Exide Technologies GB4128 User Manual

PN 047-0176 REV02

ECF – SERIES

Installation and Operation Manual

Controlled Ferro-Resonant

Sales – Service – Recycling

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

Canada 1-800-268-2698

(GB4128 2009-04)

Ferro Magnetics Corporation, St. Louis, MO

INDEX

PAGE SECTION DESCRIPTION

3 - SAFETY INSTRUCTIONS 4 1.0 INSTALLATION 4 1.1 RECEIVING 4 1.2 LOCATION 5 1.3 LINE VOLTAGE ADJUSTMENTS 6 1.4 AC SERVICE REQUIREMENTS 6 1.5 CONNECTING AC SERVICE TO CHARGER 6 1.6 GROUNDING THE CHARGER 6 1.7 BATTERY CONNECTOR AND CHARGING CABLE 6 1.8 CHARGING RATE ADJUSTMENT

7 2.0 OPERATION 7 2.1 046-0172 CONTROL 7 2.1.1 8 2.1.2

9 2.1.3 10 2.1.4 10 2.1.5 10 2.1.6 10 2.1.7 11 2.1.8 12 2.1.9 12 2.1.10

14 3.0 OPTIONAL FEATURES 14 3.1 FUSIBLE DOOR-INTERLOCK SWITCH (JIC SWITCH) 14 3.2 REMOTE CONTROL 14 3.3 STACKING OF TWO CABINETS (MAXIMUM)

15 4.0 TROUBLESHOOTING & GENERAL MAINTENANCE 15 4.1 SYMPTOMS AND POSSIBLE CAUSES 15 4.2 GENERAL MAINTENANCE

16 5.0 REPLACEABLE PARTS 16 5.1 ORDERING INFORMATION 16 5.2 RECOMMENDED SPARES 17 5.3 SPARE PARTS LIST

18 - SCHEMATIC

FEATURE SUMMARY NORMAL DAILY CHARGE EQUALIZE CHARGE TIME OF DAY START SETTING TIME OF DAY EMERGENCY STOP SETTING BATTERY COOL DOWN TIME CHARGE INDICATIONS F3 (LOW BATTERY) OVERRIDE DISPLAYING ADDITIONAL CHARGE INFORMATION

Ferro Magnetics Corporation, St. Louis, MO

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. 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.

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

5. 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.

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

7. 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.

8. 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.

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

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

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

Ferro Magnetics Corporation, St. Louis, MO

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 outsid e of the packing for signs of rou gh handli ng before accepting the cha rger from the carrier. If there is evid ence of damag e, the recei pt sho uld be signed, an d b oth copi es (carrier's an d receiving copies) marked "Shipment Received Damaged". The carri er'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 calle d and requested to make a "Carrie r'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 shi pment error, provide the Model , and S erial Number of the charger, and a full description of the damage or error. It i s good practice to move the charger to the installation site before uncrating. When using bars, hammers, etc. for uncrating, use care to avoid damage to the charger

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

1.2. LOCATION

For the best operating conditions and longest life, take care in selecting an installation site. Avoid locations exposed to high humidity, temperature extremes or dust. Moisture condensing on machine parts and electrical components can cause corrosion, which seriously affects operation, efficiency and life. All units are designed for floor mounting. Standard cases may be stack-mounted if required, up to 2 high. If so, optional stacking brackets are required and available as an option. See section 3.0 for more details. 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.

Ferro Magnetics Corporation, St. Louis, MO

1.3. LINE VOLTAGE ADJUSTMENTS

All chargers are shipped with the AC line voltage ju mper wires set for the AC voltage spe cified 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 as shown in Figs. 1.3.1 through 1.3.2.

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

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

A.C. Voltage Adjustments

1Ø & 3Ø 60Hz. (208/240/480)

A.C. Voltage Adjustments

POWER TRANSFORMER SETTING

L1 L1

1234

480

1234 132 4

CONTROL

TRANSFORMER

Fig. 1.3.1.

“B” Voltage Code

Fig.1.3.2.

3 Ø 60Hz. (480/575)

“K” Voltage Code

L2 L2

1234

CONTROL

TRANSFORMER

575

Ferro Magnetics Corporation, St. Louis, MO

1.4. AC SERVICE REQUIREMENTS

Follow local code requirements if they are different than the in structions i n this man ual. After ch ecking the transformer connections as d escribed in Parag raph 1.3, refer to Table 1-1, to determine the corre ct 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

The charging rate has been set at the factory; therefore, field adjustment should not be necessary. Consult factory.

Ferro Magnetics Corporation, St. Louis, MO

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