Exide S47-0079 User Manual

GNB

A division of

Exide Technologies

Industrial Battery Charger

Installation and Operation Manual

1

INDEX

Page Section Description

3 - Safety Instructions
4 1.0 Installation
4 1.1 Receiving
4 1.2 Location
4 1.3 Line Voltage Adjustments
6 1.4 AC Service Requirements
6 1.5 Connecting AC Service to Charger

7 1.6 Grounding the Charger
7 1.7 Battery Connector and Charger Cable
7 1.8 Charging Rate Adjustment
8 2.0 Operation
8 2.1 046-0371 Control
13 3.0 Optional Features
13 4.0 Troubleshooting & Maintenance
15 5.0 Replaceable Parts
15 5.1 Ordering Information
15 5.2 Recommended Spares
16 5.3 Spare Parts List
17 6.0 Schematics

SAFETY INSTRUCTIONS

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WARNING

THIS EQUIPMENT CONTAINS LETHAL VOLTAGE LEVELS. INSTALLATION AND

SERVICING MUST BE PERFORMED BY QUALIFIED PERSONNEL

IMPORTANT: SAVE THESE INSTRUCTIONS!

READ AND FOLLOW ALL INSTRUCTIONS BEFORE INSTALLING, OPERATING, OR

SERVICING CHARGER. ANY DEVIATION CAN CAUSE SERIOUS AND PERMANENT

DAMAGE. FAILURE TO FOLLOW THE INSTRUCTIONS VOIDS THE WARRANTY.

1. Install and ground the charger in accordance with the National Electric Code and your local
electric code. Failure to properly ground the charger could result in a fatal electric shock.

2. To reduce the risk of fire, install chargers on a surface of non-combustible material, such as
concrete, stone, brick or grounded metal.

3. This charger has been designed to only charge flooded, lead-acid batteries. It should not be
used for charging other types of flooded batteries or sealed batteries.

4. Connect only batteries of the same number of cells and ampere-hour rating as listed on the
charger nameplate. Damage to the battery could occur, particularly if the battery has fewer cells
than the rating of the charger.

5. Do not touch uninsulated parts of the output connector or battery terminals. A possibility of
serious electrical shock exists.

6. During charge, batteries produce hydrogen gas, which can explode if ignited. Never smoke, use
an open flame, or create sparks in the vicinity of the battery. Ventilate well when the battery is in
an enclosed space.

7. Do not connect or disconnect the battery plug while the charger is on. Doing so will cause
arching and burning of the connector resulting in charger damage or battery explosion.

8. Lead-acid batteries contain sulfuric acid, which is caustic and can cause chemical burns to the
skin. Refer to the battery manufacturers instructions for safe handling of batteries. Use proper
personnel protective equipment. Do not get in eyes, on skin, or on clothing. In cases of contact
with eyes, flush immediately with clean water for 15 minutes. Seek medical attention
immediately.

9. Do not operate the charger with the door open or with any panels removed. De-energize all AC
and DC power connections before servicing the charger.

10. The charger is not for outdoor use. Do not expose the charger to water spray, rain or snow.

11. Do not operate the charger with damaged cables, including cables with exposed conductors or
damaged connectors. Replace damaged cables before operation.

12. Do not operate the charger if it has been dropped, received a sharp blow, or otherwise damaged
in any way. Call your service representative.

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SECTION 1 - INSTALLATION

1.1. Receiving

Immediately upon receipt of the charger, check it against the shipping invoice to ensure the shipment is
complete and undamaged.

Examine the outside of the packing for signs of rough handling before accepting the charger from the
carrier.

If there is evidence of damage, the receipt should be signed, and both copies (carrier's and receiving
copies) marked "Shipment Received Damaged". The carrier's representative should be called
immediately and asked to make a "Carrier's Damage Report".

If concealed damage is later detected, the carrier should be called and requested to make a "Carrier's
Inspection for Concealed Damage Report".

After inspection by the carrier, arrangements should be made with the charger representative to have
the charger repaired before placing it in service.

When contacting your charger representative for assistance on a damage claim or shipment error,
provide the Model, and Serial Number of the charger, and a full description of the damage or error.

It is good practice to move the charger to the installation site before uncrating. When using bars,
hammers, etc. for uncrating, use care to avoid damage to the charger

WARNING: To reduce the risk of fire, install the battery charger on a non-combustible surface
such as concrete, stone, brick, or steel. DO NOT operate the charger on its shipping skid
materials.

.

1.2. Location

For the best operating conditions and longest life, take care in selecting an installation site. Avoid
locations exposed to high humidity, temperature extremes or dust. Moisture condensing on machine
parts and electrical components can cause corrosion, which seriously affects operation, efficiency and
life. All units are designed for floor mounting. Standard cases may be stack-mounted if required, up to 3
high. If so, optional stacking brackets are required and available. Consult factory.

Dust and dirt will also decrease heat radiation from heat-generating components, such as transformers
and diodes. This will result in higher operating temperatures and shorter life. Adequate air circulation is
needed at all times in order to ensure proper operation. Provide a minimum of 6 inches of free air space
at the sides and rear of the charger. The front of the charger must remain unobstructed for serviceability.

1.3. Line Voltage Adjustments

All chargers are shipped with the AC line voltage jumper wires set for the AC voltage specified on the
purchase order. Before connecting the charger to the AC service, it should be verified that the internal
AC voltage connections match the available AC service voltage. If necessary change the AC voltage
jumper wires shown in Figs. 1.3.1 through 1.3.3.

NOTE: For 50 Hz. Single or three phase fixed voltage chargers, there are no adjustments.

CAUTION: It will be necessary in most cases to change the AC fuses when the AC voltage

jumpers are changed. Refer to the fuse chart on the inside door of the charger for the correct fuse
rating.

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NOTE: When a 120/208/240 AC input unit is set for 120VAC a fuse neutral (brass tube) is required in

the Line 2 (neutral) fuse position.

Fig. 1.3.1.

A.C. Voltage Adjustments

1 Ø 60Hz. (120/208/240)

“A” Voltage Code

A.C. Voltage Adjustments

1Ø & 3Ø 60Hz. (208/240/480)

A.C. Voltage Adjustments

POWER TRANSFORMER SETTING

L1 L1

1234

Fig. 1.3.2.

“B” Voltage Code

Fig.1.3.3.

3 Ø 60Hz. (480/575)

“K” Voltage Code

L2 L2

56

1234

56

480

1234 132 4

CONTROL

TRANSFORMER

TRANSFORMER

5

575

CONTROL

1.4. AC Service Requirements

Follow local code requirements if they are different than the instructions in this manual. After checking
the transformer connections as described in Paragraph 1.3, refer to Table 1-1, to determine the correct
ratings for the AC cable, AC fuses, and AC service disconnect switch for the line amperes as listed on
the nameplate of the charger for the available AC voltage

Line Amperes Disconnect Switch Fuse Size Amps

000.0 - 02.5 30A 05

003.0 - 04.5 30A 07

005.0 - 07.5 30A 10

008.0 - 11.0 30A 15

011.5 - 15.5 30A 20

016.0 - 18.0 30A 25

018.5 - 22.0 30A 30

022.5 - 27.0 60A 35

027.5 - 32.0 60A 40

032.5 - 40.0 60A 50

040.5 - 48.0 60A 60

048.5 - 64.0 80A 80

065.0 - 80.0 100A 100

081.0 - 95.0 125A 125

096.0 - 125.0 150A 150

TABLE 1-1

For voltages up to 240, use a 240 volt disconnect switch.
For voltages greater than 240 to 600, use a 600 volt disconnect switch.

• Two conductors and ground wire required for single phase.

• Three conductors and ground wire required for three-phase

1.5. Connecting AC Service to the Charger

1.5.1 Single-Phase Models

Connect the AC service to the L1 and L2 terminals located at the end of the AC fuse block.
Note: If the charger has been ordered with an AC input door-mounted disconnect switch, the AC input

wires will be connected to the L1 and L3 terminals at the top of the switch body.

1.5.2 Three-Phase Models

Connect the AC service to the L1, L2 and L3 terminals located at the end of the AC fuse block.
Note: If the charger has been ordered with an AC input door-mounted disconnect switch, the AC input

wires will be connected to the L1, L2 and L3 terminals at the top of the switch body.

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