Exide Technologies GB4127 User Manual

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EF – SERIES

Installation and Operation Manual

Ferro-Resonant Charger

Toll Free: U.S.A. 1-888-563-6300

PN 047-0175 REV04 (GB4127 2010-06)

Sales – Service – Recycling

Canada 1-800-268-2698

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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 14 2.2 046-0372 Control 26 3.0 Optional Features 26 4.0 Troubleshooting & Maintenance 28 5.0 Replaceable Parts 28 5.1 Ordering Information 28 5.2 Recommended Spares 29 5.3 Spare Parts List 30 6.0 Schematics

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SAFETY INSTRUCTIONS

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 dam age 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 redu ce the risk of fire, install th e batter y charger on a n on-combustible sur face such as concrete, s tone, brick, or ste el. DO NOT oper ate th e ch arger on its shipping ski d 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 chang e the AC fu ses when the AC voltage jum pers

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)

POWER TRANSFORMER SETTING

L1 L1

1234

Fig. 1.3.2.

“B” Voltage Code

Fig.1.3.3.

A.C. Voltage Adjustments

3 Ø 60Hz. (480/575)

“K” Voltage Code

L2 L2

1234

480

1234 132 4

CONTROL

TRANSFORMER

575

CONTROL

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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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1.6 Grounding the Charger

The charger must be grounded to the AC system ground for personnel safety. The green ground wire in the AC input wiring must be connected to the charger ground stud

(identified by a green dot and ground symbol).

1.7 Battery Connector and Charging Cable

Verify that the connectors on both the battery and the charger are attached so that the positive output terminal of the charger is connected to the positive battery terminal.

CAUTION: If the polarity is reversed, the DC fuse will blow.

If in doubt, check the polarity with a DC voltmeter.

1.8 Charging Rate Adjustment

Note: Charging rate adjustments may be necessary to compensate for locations of extreme AC line variation or may be used to tailor the charger output for aging batteries.

The charging rate has been set at the factory; therefore, field adjustment should not be necessary. If there appears to be a charging rate problem, refer to the troubleshooting chart, Section 4. If it is necessary to either increase or decrease the charging rate, a rate adjustment terminal block is provided

on the top rear of the transformer mounting bracket. Change only one step at a time and observe the effect on the battery before making a second change. The charging rate is increased by moving to the next higher tap setting in Table 1-2. The charging rate is decreased by moving to the next lower tap setting. No adjustments should be made without consulting the factory.

TABLE 1-2

CHARGING RATE ADJUSTMENTS

CONNECT RED

JUMPER WIRE TO

CONNECT

BLACK WIRE TO

OUTPUT

9 12 HIGHEST 9 11 9 10

9 8 NORMAL 12 11 12 10

12 9 LOWEST

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SECTION 2 - OPERATION

The charger utilizes a standard ferro-resonant transformer, which provides isolation from the AC service line and regulates the charging current. The transformer output is connected to a full-wave bridge of silicon diodes, which provides DC charging current to the battery.

The starting charge amps and length of time required for a charge vary depending on the charger model. See the data plate on the charger for information.

2.1.1 046-0371 Control Feature Summary

• Charges flooded or sealed batteries.

• Automatic start when battery is connected or manual start (if selected).

• Automatic stop when charge is finished.

• Fully charges partially discharged batteries without overcharging.

• Dead battery ‘jump start’ for overly-discharged batteries.

• Equalize charge by user request or automatic equalize settable from 1-30 charges.

• Automatic refresh charging when set time has elapsed.

• Automatically resumes charge after a power failure (if auto-start selected).

• Displays charging amps and volts per cell during the charge cycle.

• End Voltage, end current, AH, and run time can be displayed during charge, at the end of charge, or after

disconnecting the battery.

• Delayed start adjustable from 0 to 24 hours (if auto-start selected).

• Displays code if an abnormal charge indication is detected.

• Cool down timer after the charge is complete (if selected).

2.1.2 Description

The front panel has a 16 character LCD display which normally shows charging amps and volts per cell along with a periodic message showing the charger state. This display also presents messages if an abnormal charge indication is detected. A yellow ‘Charging’ indicator lights while the charger is charging. A green ‘Complete’ indicator lights when the charge is complete. A red ‘Fault’ indicator lights if an abnormal charge indication is detected.

The front panel has STOP, =, EDIT and INFO buttons. A charge can be stopped by pressing STOP and resumed by pressing STOP again. While charging, an equalize charge can be requested by pressing = and turned off by pressing =. During or afte r charge, the charge information may be obtained by pressing INFO.

2.1.3 Operation

The 046-0371 control is used in ferro-resonant taper chargers to provide fully automatic battery charging. The control has a charging profile that handles standard flooded lead-acid batteries. The charging profile, or algorithm, uniquely monitors the output current and voltage to optimally charge the battery, based on battery manufacturer’s recommendations.

The control offers several safeguards to protect the battery. If a wrong voltage battery is connected, the charger does not start and a Low-Battery-Voltage (F3) or High-Battery-Voltage (F4) message is displayed. While charging, if the battery voltage exceeds a profile-specific cut-off value, the charge terminates with an end on voltage message.

2.1.4 Normal Daily Charge

When no battery is connected, the LED indicators are off and the LCD display shows ‘0A 0.00VC’. With the auto-start feature enabled, connecting a battery to the charger causes it to begin a charge cycle. The charger first performs a self-diagnostic test to verify the control is working properly. During this time a lamp test is performed causing all display segments and indicators to light. This allows the operator to observe any defective segments or indicators. When the self-diagnostic is complete, the charge starts if no delay is set, and the yellow ‘Charging’ indicator lights. The display shows the charging amps and battery volts per cell along with a message to indicate the charger is in phase 1 of the charge cycle. If auto start is disabled, the display shows ‘CHARGER OFF’. Press STOP to manually sta rt the cha rge.

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When the battery is 80% charged, the charger starts phase 2 of the charge cycle.

When a charge is finished, the charger automatically turns off. The yellow ‘Charging’ indicator goes out. If cool down is enabled, the display shows the cool down time remaining. If cool down is disabled or the time has elapsed, the display shows ‘0A x.xxVC ’ along with a message indicating the battery is ready and the green ‘Complete’ indicator lights.

2.1.4.1 Disconnecting the Battery

Warning: Risk of explosion. Do not disconnect the battery while the charger is running. Hydrogen gas produced by the battery during charging can be ignited by arcing that occurs when the battery cable is disconnected.

If the battery must be disconnected before the end of the charge cycle, the charger should be turned off first. Press STOP, and verify the yellow ‘Charging’ indicator goes out. The LCD display shows ‘CHARGER OFF’. The battery may then be safely disconnected. If the green ‘Complete’ indicator is lit, the battery may be disconnected at any time.

2.1.5 Equalize Charge

Over time batteries can develop inequalities in cell charge. This can lower the effective capacity of the battery and shorten life. An equalizing charge re-balances the charge in the battery cells. Perform an equalize charge if any of the following conditions exist:

1. On flooded batteries the specific gravity of any cell at the end of charge is 20 points less than the average of all

the cells.

2. The on-charge voltage of any cell at the end of charge is 20 millivolts less than the average of all the cells.

3. The battery has been stored for 30 days.

The 046-0371 control can perform an equalize automatically if auto equalize is enabled. Normal equalize consists of an additional 3 hour charge time at the end of a normal charge cycle. The 046-0371 control can also perform an equalize charge when requested manually. First connect the battery and allow the charge to start normally. Then press =. The display shows ‘=’ on the left side and the charge time is extended by 3 hours to allow the cells to equalize their charge.

The auto-equalize or manual equalize cycle can be cleared by pressing = while in the normal charge cycle. The ‘=’ indication on the display turns off. The next auto equalize charge occurs after the set number of charge cycles if auto equalize is enabled. If the set number of charge cycles have been completed, the charger attempts to equalize after the next charge cycle and continues to attempt to equalize until an equalize cycle has completed.

The default setting for automatic equalize is every 7 cycles. To change the number of charge cycles for automatic equalize, refer to the programming section.

2.1.6 Delayed Start

The delayed-start feature allows the operator to delay starting the charge cycle. This might be desired to reduce peak energy surcharges if the charger were ready to start during a peak energy period. The delay time could be set to keep the charger from starting until af ter the peak period ends.

To view or change the delayed start setting, refer to the programming section.

2.1.7 Auto- Refresh Charge

The 046-0371 control can provide an auto-refresh charge as long as the battery remains connec ted to the charger if enabled. If AC power is lost during the wait period, the control resumes from where it left off after power is restored. During the auto-refresh charge, the amp-hours and charge time are added to the original charge. The refresh charge consists of 30 minutes at the equalize current. To change the autorefresh settings, refer to the programming section.

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2.1.8 Viewing Charge Information

Additional charge information is available any time by pressing the INFO button. This information is retained after the battery is disconnected until the next battery is connected. After 20 seconds the display returns to the default display of amps and volts per cell. The following information can be viewed:

Parameter DISPLAY DESCRIPTION

Charger State XXXXXX

Amps CHARGER DC AMPS

AA: xxxA

Volts/Cell BATTERY V/C

VC: x.xxVC

Amp Hours ACCUMULATED AH

AH: xxxxAH

Charge Time CHARGE TIME

TC: xx:xxHM

Percent Return % AH RETURNED

PR: xxx%

Voltage BATTERY VOLTS

VV: xx.xV

End Current CHARGE END AMPS

EA: xxxA

End Voltage CHARGE END VOLTS

EV: x.xxVC

Software SOFTWARE VERSION

SW: x.xx

Message describing charger state. Charger current in amps.

Battery voltage in volts per cell (v/c).

Amp Hours returned for the current (or last) charge cycle.

Charge time for the current (or last) charge cycle in hours and minutes.

Percent of Amp Hours returned as a function of battery AH rating.

Total battery voltage in volts.

End current for the last charge cycle (current amps if charging)

End voltage for the last charge cycle (current voltage if charging)

Control software version

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2.1.9 Charge Indications

The following indications are not necessarily a result of a charger problem. They are typically caused by external problems such as AC line, poor battery conditions, connections, etc. If abnormal charge conditions are detected, the charge is terminated, the red fault LED lights and the display shows:

DISPLAY DESCRIPTION POSSIBLE CAUSE

SHORTED

CELL

#.##VC

##:##HM

SHORTED

CELL

#.##VC

##:##HM

F3 LOW

VOLTS

###A

#.##VC

F4 HIGH

VOLTS

###A

#.##VC

F5 NO DC

CURRENT

###A

#.##VC

F6 F7 LONG CHARGE

#.##VC

##:##HM

CHARGER

###A

#.##VC

F9 BAD

KEYPAD

###A

#.##VC

F10 HIGH

CURRENT

###A

#.##VC

Battery voltage did not reach 2.00 V/C within 30 minutes. #.##VC is the volts per cell at end of charge and ##:##HM is the charge time.

Battery did not reach gassing voltage within the allowable time. #.##VC is the volts per cell at end of charge and ##:##HM is the charge time.

Low battery voltage, less than 1.60 V/C at start up. ###A is the charger current and #.##VC is the battery volts per cell.

High battery voltage, more than 2.40 V/C at start up. ###A is the charger current and #.##VC is the battery volts per cell.

No charging current to the battery. ###A is the current at the end of charge and #.##VC is the volts per cell at end of charge.

- Incorrect control setup Long charge, the charger ran longer than the allowed time. #.##VC is the volts per cell at end of charge and ##:##HM is the charge time.

Charger stayed on when control requested it to shut off. ###A is the charger current and #.##VC is the battery volts per cell.

Faulty keypad detected. One or more buttons are stuck on. ###A is the charger current and #.##VC is the battery volts per cell.

Charging current exceeds 110% of shunt setting. ###A is the current at the end of charge and #.##VC is the volts per cell at end of charge.

- Shorted Cell

- Open diode

- Low Charging amps

- Low AC line voltage

- Wrong size battery

- Battery over-discharged

- Shorted Cell

- Open diode

- Low Charging amps

- Low AC line voltage

- Wrong size battery

- Battery over-discharged

- Wrong size battery

- Battery over-discharged

- Voltage jumper setting incorrect

- Wrong size battery

- Battery fully charged

- Voltage jumper setting incorrect

- Faulty AC line contactor

- Open diode

- Faulty resonant capacitor

- Poor battery connections

- Open cell

- Faulty control board

- Open diode

- Low Charging amps

- Low AC line voltage

- Wrong size battery

- Battery over-discharged

- AC line contactor stuck on

- Open shunt sense lead or loose connection

- Incorrect control setup

- Missing or damaged current sensor

- Faulty control board

- Faulty keypad

- Faulty control board

- High charging amps or high AC line voltage

- Missing or damaged current sensor

- Incorrect shunt size

- Open shunt sense lead or loose connection

- Faulty control board

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Note: F3 and F4 clear automatically if the battery voltage falls within acceptable limits. All indications except F8, F9 and F10 can be cleared by disconnecting the battery. For F8, F9 and F10, correct the condition that caused the indication and disconnect the battery to clear the indication.

CAUTION: If F8 is showing, and the charger is providing current to the battery, remove AC power from the charger before disconnecting the battery.

2.1.10 F3 (Low Battery) Override

If battery voltage is below 1.60 volts per cell the charger does not start automatically. If this is due to an overly discharged battery of the correct voltage, the F3 indication can be manually overridden by pressing ‘STOP’ while the F3 message (Low Battery) displays.

2.1.11 Jumper Settings

CAUTION: Remove AC and DC power from the charger before changing any jumper settings.

Refer to figure 1 for location of jumpers.

- Jumper J5 should be set to match the battery voltage.

Volts 80V 72V 64V 48V 36V 24V

12V

For non-standard battery voltages above 80V, the jumper is set on 12 and a resistor is installed in the charger wire

harness based on the following calculation: R = 1250 x (Nominal Battery Voltage) – 15000.

For non-standard battery voltages between 12V and 80V, the jumper is set on SP and resistor R9 is installed on the

control based on the following calculation: R9 = 1250 x (Nominal Battery Voltage) – 15000.

- Jumper J4 is used to lock out several parameters in the programming mode.

- Header J1 is used to select the charger type.

CHARGER TYPEPARAMETER LOCKOUT

LOCKED

UNLOCKED

FERRO

HF*

J4 J4

*J1 used for interface to HF module

Caution: Placing jumpers on any other position on J1 or J4 may damage the control and voids the warranty.

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2.1.12 Programming

To enter programming mode, press and hold the EDIT button and while holding it, press the INFO button. The display shows a message describing the current parameter followed by the parameter‘s value. While in programming mode, the buttons have the following functions:

STOP: Exit programming mode and save all parameters =: Shift position of parameter being edited EDIT: Change value of current position of parameter being edited INFO: Change parameter to edit

Some of the parameters may be locked out in the programming mode. If a parameter is locked, the parameter is displayed along with the current value and a lock is displayed on the left side of the display. The parameter can not be changed. Refer to jumper settings section for information on locking out parameters. The following parameters are available for editing:

PARAMETER MESSAGE RANGE NOTES LOCK

BS BATTERY AH SIZE 100-2200AH

VR BATTERY VOLTAGE 12-999V ●

SR SHUNT RATING 0-600A A setting of 0 enables current sensor operation ●

AS AUTO START MODE 0-2

CR CABLE RESISTANCE 0-25mΩ SA START A/100AH 5.0-50.0 A/100AH ● TP 80% TRIP POINT 2.35-2.45 V/C ● FA FINISH A/100AH 0.1-10.0 A/100AH ● FV FINISH VOLTAGE 2.50-3.00 V/C ●

CV CUTOFF VOLTAGE 2.50-3.00 V/C Exceeding this voltage terminates the charge immediately. ●

ST 80% TIMEOUT 0:00-24:00

FT CHARGE TIMEOUT 0:00-24:00

MP MAX POWER RATING 0.1-25.0 kW *DO NOT EXCEED RATING OF CHARGER ●

CF CHARGE FACTOR 0-150%

DS DELAY START TIME 0:00-24:00 CT COOL DOWN TIME 0:00-24:00

CU DVDT PERIODS 0-15

EM EQUALIZE MODE 0-1

EI EQUALIZE A/100AH 0.1-10.0 A/100AH ● ET EQUALIZE TIME 0:00-24:00 ● EC EQUALIZE CYCLES 0-30 Setting this to 0 disables automatic equalize. N1 F1 FAULT DISABLE 0-1 0: Enabled, 1: Disabled ● N3 F3 FAULT DISABLE 0-1 0: Enabled, 1: Disabled ● N4 F4 FAULT DISABLE 0-1 0: Enabled, 1: Disabled ● N6 F6 FAULT DISABLE 0-1 0: Enabled, 1: Disabled ● N7 F7 FAULT DISABLE 0-1 0: Enabled, 1: Disabled ●

AR REFRESH TIME 00:00-72:00 Setting this to 0:00 disables automatic refresh.

0: Manual Start 1: Auto-Start 2: Auto Start (restart on AC power)

Exceeding this time results in an F1 if F1 is enabled and ends normally if F1 is disabled. (see N1 parameter) Exceeding this time results in an F7 if F7 is enabled and ends normally if F7 is disabled. (see N7 parameter)

Maximum return based on battery AH size. Setting this to 0 disables the charge factor.

Each period is 5 minutes. Setting this to 0 causes the charge to terminate when the trip point is reached. (opportunity charge) 0: Equalize disabled 1: Normal equalize

●

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SECTION 2 – OPERATION (continued)

2.2 046-0372 CONTROL

2.2.1 DESCRIPT ION

The 046-0372 charger control provides fully automatic battery charging in standard taper ferro-resonant chargers. The control is powered from a 24VAC transformer that provides isolation from the AC service line. The presence of a battery is detected by the control and causes a charge cycle to begin automatically. Each charging profile, or algorithm, uniquely controls the output current and voltage to optimally charge a particular type of battery, based on battery manufacturer’s recommendations. The control can be set to start charging at a certain time of day. It can be used with the I’m Cool System and the TOBi

A 16-key keypad allows the user to display various parameters and to customize the operation of the charger.

Battery Management System.

2.2.2 PROGRAMMING

A minimum of five parameters must be programmed for proper operation: 1) the time of day and date, 2) the algorithm, which is determined by the type of battery being charged, 3) the amp-hour rating of the battery which is obtained from the charger data plate, 4) the nominal battery voltage which is obtained from the charger data plate, and 5) the current shunt rating which is imprinted on the side of the current shunt located inside the charger. Gather this information before programming the control.

Press the SET key to enter the programming mode. The display shows ‘SET PARAMETER’. Then another key or

keys are pressed for the parameter to be programmed. The display then shows a brief description of the parameter and its current value. The parameter is changed by entering a new value using the numeric keys on the keypad. Data entry is from left to right. If more than four digits are entered, the left-most digits scroll off the left end of the display. If an incorrect number is keyed in, press 0 four times to scroll the bad number off the display and continue entering the correct value. (Note that if no keys are pressed within about 8 seconds, the programming mode times-

out and the control returns to the normal ‘#A #.##VC’ display). Once the value is entered, press ENTER. If the value entered is correct, the display shows ‘PARAMETER SAVED’ to confirm the value. (If an incorrect value is entered the display shows ‘!! ERROR !!‘ and then returns to the normal ‘#A #.##VC’ display.)

Some of the programming parameters can be locked out to prevent a user from intentionally or unintentionally changing the settings. When a parameter is locked, a lock appears on the display and the value cannot be changed. Refer to the section on jumper settings for information on locking out parameters.

2.2.2.1 Setting the Time-of-Day

Press SET, then CLOCK. The display shows ‘TIME OF DAY’ followed by ‘TD:’ and then the time-of-day. Time is

entered in 24 hour format (military time). If the actual time is 3:27 PM, it is entered as 15.27. Enter the correct local time using the numeric keys on the keypad. Press ENTER to save it.

2.2.2.2 Setting the Date

The date is set in 3 steps, first the month, then the day, then the year. Press SET, then 5, and then CLOCK. The

display shows ‘MONTH (1-12)’ followed by ‘MO:’ and the month, 1-12. Enter the month using the numeric keys on the keypad and press ENTER to save it. If the month is accepted, the display then shows ‘DAY (1-31)’ followed by ‘DY:’ and the day-of-month, 1-31. Enter the day using the numeric keys on the keypad and press ENTER to save it. If the day is accepted, the display then shows ‘YEAR (0-99)’ followed by ‘YR:’ and the year, 0-99. Enter the year

using the numeric keys on the keypad and press ENTER to save it.

2.2.2.3 Setting the Algorithm

Some algorithms have additional parameters that must be set for proper operation. Refer to table 2 to determine which algorithm to use for your charger and battery type, as well as any additional parameters that need to be set. If uncertain about which algorithm to use, contact the factory before attempting to program the control.

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046-0372 Setup

Press SET, then 5, then START. The display shows ‘CHARGE ALGORITHM’ followed by ‘AL:’ and the

algorithm number. Enter the algorithm number using the numeric keys on the keypad and press ENTER to save it.

2.2.2.4 Setting the Amp-Hour Rating

Press SET, then 0. The display shows ‘BATTERY AH SIZE’ followed by ‘BS:’ and the battery size in amp-

hours. Enter the amp-hour rating using the numeric keys on the keypad and press ENTER to save it.

2.2.2.5 Setting the Battery Voltage

Press SET, then 5, then 4. The display shows ‘BATTERY VOLTAGE’ followed by ‘VR:’ and the battery rating

in volts. Enter the voltage rating using the numeric keys on the keypad and press ENTER to save it.

2.2.2.6 Setting the Current Shunt Rating

Press SET, then 5, then 5 again. The display shows ‘SHUNT RATING’ followed by ‘SR’ and the shunt rating in

amps. Enter the shunt rating using the numeric keys on the keypad and press ENTER to save it (if a current sensor is used, enter 0 for the shunt rating).

2.2.3 OPTIONAL PARAMETERS

2.2.3.1 Setting the Cable Resistance

The cable resistance parameter is used to adjust the charger to compensate for extra long charging cables. To set the parameter, connect a proper sized battery to the charger and allow the charge to start and the current to stabilize. Press VOLTS twice to display the full battery voltage. Measure the voltage at the battery terminals using a calibrated DC volt meter. If the readings differ, calculate the resistance as (Vcharger-Vbattery)/current.

To change the setting, press SET, then 3. The display shows ‘CABLE RESISTANCE’ followed by ‘CR:’ and the

resistance in mΩ (milliohms). Enter the new value and press ENTER to save it. Repeat this process as needed until the voltage readings are the same.

2.2.3.2 Setting Start Times and Peak Energy Block Out

The control has two different ways to delay the start of a charge cycle. They are the time of day start and delayed start parameters. The time of day start setting allows the charger to start only at the specified time regardless of when the battery is connected. The delayed start setting delays the start of the charge the specified amount of time after the battery is connected (Note: If both parameters are set, the control uses the time of day start). The control also has energy management settings which allow a peak energy time to be blocked out. If a battery is connected

and charging during this time, the charger turns off and displays ‘ENERGY SAVE ON’. Once the period has

ended, the charger resumes from where it left off. All of these parameters are grouped together. To set these

parameters, press SET, then START. The display shows ‘TIM E OF DAY STRT’ followed by ‘TS:’ and the time of day start setting. Enter the desired time (99:99 to disable) and press ENTER. The display shows ‘DELAY START TIME’ followed by ‘DS:’ and the delay time. Enter the desired delay time and press ENTER. The display shows ‘ENERGY SAVE ON’ followed by ‘PS:’ and the peak period start time. Enter the desired time of day for the start of the peak period (99:99 to disable) and press ENTER. The display shows ‘ENERGY SAVE OFF’ followed by ‘EP:’ and the peak period end time. Enter the desired time of day end of the peak period

(99:99 to disable) and press ENTER to save it.

2.2.3.3 Setting the Automatic Watering

The control has the ability to automatically water the battery. A 24VAC solenoid/valve must be installed (refer to charger schematic) and the battery must have a single point watering system installed. To set the automatic

watering, press SET, then 5, then 1. The display shows ‘WATERING MODE’ followed by ‘WA:’ and th e

watering mode setting. Enter the desired mode (0:disable watering, 1:water every charge cycle, 2:water after

equalize only) and press ENTER to save it. If watering is enabled, the display shows ‘WATERING CYCLES’ followed by ‘WC:’ and the number of watering cycles. Enter the desired number of cycles (each cycle is 15

seconds on and 45 seconds off) and press ENTER to save it.

2.3.4 Setting Automatic Equalize

The control has the ability to automatically equalize the battery based on the number of cycles or on a specific day of the week. The equalize cycle can also be delayed a specified amount of time. To set the automatic equalize

parameters, press SET, then 5, then 3. The display shows ‘EQUALIZE CYCLES’ followed by ‘EC:’ and the

number of cycles before equalize occurs. Enter the desired number of cycles (0 to disable) and press ENTER.

The display shows ‘EQUALIZE DAY’ followed by ‘ED:’ and the equalize day. Enter the desired day (0 to disable, 1-7 for Sunday-Saturday) and press ENTER. The display show ‘DELAYED EQUALIZE’ followed by ‘DE:’ and the equalize delay time. Enter the desired delay time and press ENTER to save it.

2.2.3.5 Setting Cool Down Time

The control has the ability to set a cool down time to allow the battery to cool before it is used or to display the elapsed time to determine the coolest battery. To set the cool down time, press SET, then 5, then 7. The display

shows ‘COOL DOWN TIME’ followed by ‘CT:’ and the cool down time. Enter the desired time and press ENTER. If a time is set, the display shows ‘COUNT DIRECTION’ followed by ‘TU:’ and the direction. Enter

12/9/09 047-0175 EXIDE REV04 Page 15 of 31

Page 17

046-0372 Setup

the desired setting (0: count down, 1: count up) and press ENTER to save it. If the direction is set to count down, the battery ready light does not come on until the cool down time has elapsed. If the direction is set to count up, the battery ready light comes on when the charge is complete and the elapsed time since the charge completed is displayed.

2.2.3.6 Setting Automatic Refresh

To set the automatic refresh interval, press SET, then 5, then 8. The display shows ‘REFRESH TIME’ followed by ‘AR:’ and the refresh interval time. Enter the desired interval for automatic refresh (00:00 to disable) and

press ENTER. A refresh consists of 30 minutes of charging at the equalize current.

2.2.3.7 Setting Charger Alerts To set the alert parameter, press SET, then 5, then 0. The display shows ‘ALERT ENABLE’ followed by ‘AO:’

and the alert setting. Enter the desired setting (0: disable alerts, 1: enable alerts) and press ENTER. The display

shows ‘ALERT INTERVAL’ followed by ‘AI:’ and the alert interval in seconds. Enter the desired setting and

press ENTER. With alerts enabled, the control displays a message describing the charger state at the set interval.

2.2.3.8 Setting Automatic Start Mode To set the automatic start mode, press SET, then STOP. The display shows ‘AUTO START MODE’ followed by

‘AS:’ and the automatic start setting. Enter the desired setting (0: manual start, 1:auto start, 2:auto start on AC)

and press ENTER. If manual start is set, the charger never starts automatically. When the battery is connected,

the display shows ‘CHARGER OFF’. Press STOP to manually start the charge. Also, in manual start mode the

charger does not begin a refresh or automatic equalize cycle once the charger has turned off. If auto start on AC is set, the charger begins a new charge cycle whenever AC power is removed and restored to the charger. This is useful in applications where the charger is permanently connected to the battery and a charge cycle is initiated by plugging in the charger AC power cord.

2.2.4 Setting the Other Parameters

If the charger is part of an I’m Cool system or the TOBi (ID) must be set. This and other additional parameters are programmed in a manner similar to that above. Table 1 describes the parameters and key-strokes used for programming them. When more than one parameter is in the same row of the table, the control automatically sequences through the additional parameters.

2.2.5 JUMPER SETTINGS

Refer to figure 1 for jumper locations.

Jumper location J4 is used to lock or unlock certain parameters from programming mode.

Header J1 is used to select the charger type.

Battery Management System then the charger identifier

PARAMETER LOCKOUT

LOCKED

UNLOCKED

CHARGER TYPE

FERRO/CF

HF*

*J1 used for interface to HF module

12/9/09 047-0175 EXIDE REV04 Page 16 of 31

Page 18

(

)

(˚F)

Table 1. Programmable Parameter List

First Key Second Key Third KeyParameter(s) Description Allowable Settings Default Notes Locked

SET SET none none n/a n/a n/a SET 1 (AMPS) None SA Set Amps 0.0-100.0 (A/100Ah) 0.0 3 ● SET 2 (VOLTS) None SV Set Volts 0.0-999.9 (V) 0.0 3 ● SET 3 (AH) None CR Cable Resistance 0-25 (mΩ)2

SET START None

SET 4 (TOC) None ST Set Charge Time 00:00-99:99 (hh:mm) (99:99 runs forever) 00:00 3 ● SET 5 SET none n/a n/a n/a SET 5 1 (AMPS) WA Watering Enable 0 (disable); 1 (every cycle); 2 (after equalize) 0

WC Watering Cycles 0-60 (15s ON/ 45s OFF) 0 SET 5 2 (VOLTS) CV Charge Cutoff Voltage 1.40-3.55 (v/c) 2.80 2 ● SET 5 3 (AH) EC Equalize by Number of Charges 0-100 7 2

ED Equalize by Day 0(disable); 1-7(Sun-Sat) 0 2

DE Equalize Delay Time 00:00-24:00 (hh:mm) 00:00 2 SET 5 START AL Charge Algorithm 1-17 n/a 1 ● SET 5 4 (TOC) VR Battery Voltage Rating 12-999 (V) 24 ● SET 5 5 (VER.) SR Charger Shunt Rating 0(current sensor); 50-600 (A) 200 ● SET 5 6 (I.D.) EM Equalize Mode 0 (None); 1(Normal) 1 2 ●

EI Equalize Current 0.1-10.0 (A/100Ah) 5.0 2 SET 5 CLOC

DY Day (of the month) 1-31 n/a

YR Year 0-99 (years since 2000) n/a

SET 5 7 (TEMP)

SET 5 8 (% RET.) AR Auto Refresh Time 00:00-72:00 (hh:mm) (0:00 disables) 0:00 SET 5 9 (80%) TP DVDT Trip Poin SET 5 ENTER N2 F2 Indication Disable 0 (enable); 1 (disable) 1 2

N3 F3 Indication Disable 0 (enable); 1 (disable) 0 2

N4 F4 Indication Disable 0 (enable); 1 (disable) 0 2

N6 F6 Indication Disable 0 (enable); 1 (disable) 0 2 SET 5 = ET Equalize Time 00:00-24:00 (hh:mm) 3:00 2 ● SET 5 0 (TEST) AO Alert On Enable 0 (disable); 1 (enable) 1

AI Alert Interval 10-60 (s) 60 SET 5 STOP BC Battery Module Comm. Enable 0 (disable); 1 (enable); 2 (enable and upload alg.) 0 SET 6 (I.D.) None ID Charger I.D. (for Tobi or I'm Cool) 1-1000; 9999 9999 SET CLOCK none TD Time of Day (Clock) 00:00-23:59 (hh:mm) n/a SET 7 (TEMP) none OT OK to Charge Temp 0-185 (˚F) (0 disables sensor) 0 2

SET 8 (% RET.) none CF Charge Back Facto SET 9 (80%) none MP Max Power Rating 0.1-25.0 (kW) 3.3 2 ●

SET ENTER none custom alg. 1,2,3 ● SET = none CU DVDT Periods 0-15 (5 minutes each) 5 ● SET 0 (TEST) none BS Battery AH Rating 100-2200 (Ah) 0 SET STOP none AS Auto Start Mode 0 (manual start); 1 (auto start); 2 (auto start on ac) 1

Notes:

1. The Algorithm is set for the particular charger and battery type. If you are unsure of which algorithm to use, consult factory before setting.

2. These parameters are part of the algorithm. Any changes made to these are overwritten whenever the algorithm parameter is set.

3. These parameters are only used for certain algorithms. Consult the factory before changing any unfamiliar parameters.

TS DS PS EP

MO Month 1-12 (Jan-Dec) n/a

Time of Day Start

Delayed Start

Energy Management Peak Start

Ener

Management Peak End

Cool Down Time

Count U

Low Charge Temp

No Char

/Down

e Tem

00:00-23:59; 99:99 (disable)

00:00-24:00 (hh:mm) 00:00-23:59; 99:99 (disable) 00:00-23:59; 99:99

00:00-24:00 (hh:mm)

0(count down); 1(count u

1.20-2.55 (v/c) 2.38 2 ●

0-185 (˚F) 0-185

0-150 (% of AH rating) (0 disables) 120 ●

disable

99:99 00:00 99:99 99:99

0:00

115 125

2 2

●

Page 19

Table 2. Algorithm List

Algorithm Battery Type Charger Type Algorithm Type Description

1 Flooded Controlled Ferro Normal DVDT Phase 1: Constant current at the start rate until 2.38 v/c.

Lead-Acid HF Phase 2: Constant Voltage at 2.38 v/c until dvdt or the current falls to 5A/100Ah Phase 3: Constant Current at 5A/100Ah until dvdt. Phase 4: not used.

2 Flooded Ferro-Resonant Normal DVDT Phase 1: Full output until 2.38 v/c.

Lead-Acid Phase 2: Full output until dvdt. Phase 3: not used. Phase 4: not used.

3 Flooded Ferro-Resonant Hysteresis Phase 1: Full output until 2.38 v/c.

Lead-Acid Phase 2: Full output until dvdt. Phase 3: Charger off until voltage drops to the hysteresis point, then reverts to phase 1. Phase 4: not used.

4 Champion Sealed Controlled Ferro Normal DVDT Phase 1: Constant current at 16.5A/100Ah until 2.37 v/c.

HF Phase 2: Constant voltage at 2.37v/c until the current falls to 2.5A/100Ah or 5 hours. Phase 3: Constant current at 2.5A/100Ah until dvdt or 2.55v/c. Phase 4: Constant voltage at 2.55v/c until dvdt or 30 minutes.

5 Champion Sealed Ferro-Resonant Normal DVDT Phase 1: Full output until 2.37 v/c.

Phase 2: Full output until dvdt or 2.52v/c. Phase 3: not used. Phase 4: not used.

6 Sonnenschein gel Controlled Ferro Special Phase 1: Constant current at 16.5A/100Ah until 2.35v/c.

HF Phase 2: Constant voltage at 2.35v/c until the current falls to 1.3A/100Ah. Phase 3: Constant current at 1.3A/100Ah for 1 to 4 hours depending on time so far. Phase 4: not used. Note: Equalize occurs 10 hours after the charge at 0.6A/100Ah.

7 Deka gel Controlled Ferro Float Phase 1: Constant Current at 15.5A/100Ah until 2.33v/c.

HF Phase 2: Constant voltage at 2.33v/c until the current falls to 0.3A/100Ah or 10 hours. Phase 3: not used. Phase 4: not used.

8 Saft Ni-Cad Controlled Ferro Special Phase 1: Constant current at 20A/100Ah until 1.59v/c or 6 1/2 hours.

HF Phase 2: Constant current at 5A/100Ah until 15% more Ah are put in. Phase 3: not used. Phase 4: not used.

9 DO NOT USE

continued

*Additional Settings: start rate = SA parameter.

*Additional Settings: hysteresis point = SV parameter.

* Refer to table 1 for information on how to program Additional Settings.

Page 20

10 Any Controlled Ferro Shop Charger Phase 1: Constant current at the start rate until the float voltage is reached or for the total run time.

HF Phase 2: Constant voltage at the float voltage for the remainder of the total run time. Phase 3: not used. Phase 4: not used.

11 Geltec/Crown gel Controlled Ferro Special Phase 1: Constant current at 16A/100Ah until 2.40v/c.

HF Phase 2: Constant voltage at 2.40v/c until the current falls to 1.5A/100Ah or 6 hours. Phase 3: Constant current at 1.5A/100Ah for the remainder of the 6 hours from phase 2. Phase 4: not used.

12 Flooded Controlled Ferro AGV Trickle Charge Phase 1: Constant current at the start rate until 2.40v/c.

Lead-Acid HF Phase 2: Constant voltage at 2.40v/c until the current falls to 1A/100Ah or dvdt. Phase 3: Constant current at 4.5A/100Ah until 2.65v/c or 3 hours if manual equalize selected. Phase 4: Constant voltage at 2.25v/c as long as the battery is connected.

13 Douglas VRLA Controlled Ferro Special Phase 1: Constant current at 16A/100Ah until 2.40v/c.

HF Phase 2: Constant voltage at 2.40v/c until the current falls to 3A/100Ah or dvdt. Phase 3: Constant current at 3A/100Ah until dvdt or 2.70v/c. Phase 4: Constant voltage at 2.70v/c until dvdt.

14 n/a Any Factory Test Phase 1: Full output for 1 minute.

Phase 2: Constant current at maximum regulation point for 1 minute. Phase 3: Constant current at minimum regulation point for 1 minute. Phase 4: Minimum output for 1 minute.

Lead-Acid HF Phase 2: Off until the time of day reaches the set time. Phase 3: Constant Voltage at 2.38 v/c until dvdt or the current falls to 5A/100Ah. Phase 4: Constant Current at 5A/100Ah until dvdt.

16 Flooded Ferro-Resonant Opportunity Charge Phase 1: Full output until 2.38 v/c.

Lead-Acid Phase 2: Off until the time of day reaches the set time. Phase 3: Full output until dvdt. Phase 4: not used.

HF Phase 2: Constant voltage at 2.37v/c until the current falls to 2A/100Ah or dvdt or 3.5 hours. Phase 3: Constant current at 2A/100Ah until dvdt or the remainder of the 3.5 hours from phase 2. Phase 4: not used.

18 Lithium Controlled Ferro Special Phase 1: Constant current at the start rate until the float voltage is reached.

HF Phase 2: Constant voltage at the float voltage until the current falls to 1.5A/100Ah or dvdt. Phase 3: not used. Phase 4: not used.

Flooded Controlled Ferro Opportunity Charge Phase 1: Constant current at the start rate until 2.38 v/c.

Exide Element Controlled Ferro Special Phase 1: Constant current at 15.5A/100Ah until 2.37v/c.

*Additional Settings: start rate = SA parameter. float voltage = SV parameter. total run time = ST parameter.

*Additional Settings: start rate = SA parameter.

*Additional Settings: start rate = SA parameter. set time = ST parameter.

*Additional Settings: set time = ST parameter.

*Additional Settings: start rate = SA parameter. float voltage = SV parameter. * Refer to table 1 for information on how to program Additional Settings.

Table 2. Algorithm List Continued.

Page 21

2.2.6 OPERA TION

If alert messages are turned on, periodically a message shows for about 2 seconds in the display. With no battery

connected, the control displays ‘0A 0.00VC’, and a ‘FERRO MAGNETICS’ alert is shown. When a battery is

connected, a lamp test is performed. The charge begins, the yellow CHARGING indicator lights and the display shows

‘CHARGE PHASE 1’ periodically along with the charging amps and battery v/c. If equalize is active, an ‘=’ appears on

the left side of the display to indicate an equalizing charge.

When phase 1 is completed, the charger starts phase 2 of the charge cycle. The display shows ‘CHARGE PHASE 2’ along

with the charging amps and battery v/c. Depending on the charger and battery type, the charger may utilize up to 4 phases to complete a charge.

During the equalize portion of the charge cycle the display shows ‘EQUALIZING’ periodically along with the charging

amps and battery v/c.

When a charge is finished, the charger automatically turns off. The display shows ‘BATTERY READY’ and the green

COMPLETE indicator lights. The battery may then be disconnected at any time.

2.2.7.1 EQUALIZE CHARGE

1. On flooded batteries the specific gravity of any cell at the end of charge is 20 points less than the average of all

the cells.

2. The on-charge voltage of any cell at the end of charge is 20 millivolts less than the average of all the cells.

3. The battery has been stored for 30 days.

The control can perform an equalize automatically based on the number of charge cycles or on a specific day of the week. Normal equalize consists of an additional 3 hour charge time at the end of a normal charge cycle.

The control is set at the factory to perform a normal equalize every 7 charging cycles for flooded lead-acid batteries.

The control can also perform an equalize charge when requested manually. Press the = key. An ‘=’ appears on the left side

of the display indicating an equalize charge for the current charge. If no battery is connected, the equalize occurs on the next charge cycle to allow the cells to equalize their charge.

The auto-equalize or manual equalize charge can be cleared by pressing the = key again. The next auto equalize charge occurs after the programmed number of charge cycles.

2.2.7.2 THERMAL SENSOR OPERATION

The control has the ability to read the battery temperature with an optional thermal sensor. In order for the sensor to function properly, it must be enabled in the control. This is accomplished by setting the ‘OK to charge temp’ (OT) parameter to a non-zero value (see table 1). This value indicates the maximum temperature that allows the charge to start. If the battery is above this temperature when it is connected, the control displays the temperature and waits for the battery to cool down before starting the charge.

If the thermal sensor is enabled and is missing or damaged, the control displays an F11 indication when the battery is connected.

The ‘Low charge temp’ (LT) parameter indicates the temperature at which the charge current is reduced to limit the temperature rise of the battery. The current is reduced proportional to the amount the battery temperature exceeds the limit.

The ‘No charge temp’ (NT) parameter indicates the temperature at which the charge is terminated. If this temperature is reached during charge, the charger shuts down and displays an F2 indication.

Refer to the battery manufacturers recommendations before setting these parameters.

If the thermal sensor is enabled, the battery voltage milestones on charge (trip point, cutoff, etc.) are compensated by

2.5mV/C per degree F (1.5mV/C per degree F for NiCad) above or below 77 degrees F. If the temperature is below 77

degrees, the voltage is adjusted up and if the temperature is above 77 degrees, the voltage is adjusted down.

Page 22

2.2.7.3 TOBI® PI OPERATION

The control has the ability to communicate with a Tobi® PI battery module. In order for communication to occur, it has to be enabled in the control. This is accomplished by setting the ‘BC’ parameter (see table 1).

Setting the BC parameter to 0 disables communication.

Setting the BC parameter to 1 enables normal communication. While the battery is connected to the charger, information is transferred between the charger and the Tobi® PI on the battery including the battery temperature. In order for the charger to utilize the temperature, the temperature sensor must also be enabled. Refer to the preceding section on thermal sensor operation.

Setting the BC parameter to 2 enables normal communication as well as algorithm upload. In addition to the information transferred during normal mode, the charger also uploads and utilizes a charge algorithm from the Tobi® PI on the battery. This can be useful if multiple battery types or AH sizes are used on the same charger. Refer to the Tobi® PI manual for instructions on setting the charge algorithm. Note: If the communication between the charger and Tobi® PI fails, the charger utilizes its own algorithm settings to charge the battery.

Page 23

2.2.7.4 CHARGE INDICATIONS

DISPLAY DESCRIPTION POSSIBLE CAUSE

SHORTED

CELL

#.##VC

##:##HM

SHORTED

CELL

#.##VC

##:##HM

F2 HOT

BATTERY

###°F #.##VC

F3 LOW

VOLTS

###A #.##VC

F4 HIGH

VOLTS

###A #.##VC

F5 NO DC

CURRENT

###A #.##VC

F6 CHARGE

ERROR

###A #.##VC

F7 LONG CHARGE

#.##VC

##:##HM

CHARGER

###A #.##VC

F9 BAD

KEYPAD

###A #.##VC

F10 HIGH

CURRENT

###A #.##VC

F11

TEMP

ERROR

255°F #.##VC

Battery voltage did not reach 2.00 V/C within 30 minutes. #.##VC is the volts per cell at end of charge and ##:##HM is the charge time.

Battery did not reach gassing voltage within the allowable time. #.##VC is the volts per cell at end of charge and ##:##HM is the charge time.

Hot battery. The battery exceeded the NT temperature. ###°F is the battery temperature and #.##VC is the volts per cell at end of charge. Low battery voltage, less than 1.60 V/C at start up. ###A is the charger current and #.##VC is the battery volts per cell. High battery voltage, more than 2.40 V/C at start up. ###A is the charger current and #.##VC is the battery volts per cell. No charging current to the battery. ###A is the current at the end of charge and #.##VC is the volts per cell at end of charge.

Charger current or voltage not what was requested by control. ###A is the current at the end of charge and #.##VC is the volts per cell at end of charge.

Long charge, the charger ran longer than the allowed time. #.##VC is the volts per cell at end of charge and ##:##HM is the charge time.

Charger stayed on when control requested it to shut off. ###A is the charger current and #.##VC is the battery volts per cell.

Faulty keypad detected. One or more buttons are stuck on. ###A is the charger current and #.##VC is the battery volts per cell. Charging current exceeds 110% of shunt setting. ###A is the current at the end of charge and #.##VC is the volts per cell at end of charge.

No thermal sensor. #.##VC is the battery volts per cell. - Missing or damaged thermal sensor

- Shorted Cell

- Open diode

- Low Charging amps

- Low AC line voltage

- Wrong size battery

- Battery over-discharged

- Shorted Cell

- Open diode

- Low Charging amps

- Low AC line voltage

- Wrong size battery

- Battery over-discharged

- Battery is overheated

- Damaged thermal sensor

- Faulty control board

- Wrong size battery

- Battery over-discharged

- Voltage jumper setting incorrect

- Wrong size battery

- Battery fully charged

- Voltage jumper setting incorrect

- Faulty AC line contactor

- Open diode

- Faulty resonant capacitor

- Poor battery connections

- Open cell

- Faulty control board

- Incorrect control setup

- Poor battery connections or open Cell

- Faulty HF module

- Faulty adapter board or cable

- Faulty control board

- Open diode

- Low Charging amps

- Low AC line voltage

- Wrong size battery

- Battery over-discharged

- AC line contactor stuck on

- Open shunt sense lead or loose connection

- Incorrect control setup

- Missing or damaged current sensor

- Faulty control board

- Faulty keypad

- Faulty control board

- High charging amps or high AC line voltage

- Missing or damaged current sensor

- Incorrect shunt size

- Open shunt sense lead or loose connection

- Faulty control board

- Thermal sensor enabled when not installed

- Faulty control board

Page 24

CAUTION: If F8 indication is showing, and the charger is providing current to the battery, remove AC power from the charger before disconnecting the battery.

2.2.7.5 F3 (LOW BA TTERY) OVERRIDE

If battery voltage is below 1.6 volts per cell the charger does not start automatically. If this is due to an overly discharged battery of the correct voltage, the F3 indication

can be manually overridden by pressing STOP while the F3 message (Low

Battery) displays.

2.2.8 DISPLAYING ADDITIONAL CHARGE INFORMATION

The user can view many different parameters associated with a charge. By pressing an appropriate key, information such as charger run time or amp-hours returned can be viewed. The display times out after about 2 seconds and returns to the default display which is usually amps and v/c.

2.2.8.1 Display Software Version

To display the software version number press VER. The display shows ‘SOFTWARE VERSION’ followed by ‘SW:’ and

the software version number (e.g. 1.00).

2.2.8.2 Display Charging Current

In most applications charging current is normally displayed. If charging current is not already being displayed, press

AMPS to view. The display shows ‘CHARGER DC AMPS’ followed by ‘AA:’ and the charging current in amps. If the charge has completed or no battery is connected, the display shows ‘CHARGE END AMPS’ followed by ‘EA:’ and the

end current for the last charge cycle.

2.2.8.3 Display Volts Per Cell

In most applications volts per cell is normally displayed. If volts per cell is not already being displayed, press VOLTS

twice to view. The display shows ‘BATTERY V/C’ followed by ‘VC:’ and the battery volts per cell. If the charge has completed or no battery is connected, the display shows ‘CHARGE END VOLTS’ followed by ‘EV:’ and the end voltage

for the last charge cycle.

2.2.8.4 Display Full Battery Voltage

To view battery voltage while charging, press VOLTS. The display shows ‘BATTERY VOLTS’ followed by ‘VV:’ an d the

full battery voltage.

2.2.8.5 Display Amp-Hours

To view amp-hours returned to the battery, press AH. The display shows ‘ACCUMULATED AH’ followed by ‘AH:’ and

the amp-hours returned to the battery during the current charge or last charge cycle.

2.2.8.6 Display Total Charger Amp-Hours

To view the total amp-hours accumulated by the charger, press AH twice. The display shows ‘TOTA L AH’ followed by

the total amp-hours accumulated by the charger since the control was installed. The upper 4 digits are displayed in the left section of the display and the lower 4 digits are displayed in the right section of the display. For example, a display of

‘1234 5678AH’ would indicated a total amp-hours accumulated of 12,345,678 Ah.

2.2.8.7 Display Time-of-Day Start Time

To view the time-of-day start time, press START. The display shows ‘TIME OF DAY STRT’ followed by ‘TS:’ and the

time-of-day start time in hours and minutes. The time-of-day is in 24-hour format. Thus a start time of 4:30PM would be

displayed as ’16:30’. If the time-of-day start is not active, the display shows ’99:99’.

2.2.8.8 Display Charger Run Time

To view charger run time, press TOC. The display shows ‘CHARGE TIME’ followed by ‘TC:’ and the time on charge in

hours and minutes.

Page 25

2.2.8.9 Display Charger Identification Number

Chargers that are part of an I’m Cool Battery Selection System or a TOBi

Battery Management System have a unique

identifying number. To view this ID number, press I.D. The display shows ‘CHARGER ID NO’ followed by ‘ID:’ and th e charger ID number. If no number is set, the display shows ‘9999’.

2.2.8.10 Display Time of Day

To view the current time, press CLOCK. The display shows ‘TIME OF DAY’ followed by ‘TD:’ and the time-of-day in

24-hour format.

2.2.8.11 Display Battery Temperature in ˚F

2.2.1.1. To view the battery temperature in ˚F, press TEMP. The display shows ‘TEMPERATURE (°F)’ followed by ‘TM:’ and the current battery temperature in degrees F. Note: A thermal sensor or Tobi® PI must be installed and connected properly for the control to read and display temperature, otherwise the temperature is displayed as 255°.

2.2.8.12 Display Battery Temperature in ˚C

2.2.1.2. To view the battery temperature in ˚C, press TEMP twice. The display shows ‘TEMPERATURE (°C)’ followed by ‘TM:’ and the current battery temperature in degrees C. Note: A thermal sensor or Tobi® PI must be installed and connected properly for the control to read and display temperature, otherwise the temperature is displayed as 255°.

2.2.8.13 Display Percent Amp-Hours Returned

To view amp-hours returned as a percentage of the battery size press % RET. The display shows ‘% AH RETURNED’ followed by ‘PR:’ and the percentage of amp-hour capacity returned for the current or last charge cycle.

2.2.8.14 Display Trip Point

To view the cell voltage at which the battery is 80% charged, press 80%. The display shows ‘80% TRIP POINT’ followe d by ‘TP:’ and the 80% voltage in volts per cell.

2.2.8.15 Perform Lamp Test

To check the display for bad segments press TEST. All segments in the display should light.

2.2.9 ADDITIONAL KEYPAD FUNCTIONS

The following additional keypad functions are available:

F3 (Low Battery) Override

Press STOP while the F3 message (Low Battery) displays.

Water Valve Test

Verify the watering parameter ‘WA’ is ‘ON’. Press 7 and STOP simultaneously to toggle water valve on and off. If left on, valve turns off after 3 minutes.

Reset

Press 4, 5, and 6 simultaneously. Resets and restarts the processor.

Load Default Values

Disconnect battery. Press 1, 2, and 3 simultaneously. This removes all program changes and loads the default parameter

values. The display shows ‘NO ALGORITHM SET’. The control must then be re-programmed as described in

‘PROGRAMMING’ above.

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SECTION 3 - OPTIONAL FEATURES

3.1 Fusible Door-Interlock Switch (JIC Switch)

The door interlock switch assembly connects the AC service to the charger’s input fuses for each AC line. The switch is mechanically latched by the door so that it must be in the OFF position before the door can be opened. Operation of the charger is identical to that of the standard model, except the charger cannot be energized if the door is open.

3.2 Remote Control

The remote control option makes it possible to operate the charger at a point within 15 feet of the charger. It includes a box equipped with the control option ordered, and either 15, 20, or 30 feet of jacketed control harness. Operation is identical to that of a standard charger except that the control is not mounted on the front of the charger.

3.3 Watering Valve

On chargers ordered with the 046-0372 control, an optional 24VAC watering solenoid can be ordered. The valve will activate at the end of the charge cycle. It works in conjunction with an automatic watering system that is supplied by others. Note: Watering valves have a one year part replacement warranty only.

3.4 Charger Stand

The charger stand is a metal frame that is designed to bolt the charger cabinet on top of it. It raises the cabinet up to the operator’s level, rather than having the cabinet sitting on the floor.

SECTION 4 – TROUBLESHOOTING & GENERAL MAINTENANCE Caution: There are lethal voltages exposed when the charger is energized with the door open. Always disconnect

the AC service voltage to the charger before opening the door. The following chart lists the most probable cause of a malfunction.

SYMPTOMS AND POSSIBLE CAUSES

4.1. No charging current, the control has no display, contactor does not operate. POSSIBLE CAUSE

A. Blown AC fuse. B. No AC service voltage. C. Incorrect AC voltage. D. Control transformer output fuse blown. E. Defective control transformer. F. Defective control board.

4.2. No charging current, control has a display.

POSSIBLE CAUSE

A. Blown DC fuse. B. Defective ammeter. C. Open battery cell. D. Defective diode. E. Defective capacitor. F. Shorted power transformer secondary.

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4.3. AC fuse blows.

POSSIBLE CAUSE

A. Incorrect fuse rating. B. Incorrect AC voltage. C. Fuse Block holding clips loose. D. Shorted transformer winding.

4.4. DC fuse blows.

POSSIBLE CAUSE

A. Reversed battery connector. B. Incorrect fuse rating. C. Shorted diode.

4.5. Excessive water loss in battery.

POSSIBLE CAUSE

A. Charging rate is too high. See Section 1.8. B. Charger amp-hour rating exceeds the battery amp-hour rating. C. Battery has defective cells.

4.6. Low specific gravity at the end of the charge cycle.

POSSIBLE CAUSE

A. Battery was over-discharged. B. Charger amp-hour rating is less than the battery AH rating. C. Defective open diode. D. Charging rate is too low. See Section 1.8. E. Battery has defective cells. F. Battery has been over-watered.

4.7. Charger does not turn off when the control terminates the charge cycle.

POSSIBLE CAUSE

A. Defective control. B. AC contactor has welded contacts.

4.8. General Maintenance

The charger requires a minimum of maintenance. Connections and terminals should be kept clean and tight. The charger should be periodically cleaned with an air hose to prevent any excessive dirt build up on components. Care should be taken not to bump or move any adjustments during cleaning. Make sure that both the AC lines and the battery are disconnected before cleaning. The frequency of this type of maintenance depends on the environment in which this unit is installed. If any cabinet sheet metal panels are removed for cleaning, be certain they are properly reinstalled upon completion.

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SECTION 5 – REPLACEABLE PARTS

5.1 Ordering Information

The following information must be supplied when ordering a replacement part from your service agent in order to ensure that the correct part is supplied:

A. Model or Spec. number of charger (Located on charger data plate) B. Serial number of charger (Located on charger data plate) C. Schematic reference symbol or part D. Description of part

5.2 Recommended Spares

The quantity of spares stocked should be increased as the number of chargers increases.

The following chart is the minimum quantity recommended per model for multiple charger installations:

# OF SPARE PARTS KITS

QUAN. USED QUANTITY RECOMMENDED

SCHEMATIC REF

SYMBOL

ACF AC FUSE, 1 PH. 2 4

# OF CHARGERS

1-3 1

4-10 2

11-25 3

26-50 4

51-100

DESCRIPTION

ACF AC FUSE, 3 PH. 3 6

DCF DC FUSE 1 2

CONTROL CONTROL BOARD 1 1

AK A.C. CONTACTOR 1 1

SD1,SD2 SILICON DIODE, 1 PH. 2 2

SD1-SD6 SILICON DIODE, 3 PH. 6 3

TP TRANSFORMER, 1 PH. 1 0

TP TRANSFORMER, 3 PH 3 0

C CAPACITOR VARIES 1

CT CONTROL TRANSFORMER 1 1

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5.3 Spare Parts List

Part Number

Condensers

008-0002 2 MFD 440 Volt 008-0004 4 MFD 440 Volt 008-0006 6 MFD 440 Volt 008-0008 8 MFD 440 Volt 008-0010 10 MFD 440 Volt 008-0012 12.5 MFD 440 Volt 008-0015 15 MFD 440 Volt 008-0017 17.5 MFD 440 Volt 008-0020 20 MFD 440 Volt 008-0030 30 MFD 440 Volt 008-0040 40 MFD 440 Volt

Resistors

037-0017 1.25 Ohm 100 Watt 037-0018 1.25 Ohm 200 Watt 037-0015 2.50 Ohm 100 Watt 037-0010 2.50 Ohm 200 Watt

Diodes

024-0001 70 A 600 Volt 024-0003 150 A 600 Volt

Contactors

009-0020 30 Amp 3 Pole 009-0021 30 Amp 2 Pole 009-0049 60 Amp 3 Pole

Controls

046-0371 4 Button - LCD control 046-0372 16 Button - LCD control

Control Transformers

003-1210 240/480P, 24S, 50 VA 003-1211 120/240P, 24S, 50 VA 003-1213 480/600P, 24S, 50 VA

DC Fuses

011-0243 80 Amp, 130 Volt 011-0044 100 Amp, 130 Volt 011-0045 150 Amp, 130 Volt 011-0046 200 Amp, 130 Volt 011-0047 250 Amp, 130 Volt 011-0048 300 Amp, 130 Volt 011-0049 400 Amp, 130 Volt

Description

Page 30

Three Phase Charger Schematic # 02-400

Page 31

Single Phase Charger Schematic # 02-416

Exide Technologies GB4127 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual