - E

Drawn by: Trev Peacock Trev Peacock 10 12 03

Trev Peacock Trev Peacock

13 12 02

19 12 03 17 03 04

Checked by:

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MOD No: REV:

C000007

C000044 C000045

C000068

B C D

If any errors are apparent within this diagram please inform CMP engineering.

Materials: White Polypropylene 60u PP198 TC

Clear Overlaminate 60u PP20 Adheasive: AP51 Size: A5 (210 mm x 147mm) Text: As shown Colour: Black on white

CMP Batteries Ltd, Charger Division, Unit 2 Pisces, Mosley Road, Trafford Park, Manchester. M17 1PF.

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Component No: CLT6005

For 120V input connect to 120V

connections on T1

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

2 0 V

APPENDIX D

DRAWING TITLE: GNB [UL] Single phase wiring diagram Fuse / Breakers

KEY

2 4 0 V

bl BLUE bk BLACK br BROWN gy GREY rd RED wh WHITE YL/G YELLOW / GREEN

YL/G

4 0 V

240V

PCB1

CON1

FS1

blgybl

1234

12345678

CON 5

Shunt

FS2

bl rd

DRAWING No: 4 - CMP - 2600 - 02 - WD - E

Drawn by:

Trev Peacock Trev Peacock Trev Peacock

Trev Peacock

17 04 03 10 12 03 19 12 03

17 03 04

Checked by:

MOD No: REV: C000007

C000044 C000045

C000068

B C

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If any errors are apparent within this diagram please inform CMP engineering.

Materials: White Polypropylene 60u PP198 TC

Clear Overlaminate 60u PP20 Adheasive: AP51 Size: A5 (210mm x 147mm) Text: As shown Colour: Black on white

CMP Batteries Ltd, Charger Division, Unit 2 Pisces, Mosley Road, Trafford Park, Manchester. M17 1PF.

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APPENDIX E – DIMENSIONS

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”

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SALES – SERVICE - RECYCLING

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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.gnb.com