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: [phone]
Fax: [phone]

GNB Industrial Power
Motive Power

8301 Keele Street
Maple, Ontario
Canada L6A 1T2
Tel: [phone]
Fax: [phone]

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: [phone]

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.

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FIGURE 1: SINGLE PHASE INPUT

BRN

BRN

BRN

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

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

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

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

L2

L3

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

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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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