Exide Technologies SCRFLX User Manual

INSTALLATION & OPERATING

INSTRUCTIONS

SCR FLX SERIES

INDUSTRIAL BATTERY CHARGERS

PACIFIC CHLORIDE

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-3889 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 Display and Fault 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 SCRFLX CHARGER OPERATION 14

9.1 SCRFLX Charger Functional Description 15

10.0 CHARGE TIME 16

11.0 AC POWER FAILURE 16

12.0 MAINTENANCE 16

13.0 TROUBLESHOOTING 17

APPENDIX A: SCRFLX BATTERY CHARGERS. LIST OF DISPLAY INDICATIONS 19 APPENDIX B: ELECTRICAL SCHEMATIC DRAWINGS 21

Instr. 4770-65-95005-10 Page

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Rev 15/08/2002

SCRFLX 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”. To restart the charger, plug in the next

battery. 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 flooded 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.

Instr. 4770-65-95005-10 Page

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2.0 INTRODUCTION

The GNB SCRFLX battery chargers are convection cooled, solid state, micro-processor controlled SCR regulated chargers designed to make battery charging simple. They are designed to charge flooded lead-acid batteries only.

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.

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 SCRFLX 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, 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. 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 or 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 #1/4-20 UNC bolts (steel rack) or #1/4 lag screws and anchors (concrete floor). All charger models with a Z, SCRFLX-XX-XXXT1Z of SCRFLX-XX-XXX-S1Z, can be stacked to a maximum of three high.

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 d) 208/240/480VAC, 60Hz b) 208/240/480VAC, 60Hz e) 480VAC, 60Hz c) 240VAC, 50Hz f) 380VAC, 50Hz

g) 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 configuartion 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 208, 240, 480 VAC (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 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.

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

Instr. 4770-65-95005-10 Page

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.

3

FIGURE 1: SINGLE PHASE INPUT

BRN

BLK

BRN

L1

L2

L1

L1L1L2

L1

L1L2L2

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)

BLK

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

BLK

L2

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

BLK

L2

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

BLK

BRN

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

Instr. 4770-65-95005-10 Page

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FIGURE 2: THREE PHASE INPUT

L3

L2

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

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

L2

L1

L2

L1

L3

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

L3 L3

L2 L2

L1

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

L1

L3

L1

L3

Instr. 4770-65-95005-10 Page

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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) (SCRFLX- XX-XXXXT1Z ONLY)

L1

L2

L3

L1

240VAC CONFIGURATION (208/240/480V INPUT) (SCRFLX -XX-XXXXT1Z ONLY)

L1

L2 L3

L2

L3

L1

480VAC CONFIGURATION (208/240/480V INPUT) (SCRFLX -XX-XXXXT1Z ONLY)

L1

L2 L3

Instr. 4770-65-95005-10 Page

L1

L3L2

6

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 AND ELIMINATES CHARGER WARRANTY.

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 start-up, it means that there is a low or high AC voltage (+35%) or AC phase missing. Refer to the Troubleshooting Section (Section 13, page 17) for more details.

FIGURE 4: GROUNDING METHOD

Instr. 4770-65-95005-10 Page

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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 DISPLAY AND FAULT CODES

Refer to Appendix A (on page 19) for a complete list of codes.

7.2 OPTIONS

7.2.1 JIC SWITCH ASSEMBLY

All SCRFLX 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 switch can only be factory installed and it 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 SCRFLX 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. 4770-65-95005-10 Page

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TABLE 2 – SINGLE PHASE TECHNICAL DATA

STANDARD MODEL

SCRFLX-XX-XXXX-S1Z

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

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

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

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

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

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

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

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

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

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

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

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

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

SCRFLX-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

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

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

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

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

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

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

SCRFLX-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

40

74

93

134

150

74

93

134

150

40

74

93

116

134

150

40

74

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 -

TABLE 2 – SINGLE PHASE TECHNICAL DATA

STANDARD MODEL

SCRFLX-XX-XXXX-S1Z

SCRFLX-18-600S1Z

SCRFLX-18-750S1Z

SCRFLX-18-865S1Z

(50 Hz)

SCRFLX-24-260S1Z

SCRFLX-24-475S1Z

(50 Hz)

SCRFLX-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

93

116

134

40

74

93

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.

-

C.F.

-

X X

-

C.F.

- 30

C.F.

-

X X

-

C.F.

X X X X

48 60 48 60

-

22

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

30

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

TABLE 3 – THREE PHASE TECHNICAL DATA

AC AMPS @ AC VOLTS

STANDARD MODEL DC 60Hz 50Hz CABINET WEIGHT

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

SCRFLX-06-475T1Z

SCRFLX-06-600T1Z

SCRFLX-06-865T1Z

SCRFLX-06-965T1Z

SCRFLX-06-1050T1Z

SCRFLX-06-1450T1Z

SCRFLX-09-600T1Z

SCRFLX-12-475T1Z

SCRFLX-12-600T1Z

SCRFLX-12-750T1Z

SCRFLX-12-865T1Z

SCRFLX-12-965T1Z

SCRFLX-12-1050T1Z

SCRFLX-12-1200T1Z

SCRFLX-12-1450T1Z

SCRFLX-18-260T1Z

SCRFLX-18-475T1Z

SCRFLX-18-750T1Z

SCRFLX-18-865T1Z

SCRFLX-18-965T1Z

74

93

116

134

150

163

186

225

93

74

93

116

134

150

163

186

225

40

74

93

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

12 12 6 10 9 5

C.F.

C.F. C.F.

3.5 B 190 86.2

-

5

B 220 99.8SCRFLX-06-750T1Z

- -

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 118SCRFLX-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 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 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.

-

C.F.

-

8 B 255 116

12

10 B / C* 300 136SCRFLX-18-600T1Z

15 20 18 9 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. 4770-65-95005-10 Page

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TABLE 3 – THREE PHASE TECHNICAL DATA

AC AMPS @ AC VOLTS

STANDARD MODEL DC 60Hz 50Hz CABINET WEIGHT

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

SCRFLX-18-1050T1Z

SCRFLX-18-1200T1Z

SCRFLX-18-1700T1Z

SCRFLX-24-475T1Z

SCRFLX-24-600T1Z

SCRFLX-24-865T1Z

SCRFLX-24-965T1Z

SCRFLX-24-1050T1Z

SCRFLX-24-1200T1Z

SCRFLX-24-1450T1Z

SCRFLX-24-1700T1Z

SCRFLX-36-475T1Z

SCRFLX-36-600T1Z

SCRFLX-36-750T1Z

SCRFLX-36-865-T1Z

163

186

225

264

74

93

116

134

150

163

186

225

264

74

93

116

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

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 27 26 C 450 204SCRFLX-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 157SCRFLX-24-750T1Z

40 35 15 25 20 31 27 14 18 17.2 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 48 46 23 28 C.F. C 440 200

60 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 C 460 209 35 27 C 480 218 35

SCRFLX-36-965-T1Z

SCRFLX-36-1450-T1Z

SCRFLX-40-1200-T1Z

SCRFLX-48-600-T1Z

SCRFLX-48-865-T1Z

150

225

74

186

93

134

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

AMPS

FUSE

C.F. C.F.

- -

27 40

C.F.

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

50

33 45

-

C.F.

-

C.F. C.F.

- -

C.F. C.F.

- -

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

60

19.5 C 450 204SCRFLX-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. 4770-65-95005-10 Page

12

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. 4770-65-95005-10 Page

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9.0 SCRFLX CHARGER OPERATION

LED DISPLAY DESCRIPTION (NONE)

DELAY (Orange), dEL, then

delay time remaining in Hours. minutes

CHARGING (Orange)

(DISPLAY OF CHARGE CURRENT)

80% CHARGED (Yellow)

(DISPLAY OF FINISH RATE CURRENT)

FAULT (Red)

OFF FLd*

OFF dEL time

XXX

OFF

PLUG IN THE BATTERY TO COMMENCE CHARGING CHARGER SET FOR FLOODED BATTERIES

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

HIGH RATE CHARGING

FINISH RATE CHARGING

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

CHARGE COMPLETE (Green) on, remaining refresh time displayed in Hours. minutes

EQUALIZE (Orange)

(DISPLAY OF CHARGE CURRENT)

OFF/ XXX

OFF CoL* time

OFF rFr* time

XXX

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.

BATTERY CAN BE UNPLUGGED AND USED.

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

*

∗∗

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

Instr. 4770-65-95005-10 Page

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9.1 SCRFLX CHARGER FUNCTIONAL DESCRIPTION

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

9.1.1 DELAY STAGE

9.1.1.1 DELAY CIRCUIT

9.1.2 CHARGING

9.1.2.1 CHARGING LED

This LED indicates that the charger is ON.

9.1.2.2 80 % CHARGED LED

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

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 4 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 4

SW5 1 2 3 4 START DELAY

(HOURS)

ON ON ON ON 0 (DEFAULT)

OFF ON ON ON 1

ON OFF ON ON 2

OFF OFF ON ON 3

ON ON OFF ON 4

OFF ON OFF ON 5

ON OFF OFF ON 6

OFF OFF OFF ON 8

9.1.1.2 DELAY LED

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.

9.1.2.3 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.

9.1.2.4 FAULT LED

This LED is associated with any fault that is described in Appendix A LIST OF DISPLAY INDICATIONS (page

19). 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.

9.1.5 BATTERY COOLDOWN OPERATION STAGE

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 battery is unplugged during cooldown the display will show “OFF”. During cooldown period, Equalize can be activated by pressing the Equalize button. If this occured, cooldown will not start until after Equalize charging is complete.

9.1.1.3 START DELAY OVERRIDE

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

Instr. 4770-65-95005-10 Page

9.1.6 REFRESH CHARGE STAGE

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.

15

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

This LED indicates that the equalize mode has been selected. A flashing equalize LED indicates that it is in process.

10.0 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 in 3.5 hours (in case of an 8 hour charge time) or less if terminated by dv/dt. Normal charge cycles will average about 8 hours total.

11.0 AC POWER FAILURE

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

12.0 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).

Instr. 4770-65-95005-10 Page

16

13.0 SCRFLX TROUBLESHOOTING

1.Symptom =>

NO DISPLAY INDICATION AFTER CONNECTION OF AC POWER

Possible Cause Action

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 => DISPLAY INDICATES FAC OR F3 AFTER CONNECTION OF AC POWER

Possible Cause Action

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

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.

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

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

Charge cycle was interrupted by DC cable

3.2

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

DISPLAY INDICATES FDC BEFORE CONNECTION OF BATTERY.

Possible Cause Action

Instr. 4770-65-95005-10 Page 17

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 OFF 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

Charger’s DC fuse blown.

3.3

Indication FdC and FAULT LED is on.

Disconnect battery and AC power. Consult GNB technician.

4. Symptom =>

4.1

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

4.2

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

4.3

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

4.4

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

5. Symptom =>

5.1

Battery failed to reach gassing voltage. Consult GNB technician.

6. Symptom =>

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.

DISPLAY INDICATES FCC OR F2 AT THE END OF CHARGE CYCLE

Possible Cause Action

Check matching of charger and battery: Ah, type.

DISPLAY INDICATES FAC OR F3 DURING CHARGE CYCLE

Possible Cause Action

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

6.1

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

6.2

Failure of Control Card. Consult GNB technician.

6.3

7. Symptom =>

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

7.1

8. Symptom =>

8.1 Charger control board was set improperly. Prior to connection the display indicated OFF/CHP not OFF/Fld

DISPLAY INDICATES OFF (ONLY) AND FAULT LED IS ON

Possible Cause Action

DISPLAY INDICATES FCS AFTER CONNECTION ON BATTERY

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.

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

Call your local GNB representative for procedure to change this setting.

Instr. 4770-65-95005-10 Page 18

APPENDIX A: SCRFLX 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 FdC Failure of dC Fuse

FFF F…Fatal Failure

FOC Failure of Overall Charge

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

timer

Control board is set to 2.55VPC not 2.70VPC.

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 Output DC Fuse Failure Fatal Failure of the charger (Overvoltage or

Overcurrent protection or multifunction of Start Stop signal) Overall charge cycle timer protection

FLd FLooded