Exide Technologies V19CIL5200ULF User Manual

FLX200 SERIES

INDUSTRIAL BATTERY CHARGERS

INSTALLATION & OPERATING

INSTRUCTIONS

TABLE OF CONTENTS

TITLE Page

1. Important Operating Instructions 2

2. Introduction 3

3. Receiving Instructions 3

4. Location and Installation of Charger 3

5. Stacking 3-4

6. AC Electrical Supply 5-9

6.1 Branch Circuit Protection 5

6.2 AC Voltage Connections 9

6.3 Ground Connection 9

7. DC Output 10

8. Fault and Display Codes 10

9. Options 10

9.1 JIC Switch 10

9.2 Momentary Remote and Stop Operation 10

10. FLX200 Standard Charger Operation 11

11. Charger Functional Description 12

11.1 LED Descriptions 12

11.2 Display 12

11.3 Pause Push Button 12

11.4 Smart Start Stage 12

11.5 Auto Balance 13

11.6 Equalize Stage 13

11.7 Equalize Pushbutton 13

11.8 Low Battery Override/Recovery 13

11.9 Delayed Start of Charge 14

11.10 Battery Cooldown Operation Stage 14

11.11 Refresh Charge 14

11.12 Charge Time 15

11.13 Incorrect Battery Limits 15

11.14 Charge Cycle Reset 15

11.15 AC Power Failure 15

12. Maintenance 15 Appendix A Fault Codes 16 Appendix B FLX200 Troubleshooting 17 Appendix C Single Phase Technical Data 18 Appendix D Three Phase Technical Data 19 Appendix E Circuit Diagrams 20-25 Appendix F Cabinet Dimensions 26

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FLX200 SERIES INDUSTRIAL BATTERY CHARGERS

1. 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 marking s on the charger, battery, and all the associated equipment.

b) Do not touch un-insulated 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 PAUSE pushbutton before unplugging the battery to prevent arcing or burning.

d) If the battery is unplugged during charging, the charger will indicate “F18”. To

restart the charger, plug in the next battery. Do not connect the next battery

before you see indication “- - - -” or “F18”. e) Only qualified personnel should operate or service this equipment. f) De-energize all AC and DC po wer 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. The operating

environment should not contain any materials 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 Industrial Power service center. j) Do not disassemble the charger. Have the charger examined by an GNB

Industrial Power 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 9 ft and a

battery DC cable length of 25 in. If DC cable lengths are adjusted, please

contact your local GNB Industrial Power service representative.

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1. INTRODUCTION

The GNB® FLX200 battery chargers are fan cooled, solid state, microprocessor controlled, SCR regulated chargers designed to make battery charging simple. They are factory set to charge flooded lead-acid batteries, but an upgrade can be purchased from a GNB Industrial Power service representative to enable the charger

™

to service ELEMENT

valve regulated 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, two button keypad and LED display report on the charger and battery status.

2. 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 FLX200 chargers are delivered on skids for easy handling using a forklift truck.

3. LOCATION AND INSTALLATION OF CHARGER

Proper installation is important in order to achieve good charger performance and long trouble free operation and to prevent damage to the charger and batteries. The charger should be located in a clean, cool, normal ambient room temperature (between +32

F/0oC and 104oF/40oC), 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 or on top of the charger.

4. STACKING

The following recommendations should be taken into consideration when stacking these units:

a) The base unit should be secured to the floor or a solid base using appropriate

bolts and with accordance to local building codes and regulations. b) These units can be stacked to a maximum 3 high. c) If a lifting sling is used, the sling should be placed under the unit where the base

plate is located to avoid damage to the units. Lifting Sequence is as follows: a) Secure the base unit to the floor or solid base. T he bolts can be accessed and

secured from the underside of the unit at the front and rear or from inside the unit

where the large holes are located directly above mounting holes (see appendix G

for mounting hole locations). When accessing the mounting holes from the

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inside, it is recommended you use a long handle hexagon key or screwdriver with

the hexagon key inserted. This will allow you to go t hrough the base plate to the

bolts, which are located on the flange. b) Remove the bolts from the top cover of the base unit, but do not discard these,

as they will be required to fix the two units together. c) Use an appropriate lifting sling to lift the second unit on to the base unit, inch the

second unit over the base unit and align the holes before resting the second unit

on top. d) Secure the two units together using the bolts removed from the top cover of the

base unit. Use the access between the two units or inside the second unit using

the tools as recommended above. e) If stacking three high, use the above procedure for stacking the third unit.

WARNING: THESE PROCEDURES MUST BE FOLLOWED EXACTLY TO AVOID

INJURY OR RISK OF ELECTRIC SHOCK.

WARNING: TO REDUCE THE RISK OF FIRE, INST ALL 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.

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5. AC ELECTRICAL SUPPLY

The charger must be connected to either a single phase or three phase, 60 Hertz (± 2%) AC power source. Three phase chargers cannot be powered with a single phase source.

The following transformer options are available:

TABLE 1 – TRANSFORMER OPTIONS

Single phase Three phase

120/208/240 VAC 60Hz* 208/240/480 VAC, 60Hz* 208/240/480 VAC, 60Hz* 240/480 VAC, 60Hz* 240/480 VAC, 60Hz* 480 VAC, 60Hz 600 VAC, 60Hz 600 VAC, 60Hz

*Only the AC input wire configuration for multi-input chargers can be changed Follow Figure 1 (page 6) for single-phase input with 120/208/240 VAC transformers, Figure 2 (page 7) for single-phase input with 208/240/480 transformers or Figure 3 (page 8) for three-phase input transformers.

Use the 208/240/480 diagram for the 240/480 transformers. The 208 tap will be eliminated from the charger as a selection.

A qualified electrical contractor should perform this adjustment.

6.1 BRANCH CIRCUIT PROTECTION The charger comes with an internal supplementary protective device rated to

accommodate the highest possible current and voltage for that model.

CAUTION: TO REDUCE THE RISK OF FIRE, USE ONLY ON CIRCUITS PROVI DED

WITH BRANCH CIRCUIT PROTECTION CONSISTENT WITH THE CURRENT INDICATED ON THE FRONT PANEL-RATING LABEL AND IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE, ANSI/NFPA 70.

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L 0

L L N

FIGURE 1: 120/208/240 VAC, SINGLE-PHASE INPUT

WARNING: IM PROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE

DAMAGE TO THE CHARGER AND BATTERY

NOTE: Live connection ‘L’ Must be connected to the breaker. The mains input are the

only user configurable connections. The blue and brown PCB connections must

be altered from factory setting.

NOT

120 VAC 60Hz CONFIGURATION (120/208/240VAC INPUT)

120

208

120

208

Mains Input

(Black) (Black)

Mains Input

(Black)

N L

208 VAC 60Hz CONFIGURATION (120/208/240VAC INPUT)

N L

240VAC 60Hz CONFIGURATION (120/208/240VAC INPUT)

240

PCB

(Blue)

(Brown)

PCB

(Blue)

(Brown)

Mains Input

(Black)

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PCB

(Blue) (Brown)

FIGURE 2: 208/240/480 VAC, SINGLE-PHASE INPUT

L 0

L L N

WARNING: IM PROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE

DAMAGE TO THE CHARGER AND BATTERY

NOTE: Live connection ‘L’ Must be connected to the breaker. The mains input are the

only user configurable connections. The blue and brown PCB connections must

be altered from factory setting.

NOT

208 VAC 60Hz CONFIGURATION (208/240/480V INPUT)

208

240

Mains Input (Black)

(Black)

Mains Input

(Black)

N L

240 VAC 60Hz CONFIGURATION (208/240/480V INPUT)

208

480 VAC 60Hz CONFIGURATION (208/240/480V INPUT)

240

480

PCB

(Blue)

(Brown)

PCB

(Blue) (Brown)

208

240

Mains Input

(Black)

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480

PCB

(Blue) (Brown)

FIGURE 3: 208/240/480 VAC, THREE-PHASE INPUT

WARNING: IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE

DAMAGE TO THE CHARGER AND BATTERY

NOTE: The blue and brown PCB connections must NOT

208VAC 60 Hz CONFIGURATION (208/240/480V INPUT)

be altered from factory setting.

Mains Input

(Black)

Mains Input

(Black) (Black)

(Black)

208

240VAC 60 Hz CONFIGURATION (208/240/480V INPUT)

208

240

480VAC 60 Hz CONFIGURATION (208/240/480V INPUT)

480

240

480

208 208

480

240240

480

PCB (Brown)

(Blue)

240240

480

PCB

(Brown)

(Blue)

208

480

240

208 208

Mains Input (Black)

(Black)

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480

240240

480

PCB

(Brown)

(Blue)

+ 19 hidden pages

Exide Technologies V19CIL5200ULF User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual