Exide Technologies SCR100 User Manual

Download

INSTALLATION & OPERATING

INSTRUCTIONS

SCR 100 SERIES

INDUSTRIAL BATTERY CHARGERS

This Warranty Agreement entered into between GNB Technologies, "GNB", and the Original User in respect to GNB

electric vehicle

battery chargers for electric vehicle usage.

1.0 GENERAL

GNB warrants that each new electric vehicle battery charger supplied by it, is of good workmanship and is free from any inherent mechanical defects, provided:

1.1 The product is installed and operated in accordance with generally accepted industrial standards and in accordance with the printed instructions supplied with the charger.

1.2 The charger is used under conditions for which it was designed and is not subject to misuse, negligence or accident.

1.3 The charger receives proper care, protection, and maintenance under supervision of competent personnel.

1.4 The charger is used within the published performance rating for the unit involved.

1.5 The charger is used exclusively by the original user and by no other persons.

2.0 PERSONS COVERED

This warranty is extended by GNB only to the original user who purchases or leases a new charger product from GNB or one of its authorized representatives. The product purchased or leased under this agreement shall be used exclusively by the origi nal user and its employees and by no other persons and, therefore, there shall be no third party beneficiary to this warranty.

3.0 WARRANTY PERIOD

The charger is warranted for four (4) years from the date of manufacture as determined by the product serial number, with the following exceptions:

3.1 Power transformers, SCR's and silicon diodes are warranted for ten (10) years from the date of manufacture of the

charger(s) of which they are a part.

3.2 Primary switch contacts, fuses, bulbs, and filters are not warranted unless found to be defective prior to use.

4.0 LIMITATION OF REMEDY

Any claimed defect is subject to GNB's inspection and judgment, after the defective product has been returned by the o

riginal

user at its expense to GNB’s designated point of shipment.

4.1

GNB’s liability is

limited

the repair of the defect or, at GNB’s option, the replacement of the defective parts. During the initial

three

(3)

years of charger

warranty

period, GNB will bear all parts and labor costs of such repair or replacement. During year

four (4) of the warranty

, GNB

will

only cover parts, no labor or travel will be provided by GNB. During the last six (6) years

of the ten

(10)

year warranty

power transformers, SCR's and silicon diodes, GNB will bear costs of parts replacement only;

no labor or other services will be provided by GNB. GNB shall not be obligated to reimburse the original user or any

other

person for any work performed.

4.2 Replacement and exchange parts will be warranted for a period of ninety (90) days.

4.3 GNB and its authorized representatives shall not be liable for direct or indirect, special or consequential damages in excess o

f such repair or replacement. In no event shall the original user be entitled to recover for contingent expenses

resulting from but not limited to, telephone calls, telegrams, travel expenses, lodging, duties and taxes, labor, rental or replacement equipment, loss of business or profits or other commercial losses.

4.4 GNB will only bear costs for freight 12 months from the initial date of shipment on any replacement or repair.

5.0 USE OF DEFECTIVE PRODUCT

Continued use of a defective charger after discovery of a defect will void all warranties.

6.0 REPAIRED OR MODIFIED EQUIPMENT

Except as authorized in writing, this warranty does not cover any equipment that has been repaired or modified by any party other than GNB.

EXCEPT AS STATED ABOVE, ALL OTHER WARRANTIES AND CONDITIONS, EITHER EXPRESS OR IMPLIED, INCLUDING IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE EXCLUDED AND ORIGINAL USER ASSUMES ALL RISK AND LIABILITY RESULTING FROM USE OF THE PRODUCT. GNB NEITHER ASSUMES NOR AUTHORIZES ANY PERSON

TO ASSUME FOR GNB ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OR USE OF THE PRODUCT, AND THERE ARE NO ORAL AGREEMENTS OR WARRANTIES COLLATERAL TO OR AFFECTING THIS WRITTEN WARRANTY.

SCR 100 CHARGER WARRANTY

Exide Technologies Chloride Motive Power

P.O. Box 1, Salford Road Over Hulton, Bolton BL5 1DD United Kingdom Tel: 44.1204.661.230 Fax: 44.1204.652.100

GNB Industrial Power Motive Power

8301 Keele Street Maple, Ontario Canada L6A 1T2 Tel: 905.669.9326 Fax: 905.669.7688

GB-3654 RPT 11/01

GNB Industrial Power Motive Power

829 Parkview Boulevard Lombard, IL 60148-3249 U.S.A . Tel: 877.GNB.INFO Fax: 630.691.7869

Printed on recycled paper

www.gnb.com

TABLE OF CONTENTS

TITLE PAGE

1.0 IMPORTANT OPERATING AND SAFETY INSTRUCTIONS 2

2.0 INTRODUCTION 3

3.0 RECEIVING CHARGER 3

4.0 LOCATION AND INSTALLATION OF CHARGER 3

4.1 Stacking 3

5.0 AC ELECTRICAL SUPPLY 3

5.1 AC Fuse Mounting 3

5.2 Input Voltage Change 3

5.3 AC Voltage Connections 7

5.4 Ground connection 7

6.0 DC OUTPUT 7

7.0 APPLICATION 8

7.1 Fault and Display Codes 8

7.2 Options 8

TABLE 2 - SINGLE PHASE RATINGS 9 TABLE 3 - THREE PHASE RATINGS 11

8.0 CABINET OUTLINE/DIMENSIONS 13

9.0 SCR100 CHARGER OPERATION 14

9.1 SCR100 Charger Functional Description 15

10.0 OPPORTUNITY CHARGING 16

11.0 CHARGE TIME 16

12.0 AC POWER FAILURE 16

13.0 MAINTENANCE 16

14.0 TROUBLESHOOTING 17

APPENDIX A: SCR100 BATTERY CHARGERS LIST OF DISPLAY INDICATIONS 20 APPENDIX B: ELECTRICAL SCHEMATIC DRAWINGS 21

Instr. 4770-65-95005-00 Page

Rev. 08/15/2002

SCR100 SERIES INDUSTRIAL BATTERY CHARGERS

1.0 IMPORTANT OPERATING AND SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

a) Before using the battery charger, read all the instructions in addition to the CAUTION, WARNING, and DANGER

markings on the charger, battery and all the associated equipment.

b) Do not touch uninsulated parts of the DC output connector or the battery terminals, as there is a possibility of

electric shock.

c) Connect or disconnect the battery plug only when the charger output is off; ALWAYS press the STOP

pushbutton before unplugging the battery to prevent arcing or burning.

d) If the battery is unplugged during charging, the charger will indicate “OFF/FCA”. To restart the charger, plug in the

next battery. Do not connect the next battery before you see indication “OFF/FCA”. e) Only qualified personnel should operate or service this equipment. f) De-energize all AC and DC power connections before servicing this unit. If injury does occur, apply the prescribed

treatment for electrical shock and obtain medical attention immediately. g) The charger is NOT for outdoor use. Do not expose the charger to rain or snow. h) This charger is factory set to charge lead-acid batteries only. Operating environment should not contain any

contaminations that may cause corrosion or contamination that would degrade the performance of a charger. i) Do not operate this unit if it has received a sharp blow, been dropped or otherwise damaged. Take it to a qualified

GNB service center. j) Do not disassemble the charger. Have the charger examined by a GNB service representative or local qualified

service facility. Incorrect re-assembly of the charger may result in an explosion, electric shock or fire. k) The charger profile is set at the factory for a charger DC cable length of 9ft and a battery DC cable length of 25in.

If DC cable lengths are adjusted please contact you local GNB service representative.

Instr. 4770-65-95005-00 Page 2

2.0 INTRODUCTION

The GNB SCR100 battery chargers are convection cooled, solid state, micro-processor controlled SCR regulated chargers designed to make battery charging simple. They are factory set to charge sealed lead-acid batteries but it may be configured by a GNB service representative to charge flooded lead-acid batteries.

The charger has a comprehensive self-checking diagnostic program to control all charger functions, monitor the quality of charge and check its own safety conditions. Large easy to read LEDs, three button keypad and LED display report on charger and battery status.

3.0 RECEIVING CHARGER

Examine the charger thoroughly before using, to make sure that no parts have been loosened or damaged during shipment. Check the contents of the package against the delivery slip before disposing of the shipping package. If any shipping damage or partial loss is found, file a claim with the carrier without delay and take any necessary steps to protect your rights. Before installing check that the charger nameplate data corresponds to the packing slip and to the model specified on the original sales order. The SCR100 chargers are delivered on skids for easy handling using a fork lift truck.

4.0 LOCATION AND INSTALLATION OF

CHARGER

Proper installation is important in order to achieve good charger performance and long troublefree operation and to prevent damage to the charger and batteries. The charger should be located in a clean, cool, normal ambient room temperature (between +45°F/7.2°C and 90°F/32.2°C) dry and well ventilated area. In order to permit free air flow for convection cooling allow four inches minimum between the charger and any wall, six inches from other equipment, and never store anything beneath and on top of the charger.

4.1 STACKING

When stacking chargers on top of each other, ensure that cabinets are bolted together using properly sized black #1/4-20 UNC hardware provided in all four corners on top cover. The floor mounting must be done with #3/8-16 UNC bolts (steel rack) or #3/8 lag screws and anchors (concrete floor). All charger models with a Z, SCR100-XX-XXXT1Z OR SCR100-XX-XXXS1Z, can be stacked to a maximum of three high.

WARNING: THE ABOVE PROCEDURES MUST BE FOLLOWED EXACTLY TO AVOID INJURY OR RISK OF ELECTRIC SHOCK. WARNING: TO REDUCE THE RISK OF FIRE, INSTALL BATTERY CHARGER ON A FLOOR OF NON-COMBUSTIBLE MATERIAL SUCH AS

STONE, BRICK, CONCRETE OR METAL. IF THIS IS NOT AVAILABLE, A FLOOR PLATE OF AT LEAST 1.43mm GALVANIZED OR 1.6mm UNCOATED STEEL EXTENDED AT LEAST 150mm BEYOND THE EQUIPMENT ON ALL SIDES MUST BE INSTALLED.

5.0 AC ELECTRICAL SUPPLY

The charger must be connected to either a single phase, or three phase 50 or 60 Hertz (± 2%) AC power source. The following options are available:

TABLE 1 – INPUT VOLTAGE CHOICES

Single phase Three phase a) 120/208/240VAC, 60Hz e) 208/240/480VAC, 60Hz b) 208/240/480VAC, 60Hz f) 480VAC, 60Hz c) 600VAC, 60Hz g) 600VAC, 60Hz

d) 240VAC, 50Hz h) 380/415VAC, 50Hz Only the AC input wire configuration for multi-input chargers can be changed. Follow Figure 1 (page 4) for single phase input or Figure 2 and Figure 3 (pages 5-6) for three phase input transformers. This change should be done by a qualified electrical contractor.

5.1 AC FUSE MOUNTING

The charger comes with a fuseblock rated big enough to accommodate the highest possible current and voltage for that particular model. Proper fuse ratings can be found in Table 2 and Table 3(see pages 9-12) for AC input fuses (F1, F2 in case of a single phase input or F1, F2, F3 in case of a three phase input). Fuses with an ampere rating of 30A or less are smaller and need fuse reducers when placed in a 60A fuseblock.

5.2 INPUT VOLTAGE CHANGE

Before proceeding check which transformer tap configuration you have. When changing the taps on the input side between 1) 120, 208, 240 VAC or 2) 208, 240, 480 VAC (single phase input), be sure to change the wires and/or jumpers according to Figure 1 (page 4). Once finished, refer to Table 2 (pages 9-10) for the correct size of AC input fuses. Similarly when changing input voltage between 1) 208, 240, 480 VAC or 2) 380, 415VAC (three phase input) follow the schematics on Figure 2 or Figure 3 (pages 5-6) whichever is applicable. Following that, check Table 3 (pages 11-12) for the correct size of AC input fuses. Figure 3 (page 6) applies to 12 cell 475, 600, 750, 865 Ah; 18 cell 475, 600, 750, 865, 965, 1050 Ah; and 24 cell 475, 600, 750, 865Ah chargers only.

NOTE: Upon completion and proper verification of the

input voltage configuration change, markings on the door label and the unit nameplate must be revised (crossing out factory set markings); re-mark the label with a permanent marker to reflect new input voltage configuration and fuse size.

Instr. 4770-65-95005-00 Page

FIGURE 1: SINGLE PHASE INPUT

L2L2L2L1L1L1BRN

BLK

BRN

BRNL1L1

BLK

BRNL1L2

WARNING: IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE DAMAGE TO THE CHARGER AND BATTERY

120 VAC CONFIGURATION (120/208/240V INPUT)

208 VAC CONFIGURATION (208/240/480V INPUT)

208 VAC CONFIGURATION (120/208/240V INPUT)

240 VAC CONFIGURATION (120/208/240V INPUT)

240 VAC CONFIGURATION (208/240/480V INPUT)

480 VAC CONFIGURATION (208/240/480V INPUT)

Instr. 4770-65-95005-00 Page

FIGURE 2: THREE PHASE INPUT

L3L3L3

WARNING: IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE DAMAGE TO THE CHARGER AND BATTERY

208VAC CONFIGURATION (208/240/480V INPUT)

380VAC CONFIGURATION

240VAC CONFIGURATION (208/240/480V INPUT)

415VAC CONFIGURATION

480VAC CONFIGURATION (208/240/480V INPUT)

Instr. 4770-65-95005-00 Page

FIGURE 3: THREE PHASE INPUT

WARNING: IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE DAMAGE TO THE CHARGER AND BATTERY

208VAC CONFIGURATION (208/240/480V INPUT) (SCR100-XX-YYYT1Z ONLY)

240VAC CONFIGURATION (208/240/480V INPUT) (SCR100-XX-YYYT1Z ONLY)

L2 L3

480VAC CONFIGURATION (208/240/480V INPUT) (SCR100-XX-YYYT1Z ONLY)

Instr. 4770-65-95005-00 Page

L2 L3

L3L2

5.3 AC VOLTAGE CONNECTIONS

6.0 DC OUTPUT

To connect the input AC voltage, route the AC conduit through the knockout hole provided. Continue the AC wiring to fuseholder terminals L1 (N) and L2 (L) (single phase input) or L1, L2, and L3 (three phase input), ensuring that the AC source phases match the phase rotation on the AC input. For proper connection, torque the screws to approximately 25 inch-pounds.

5.4 GROUND CONNECTION

It is a requirement to ground the chassis while the charger is connected to AC power. The charger comes with a ground lug attached to the stud, clearly marked on the chassis. To ensure good continuity keep the contact area clean. The stud is designed for a 3/16” hardware. See gounding method shown below (Figure 4.).

WARNING: DO NOT OPERATE THE UNIT WITHOUT PROPER GROUNDING. IMPROPER GROUNDING CAN RESULT IN THE RISK OF AN ELECTRIC SHOCK.

CAUTION: USE MINIMUM 75°C WIRING. FOR SUPPLY CONNECTIONS, GROUND CHARGER PROPERLY USING GROUNDING STUD (GND) PROVIDED. USE COPPER-CLAD ALUMINUM, ALUMINUM OR COPPER CONDUCTORS ONLY.

The DC charging cable has a commonly used battery plug or receptacle. The polarity of the charger plug must be the same as the battery connector. The BLACK DC cable must be connected to the battery negative (-), and the RED DC cable must be connected to the battery positive (+). The charger will not operate in a reversed polarity condition.

The DC output fuse is a "fast-acting" fuse used to protect the power semiconductors of a charger.

NOTE: Use only identical replacement fuses obtainable from your GNB service representative

After electrical connection is completed, the charger is ready for operation.

NOTE: The following applies to three phase chargers

only: if the charger indicates “FAC” or “F3” upon startup, it means that there is a low or high AC voltage (+35%) or AC phase missing. Refer to the Troubleshooting section for more details.

FIGURE 4: GROUNDING METHOD

Instr. 4770-65-95005-00 Page

7.0 APPLICATION

The charger will automatically charge a battery per the Ah rating set at the factory. The charger can be re-set for anywhere between 65% to 200% of the nameplate Ah rating. Ensure that battery and charger are matched. Keep in mind if the charger is set for more than 100% of Ah of the charger rating the charging time will increase proportionately (up to 16 hours). For battery sizes not listed, contact your local GNB service representative.

7.1 FAULT AND DISPLAY CODES

Refer to Appendix A (on page 20) for a complete list of codes.

7.2 OPTIONS

7.2.1 JIC SWITCH ASSEMBLY

All SCR100 battery chargers can come with a factory installed fused JIC switch assembly option for extra protection of the operator. In the "OFF" position, the door can be opened but only AC power at the input of the switch is present while everything downstream is dead. In the "ON" position, AC power is supplied to the charger but the door cannot be opened. See applicable drawing 4770-65-73041-05, 4770-65-73041-15 or 4770-6573041-17 for electrical schematic (Appendix B, pages 21-31). NOTE: Only HRCI-R type fuses (ECSR or equivalent) with the notched ferrule at one end can be used. A JIC type charger can only be factory installed and is available in a “B”, “C” or “D” size cabinet.

convenient location for use. When installing the push buttons ensure that there are no corrosive fumes deteriorating the contacts. The Remote Stop / Equalize option is available for “Z” model chargers “B” and “C” cabinets, 6 – 36 cells only. For non “Z” models contact your local GNB service representative.

7.2.2 BATTERY WATERING OPERATION AND END OF CHARGE

The SCR100 battery charger has an available watering control and end of charge option, in the form of a relay contact at terminals TB10-1 to TB10-2 (supplied for customer connection). The relay closes thirty minutes after the charger reaches gassing voltage. It remains closed for approximately ten minutes.

NOTE:These options require different control cards per drawing 4120-65-68650-05 (see Appendix B, pages 21-

31).

RELAY CONTACT RATINGS:

- AC: 125V 0.6A 1.0PF maximum

- DC: 30V 2A resistive maximum

7.2.3 REMOTE STOP / EQUALIZE

The SCR100 battery charger can come with a factory installed Remote Stop / Equalize assembly option (partnumber V16-31365-50) in case the charger is out of reach for the operator. The end user will have to install two separate push buttons to the appropriate terminals on the Remote Stop / Equalize circuit board (see schematic 4120-66-68650-50) and locate them to a

Instr. 4770-65-95005-00 Page

TABLE 2 – SINGLE PHASE TECHNICAL DATA

STANDARD MODEL

SCR100-XX-XXXX-S1Z

SCR100-06-260S1Z AMPS 12 7 6 3 A 76 34.5

SCR100-06-475S1Z AMPS 19 11 9.5 5 A 120 54.4

(50 Hz) AMPS X X 9.5 X A 130 59.1

SCR100-06-600S1Z AMPS 26 15 14 7 B 190 86.2

(50 Hz) AMPS X X 13.5 X B 205 93.2

SCR100-06-865S1Z AMPS C.F. 20 18 9 B 255 116

SCR100-06-965S1Z AMPS C.F. 23 20 10 B 295 134

SCR100-09-475S1Z AMPS 26 15 14 6.5 B 160 72.5

SCR100-09-600S1Z AMPS C.F. 19 16 8 B 210 95

SCR100-09-865S1Z AMPS C.F. 27 23.5 12 B 260 118

SCR100-09-965S1Z AMPS C.F. 30 26 13 B 300 136

SCR100-12-260S1Z AMPS 18.5 10.5 9 5 A 120 54.4

(50 Hz) AMPS X X 9 X A 130 59.1

SCR100-12-475S1Z AMPS C.F. 19.5 17 8.5 B 200 90.7

(50 Hz) AMPS X X 17 X B 212 96.4

SCR100-12-600S1Z AMPS C.F. 25.5 22 11 B 225 102

(50 Hz) AMPS X X 22 X B 235 107

SCR100-12-750S1Z AMPS C.F. 34 29 14.5 B 270 122

SCR100-12-865S1Z AMPS C.F. 34 29 14.5 B 270 122

SCR100-12-965S1Z AMPS C.F. 38 34 17 B 305 138

SCR100-18-260S1Z AMPS C.F. 16 14 7 B 195 88.5

SCR100-18-475S1Z AMPS C.F. 30 26 14 B 240 109

DC AC AMPS @ AC VOLTS CABINET WEIGHT

AMPS 120 208 240 480 TYPE LBS KGS

134

150

134

150

116

134

150

FUSE 15 10 8 4

FUSE 25 15 12 7

FUSE - - 12 -

FUSE 35 20 20 10

FUSE - - 20 -

FUSE - 25 25 12

FUSE - 30 25 15

FUSE 35 20 20 10

FUSE - 25 20 10

FUSE - 35 30 15

FUSE - 40 35 20

FUSE 25 15 12 7

FUSE

FUSE - 25 25 12

FUSE

FUSE - 35 30 15

FUSE - - 30 -

FUSE - 45 40 20

FUSE - 50 45 25

FUSE - 20 20 10

FUSE - 40 35 20

- 12 -

- 25 -

Instr. 4770-65-95005-00 Page

TABLE 2 – SINGLE PHASE TECHNICAL DATA

STANDARD MODEL

SCR100-XX-XXXX-S1Z

SCR100-18-600S1Z

SCR100-18-750S1Z

SCR100-18-865S1Z

(50 Hz)

SCR100-24-260S1Z

SCR100-24-475S1Z

(50 Hz)

SCR100-24-600S1Z

(50 Hz)

NOTE: C.F.: CONTACT FACTORY; X: NOT AVAILABLE; -: DATA NOT AVAILABLE

DC AC AMPS @ AC VOLTS

AMPS 120 208 240 480 TYPE LBS KGS

116

134

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

C.F. 36.5 31.5 16 B 260 118

- 50

C.F.

X X

C.F.

- 30

C.F.

X X

C.F.

X X X X

48 60 48 60

39 50

48 60

40 20 44 22

60 30

44 22 60 30 44 X 60 19 10 25 15

33.5 17 45 25

33.5 X 45 41 21

60 41 60

X X

WEIGHT

CABINET

C 260 118

C 325 147

C 340 155

B 300 135

C 315 143

C 340 155

C 380 172

C 400 182

Instr. 4770-65-95005-00 Page

TABLE 3 – THREE PHASE TECHNICAL DATA

AC AMPS @ AC VOLTS

STANDARD MODEL DC 60Hz 50Hz CABINET WEIGHT

SCR100-XX-XXXX-T1Z AMPS 208 240 480 380 415 TYPE LBS KGS

SCR100-06-475T1Z

SCR100-06-600T1Z

SCR100-06-865T1Z

SCR100-06-965T1Z

SCR100-06-1050T1Z

SCR100-06-1450T1Z

SCR100-09-600T1Z

SCR100-12-475T1Z

SCR100-12-600T1Z

SCR100-12-750T1Z

SCR100-12-865T1Z

SCR100-12-965T1Z

SCR100-12-1050T1Z

SCR100-12-1200T1Z

SCR100-12-1450T1Z

SCR100-18-260T1Z

SCR100-18-475T1Z

SCR100-18-750T1Z

SCR100-18-865T1Z

SCR100-18-965T1Z

116

134

150

163

186

225

116

134

150

163

186

225

116

134

150

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

5 4.5 2.2

C.F. C.F.

B 170 77.1 7 6 3 - 7 6 3.5

10 8 5

9 8 4

C.F.

C.F. C.F.

3.5 B 190 86.2

B 220 99.8SCR100-06-750T1Z

12 12 6 - 10 9 5

C.F. C.F.

B 220 99.8

15 12 7 - 11 10 5

C.F. C.F.

B 235 107

15 15 7 - 12 11 5.5

C.F. C.F.

B 245 111

15 15 8 - -

12.7 11 5 20 15 7 15 14 7

C.F. C.F.

- -

C.F. C.F.

C 260 118SCR100-06-1200T1Z

C 290 132 20 20 10 - 12 10 5

C.F. C.F.

B 220 99.8 15 15 7 - -

9 8 4 5.5 5.0 B 215 97.6

12 12 6 8 7

11.5 10 5 7 7 B 220 100 15 15 7 10 10 15 14 7 9.2 9 B / C* 250 113.5

20 20 10 12 12 16 14 7 10 9 B 255 116 20 20 10 15 12 21 18 9

C.F. C.F.

C 260 118 30 25 12 - 22 19 9.5 12

C.F.

C 270 122 30 25 12 15 26 22 11

C.F. C.F.

C 298 135 35 30 15 - 30 26 14

C.F. C.F.

C 310 141 40 35 20 - -

9 8 4

C.F. C.F.

B 215 98 12 10 6 - 14 11 5.5 20 15 8 16 14 7 20 20 10

C.F.

8 B 255 116 12 10 B / C* 300 136SCR100-18-600T1Z 15

20 18 9.0 16 15 B / C* 310 141 30 25 12 20 20

24 21 10.5 16 15 C 325 148 35 30 15 20 20 26 22 11 18 17 C 340 155 35 30 15 25 25

Instr. 4770-65-95005-00 Page

TABLE 3 – THREE PHASE TECHNICAL DATA

AC AMPS @ AC VOLTS

STANDARD MODEL DC 60Hz 50Hz CABINET WEIGHT

SCR100-XX-XXXX-T1Z AMPS 208 240 480 380 415 TYPE LBS KGS

SCR100-18-1050T1Z

SCR100-18-1200T1Z

SCR100-18-1700T1Z

SCR100-24-475T1Z

SCR100-24-600T1Z

SCR100-24-865T1Z

SCR100-24-965T1Z

SCR100-24-1050T1Z

SCR100-24-1200T1Z

SCR100-24-1450T1Z

SCR100-24-1700T1Z

SCR100-36-475T1Z

SCR100-36-600T1Z

SCR100-36-750T1Z

SCR100-36-865-T1Z

SCR100-36-965-T1Z

SCR100-36-1450-T1Z

SCR100-40-1200-T1Z

SCR100-48-600-T1Z

SCR100-48-865-T1Z

163

186

225

264

116

134

150

163

186

225

264

116

134

150

225

186

134

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

28 24 12 19 17.5 C 380 163 40 35 15 25 25 37 32 16 26

C.F.

C 410 186

50 45 20 35 -

47.5 41 21 26 27 C 450 204SCR100-18-1450T1Z 60 60 30 35 35

48 44 22

C.F. C.F.

D 550 250 60 60 30 - 17 15 7.5

C.F.

10 B / C* 290 132 25 20 10 - 15 21 18 9.5 15 12 C 320 145 30 25 12 20 15 28 24 12 18 15 C 345 157SCR100-24-750T1Z

40 35 15 25 20 31 27 14 18 17.6 C 380 173

45 40 20 25 25 40 36 18

C.F.

20 C 400 182 60 50 25 - 30 44 38 18.5 24 22 C 425 193 60 50 25 35 30

C.F. 46 23 28 C.F. C 440 200

60 30 40

C.F. C.F. 27 27 22 C 490 222

- -

C.F. C.F.

- -

34 29 14.5 45 40 20

35 35 30

31 31 25 D 525 239

40 40 35

C.F. C.F.

C 330 150

- -

41 35 18 21 20.5 C 420 190 60 50 25 35 30 46 40 20 60 60 30

C.F.

46.5 23 60 30

C.F. C.F.

- -

27 40

C.F.

27 C 460 209 35 27 C 480 218 35

29.4 C 500 227 40

C.F. C.F. 37 C.F. 42 D 550 250

- -

39 34 17 50 45 25

C.F. C.F.

- -

48 42 21 60 60 30

33 45

C.F.

C.F. C.F.

- -

C.F. C.F.

- -

C.F. C.F. C.F. C.F. C.F.

19.5 C 450 204SCR100-40-475-T1Z 25

D 500 227

D 550 250

D 600 272

- - - - -

NOTE: C.F.: CONTACT FACTORY; X: NOT AVAILABLE -: DATA NOT AVAILABLE; *:50Hz MODELS ARE IN A “C” CABINET

Instr. 4770-65-95005-00 Page

8.0 CABINET OUTLINE/DIMENSIONS FOR –Z MODEL CHARGERS ONLY

CABINET DIM. A DIM. B DIM. C

A 15.10” 20.65” 12.75” B 22.70” 26.65” 22.25” C 32.10” 26.65” 22.25”

D 24.30” 42.00” 23.65” D (Mining) 24.30” 42.00” 23.65” E (Mining) 24.30” 59.00” 31.50”

NOTE: Mining chargers are equipped with a drip cap and four lifting eyebolts for sling lifting. Add an

additional 5.000” to the height. (DIM.B)

Instr. 4770-65-95005-00 Page

9.0 SCR100 STANDARD CHARGER OPERATION

LED DISPLAY DESCRIPTION (NONE)

PLUG IN BATTERY TO COMMENCE CHARGING

OFF/Fld* OFF/CHP*

DELAY (Orange), dEL, then

delay time remaining in Hours. minutes

OFF dEL time

CHARGING (Orange)

XXX*

(DISPLAY OF FINISH RATE CURRENT)

CHARGING (Orange)

XXX

(DISPLAY OF CHARGE CURRENT)

80% CHARGED (Yellow)

XXX

(DISPLAY OF FINISH RATE CURRENT)

OPC

FAULT (Red)

OFF

CHARGER SET FOR FLOODED BATTERIES. CHARGER SET FOR SEALED CHAMPION®

BATTERIES.

DELAY MODE, PRESS “START” BUTTON TO OVERRIDE. (Section 9.1.1, page 15)

SMART START (Section 9.1.2, page 15)

HIGH RATE CHARGING

FINISH RATE CHARGING

OPPORTUNITY CHARGING CYCLE

WHEN CHARGER IS IN OPC MODE IT WILL ALWAYS INDICATE OPC IN ADDITION TO STANDARD INDICATION.

CHARGE CYCLE WAS INTERRUPTED BY PRESSING “STOP” BUTTON BEFORE UNPLUGGING THE BATTERY

FAULT (Red)

CHARGE COMPLETE (Green)

flashing, remaining cooldown time displayed in Hours.minutes

OFF/ XXX

OFF CoL*

FAULT CONDITION EXISTS. UNPLUG THE BATTERY AND GO TO APPENDIX A FOR DETAILS. OTHER INDICATION DISPLAYED (i.e. FAC, Fdc, Lo, HI, etc.)

CHARGING IS COMPLETE. ONCE COOLDOWN TIME IS FINISHED, UNPLUG THE BATTERY.

time

CHARGE COMPLETE (Green)

on (not flashing), remaining refreshing time displayed in

Hours. minutes

OFF rFr*

BATTERY CAN BE UNPLUGGED AND USED.

time

EQUALIZE (Orange)

XXX

(DISPLAY OF CHARGE CURRENT)

∗∗

THESE DISPLAYS OR OPTIONS ARE AVAILABLE ONLY ON Z MODEL CHARGERS OR REPLACEMENT BOARDS

PRESS “EQUALIZE” BUTTON TO EQUALIZE THE BATTERY. PRESS AGAIN TO CANCEL.

Instr. 4770-65-95005-00 Page

9.1 SCR100 CHARGER FUNCTIONAL DESCRIPTION

9.1.2.1 SMART START STAGE

This section gives a brief description of each LED, pushbutton, and the delay function on the SCR100 type charger front control panel.

9.1.1 DELAY STAGE

9.1.1.1 DELAY CIRCUIT

CAUTION: HAZARDOUS VOLTAGES INSIDE. DO NOT ATTEMPT TO CHANGE THE SLIDE SWITCHES ON THE CONTROL CARD UNTIL ALL AC POWER IS DISCONNECTED FROM THE UNIT AS WELL AS THE BATTERY IS UNPLUGGED FROM THE CHARGER. USE PROPER TOOL TO OPEN THE CABINET DOOR.

1. The delay circuit enables the user to set a delay of up to eight hours between battery plug in and the start of charge.

2. The delay time must be set prior to charging. This can

be done via the slide switches located on the back of the charger control card. Refer to Table 5 below for details.

CAUTION: DO NOT TOUCH THE OTHER SLIDE SWITCHES ON THE BACK OF THE CONTROL BOARD. THESE ARE FACTORY SET AND CAN ONLY BE CHANGED BY A QUALIFIED GNB SERVICE REPRESENTATIVE.

TABLE 5

SW5 1 2 3 START DELAY

(HOURS)

ON ON ON 0 (DEFAULT)

OFF ON ON 1

ON OFF ON 2

OFF OFF ON 3

ON ON OFF 4

OFF ON OFF 5

ON OFF OFF 6

OFF OFF OFF 8

9.1.1.2 DELAY LED

Smart Start is only available on Z model chargers and replacement boards. The charge cycle starts with Finish Rate current. If the voltage reaches 2.18VPC + 1% (Sealed /Flooded) within 5 minutes, the charger goes to the Refresh Charge Stage. If it does not reach the above voltage in 5 minutes the charger will go to the High Rate charging stage.

9.1.2.2 CHARGING LED

This LED indicates that the charger is ON.

9.1.2.3 80 % CHARGED LED

This LED indicates that the battery has reached 80% charge.

9.1.2.4 CHARGE COMPLETE LED

When this LED is continuously lit it indicates that the charging cycle is complete. The battery may now be safely disconnected. In the event this LED is flashing, it indicates that cooldown is in progress.

9.1.2.5 FAULT LED

This LED is associated with any fault that is described in Appendix A SCR100 BATTERY CHARGERS. LIST

OF DISPLAY CODES (page 20). It indicates that there

is a problem prior to or during the battery charging operation.

9.1.3 DISPLAY

The display shows the charging current to the battery during the charging process. The display will show additional messages as the charging is progressing or a fault occurs.

9.1.4 STOP PUSHBUTTON

This pushbutton will STOP the charge cycle. The battery can then be safely unplugged. The red fault LED will light to indicate that the charge cycle was interrupted.

This LED indicates that the charger is in the delay mode and charging will not start until the delay time has elapsed. A flashing Delay LED indicates that the delay is in progress.

9.1.1.3 START DELAY OVERRIDE

This pushbutton will override the charger delay mode and charging will start immediately.

9.1.2 CHARGING

Instr. 4770-65-95005-00 Page

9.1.5 BATTERY COOLDOWN OPERATION STAGE

Cool Down step is only available on Z model chargers and replacement boards. A cooldown period is incorporated in the charge cycle. This stage serves to cool down the battery before being placed back in service. During this time the display will alternate between “COL” and time remaining in this stage. If the battery is unplugged during cooldown the display will show “FCD”. During the cooldown period, Equalize can be activated by pressing the Equalize button. If this

occures, cooldown will not start until after Equalize charging is complete.

9.1.6 REFRESH CHARGE STAGE

If the AC power fails during a charge cycle the charger will resume operation in progress as soon as the AC power is restored.

Refresh Charge is only available on Z model chargers and replacement boards. If a battey is left connected to the charger after cooldown, the charger will go into a refresh charge mode. This means that 24 hours after a charging was finished the battery will get a refresh charging for 10 minutes every 24 hours, at finish rate current.

9.1.7 EQUALIZE STAGE

9.1.7.1 EQUALIZE PUSHBUTTON

This pushbutton when pressed will extend the charge cycle by 3.5 hours in the equalize mode after the finish rate time has expired. If pressed a second time, it will cancel the equalize charge mode.

CAUTION: DO NOT EQUALIZE MORE OFTEN THAN REQUIRED BY THE CONDITION OF THE BATTERY, AS SPECIFIED IN THE BATTERY MAINTENANCE INSTRUCTIONS. EXCESSIVE EQUALIZING MAY DAMAGE THE BATTERY.

9.1.7.2 EQUALIZE LED

13.0 MAINTENANCE

The charger requires minimum maintenance. ENSURE THE CHASSIS IS SECURELY GROUNDED per the local/federal Electrical Code. Do not allow excessive dust to accumulate on the components inside. Blow out with clean compressed air when necessary.

The AC input and DC output of the charger are fused and should these fuses fail, the cause of the failure must be determined and corrected before the fuse(s) is (are) replaced. Never replace the fuse(s) with one of a higher capacity than the one originally fitted. (see Tables 2 and 3 pages 9-12).

This LED indicates that the equalize mode has been selected.

10.0 OPPORTUNITY CHARGING

The charger is equipped with a separate profile for applications that utilize opportunity charging for Champion® Batteries. Within 5 seconds the charger will start charging in hirate current until the gassing voltage is reached. At this point the charging will stop until the battery voltage drops to a specified (user programmed) level. The charger will operate at finish rate current until the battery reaches a second specified (also user programmed) voltage. The charger will continue through this cycle until the battery is disconnected.

11.0 CHARGE TIME

The amount of time a battery charges will vary depending on the depth of discharge (DOD). Once the battery has reached 80% charge, the cycle will be terminated 3.5 hours after finish rate (in case of an 8 hour charge time) or less if terminated by dv/dt. Normal charge cycles will average about 8 hours total.

12.0 AC POWER FAILURE

Instr. 4770-65-95005-00 Page

14.0 SCR100 TROUBLESHOOTING

1.Symptom =>

Charger connected to low AC voltage. Verify AC voltage per nameplate of the charger

1.1

Charger connected to high AC voltage. Verify AC voltage per nameplate of the charger

1.2

2. Symptom =>

Charger connected to low / high AC voltage. Verify AC voltage per nameplate of the charger

2.1

AC power partially missing. Verify AC voltage at all primary windings of

2.2

Failure of one or more of charger’s power fuses. Consult GNB technician.

2.3

Phase rotation. (Only if F3 is showing) Verify phase sequence of input AC source.

2.4

NO DISPLAY INDICATION AFTER CONNECTION OF AC POWER

Possible Cause Action

and electrician’s tag. Verify connection of primary windings of power transformer and AC fuses of charger per connected AC voltage and electrician’s tag.

Check AC fuses of charger and replace if needed. Check fuse F2 of Control Card. If this fuse is blown, replace Control Card.

DISPLAY INDICATES FAC OR F3 AFTER CONNECTION OF AC POWER

Possible Cause Action

and electrician’s tag. Verify connection of primary windings of power transformer and AC fuses of charger per connected AC voltage and electrician’s tag.

power transformer and AC fuses of charger per nameplate of the charger and electrician’s tag.

Replace fault fuse. Verify input AC voltage and output High Rate current.

Ensure that it follows the sequence indicated at the charger’s input.

3. Symptom =>

3.1

Previous charge cycle was interrupted by DC cable disconnection.

Shorted or leaky SCRs/diodes. Disconnect battery and AC power.

3.2

DISPLAY INDICATES FCA BEFORE CONNECTION OF BATTERY

Possible Cause Action

Do not interrupt charge by DC cable disconnection. Use pushbutton Stop for this purpose. Connect next battery – charger will start automatically.

Consult GNB technician.

Instr. 4770-65-95005-00 Page 17

4. Symptom =>

4.1

Previous charge cycle was interrupted during Cool Down.

DISPLAY INDICATES FCD BEFORE CONNECTION OF BATTERY

Possible Cause Action

Do not interrupt charge cycle until LED End is continuously on. Connect next battery – charger will start automatically.

5. Symptom =>

5.1

Charge cycle was interrupted during charge by DC cable disconnection with slow / bouncing disconnection of DC plug.

Charge cycle was interrupted by DC cable

5.2

disconnection during charge. Additionally, a battery was connected back before charger displayed FCA. Indication FdC and FAULT LED is on.

Charger’s DC fuse blown.

5.3

Indication FdC and FAULT LED is on.

DISPLAY INDICATES FDC BEFORE CONNECTION OF BATTERY.

Possible Cause Action

Do not interrupt charge by DC cable disconnection. Use pushbutton Stop for this purpose. Disconnection of DC cable during charge is not safe because it produces electrical arc. If DC cable disconnection is used, disconnect cable as fast as possible; never connect battery before indication FCA appears at display (takes about 2 s after disconnection of DC cable).

Disconnect battery and AC power for 5 sec. Return AC power and then connect battery.

See above

Disconnect battery and AC power. Consult GNB technician.

6. Symptom =>

6.1

Connection between charger and battery open. Repair or clean battery lugs.

6.2

Battery with wrong number of cells connected to a charger. Indication LO/rEJ or HI/rEJ and FAULT LED is on.

6.3

Battery voltage too low. Indication LO/rEJ and FAULT LED is on.

6.4

A charger operates at Delay. Indication dEL/Remaining Delay Time, LED Delay is on.

6.5

Control Card failure. Indication FFF.

CHARGING LED DOES NOT LIGHT ON AFTER BATTERY CONNECTION

Possible Cause Action

Repair and/or change charger and /or battery DC cables and contacts of DC connectors.

Replace with correct battery.

Consult GNB technician.

Wait till end of Delay or press pushbutton Start.

Consult GNB technician.

Instr. 4770-65-95005-00 Page 18

7. Symptom =>

7.1

Battery failed to reach gassing voltage. Consult GNB technician.

7.2

Battery failed to reach End Voltage (Stage 3 of OPC).

DISPLAY INDICATES FCC OR F2 AT THE END OF CHARGE CYCLE

Possible Cause Action

Check matching of charger and battery: Ah, type.

Consult GNB technician. Check matching of charger and battery: Ah, type, etc.

8. Symptom =>

Complete or partial loss of AC power. Wait until AC returns: charger will automatically

8.1

Failure of one or more of charger’s power fuses. Consult GNB technician.

8.2

Failure of Control Card. Consult GNB technician.

8.3

9. Symptom =>

Pushbutton Stop interrupted charge cycle. Use pushbutton Stop only when you want

9.1

DISPLAY INDICATES FAC OR F3 DURING CHARGE CYCLE

Possible Cause Action

complete charge cycle. If needed, battery may be disconnected during AC failure.

Replace fault fuse. Verify input AC voltage and output High Rate current.

Verify input AC voltage. Replace fault Control Card.

DISPLAY INDICATES OFF (ONLY) AND FAULT LED IS ON

Possible Cause Action

interrupt charge cycle or disconnect battery. Charger will start automatically after connection of next battery.

Instr. 4770-65-95005-00 Page 19

APPENDIX A: SCR100 BATTERY CHARGERS. LIST OF DISPLAY INDICATIONS.

Indication Abbreviation Interpretation

1.00

2.00

3.00

4.00

5.00

6.00

8.00

CHP CHamPion COL COoL Down

dEL dELay

End End

FAC or F3 Failure of AC power

FCA Failure of DC CAble

FCC

Or F2

FCd Failure of Cool down

1 hour delay set Delay before charge starts 2 hour delay set Delay before charge starts 3 hour delay set Delay before charge starts 4 hour delay set Delay before charge starts 5 hour delay set Delay before charge starts 6 hour delay set Delay before charge starts 8 hour delay set Delay before charge starts

disconnection Failure of Charge Cycle

Charger set to sealed Champion®batteries Charger operates at Cool Down Stage

Delay set or Charger operates at Delay Stage

Charge Cycle complete

Failure of mains DC cable disconnected from the battery during the

charge Battery failed to reach Gassing Voltage (Stage 2)

or Battery failed to reach End Voltage (Stage 3 of OPC)

Battery unplugged during Cool Down Stage

FdC Failure of dC Fuse

FFF F… Fatal Failure

FLd FLooded

FOC Failure of Overall