Exide Technologies SCR100 User Manual

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

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