Exide Technologies SCRFLX User Manual

4.3 (3)

INSTALLATION & OPERATING

INSTRUCTIONS

SCR FLX SERIES

INDUSTRIAL BATTERY CHARGERS

Exide Technologies SCRFLX User Manual

PACIFIC CHLORIDE ®

GNB Industrial Power

GNB Industrial Power

Exide Technologies

 

 

 

 

 

 

 

 

 

Motive Power

Motive Power

Chloride Motive Power

 

 

 

 

 

 

 

 

 

829 Parkview Boulevard

8301 Keele Street

P.O. Box 1, Salford Road

 

 

 

 

 

 

 

 

 

Lombard, IL 60148-3249

Maple, Ontario

Over Hulton, Bolton BL5 1DD

 

 

 

 

 

 

 

 

 

U.S.A.

Canada L6A 1T2

United Kingdom

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Tel: 877.GNB.INFO

Tel: 905.669.9326

Tel: 44.1204.661.230

 

 

 

 

 

 

 

 

 

 

 

www.gnb.com

Fax: 630.691.7869

Fax: 905.669.7688

Fax: 44.1204.652.100

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GB-3889 RPT 11/01

 

Printed on recycled paper

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 1

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 2

2.0INTRODUCTION

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.

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.

3.0RECEIVING 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.

4.0LOCATION 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.

4.1STACKING

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.

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.

5.0AC 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.

5.1AC 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.

5.2INPUT 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.

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. 4770-65-95005-10

Page 3

FIGURE 1: SINGLE PHASE INPUT

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

BRN

 

L2

L1

BLK

BRN

 

L2

 

 

 

 

L1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

 

BLK

 

BRN

L2

L1

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

BLK

BRN

 

L2

L1

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

 

BLK

 

BRN

L2

L1

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

 

BLK

 

BRN

L2

L1

Instr. 4770-65-95005-10

Page 4

FIGURE 2: THREE PHASE INPUT

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

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

L2

L1

L3

L2

L1

 

 

 

 

L3

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

L2

L1

L3

L2

L3

 

 

 

 

L1

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

L2

L1

L3

L2

L1

 

 

 

 

L3

Instr. 4770-65-95005-10

Page 5

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

L1

L3

L2

 

L3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

L1

L2

L3

L1

 

 

L2

 

L3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

L1

L2

L3

L1

 

 

L2

L3

Instr. 4770-65-95005-10

Page 6

5.3AC VOLTAGE CONNECTIONS

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.

5.4GROUND 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.

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

6.0DC OUTPUT

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

Instr. 4770-65-95005-10

Page 7

7.0APPLICATION

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.

7.1DISPLAY AND FAULT CODES

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

7.2OPTIONS

7.2.1JIC 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 4770-65- 73041-17 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.

7.2.2BATTERY 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 2131).

RELAY CONTACT RATINGS:

-AC: 125V 0.6A 1.0PF maximum

-DC: 30V 2A resistive maximum

7.2.3REMOTE 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

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.

Instr. 4770-65-95005-10

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