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GB4109
User Manual
32 pgs895.59 Kb0

Exide Technologies GB4109 User Manual

ELEMENTSERIES
INDUSTRIAL BATTERY CHARGERS
INSTALLATION & OPERATING
INSTRUCTIONS
TABLE OF CONTENTS
Sales xService xRecycling 888.563.6300 in the USA 800.268.2698 in Canada 1
SAFETY PRECAUTIONS
BEFORE ATTEMPTING TO OPERATE THE CHARGER, PLEASE READ THIS GUIDE CAREFULLY.
SAVE THESE INSTRUCTIONS – This guide contains important instructions for Element
High
Frequency series product line that shall be follow
ed during installation and maintenance of the charger.
Only qualified personnel should install, operate, or service this equipment.
WARNINGS:
¾WARNING Risk of High Voltages – Lethal voltages are present within the charger enclosure
whenever the ac line is energized and/or the battery/load is connected. The heatsinks and other internal components present the risk of electric shock.
¾WARNING Risk of Improper Grounding – The charger must be connected to an ac power supply
incorporating an earth/ground. The grounding conductor must be of a size equal to or larger than the line (phase) conductors.
¾WARNING Risk of Explosive Gases – Working in the vicinity of a lead-acid battery is dangerous.
Batteries generate explosive gases during charging and discharging. To reduce the risk of battery explosion, follow these safety instructions as well as those published by the battery manufacturer.
¾WARNING Protect Eye and Skin – Wear safety goggles and skin protection while installing your
battery charger or working in the vicinity of lead-acid batteries.
¾To reduce the risk of injury, only charge rechargeable lead-acid batteries. Charging other battery
types may cause damage and result in personal injury.
CAUTIONS:
¾Risk of electric shock from stored energy. Wait at least two minutes after de-energizing the ac
line and disconnecting the battery/load before removing the cover.
¾Risk of electric shock and/or electric energy - high current levels. Do not touch un-insulated
battery, connectors or terminals. All tools should be adequately insulated to avoid the possibility of shorting connections. Inspect cables often for damage to the insulation. Replace cracked or worn cables immediately.
¾Risk of fire or explosion from gases vented by batteries. Be sure to discharge static electricity
from tools and technician by touching a grounded surface in the vicinity of the batteries. To prevent damage to the connectors and reduce the risk of explosion due to arcing, connect or disconnect the battery plug only when the charger output is off. ALWAYS press the STOP pushbutton before unplugging the battery to prevent arcing.
¾Risk of electrical component failure due to improper connection. If the charger is incorrectly
wired to input or output devices, or wiring is not in accordance with local safety codes and standards, the unit is at risk of being destroyed.
¾Risk of electrical component failure due to improper installation. To prevent damage from
overheating, proper airflow must be ensured. Do not restrict fan inlets or exhaust outlets. Do not mount the charger in a confined space or where the exhaust air will recirculate.
¾There are no user serviceable parts within the charger enclosure. If service is required, contact the
local GNB Industrial Power service representative.
¾The charger is NOT for outdoor use. Do not expose the charger to rain or snow.
¾Do not disconnect the battery while under charge.
IMPORTANT:
¾Follow the battery manufacturer's published instructions when installing, charging and servicing
batteries.
¾These instructions assume a certain level of competence by the installer and/or user. The following
practices and codes contain relevant information, and should be consulted for safe handling, installation, testing, and maintaining deep cycle batteries. Applicable state and local codes must be followed.
xNESC, National Electric Safety Code, ANSI C2-1993 (or latest revision). Copies may be
obtained by writing:
The Institute of Electrical and Electronics Engineers, Inc.
th
345 East 47
Street, New York, NY 10017, USA
xNEC National Electrical Code NFPA-70 (or latest version) available from: National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269
xFederal Codes:
29CFR1926.441 "Safety Requirements for Special Equipment"
29CFR1910.151(c) "Medical Services and First Aid"
29CFR1910.305(j) "Wiring Methods, Components and Equipment"
STD 1-8.2(e) "OSHA Standing Directive"
xEMC Compliance:
This device complies with Part 15 section 103 of FCC Rules as a digital device used exclusively as a power system in public utilities or industrial plants.
Operation is subject to the following two conditions:
(1) This device may not cause harmful interference, and
(2) This device must accept any interference received, including interference that may
cause undesired operation.
Sales xService xRecycling 888.563.6300 in the USA 800.268.2698 in Canada 2
Sales xService xRecycling 888.563.6300 in the USA 800.268.2698 in Canada 3
CHARGER SPECIFICATIONS
The Elementsystem specifications are listed below.
LMT-06kW-48-xxxS LMT-10kW-48-
xxxT
LMT-10kW-80-
xxxT
Nominal VA Ratings 48V / 150A
48V / 250A 80V / 120A
Input Specs.
Voltage 480VAC, 3-phase +10% Delta Connection with Earth
Ground
Current (nominal) 8.3A rms / phase
13.8A rms / phase
13.8A rms / phase
AC Circuit Size 15A
20A 20A
Power Factor 0.96 (Active Power Factor Correction)
Output Specs.
Voltage 48V Nom. /
62.5V Max.
48V Nom. /
62.5V Max.
80V Nom. / 110V Max.
Current 150A Max.
250A Max. 120A Max.
Power 6 kW Max.
10 kW Max. 10 kW Max.
Pk-Pk Voltage Ripple < 1% Efficiency (typical) 92% at Full Load Protection
Input ¾Under voltage
¾Over Voltage
Output ¾Over Current
¾Over Voltage
¾Over temperature
¾Battery reverse polarity protection
Operating Conditions
Ambient Temperature 0 – 40oC
Humidity 10-90% RH non-condensing Interface
Communication Isolated RS-232 (Ethernet optional)
User Interface LCD/Keypad, RS-232, IR with a PDA (Palm Pilot) Cooling Forced air (fans) Mechanical
Dim. WxDxH 29"x8.5"x28"
Weight ~ 98 lb
Output Cabling 2/0 cables
Output Connectors SBX w/aux. contacts or Euro Connector
Auxiliary Contacts Interface with 5kȍbattery thermistor (optional)
Certifications UL and cUL Listed Note: Design and/or specifications are subject to change without notice. If questions arise,
contact your local sales representative for clarification.
INSTALLATION PROCEDURE
I. Charger Inspection
1. Upon receipt of the Element charger, verify that the shipping information (packing list) matches the charger rating (label on the side of the charger).
2. Upon receipt of the Element charger, ensure that there is no physical damage to the
chassis, the LCD/keypad, the E-Stop/Disconnect switches, or the AC/DC cables. If you notice any damage, inform the shipping carrier and/or GNB Industrial Power.
Do not install or operate the unit if it has received a sharp blow, been dropped or otherwise damaged.
II. Charger Physical Installation
1. Ensure that the charging area is well ventilated, dry, and adequately clean.
2. Do not restrict airflow to the bottom air filter or top cover. Leave at least 1 ft spacing
between the sides of the charger and any adjacent walls or barriers and 2 ft spacing between the bottom of the charger (air filter) and the floor / any mounting brackets.
3. Use a cardboard sheet as a template to mark the locations for the hardware on the wall.
4. Drill and install the hardware needed to mount the charger on the wall.
5. Lift the charger and mount it on the wall using the installed hardware (Figure 1).
Use ¼-20 hardware with lock washers to secure the charger to wall.
Figure 1: Charger installation
Sales xService xRecycling 888.563.6300 in the USA 800.268.2698 in Canada 4
Sales xService xRecycling 888.563.6300 in the USA 800.268.2698 in Canada 5
CAUTION: When installing, do not lift the unit from the middle of the lower cover as this may damage the filter. To reduce potential for filter damage, lift the charger using the lifting handles mounted on either side of the charger chassis (see Figure 2).
Figure 2: Charger lifting instructions
III. Installing / Removing Air Filter
The charger is equipped with an air filter located in the lower cover of the unit. The air filter needs to be checked on a regular basis and cleaned if needed.
ATTENTION: To clean the filter, use soap and water; dry thoroughly before installing.
To remove the filter, hold the open end of the filter and slide out. To re-install, slide the filter into the lower cover guide and push in until fully inserted (Figure 3).
Lifting
Handles
Air filter
Filter Guides
Figure 3: Installing / Replacing Air Filter
Sales xService xRecycling 888.563.6300 in the USA 800.268.2698 in Canada 6
Sales xService xRecycling 888.563.6300 in the USA 800.268.2698 in Canada 7
Charger Electrical Installation
1. Verify proper AC line voltage and current ratings per the charger specifications as listed on the label on the side of the unit (see table below for proper AC line ratings).
AC Line Ratings for Element Chargers
Charger Model AC Voltage AC Current
Disconnect Circuit
(@125%)
LMT-06kW-48V
480VAC 3
(±10%) & GND
8.3 A nominal 15 A
LMT-10kW-48V-250A
LMT-10kW-80V-120A
480VAC 3
(±10%) & GND
13.8 A
nominal
20 A
2. Verify that the main power and emergency stop switches on the unit are in the off (stop) positions.
3. Figure 4) then push out one of the knockouts on the top cover to pass the AC conduit through. The AC & GND wire connections are shown in
4. Figure 5.
5. Connect the input 480VAC power cable to the three pole AC block terminals marked ABC (Figure 6). Connect the GND wire to the terminal marked GND as shown in Figure 7.
6. Note that the unit is not phase rotation sensitive, but noted here to avoid confusion.
7. Verify the line and ground connections of the outlet or junction box (4-Wire Delta – No Neutral).
CAUTION: Verify that input and output wiring adheres to all local safety codes and standards.
THE UNIT IS NOW READY FOR OPERATION.
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