KEPCO KRR 12-40 User Manual

INSTRUCTION MANUAL

KEPCO

An ISO 9001 Company.

KRR

12-40

12 VOLT, 600W RAILROAD BATTERY CHARGER

I — INTRODUCTION

SCOPE OF MANUAL.

This instruction manual covers the installation and operation of the Kepco Model KRR 12-40 12-Volt, 600W Railroad Bat­tery Charger.

DESCRIPTION.

The Kepco Model KRR 12-40 12-Volt, 600W Railroad Battery Charger is a wall-mounted unit designed to charge 12-Volt
lead-acid or nickel cadmium batteries used in railroad applications. The output voltage is set to 13.50V d-c, and is adjust­able from 10.5 to 18V d-c from the front panel recessed trimpot. An optional temperature compensation probe (supplied)
provides automatic adjustment of the float voltage to accommodate temperatures from 0° to 50°C. Units may be operated
with a nominal 100V a-c to 240V a-c (input voltage range 85 to 265 Va-c), 50-60 Hz (input frequency range 47-66Hz.).
Both line and neutral lines are protected by 20A fuses. A front panel ammeter shows charging current.

The heart of the Model KRR 12-40 is a 600W solid-state switching power supply, Kepco’s RKW 15-43K-26568, which has
an integral cooling fan. A front panel CHARGER ON indicator lights while input power is applied to the a-c input terminals.
The front panel TEMP PROBE ERROR indicator lights to show that the temperature compensation probe is not connected
to the unit or is inoperable. An internal diode network across the output provides protection in the event that the battery
connections are reversed, causing the front panel circuit breaker to open.

FEATURES

• Wide Range Input - Operates from input voltage range of 85 to 265V a-c, input frequency range 47-

66Hz with no adjustment or modification required.

• Adjustable Float Voltage - The float voltage is factory set to 13.50V d-c, and is adjustable from 10.5 to
18V d-c at the front panel by connecting a precision voltmeter to the + and – VOLTAGE MONITOR test
points and adjusting the output using the V. FLOAT ADJUST potentiometer.

• Temperature Compensation - An optional temperature compensation probe (supplied) provides auto-
matic adjustment of the float voltage to accommodate temperatures from 0° to 50°C for lead-acid batter­ies.

• CHARGER ON indicator - on while a-c input power applied to unit and unit is operational.

• Charging Current ammeter - indicates charging current

• Input protection - Two line fuses (20A/250V) are provided.

• Battery connection protection - If battery connections are reversed, an internal diode network across
the output is forward biased; the resulting current flow causes the front panel circuit breaker to pop
open. The connections must be switched and the circuit breaker turned on to reset.

KEPCO, INC. " 131-38 SANFORD AVENUE " FLUSHING, NY. 11352 U.S.A. " TEL [phone] " FAX [phone]

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©2006, KEPCO, INC 1
Data subject to change without notice 228-1562

II — SPECIFICATIONS

Specifications listed in Table 1 are at nominal input voltages and at 25°C unless otherwise specified.

TABLE 1. MODEL KRR 12-40 SPECIFICATIONS

SPECIFICATION DESCRIPTION/CONDITION RATING

Nominal

Input Voltage

Input Current

Surge, cold start, interval > 30 sec

Range

Nominal Frequency

Frequency Range

100V a-c to 120V a-c

200V a-c to 240V a-c

100V a-c to 120V a-c

Surge, cold start, interval > 30 sec

200V a-c to 240V a-c

Power Factor Rated input, rated output 0.99 typical

Efficiency 100V a-c Input 80%

240V a-c Input 84%

Leakage Current: Per IEC 950 and UL 1950 0.75mA a-c max.

Output Voltage

Nominal @ 15V d-c Output

Output Current

Ta = -10°C to 50°C, derates for Ta > 50°C

Short circuit value 51A d-c

Output Power Ta = -10°C to 50°C, derates for Ta > 50°C 645W

Output Voltage

Ripple & Noise

(1)

Ripple 150mV p-p

Noise 200mV p-p

Source Effect

(85 to 132 V a-c and 170 to 265V a-c)

Stabilization

Load effect (at sensing terminals) 0.4% maximum

Temperature effect (–10° to 65°C) 1.0% maximum

Time effect (8 hours at 25°C) 0.5% maximum

Output Voltage

Temperature Compensation

Use optional temperature compensation probe

supplied 0°C to +50°C for Lead-Acid battery

Overvoltage 25V d-c max.

Overcurrent (internal > 30 sec) 51A d-c

Output Protection

(2)

Internal Overtemperature

Fan Failure

Battery Reversed

Output disconnected for output current > 50A d-c

Analog meter for output (charging) current 0 to 50A d-c, 5% accuracy

Front Panel Display

“Charger ON” LED Green indicates charger is operational

“Temp Probe Error” LED

Operation Temperature

Output performance derated above 50°C and

below 0°C

Storage Temperature -30°C to 75°C

Cooling

Weight 9.0 lbs. (4.1 Kg.)

Dimensions

100V a-c to 240V a-c

85V a-c to 265V a-c

50Hz/60Hz

47Hz to 66Hz

8.4A a-c max.

4.2A a-c max.

30A p-p max.

60A p-p max.

Factory set to 13.50V d-c,

Adjustable range: 10.5-18.0V d-c

43A d-c

0.2% maximum

3mV/(°F)(cell), 5.4mV/(°C)(cell)

Output changed to -0.7V d-c

Yellow indicates that the probe is not

connected or not operational

-10°C to +65°C

Forced air flow - one fan
(exhaust to the left side)

7.25 in (H). x 11.14 in. (W) x 9 in. (D)

184.2mm (H) x 283 (W) x 228.6 (D)

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TABLE 1. MODEL KRR 12-40 SPECIFICATIONS

SPECIFICATION DESCRIPTION/CONDITION RATING

Input Protection

(1) Ripple and noise specification is 1.5 times the indicated values for a temperature range of -10 to 0°C. Ripple and noise levels above are

satisfied when conditions are 0 to 100% load, 0 to 65°C, and measuring bandwidth

(2) After disconnecting a-c input, remove the fault, wait about 40 seconds, then reconnect a-c input.

Fuses (2) 20A, 250V, Kepco P/N 141-0100

(Bussman P/N MDA-20)

≤ 100MHz.

III — INSTALLATION

If desired, the battery charger output can be preset prior to mounting at a separate location.

PRESETTING THE OUTPUT

1. Remove the front panel window protecting input and output connections by loosening two captive screws.

2. Route the AC Input line wires through the appropriate openings in the top of the chassis and secure to L1 and L2 studs.

3. Connect the ground connection to the ground stud (see Figure 1) using the 10-32 x 3/8 ACF Brass Hex nut provided
(Kepco P/N 102-0007)

4. Turn a-c power on and connect a precision digital voltmeter (DVM) to the + and – VOLTAGE MONITOR test points at the
front panel.

5. Monitor the DVM and set the float voltage as desired using the V. FLOAT ADJUST potentiometer at the front panel. It is
recommended that the unit be tagged with the float voltage.

6. Turn a-c power off and disconnect DVM. If unit is to be mounted at a different location, disconnect ground and a-c input
connections, then reinstall window on front panel.

MOUNTING THE BATTERY CHARGER

1. Two slotted holes, 7 inches apart, are provided on the upper rear chassis (See Figure 1) to wall mount the unit. The unit
has forced air cooling from a single fan located within the integral RKW 15-43K-26568 power supply as well as ventilation
holes in the chassis which must be kept clear from obstructions to ensure proper air circulation. Enough space must be
provided around the chassis to allow the hot air to exhaust from the components inside the chassis.

2. Remove the front panel window protecting input and output connections by loosening two captive screws.

3. Route the AC source power line and neutral wires through the appropriate openings at the top of the chassis and install
on the studs labeled AC INPUT LINE, L1 and L2.

4. Connect ground wire to the ground stud (see Figure 1) using the 10-32 x 3/8 ACF Brass Hex nut provided (Kepco P/N
102-0007)

5. Proceed to CONNECTIING THE BATTERY or, if the battery will be connected later, reinstall the front panel window using
the two captive screws.

CONNECTING THE BATTERY

1. If not done previously, remove the front panel window protecting input and output connections by loosening two captive
screws.

2. Disconnect load from the battery. Route the + and – battery connections through the appropriate openings at the top of
the chassis and install on the studs labeled DC OUTPUT, + and – respectively. NOTE: Verify the polarity! If the polarity is
reversed, the front panel circuit breaker will pop. If this occurs, reconnect the battery correctly and turn on the circuit
breaker.

3. Reinstall the front panel window using the two captive screws.

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IV — OPERATION

USING TEMPERATURE COMPENSATION FOR LEAD-ACID BATTERY (OPTIONAL)

Temperature compensation allows the output voltage of the Model KRR 12-40 battery charger to be automatically decreased
or increased for temperatures above or below 77°F (25°C), respectively. Compensation is 3mV/(°F)(cell) or 5.4mV/(°C)(cell),
so for a standard 12 Volt battery using six 2-volt cells, compensation is 18mV/°F. As an example, if temperature measured
by the sensor was 80°F, (3°F above 77°F) the output voltage would be decreased by 3 x 18mV = 54mV. Since the tempera­ture is expected to rise while charging, and then fall as the battery becomes fully charged, temperature compensation can
prolong battery life by adjusting the float voltage automatically.

1. Connect the temperature probe cable to the TEMP PROBE connector at the front panel. Verify that the TEMP PROBE
ERROR indicator is not lit.

2. Attach the temperature probe to the negative (–) terminal of the battery being charged. If the threaded stud is long
enough, mount the probe on the threaded stud and attach with another nut. Otherwise, remove the existing nut and use
it to attach the temperature probe. In either case observe torque requirements when tightening the nut.

CHARGING THE BATTERY

1. If the float voltage has been preset, proceed to step 2. Otherwise, refer to PRESETTING THE OUTPUT under INSTAL­LATION and set the float voltage for the battery to be charged.

2. Connect the battery (see INSTALLATION) and install temperature compensation if desired (see above). Verify all bat­tery and a-c line connections are tight.

3. Apply a-c source power to the unit. If the circuit breaker pops, the battery connections are reversed; disconnect a-c
power, reverse the battery connections, reapply a-c power and turn on the circuit breaker. The front panel ammeter indi­cates the charging current. NOTE: If the CHARGER ON indicator fails to light, verify that a-c source power is present
and that the AC INPUT fuses have not blown.

4. When the charging current as indicated on the front panel ammeter falls to near zero, the battery is fully charged.

LL12

+

+

CURRENT

CURRENT

FIGURE 1. MODEL KRR 12-40, FRONT VIEW

KEPCO, INC. " 131-38 SANFORD AVENUE " FLUSHING, NY. 11352 U.S.A. " TEL [phone] " FAX [phone]

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