Exide Technologies GB4127 User Manual

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

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

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.

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.

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

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.

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

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.

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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