Nautel NAB05E Technical Instructions

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TECHNICAL INSTRUCTIONS

NAB05E

BATTERY CHARGER

(48 Volt)

VARIATIONS INCLUDED

NAB05E/01 - 115 V AC (Line-to - Neutral) NAB05E/02 - 250 V AC (Line to - Neutral)

Original Issue ...............01 September 2004

e-mail: support@nautel.com

web: www.nautel.com

Nautel Maine Inc. Nautel Limited 201 Target Industrial Circle, 10089 Peggy’s Cove Road, Bangor, Maine USA 04401 Hackett’s Cove, NS, Canada B3Z 3J4 Phone: (207) 947-8200 Phone: (902) 823-3900 Fax: (207) 947-3693 Fax: (902) 823-3183

ISO 9002 REGISTERED ISO 9001 REGISTERED

48 VOLT BATTERY CHARGER NAB05E

LIST OF EFFECTIVE PAGES

The list of effective pages lists the status of all pages in this manual. Pages of the original issue are identified by a zero in the Change No. column. Pages subsequently changed are identified by the date of the change number. On a changed page, the text affected by the latest change is indicated by a vertical bar in the margin opposite the changed material.

Original ................................................01 September 2004

Total number of printed sides in this manual is 45 as listed below:

CHANGE CHANGE

PAGE No. DATE PAGE No. DATE

Title 0 01 September 2004 Title (Rear) - Blank Effective (1) 0 01 September 2004 Effective (2) - Blank Safety (1) 0 01 September 2004 Safety (2) 0 01 September 2004 Safety (3) 0 01 September 2004 Safety (4) - Blank Warranty (1) 0 01 September 2004 Warranty (2) 0 01 September 2004 Contents (1) 0 01 September 2004 Contents (2) 0 01 September 2004 Contents (3) 0 01 September 2004 Contents (4) - Blank 1-1 0 01 September 2004 1-2 0 01 September 2004 2-1 0 01 September 2004 2-2 0 01 September 2004 2-3 0 01 September 2004 2-4 0 01 September 2004 2-5 0 01 September 2004 2-6 0 01 September 2004 2-7 0 01 September 2004 2-8 - Blank 3-1 0 01 September 2004 3-2 0 01 September 2004

3-3 0 01 September 2004 3-4 - Blank 4-1 0 01 September 2004 4-2 0 01 September 2004 5-1 0 01 September 2004 5-2 0 01 September 2004 5-3 0 01 September 2004 5-4 0 01 September 2004 6-1 0 01 September 2004 6-2 0 01 September 2004 6-3 0 01 September 2004 6-4 0 01 September 2004 6-5 0 01 September 2004 6-6 - Blank 7-1 0 01 September 2004 7-2 0 01 September 2004 7-3 0 01 September 2004 7-4 0 01 September 2004 7-5 0 01 September 2004 7-6 0 01 September 2004 SD-1 0 01 September 2004 SD-2 0 01 September 2004 MD-1 0 01 September 2004 MD-2 0 01 September 2004 MD-3 0 01 September 2004

Effective Pages (Page 1) 01 September 2004

48 VOLT BATTERY CHARGER NAB05E

ARTIFICIAL RESPIRATION (MOUTH-TO-MOUTH)

(a) START MOUTH-TO-MOUTH BREATHING IMMEDIATELY.

SECONDS COUNT. Do not wait to loosen clothing, warm the casualty, or apply stimulants.

(b) ASSESS RESPONSIVENESS OF CASUALTY. Do not jar

casualty or cause further physical injury (

HELP. Do not leave casualty unattended (

(d) CHECK CAROTID PULSE (

(e) LAY CASUALTY ON HIS/HER BACK and place any

available jacket or blanket under his/her shoulders.

(f) TILT THE HEAD BACK AND LIFT THE CHIN to open the

airway (

(g) PINCH CASUALTY’S NOSE AND EXHALE TWO SLOW

BREATHS INTO CASUALTY (

(h) REMOVE YOUR MOUTH and check for breathing

(i) CONTINUE GIVING ONE BREATH EVERY FIVE SECONDS

without interruption. If any air is retained in the stomach after exhalation by casualty, press gently on stomach to expel air.

(j) IF CHEST DOES NOT RISE CHECK for obstruction in

casualty’s mouth: clear foreign material using your finger, tissues, etc. Use chin lift and recommence mouth-to-mouth breathing.

(k) WHILE MOUTH-TO-MOUTH BREATHING IS CONTINUED

have someone else:

(l) DON’T GIVE UP. Continue without interruption until the

casualty is revived, or until a doctor pronounces the casualty dead. Four hours or more may be required.

(m) DO NOT PROVIDE ANYTHING ORALLY while victim is

unconscious.

Figure 4)

(a) Loosen casualty’s clothing. (b) Keep the casualty warm.

Figure 3)

Figure 5)

Figure 1)

Figure 2)

(Figure 6)

Safety (Page 1) 01 September 2004

48 VOLT BATTERY CHARGER NAB05E

GENERAL RULES FOR TREATMENT FOR BURNS, BLEEDING, AND SHOCK

1. After casualty has revived, treat for injuries and shock.

2. Reassure casualty.

3. Try to make him comfortable.

4. Keep him reasonably warm but do not apply heat.

5. If thirsty, liquids may be given but no alcohol (no liquids should be given in cases of severe burns).

6. Treat burns or wounds. Infection danger in treating burns or wounds is very great so ensure hands are clean and do not handle affected areas more than necessary.

7. Do not apply salves, grease, etc. to burns.

8. Do not remove burned clothing which adheres to the skin or break blisters.

9. Cover the burn with a dry sterile dressing, piece of sheeting, etc.

10. Bandage lightly over blisters where care must be taken to cover and not to break.

11. If severe bleeding of wound, elevate affected area, except in the case of a fracture.

12. Expose wound and apply pressure.

13. Apply dressing, pad and bandage.

14. For burns and bleeding, immobilize injured part using splints if necessary and keep patient in restful position during removal to hospital or expert medical attention.

15. In all cases, send for medical aid immediately.

Safety (Page 2) 01 September 2004

48 VOLT BATTERY CHARGER NAB05E

ELECTRIC SHOCK - RESCUE METHODS

Electricity can damage the body in a number of ways. It may interfere with the proper functioning of the nervous system and the heart action, it can subject the body to extreme heat and can cause severe muscular contractions. The path that the current of electricity takes through the body is important. Currents which pass from hand to hand or from hand to foot may pass directly through the heart and upset its normal functioning. This threat to life is related to the amount of current or amperage that will flow through a victim's body. Very little current (as little as 10 milliamps) can result in severe shock or death.

Speed in the application of first aid measures is absolutely essential in cases of electrical injury. As soon as the victim is freed safely from the source of the electrical current, if breathing has stopped, artificial respiration should be commenced immediately. If the carotid pulse cannot be felt, external cardiac massage should be commenced simultaneously. Resuscitation should be continued until the patient is breathing on his own or until medical aid arrives. Survival rates can be quite high if cardio-pulmonary resuscitation is started within 3 to 4 minutes of the injury being received.

ACT AT ONCE - DELAY OR INDECISION MAY BE FATAL

1. Turn OFF the electrical source.

2. Commence artificial respiration immediately.

3. Treat for burns, bleeding and shock.

REMOVING A CASUALTY FROM ELECTRICAL CONTACT

LOW VOLTAGE - 0 to 240 volts (household use)

Switch off the current, if possible and time permits. If the switch cannot be located immediately and the supply is through a flexible cord or cable, the current may be shut off by removing the plug or even breaking the cable or wrenching free. Never attempt to shut off current by cutting cord with a knife or scissors.

If the current cannot be shut off, the greatest care is necessary in removing the casualty. Household rubber gloves, rubber or plastic hose (if there is no water in them), a dry unpainted stick or a clean dry rope can be used to free victim.

HIGH VOLTAGE - 240 volts and up (industrial machines and power lines)

Do not touch any person or equipment in contact with a wire.

Use a dry unpainted pole, clean dry rope, dry rubber or plastic water hose to separate the casualty from the contact.

Keep as far away as possible.

Do not touch the casualty until he is free.

Safety (Page 3) 01 September 2004

48 VOLT BATTERY CHARGER NAB05E

TOXIC HAZARD WARNING

There are devices used in this equipment containing BERYLLIUM OXIDE ceramic, which is non-hazardous during normal device operation and under normal device failure conditions. These devices are specifically identified in the equipment manual’s parts list(s).

DO NOT cut, crush or grind devices because the resulting dust may be HAZARDOUS IF INHALED. Unserviceable devices should be disposed of as harmful waste.

Safety (Page 4) 01 September 2004

48 VOLT BATTERY CHARGER NAB05E

WARRANTY

Nautel Limited/Nautel Maine Incorporated, hereinafter referred to as Nautel, guarantees all mechanical and electrical parts of the equipment for a period of thirteen months from date of shipment.

1. A "Part Failure" shall be deemed to have occurred when the part has become defective, or does not have the

characteristics required for the specified equipment performance:

(a) When the equipment is operated within the design parameters, and

(b) When the equipment is installed and adjusted according to Nautel's prescribed procedures as stated in the

instruction manual.

2. Nautel shall provide replacements for all "Parts" at no cost to the Customer when they become defective during

the warranty period, and upon the return of the defective part.

3. In the event that a "Part" fails during the warranty period and causes damage to a sub-assembly that cannot be

readily repaired in the field, the entire sub-assembly so damaged may be returned to Nautel for repair. The repairs will be made without charge to the Customer.

4. Where warranty replacements or repair are provided under items 2 or 3, Nautel will pay that part of the

shipping costs incurred in returning the part/assembly to the Customer.

5. Warranty replacement parts and repair, which are provided under items 2 or 3, shall be guaranteed for a period

of ninety days from date of shipment or until the end of the original warranty period, whichever occurs later.

6. Nautel will not assume responsibility for any charges incurred by other than Nautel employees.

7. Nautel shall have the privilege of investigating whether failures have been caused by factors beyond its

control.

8. Nautel shall in no event be liable for any consequential damages arising from the use of this equipment.

9. When requesting a warranty repair/replacement, please provide complete and accurate information. Observe

the instructions regarding 'Equipment Being Returned to Nautel' on page two of this warranty and provide the information requested.

10. When ordering spare/replacement parts; please provide complete and accurate information. Refer to the parts

list of this manual for ordering information. Provide as much of the information requested for 'Equipment Being Returned to Nautel' on page two of this warranty as is practical. The information identified by an asterisk is the minimum required.

ON-LINE PART QUOTES

Nautel provides an on-line website service (www.nautel.com/in-service.html) where requests for part quotes may be submitted. Requests will normally be responded to within one working day.

Warranty (Page 1) 01 September 2004

48 VOLT BATTERY CHARGER NAB05E

FACTORY SUPPORT

TECHNICAL ASSISTANCE

Nautel's field service department provides telephone technical assistance on a 24 hour, seven days a week basis. Requests by other media (facsimile or e-mail) will be responded to the next working day if received after Nautel's normal working hours. Contact the appropriate field service centre from the following:

U.S.A. customers use:

201 Target Industrial Circle Facsimile 207-947-3693 Bangor, Maine 04401

All other customers use: Nautel Limited Telephone 902-823-3900 (24 hours)

10089 Peggy’s Cove Road Facsimile 902-823-3183 Hackett’s Cove, NS, Canada E-Mail support@nautel.com B3Z 3J4 Web www.nautel.com

MODULE EXCHANGE SERVICE

In order to provide Nautel customers with a fast and efficient service in the event of a problem, Nautel operates a factory rebuilt, module exchange service which takes full advantage of the high degree of module redundancy in Nautel equipment. This module exchange service is operated from Nautel’s factory in Bangor, Maine and Hackett’s Cove, Nova Scotia. These two locations allow us to provide a quick turn around service to keep our customers on the air. During the transmitter’s warranty period, up to thirteen months from shipment, repair and exchange of modules is at no charge to the customer. When the warranty has expired, a charge of 80% of the list price for all exchanged modules is made. If the faulty module is returned to Nautel within 30 days, a credit is issued reducing this charge by one half to 40% of the list price. U.S.A. customers are required to contact our Bangor, Maine facility. Canadian and overseas customers should contact our Nova Scotia, Canada facility.

EQUIPMENT BEING RETURNED TO NAUTEL

All equipment being returned to Nautel and all requests for repairs or replacements should be marked 'field return' and addressed to the appropriate Nautel facility.

Complete and accurate information regarding the equipment being returned will ensure prompt attention and will expedite the dispatch of replacements. Refer to the nameplate on the transmitter and/or the appropriate module/assembly to obtain name, type, part and serial number information. Refer to the parts list of this manual or the appropriate service instruction manual for additional ordering information.

The following information should accompany each request:

* Model of Equipment * Serial number of Equipment * Name of Part/Assembly Serial number of Part/Assembly * Complete reference designation of Part/Assembly * Nautel's part number of Part/Assembly * OEM's part number of Part/Assembly Number of hours in Use Nature of defect * Return shipping address

* Denotes minimum information required to order spare/replacement parts

Nautel Maine Incorporated Telephone 207-947-8200 (24 hours)

Warranty (Page 2) 01 September 2004

48 VOLT BATTERY CHARGER NAB05E

TABLE OF CONTENTS

Section Page

1 - GENERAL INFORMATION

1.1 INTRODUCTION ...................................................................................................................................1-1

1.2 TECHNICAL SUMMARY ......................................................................................................................1-1

1.3 MECHANICAL DESCRIPTION ............................................................................................................1-1

1.4 SPECIAL TOOLS AND TEST EQUIPMENT.......................................................................................1-1

2 - THEORY OF OPERATION

2.1 GENERAL .............................................................................................................................................2-1

2.2 BATTERY CHARGER OVERVIEW .....................................................................................................2-1

2.2.1 AC POWER SUPPLY OVERVIEW.......................................................................................................2-1

2.2.2 23 VDC POWER SUPPLY OVERVIEW...............................................................................................2-1

2.2.3 15 VDC POWER SUPPLY OVERVIEW...............................................................................................2-1

2.2.4 DIGITIZER OVERVIEW ........................................................................................................................2-1

2.2.5 RAMP GENERATOR OVERVIEW .......................................................................................................2-2

2.2.6 VOLTS COMPARATOR OVERVIEW...................................................................................................2-2

2.2.7 EIGHT SECOND TIMER OVERVIEW..................................................................................................2-2

2.2.8 CHARGING CURRENT CONTROL OVERVIEW ................................................................................2-2

2.2.9 THYRISTOR TURN-ON OVERVIEW...................................................................................................2-2

2.2.10 FULL-WAVE RECTIFIER OVERVIEW.................................................................................................2-3

2.3 DETAILED DESCRIPTION...................................................................................................................2-3

2.3.1 AC POWER SUPPLY............................................................................................................................2-3

2.3.2 23 VDC POWER SUPPLY....................................................................................................................2-3

2.3.3 15 VDC POWER SUPPLY....................................................................................................................2-3

2.3.4 DIGITIZER .............................................................................................................................................2-4

2.3.5 RAMP GENERATOR ............................................................................................................................2-4

2.3.6 BATTERY VOLTAGE COMPARATOR ................................................................................................2-4

2.3.7 EIGHT SECOND TIMER ......................................................................................................................2-5

2.3.8 CHARGING CURRENT CONTROL .....................................................................................................2-5

2.3.9 THYRISTOR TURN-ON CONTROL.....................................................................................................2-5

2.3.10 FULL-WAVE RECTIFIER......................................................................................................................2-6

3 - INSTALLATION AND PREPARATION FOR USE

3.1 GENERAL .............................................................................................................................................3-1

3.2 TEST EQUIPMENT ...............................................................................................................................3-1

3.3 SITE REQUIREMENTS ........................................................................................................................3-1

3.3.1 ELECTRICAL POWER..........................................................................................................................3-1

3.3.2 ELECTRICAL POWER CABLE ............................................................................................................3-1

3.3.3 BATTERY CABLE .................................................................................................................................3-1

3.4 UNPACKING .........................................................................................................................................3-1

3.5 ANCILLARY PARTS ............................................................................................................................3-1

3.6 INFORMATION TO BE DETERMINED PRIOR TO FINAL INSTALLATION ....................................3-1

3.6.1 AC POWER SOURCE ..........................................................................................................................3-1

3.6.2 TYPE OF BATTERY..............................................................................................................................3-1

3.6.3 BATTERY VOLTAGE (NO LOAD)........................................................................................................3-1

3.6.4 CHARGING CURRENT ........................................................................................................................3-1

3.6.5 SPECIFIC GRAVITY .............................................................................................................................3-1

Contents (Page 1) 01 September 2004

48 VOLT BATTERY CHARGER NAB05E

TABLE OF CONTENTS (Continued)

Section Page

3 - INSTALLATION AND PREPARATION FOR USE (Continued)

3.7 PARTS REQUIRED BUT NOT SUPPLIED .........................................................................................3-2

3.7.1 AC POWER CABLE ..............................................................................................................................3-2

3.7.2 BATTERY CABLE .................................................................................................................................3-2

3.8 INSTALLATION PROCEDURES .........................................................................................................3-2

3.8.1 PHYSICAL MOUNTING........................................................................................................................3-2

3.8.2 SELECTING PROPER TAPS OF POWER TRANSFORMER T1.......................................................3-2

3.8.3 CONNECTION OF AC POWER WIRING ............................................................................................3-2

3.8.4 CONNECTION OF BATTERY INTERCONNECTING WIRING ..........................................................3-2

3.8.5 POSITIONING OF BATTERY TEMEPRATURE SENSOR .................................................................3-3

3.8.6 POST-INSTALLATION INSPECTION ..................................................................................................3-3

3.9 INITIAL TURN-ON PROCEDURES .....................................................................................................3-3

4 - OPERATING INSTRUCTIONS

4.1 GENERAL .............................................................................................................................................4-1

4.2 EMERGENCY SHUTDOWN PROCEDURE........................................................................................4-1

4.3 PERSONNEL SAFETY.........................................................................................................................4-1

4.4 CONTROLS AND INDICATORS .........................................................................................................4-1

4.5 TURNING ON THE BATTERY CHARGER .........................................................................................4-1

4.6 OPERATING PRECAUTIONS .............................................................................................................4-1

4.7 FAULT INDICATION .............................................................................................................................4-2

5 - ADJUSTMENT AND TESTING

5.1 GENERAL .............................................................................................................................................5-1

5.2 TEST EQUIIPMENT REQUIRED .........................................................................................................5-1

5.3 ADJUSTMENT PROCEDURES ...........................................................................................................5-1

5.3.1 OPERATION OF EQUIPMENT ...........................................................................................................5-1

5.3.2 ADJUSTMENT PRE-REQUISITES .....................................................................................................5-1

5.3.3 ADJUSTMENT METHOD 1 .................................................................................................................5-1

5.3.4 ADJUSTMENT METHOD 2 .................................................................................................................5-2

5.4 FUNCTIONAL TEST .............................................................................................................................5-4

6 - MAINTENANCE

6.1 GENERAL .............................................................................................................................................6-1

6.2 SCHEMATICS/LOGIC DIAGRAMS .....................................................................................................6-1

6.2.1 COMPONENT VALUES........................................................................................................................6-1

6.2.2 GRAPHIC SYMBOLS............................................................................................................................6-1

6.2.3 LOGIC SYMBOLS.................................................................................................................................6-1

6.2.4 REFERENCE DESIGNATIONS ...........................................................................................................6-1

6.3 WIRING INFORMATION ......................................................................................................................6-1

6.4 MECHANCIAL DRAWINGS .................................................................................................................6-1

6.5 TEST EQUIPMENT ...............................................................................................................................6-1

6.6 SCHEDULED MAINTENANCE ............................................................................................................6-1

6.7 CORRECTIVE MAINTENANCE...........................................................................................................6-1

Contents (Page 2) 01 September 2004

48 VOLT BATTERY CHARGER NAB05E

TABLE OF CONTENTS (Continued)

Section Page

7 - PARTS LIST

7.1 INTRODUCTION ...................................................................................................................................7-1

7.2 FAMILY TREE .......................................................................................................................................7-1

7.3 MANUFACTURER'S INDEX ................................................................................................................7-1

7.4 HOW TO LOCATE INFORMATION FOR A SPECIFIC PART...........................................................7-1

7.5 REFERENCE DESIGNATION INDEXES ............................................................................................7-1

7.6 COLUMN CONTENT EXPLANTATION ..............................................................................................7-1

7.6.1 USE CODE COLUMN ...........................................................................................................................7-1

7.6.2 REF DES COLUMN ..............................................................................................................................7-2

7.6.3 NAME OF PART AND DESCRIPTION COLUMN ...............................................................................7-2

7.6.4 NAUTEL'S PART NO COLUMN ...........................................................................................................7-2

7.6.5 JAN, MIL or MFR PART NO COLUMN ................................................................................................7-2

7.6.6 (OEM) CODE COLUMN........................................................................................................................7-2

LIST OF ILLUSTRATIONS

Number Title Page

2-1 Timing Information ...........................................................................................................................................2-7

6-1 Waveforms .......................................................................................................................................................6-4

SD-1 Block Diagram - NAB05E Battery Charger..................................................................................................SD-1

SD-2 Electrical Schematic - NAB05E Battery Charger.........................................................................................SD-2

MD-1 Assembly Detail - NAB05E Battery Charger............................................................................................... MD-1

MD-2 Assembly Detail - Battery Charger PWB (P/N 147-1310-08)..................................................................... MD-2

MD-3 Dimensional Information - NAB05E Battery Charger ................................................................................. MD-3

Number Title Page

1-1 Technical Summary .........................................................................................................................................1-1

1-2 Test Equipment................................................................................................................................................1-2

6-1 System Troubleshooting Assistance Chart.....................................................................................................6-2

6-2 Wiring List - NAB05E Battery Charger............................................................................................................6-3

7-1 Manufacturers' Code to Address Index........................................................................................................... 7-3

7-2 Ref Des Index - NAB05E Battery Charger...................................................................................................... 7-5

LIST OF TABLES

Contents (Page 3) 01 September 2004

48 VOLT BATTERY CHARGER NAB05E

SECTION 1

GENERAL INFORMATION

INTRODUCTION

1.1 The battery charger is a pulsed current,

battery charger that will provide a constant charging current of up to 3.0 amperes to a nominal 48 volt battery bank. The battery charger is intended to be used with a battery bank that has a full charge, no load, voltage of 51.0 to 67.0 volts. The charging current is applied to the battery bank in eight second pulse strings, with the time between pulses determined by the charge status of the batteries. When the battery bank is deeply discharged, the pulse strings will occur continuously and then decrease towards an infinite level as the battery bank reaches its full charge voltage.

TECHNICAL SUMMARY

1.2 Table 1-1 - Technical Summary, contains a

detailed technical summary.

Table 1-1 Technical Summary

MECHANICAL DESCRIPTION

1.3 The battery charger comprises an enclosed,

semi-watertight, steel cabinet with external connections made through cable entry holes in the bottom of the cabinet and connected to two terminal blocks on the rear panel inside the cabinet. The battery charger circuitry, comprising a supply transformer; choke; two thyristors; two fuses; one power on/off switch and a printed wiring board (PWB) assembly, is mounted on the rear panel on a metal plate inside the steel cabinet. A hinged door, that can be opened by loosening six securing clamps, provides easy access to the circuitry.

SPECIAL TOOLS AND TEST EQUIPMENT

1.4 There are no special tools required to

maintain the battery charger. Table 1-2 - Test Equipment, lists the test equipment recommended for calibration, testing and maintenance.

Equipment Name:....................................................................................................................... 48 Volt Battery Charger

Nautel Equipment Type Number:...................................................................................................................... NAB05E

Battery Charging Data:

Battery Voltage (Full charge, no load) ............................................................................................ 51.0 to 67.0 Volts

Charging Current........................................................................................... Adjustable up to 3 amperes (maximum)

.............................................. into a discharged battery

Power Requirements:

NAB05E/01.....................................................................................115 V ac (Line-to-Neutral), 50/60 Hz@ 250 VA

NAB05E/02.....................................................................................230 V ac (Line-to-Neutral), 50/60 Hz@ 250 VA

Environmental Limits:

Temperature..........................................................................................................................................-10°C to +55°C

Relative humidity ............................................................................................................................................ 0 to 90%

Dimensions

Height ............................................................................................................................................... 14 inches (35 cm)

Width ................................................................................................................................................ 12 inches (30 cm)

Depth .................................................................................................................................................. 6 inches (15 cm)

Weight ...............................................................................................................................................40 pounds (18.2 kg)

Page 1-1 01 September 2004

48 VOLT BATTERY CHARGER NAB05E

Table 1-2 Test Equipment

NOMENCLATURE (EQUIVALENTS MAY BE USED) APPLICATION

PART, MODEL, OR TYPE NUMBER

Digital Voltmeter Any good quality 3 1/2 digit digital

voltmeter

Measure ac/dc voltages and resistance during calibration and trouble shooting procedures

DC Ammeter 5 amperes measurement capability Precise measurement of dc

charge current.

Hydrometer Any good quality hydrometer with a

calibrated specific gravity scale.

Measurement of specific gravity of battery electrolyte.

Oscilloscope Any good quality oscilloscope with a

calibrated time base.

Monitor waveforms during trouble shooting procedures

♦ Dc Power Supply

Any good quality dc power supply (0 - 70 volts)

Simulate precise, full charge, no load, battery voltage during calibration.

♦ Variac

Any good quality variac with an input voltage rated at the ac voltage to be

Varies ac power source voltage

during calibration. applied to the battery charger. Output voltage must be rated at a minimum of 250 Va and allow adjustment of plus or minus ten percent of nominal input ac voltage.

NOTE: ♦ - Denotes these items of test equipment are optional. They are not necessary if the

simplified procedures of paragraph 5.3.3 are used for test and adjustment. If the detailed test/adjustment procedure of paragraph 5.3.4 is to be used, they are required.

Page 1-2 01 September 2004

48 VOLT BATTERY CHARGER NAB05E

SECTION 2

THEORY OF OPERATION

GENERAL

2.1 The theory of operation for the battery

charger is presented in this section. The information is presented in detail using figure SD-2 - electrical schematic as a reference.

BATTERY CHARGER OVERVIEW

2.2 The 48 volt dc battery charger operates on

the principle that the terminal voltage of batteries being charged will eventually stabilize at a voltage that can be predetermined when they are fully charged, under no load conditions. Prior to reaching the full-charge condition, the battery terminal voltage will approach or reach this full charge voltage when a charging current is being applied and then decay to a lesser voltage when the charging current is removed. If the battery terminal voltage is compared to a reference voltage that is slightly less than the full-charge, no load, terminal voltage, it will take progressively longer for the battery terminal voltage to decay to a level that is less than the reference voltage as the battery approaches the full charge condition. This feature is utilized in the battery charger and is used to control the application of eight second bursts of current to the batteries being charged. When the batteries are in a discharged condition, the eight second current bursts will occur at frequent intervals. As the batteries approach the fully charged condition, the eight second current bursts will occur less frequently until the interval time is nearly infinite. The following provides an overview of the subject battery charger, using the block diagram shown in figure SD-1.

2.2.1 AC POWER SUPPLY OVERVIEW: The ac power supply consists of an EMI filter, an on/ off switch, a fuse and a power transformer. The EMI filter, removes unwanted transients from the ac power source. The power transformer has two identical 115 volt primary windings and two sets of secondary windings. When the ac power source voltage is 115 vac, 60 Hz, the primary windings of the power transformer are connected in parallel. When the ac power source voltage is 230 V ac, 50 Hz, the primary windings are connected in series. One set of secondary windings provides 17.5 V ac, RMS for the

Page 2-1 01 September 2004

low voltage power supplies. The second set of secondary windings provides a centre tapped 150 (75-0-75) V ac RMS for the battery charging dc voltage source.

2.2.2 23 V DC POWER SUPPLY OVERVIEW: The 17.5 volt ac, RMS voltage from the power transformer is applied to a full-wave bridge rectifier. The output of the bridge rectifier will be an unregulated, ripple, dc voltage with a nominal level of 23 V dc. The ripple frequency will be twice the frequency of the ac power source. Their are two outputs from the 23 V dc power supply, one is the unsmoothed, ripple, dc voltage and the other is a smoothed, unregulated, 23 V dc. The dc return path for the 23 V dc power supply is not connected to chassis ground but is connected to the positive terminal of the battery voltage. This point is the dc reference level for all of the logic circuits. A light emitting diode is connected across the 23 V dc output and will indicate the battery charger is functioning by turning on when 23 V dc is present.

2.2.3 15 V DC POWER SUPPLY OVERVIEW: The regulated 15 V dc power supply consists

of an integrated circuit device that acts as a voltage regulator. The output of the regulator is maintained at +15 V dc with respect to the same dc reference level as the 23 V dc power supply, regardless of the fluctuations in the output of the 23 V dc power supply output.

2.2.4 DIGITIZER OVERVIEW: A logic circuit compares the ripple dc voltage from the unregulated 23 V dc power supply to a fixed, dc reference voltage and produces a rectangular waveform at the ripple frequency. The frequency of the ripple and therefore the repetition frequency of the rectangular waveform is twice the frequency of the ac power source. The rectangular waveform will be high (+23 V dc) when the reference voltage is more positive than the ripple voltage. It will remain in this state for a relatively short duration. It will switch low (dc reference level) when the reference voltage is less positive than the ripple voltage and will remain in this state until the ripple voltage falls below the reference voltage.

48 VOLT BATTERY CHARGER NAB05E

2.2.5 RAMP GENERATOR OVERVIEW: The ramp generator consists of a switching transistor and an integrating circuit. When a 'ramp inhibit' signal is not applied to the ramp generator from the 8second timer; a 'high' output from the digitizer will turn on the transistor. When the transistor is turned on, the voltage across the capacitor in the integrating circuit, which is the output of the ramp generator, will discharge to the dc reference level. When the output of the digitizer, switches to 'low', the transistor will turn off. The capacitor in the integrating circuit will charge towards +23 V dc. The ramp generator's output will be a relatively linear ramp voltage (the R/C time constant of the integrating circuit is long at the switching repetition rate), that increases from the dc reference level to a positive dc voltage. A linear ramp waveform will be generated for each half cycle of the ac power supply voltage applied to the 23 V dc power supply. When a 'ramp inhibit' signal is applied to the ramp generator, the charging voltage for the capacitor in the integrating circuit is removed and the ramp generator's output will be maintained at the dc reference level.

2.2.6 VOLTS COMPARATOR OVERVIEW: The battery voltage comparator circuit utilizes a logic circuit that compares the battery terminal voltage to a temperature compensated, adjustable, reference voltage. The reference voltage is preset to a level that is slightly below the fully charged, no load, terminal voltage of the battery. The fully charged, no load terminal voltage of batteries with different electrolyte will differ. The precise no load, voltage; of the batteries to be charged must be obtained from the battery manufacturer. When the battery terminal voltage decays to a level that is below the reference voltage, the output of the logic circuit generates a 'master reset' signal for an eight second timer. If the battery terminal voltage does not decay to a level that is below the reference voltage, the 'master reset' signal is not generated. A temperature sensor, that is monitoring the ambient air in the vicinity of the batteries, automatically changes the reference voltage with changes in temperature. This feature reduces boiling off of battery electrolyte, when the ambient temperature is high, by lowering the reference voltage as the sensed temperature increases and effectively increasing the time required to generate a 'master reset' signal as the batteries approach their fully charged condition.

2.2.7 EIGHT SECOND TIMER OVERVIEW: An oscillator/timer integrated circuit

device is used as the eight second timer. In the absence of a 'master reset' signal, the output of the eight second timer will apply a 'ramp inhibit' signal to the ramp generator. When a 'master reset' is applied, the timer will remove the 'ramp inhibit' signal for eight seconds and then reapply it until the next 'master reset' signal is generated.

2.2.8 CHARGING CURRENT CONTROL OVERVIEW: The charging current control circuit

consists of an operational amplifier that produces an adjustable dc voltage as its 'control voltage'. The control voltage is proportional to the differ-ence between a dc reference and a dc voltage (charging current voltage) that is representative of the battery charging current. The 'charging current voltage' is developed across a resistor in the battery charging circuit. The dc reference voltage is adjusted, during calibration, to a level that represents the maximum charge current to be applied to the batteries. When current is being applied to the batteries at the desired magnitude, the 'charging current voltage' will be equal to the dc reference voltage. The resultant 'control voltage' output will stabilize to a level that will cause the 'thyristor control' pulse to be generated during the portion of each ac power supply voltage half cycle that will result in the average dc voltage output, of the switched full-wave rectifier, maintaining the charging current at the desired level. If the charging current attempts to change, as the result of the internal resistance of the battery changing, the 'control voltage' output will change in the appropriate direction (increase if less current is required or decrease if more current is required) and cause the 'thyristor control' pulse to be generated later or earlier in each ac power supply voltage half cycle and maintain the charging current at the desired level.

2.2.9 THYRISTOR TURN-ON OVERVIEW: The thyristor turn-on control consists of a comparator and a switching transistor. The comparator compares the voltage level of the ramp generator's output to the 'control voltage' output of the charging current control circuit. When the ramp generator's output is less positive than the 'control voltage', the comparator's output will be a high (+23 V dc) level and the switching transistor will be turned off. An output will not be produced by the thyristor turn-on control circuit. When the ramp voltage goes more positive than the

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48 VOLT BATTERY CHARGER NAB05E

'control voltage', the comparator's output will switch to a low (dc reference) level and cause the switching transistor to turn on. A positive voltage, 'thyristor control' pulse will be applied to the control gate of both thyristors in the switched full-wave rectifier circuit. Since the ramp voltage increases linearly with time and it is reset to the dc reference voltage, at the start of each half cycle of the ac voltage applied to the unregulated 23 volt dc bridge rectifier, the level of the 'control voltage' will determine at what point of time, relative to the start of each ac voltage half cycle, the leading edge of the 'thyristor control' pulse will occur. As the 'control voltage' goes more positive, the leading edge of the 'thyristor control' pulse will occur at a progressively later period of time. As the 'control voltage' goes less positive, the leading edge of the 'thyristor control' pulse will occur at an earlier period of time.

2.2.10 FULL-WAVE RECTIFIER OVERVIEW: The switched full-wave rectifier

circuit produces a dc voltage that maintains the battery charging current at the preset, desired level when a 'thyristor control' pulse is applied. The circuit consists of two thyristors that have the ac voltage on the centre tapped secondary (75-0-75 volts RMS ac) of the ac power supply applied to their anodes. The voltage on each anode is 180 degrees out of phase with the other; but, since they are obtained from the same transformer as the ac power source for the unregulated 23 volt dc bridge rectifier, the crossover point for each half cycle will be synchronized with the start of the ramp waveform output of the ramp generator. The 'thyristor control' pulse will occur at some point of time during each half cycle. Each thyristor will only turn on when its anode is positive relative to its cathode and it will remain on for the remainder of that half cycle. The output of the switched full- wave rectifier circuit will be dc voltage pulses with an average value determined by the period of each half cycle that the thyristors are turned on. When the 'thyristor control' pulses occur at the appropriate time, this average dc voltage will maintain the battery charging current at the desired, preset level. A choke is installed in the centre tapped ac return path to filter the average dc voltage. It also contains a free wheeling diode that prevents oscillations when the 'thyristor control' pulses are removed and the current in the choke collapses.

DETAILED DESCRIPTION

2.3 The following provides an in-depth under-

standing of complex or non-obvious circuit functions. The descriptions are keyed to the block diagram referenced in paragraph 2.2 and expand on the associated block diagram descriptions.

2.3.1 AC POWER SUPPLY: The ac power source (115 volts ac RMS, 60 Hz or 230 volts ac RMS, 50 Hz) is connected between TB1-4 (line) and TB1-5 (neutral) with the ac ground connected to the safety ground stud. The ac line is applied thru EMI filter U2 thru

POWER switch S1, thru fuse F1, thru

TB1-1 to one side of power transformer T1's primary windings. The ac neutral is connected to the other side of T1's primary windings thru TB1-2. Power transformer T1 has two identical 115 volt primary windings. Two sets of secondary windings provide the step down voltages required by the battery charger's dc power supplies. One set of secondary windings provides 17.5 V ac, RMS and the other set provides a centre tapped 150 (75-0-75) V ac RMS.

2.3.2 V DC POWER SUPPLY: 17.5 V ac, RMS, from power transformer T1, is applied to full-wave bridge rectifier A1U1. The resultant output of A1U1 is a nominal 23 V dc, which is not regulated and contains a ripple component that is twice the frequency of the ac power source. This ripple dc voltage is applied to the inverting input of comparator A1U3A and thru diode A1CR1 to smoothing capacitor C1. Smoothing capacitor C1 smooths the unregulated 23 V dc output to an acceptable level, while RF bypass capacitor A1C1 removes any high frequency component. The negative side of the 23 V V dc power supply is not connected to chassis ground but is connected to the positive voltage side of the battery charging voltage (positive battery terminal). This point is the dc reference level for all of the logic circuits. Light emitting diode DS1 will turn on when the 23 V dc power supply is producing an unregulated 23 V dc output.

2.3.3 15 V DC POWER SUPPLY: The smoothed unregulated 23 V dc is applied to the input of 15 V dc regulator A1U1. The output of 15 V dc regulator A1U1 is maintained at +15 V dc with respect to the dc reference level, regardless of the fluctuations in the unregulated 23 V dc, provided it remains above 15 V dc.

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2.3.4 DIGITIZER: The digitizer consists of operational amplifier A1U3A, which is employed as a comparator, and its associated components. Resistors A1R3/R4 form a voltage divider that applies a nominal +0.18 V dc, from their junction, to the non-inverting input of A1U3A as a reference voltage. The unregulated, 23 volt dc ripple voltage, from the 23 volt dc power supply is applied to A1U3A's inverting input. When the ripple voltage is less positive than the reference voltage on its non-inverting input, the output of A1U3A will be high (23 V dc). When the ripple voltage is more positive than the reference voltage, the output of A1U3A will be low (dc reference level). Since each ripple in the 23 volt dc ripple voltage input represents one half cycle of the ac power source, the resultant output of A1U3A is a rectangular waveform that goes high shortly after the start of each half cycle of the ac power source; remains high for a relatively short period of time and then goes low for the remainder of the half cycle. The repetition frequency of the rectangular waveform will be twice the frequency of the ac power source.

2.3.5 RAMP GENERATOR: The ramp generator consists of A1Q1, resistors A1R5/R6/R7 and capacitor A1C4. The rectangular waveform output of A1U3A is applied to the base of transistor A1Q1, which is employed as a switching transistor. Resistors A1R5/R6 form a voltage divider that ensures A1Q1's base does not exceed a nominal 2.0 V dc when the output of A1U3A is 'high'. When the rectangular waveform is 'high', A1Q1 will be forward biased and it will turn on. When the rectangular waveform is 'low', A1Q1 will be reverse biased and it will turn off. Resistor A1R7 and Capacitor A1C4 form an integrating circuit that has a relatively long time constant at the repetition frequency of the rectangular waveform. When A1Q1 is turned on, capacitor A1C4 will discharge instantly to the dc reference level thru A1Q1. When A1Q1 is turned off, capacitor A1C4 will charge towards 23 V dc thru A1R7. A1Q1 will turn on again while A1C4 is in the relatively linear portion of its charging curve, resulting in a relatively linear ramp waveforms. The switching action of A1Q1 is controlled by transistor A1Q2, which in turn is controlled by the status of the eight second timer. When A1Q2 is turned on, the collector of A1Q1 will be clamped to the dc reference

level and the switching action of A1Q1 will be inhibited. When A1Q2 is turned off, it is effectively removed from the circuit and has no influence on A1Q1. The output of the ramp generator will be an eight second string of linear ramp waveforms, that are synchronized with the start of each half cycle of the ac power source, each time the eight second timer is enabled. During the remainder of the time, the ramp generator's output will be clamped to the dc reference level.

2.3.6 BATTERY VOLTAGE COMPARATOR: The battery voltage comparator

circuit consists of operational amplifier A1U3D, which is employed as a comparator; OR gate A1U5D; temperature transducer and their associated components. The voltage present on the negative battery terminal is applied to a voltage divider formed by resistors R2/A1R11. The resultant voltage at their junction will be a negative voltage that is approximately nine percent of the sensed voltage. Resistor A1R22 and zener diode A1CR2 form a voltage clamp that is connected between this negative voltage and +15 V dc. The resultant voltage at the junction of A1R22/ CR2, which is applied to the inverting input of A1U3D, is clamped to a voltage that is 9.0 V dc more positive than the negative voltage at the junction of R2/A1R11. This voltage is representative of the battery voltage and will always be a positive voltage, that will be the least positive when the battery terminal voltage is maximum and will go more positive as the battery terminal voltage decays. Resistors A1R23/R24/R25 and temperature transducer form a second voltage divider; that provides an adjustable, temperature compensated, positive, dc voltage to the non- inverting input of A1U3D as a reference voltage. Potentiometer A1R24 is adjusted, during calibration, to provide a reference voltage that is the same as or marginally more positive than the voltage applied to the inverting input of A1U3D, when the batteries are fully-charged. When the battery terminal voltage is maximum, the voltage on A1U3D's inverting input will be less positive than the reference voltage on its non-inverting input and the output of A1U3D will be 'high' (23 V dc). When the battery terminal voltage decays to a level that will cause the voltage on A1U3D's inverting input to be more positive than the reference voltage on its non-inverting input, the output of A1U3D will switch

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to low (dc reference level). Resistors A1R26/R27 are connected as a voltage divider to ensure the voltage applied to A1U5B-6 does not exceed +15 V dc when the output of A1U3D is 'high'. The output of OR gate A1U5B follows and inverts logic level changes on the output of A1U3D, provided the input to A1U5B-5 is being held 'low' by the 'Q' output of oscillator/timer A1U4. Capacitor A1C8 and resistor A1R21 form a differentiating circuit, that provides a positive voltage pulse, as the output of the battery voltage comparator, when the battery voltage decays below the reference level and the output of A1U3D goes 'low'. A1U5B-5's input will be held 'high' and hold the output of A1U5B 'low' when oscillator/timer is counting through one of its eight second periods. This feature prevents A1C4 from generating a positive voltage pulse, to reset the eight second timer, once the timer has started to count.

2.3.7 EIGHT SECOND TIMER: The eight second timer circuit consists of oscillator/timer A1U4; OR gate A1U5D, which is connected as an inverter; transistor A1Q2 and their associated components. Oscillator/timer A1U4 is an integrated circuit device that has been connected to produce a 'high' (15 V dc) on its 'Q' output for eight seconds after the application of a positive voltage pulse to its master reset input. Its 'Q' output will revert to a 'low' (dc reference level), after this eight second period and remain there until the next application of a positive voltage pulse to its master reset input.for eight seconds after the application of a positive voltage pulse to its master reset input. When the 'Q' output of A1U4 is held 'low' (between eight second counting periods), inverting gate A1U5D will apply a 'high' to the base of transistor A1Q2. A1Q2 will be forward biased and turned on. It's collector/emitter junction will be a short circuit to the dc reference level. This short circuit will clamp the collector of transistor A1Q1 to the dc reference level and inhibit the operation of transistor A1Q1. When A1U4's 'Q' output is held 'high', during the eight second counting period; inverting gate A1U5D will apply a 'low' to the base of transistor A1Q2. A1Q2 will be reverse biased and turned off. It's collector/emitter junction will be an open circuit and it will have no influence on the operation of transistor A1Q1.

2.3.8 CHARGING CURRENT CONTROL: The charging current control circuit consists of operational amplifier A1U3C and its associated components. Operational amplifier is connected as a fixed gain, linear amplifier that has a gain factor of approximately 100 to 1. The voltage drop across resistor R1, as the result of the battery charging current passing thru them, is applied to the non-inverting input of A1U3C. Resistors A1R17/R18 form a voltage divider that applies an adjustable, reference voltage to the inverting input of A1U3C. Potentiometer A1R18 is adjusted, during calibration, to provide a dc control voltage, at the output of A1U3C, that will ultimately control the turn on time of thyristors Q1/Q2 and maintain the charging current to the batteries at the desired level. Capacitor A1C7 filters any ac ripple component on the output of A1U3C and maintains its control voltage output as a smoothed dc. If the voltage drop across R1 decreases, the non-inverting input of A1U3C will go less positive than its inverting input. The output of A1U3C will go less positive and cause thyristors Q1/Q2 to turn on earlier during each positive half cycle applied to their anodes. If the voltage drop across R1 increases, the non-inverting input of A1U3C will go more positive than its inverting input. The output of A1U3C will go more positive and cause thyristors Q1/Q2 to turn on later during each positive half cycle applied to their anodes.

2.3.9 THYRISTOR TURN-ON CONTROL: The thyristor turn-on control circuit consists of operational amplifier A1U3B, which is connected as a comparator; transistor A1Q3, which is connected as a switching transistor and their associated components. The positive voltage going, linear, ramp waveform from capacitor A1C4 is applied to the inverting input of A1U3B, while the variable, positive, dc control voltage from A1U3C is applied to A1U3B's non- inverting input. During the period of time the linear, ramp waveform on A1U3B's non-inverting input is less positive than the control voltage on its inverting input, A1U3B's output will be 'high' (23 V dc). Transistor A1Q3 will be reverse biased and turned off. When the linear, ramp waveform voltage goes more positive than the control voltage, A1U3B's output will switch to a 'low' (dc reference level). A1Q3 will be forward biased and turned on. When A1Q3 turns on, a positive voltage pulse is produced at the junctions of

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A1R13/R15 and A1R14/R16 as the output of the thyristor control circuit. Since the linear ramp waveforms occur at twice the frequency of the ac source voltage and their dc reference starting point coincides with the start of each half cycle of this ac voltage, the level of the control voltage applied to A1U3B's non-inverting input will determine when, during each half cycle of the ac source voltage, the positive voltage pulses will occur. Any increase in the control voltage will cause the positive voltage pulses to occur later, while any decrease will cause them to occur earlier. Refer to figure 2-1 for timing information.

2.3.10 FULL-WAVE RECTIFIER: The switched full-wave rectifier circuit consists of thyristors Q1/Q2, which are connected as a full- wave rectifier; free wheeling diode CR1, inductor L1 and the 150 volt ac, centre tapped secondary winding of power transformer T1. The centre tap of T1's

the anodes of thyristors Q1 and Q2, with the anode of each 180 degrees out of phase with the other. Whichever thyristor has a positive voltage on its anode will turn on when the positive voltage pulse, from the thyristor turn-on control circuit, is applied to their control gates. The conducting thyristor will remain turned on until its anode goes negative. Current pulses will be applied to the batteries being charged each time the anode voltage of the conducting thyristor exceeds the battery terminal voltage. Inductor L1 and the internal capacitance of the battery will smooth these current pulses to an average value. The timing of the positive voltage pulses, applied to the thyristor control gates, is controlled, as described in paragraphs 2.3.8 and 2.3.9, to ensure they occur during the portion of each half cycle that will maintain the average dc current at the desired charging current level. Freewheeling diode CR1 prevents oscillation in inductor L1 during abrupt changes in current flow

thru L1. secondary winding is connected to TB2-1, thru inductor L1 as the negative voltage terminal for voltages developed by the switched full-wave rectifier. The 75-0-75 RMS ac voltage from T1's secondary winding is applied to

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48 VOLT BATTERY CHARGER NAB05E

Figure 2-1 Timing Information

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48 VOLT BATTERY CHARGER NAB05E

SECTION 3

INSTALLATION AND PREPARATION FOR USE

GENERAL

3.1 This section contains the information

required to prepare the equipment site to receive the battery charger and the information required to unpack, install and prepare the battery charger for use.

TEST EQUIPMENT

3.2 The test equipment required for initial

installation is listed in table 1-2.

SITE REQUIREMENTS

3.3 The battery charger is intended to be mounted on the interior wall of a building. It should have a minimum clearance of 12 inches (30 cm) at the top, bottom and sides. There should be adequate room at the front to permit the cabinet door to open and permit a maintainer to test/trouble shoot the battery charger.

3.3.1 ELECTRICAL POWER: /01 variations require a 115 volt, line-to-neutral, 50/60 Hz ac power source and /02 variations require a 230 volt, line-toneutral, 50/60 Hz ac power source. Either source should be rated at a minimum of 500 Volt amperes.

3.3.2 ELECTRICAL POWER CABLE: The ac power source cable should be a three wire (two conductors plus ground) cable. It enters the battery charger through a cable entry hole in the bottom of its cabinet. Individual wires are connected to TB1-4 (line), TB1-5 (neutral) and safety ground stud.

3.3.3 BATTERY CABLE: The wiring from the battery charger to the batteries to be charged should be a two-conductor cable. The conductors should be a minimum of 16 AWG (rated for seven ampere maximum load). The battery cable enters the battery charger through a cable entry hole in the bottom of its cabinet. Individual wires are connected to TB2-2 (+) and TB2-1 (-).

UNPACKING

3.4 The battery charger is packed, fully

assembled, in a wooden crate that is 20 inches (51 cm)

wide, 18 inches (46 cm) deep and 11 inches, (28 cm)

high. Shipping weight is approximately 55 pounds

(25 kg). A packing list provides a detailed listing of

crate contents.

ANCILLARY PARTS

3.5 An ancillary parts kit is provided with each

battery charger. These parts include the ferrite toroids

(LXP38) as well as hardware required for installation.

An itemized listing of the ancillary parts kit is

included in its packing list.

INFORMATION TO BE DETERMINED PRIOR

TO FINAL INSTALLATION

3.6 The following information must be

obtained by the end user prior to applying ac power

and final adjustment of battery charging current and

full charge shutoff voltage.

3.6.1 AC POWER SOURCE: The RMS

voltage of the ac power source (115 V ac or 230 V ac)

to be used must be determined.

3.6.2 TYPE OF BATTERY: The type of bat-

tery to be charged must be determined.

3.6.3 BATTERY VOLTAGE (NO LOAD):

The full charge, no load battery voltage at 25°C

(77°F) must be determined from the battery manufac-

turer's specification sheets.

3.6.4 CHARGING CURRENT: Determine the

constant charge current to be applied to the batteries,

based on the battery manufacturer's recommendations.

3.6.5 SPECIFIC GRAVITY: If batteries to be

charged contain provision to check their specific

gravity, determine what their specific gravity should

be when they are fully charged, from the battery

manufacturer's specification sheets.

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PARTS REQUIRED BUT NOT SUPPLIED

3.7 The electrical wiring interconnecting the

battery charger to the ac power source and the batteries to be charged is not provided. The end user must obtain this wiring and, if used, any conduit to protect the wiring. The following should be used as a guide when selecting the interconnecting wiring. Five terminal lugs, for a #6 screw, that are the appropriate size for the interconnecting wire must also be provided.

3.7.1 AC POWER CABLE: A 3-conductor cable, to interconnect the battery charger and the ac power source, must be obtained by the user. It must be rated for the ac power source voltage to be used. The wire size will be determined by the length of cable. Three terminal lugs, rated for the selected wire size and for installation on a #6 screw, must also be obtained.

3.7.2 BATTERY CABLE: A 2-conductor cable, to interconnect the battery charger and the batteries to be charged, must be obtained by the user. The conductor size (minimum of 16 AWG) will be determined by the length of cable. Three terminal lugs, rated for the selected wire size and for installation on a #6 screw, must also be obtained.

INSTALLATION PROCEDURES

3.8 Install the battery charger as follows:

3.8.1 PHYSICAL MOUNTING: Mount the battery charger on an interior wall and secure in position using four mounting holes in its base as the mounting points.

NOTE

The battery charger should be located within five feet (153 cm) of the batteries to be charged and must be in an area that is free of corrosive acids and grasses.

3.8.2 SELECTING PROPER TAPS OF POWER TRANSFORMER T1: Connect or verify

that the wiring connected to the primary winding taps of power transformer T1 is connected to accommodate the voltage of the ac power source to be sued, as follows:

(a) When ac power source voltage is 115 volts ac,

60 Hz; connect or verify wire #32 is connected to T1-4, wire #33 is connected to T1-1, wire #34 is connected between T1-2 and U2-1 and wire #35 is connected to T1-3.

(b) When ac power source voltage is 230 volts ac,

50 Hz; connect or verify wire #32 is connected to T1-4, wire #33 is connected to T1-1 and wire #34 is connected between T1-2 and T1-3. Remove wire #35 from T1-3 or verify it is not installed.

3.8.3 CONNECTION OF AC POWER WIR-

ING: Connect the ac power source wiring to terminal

board TB1 and safety ground stud as follows:

(a) Route the ac power cable through the right-hand

cable entry hole, ensuring it passes through a cable clamp.

(b) Cut the conductors to the length required to

attach them to the appropriate terminals of TB1 and safety ground stud (for ground).

from each conductor, wrap the wire through a terminal lug intended for a #6 screw and solder the wire to the lug.

(d) Connect ac power wires to TB1 as identified by

the silkscreen markings adjacent to the terminal board (ground to safety ground stud located near TB1, line to TB1-4 and neutral to TB1-5).

3.8.4 CONNECTION OF BATTERY INTER-

CONNECTING WIRING: Connect the wiring that

interconnects the battery charger and the batteries to

be charged as follows:

NOTE

Ensure temperature sensor is routed thru left-hand

cable entry hole and passes through its cable clamp

before installing wiring that interconnects the battery

charger and the batteries to be charged.

(a) Route the cable, interconnecting the battery

charger and the batteries to be charged, through the left-hand cable entry hole, ensuring it passes through a cable clamp.

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(b) Cut the conductors to the length required to

attach them to appropriate terminals of TB2.

from each conductor and install a terminal lug intended for a #6 screw.

(d) Connect wires to TB2 as identified by the silk

screen markings adjacent to the terminal board (positive to TB2-2, negative to TB2-1).

NOTE

Wind wires in step (d) through two turns of LXP38 toroid located in ancillary kit.

(e) Connect the other end of the wires to the

batteries or battery bank to be charged, ensuring the wire connected to TB2-2 goes to the positive terminal of the battery and the wire connected to TB2-1 goes to the negative terminal.

NOTE

It is recommended that an on/off switch and a five ampere fuse be placed in one of the wires going to the batteries being charged.

3.8.5 POSITIONING OF BATTERY TEMPERATURE SENSOR: Locate battery temperature

sensor U1 where it will sense the ambient temperature of the air surrounding the batteries being charged, observing the following:

(a) Verify the leads of temperature sensor U1 are

connected to terminal board TB2 as identified by the silk screen markings adjacent to the terminal board (white to TB2-3 and red to TB2-4).

(b) Verify the leads of temperature sensor are

routed though the left-hand cable entry hole and pass through the cable clamp securing the wiring to the batteries being charged.

it will not be exposed to corrosive acids or gasses.

3.8.6 POST-INSTALLATION INSPECTION:

Visually inspect the battery charger's interior after

installation and prior to applying power as follows:

(a) Check for obvious damage and missing parts.

(b) Verify attaching hardware is firmly tightened.

insulation, loose or improper connections and broken, shorted or pinched conductors.

(d) Verify connector P1 is mated with connector

A1J1 on printed wiring board A1, ensuring pins are fully engaged.

(e) Check for and remove any unwanted foreign

objects from the interior of the cabinets, paying particular attention for floating conductive materials such as strands of wire, metal slivers/filings and loose hardware.

INITIAL TURN-ON PROCEDURES

3.9 Special precautions must be taken, during

the initial turn-on of the battery charger, to safeguard

against failures incurred during transit and

installation. Prepare the battery charger for initial

turn-on after installation as follows:

(a) Verify the requirements of paragraph 3.8 have

been completed.

(b) Remove any loads that may be connected to the

batteries.

detailed in paragraph 5.1.

NOTE

If fully charged batteries are connected to the battery

charger during initial turn-on, it will be necessary to

partially discharge them to complete the calibration

procedures.

If discharged batteries are connected to the battery

charger during initial turn-on, the time required to

complete the calibration procedure will be determined

by degree of discharge and the capacity of the

batteries.

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SECTION 4 OPERATING INSTRUCTIONS

GENERAL

4.1 This section provides the information required

to place the battery charger into operation. The following instructions are primarily intended for persons involved in testing or maintenance of the equipment.

EMERGENCY SHUTDOWN PROCEDURE

4.2 There are no special precautions to be taken if

an emergency shutdown is required. Switch off ac power by placing

POWER switch S1 in the OFF

position or turn off ac power source at the supply panel.

PERSONNEL SAFETY

4.3 Exercise caution when working in the vicinity

of uninsulated termination points of wires carrying the ac power source voltage.

CONTROLS AND INDICATORS

4.4 The controls and indicators of the battery

charger are straight forward. The following is a brief description of their function:

POWER switch S1 applies the ac power to the

battery charger when it is set to ac power source when set to

ON and removes the

OFF.

- Light emitting diode DS1 turns on when ac power

is being applied to the battery charger and switch S1 is

ON.

POWER

- Potentiometer A1R18 provides a calibration

adjustment to set the constant charging current to the desired level (maximum of 3.0 amperes).

- Potentiometer A1R24 provides a calibration adjust-

ment to set the charge current switch-off voltage (voltage that represents the full charge voltage of the batteries being charged).

TURNING ON THE BATTERY CHARGER

4.5 There are no special turn-on procedures.

Verify the requirements of paragraph 3.8 have been

satisfactorily completed and observe the precautions

specified in paragraph 4.6.

OPERATING PRECAUTIONS

4.6 Severe damage to the batteries can result if

they are connected improperly. Observe all

precautions specified by the battery manufacturer,

paying particular attention to the following:

(a) When a number of batteries are to be connected

in series, ensure the fully charged voltage of the series string is within the charging range of the battery charger.

(b) If batteries are connected in a series parallel

arrangement, ensure the fully charged voltage of each series string is identical.

with a meter before connecting them in series.

(d) Check polarity of the voltage on the inter-

connecting wires, at the battery charger end, before making the final connection to the battery charger. Ensure the battery negative is connected to the battery charger negative.

(e) If the batteries are being subjected to their initial

charge or if they are fully discharged, observe any recommendations specified by the battery manufacturer.

(f) If possible, it is recommended that all batteries

be near the same charge/discharge state when they are initially connected to the battery charger. The current required to charge a battery that is discharged more than the other batteries in a series string will flow through all of the batteries and may cause excessive boiling off of the electrolyte in the batteries that were originally closer to being fully charged.

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48 VOLT BATTERY CHARGER NAB05E

FAULT INDICATION

4.7 There is no provision to automatically indi-

cate a fault has occurred in the battery charger or the batteries being charged. The only way to determine the battery charger is functioning normally is to periodically measure the voltage of the batteries connected to the battery charger. They should be maintained at their fully charged state, unless the equipment that is connected to them is or has recently been drawing current from the batteries. Check the specific gravity of the electrolyte (with a hydrometer) in batteries that have removable caps on their cells. The only way to verify the battery charger is fully operational is to partially discharge the batteries and verify the battery charger recharges the batteries at the desired rate and then switches off when the fully charged state is obtained.

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48 VOLT BATTERY CHARGER NAB05E

SECTION 5

ADJUSTMENT AND TESTING

GENERAL

5.1 The battery charger has been factory set to

charge a 48 volt battery bank at a constant rate of 3 amperes with a battery open circuit terminal voltage of 56.4 volts when the ambient temperature is 21°C. This represents a charge voltage of 2.35 volts per cell for a standard 24 cell lead acid battery. If the battery bank to be charged has a different fully charged, open circuit, terminal voltage; the settings may be changed using one of two adjustment procedures. This section contains a detailed step-by-step adjustment procedure for both methods. It is recommended that personnel, who are not familiar with detailed circuit theory or who do not realize what impact specific adjustments will have, follow the instructions in the order presented. It is recommended that the instructions be followed sequentially during initial turn-on.

TEST EQUIPMENT REQUIRED

5.2 Details of the test equipment required to

perform all adjustment procedures is given in table 1-2. Adjustment method 1 below requires only the dc ammeter and digital voltmeter (or hydrometer).

ADJUSTMENT PROCEDURES

5.3 Both method 1 and method 2 set the

constant charge current and full charge shut-off voltage to precise values, which are determined to suit the battery type to be used. Calibrate the battery charger control circuits during initial installation and whenever the output of the battery charger is suspect as follows.

5.3.1 OPERATION OF EQUIPMENT: Observe the precautions presented in section 4 when operating the battery charger.

5.3.2 ADJUSTMENT PRE-REQUISITES: Prior to adjusting the battery charger, ensure the following is observed:

(a) Determine the fully charged, open-circuit

terminal voltage of the battery bank. See paragraph 3.6.3.

(b) Determine the maximum charge current to be

applied to the battery bank. See paragraph

3.6.4.

voltage determined in step (a) is between 51 and 67 V dc (operating voltage range of the battery charger).

(d) Verify the wiring from the battery bank is

connected to battery charger with the correct polarity (-) to TB2-1 and (+) to TB2-2.

(e) Switch off ac power at the service entrance.

(f) Disconnect all loads from the battery bank.

5.3.3 ADJUSTMENT METHOD 1 (Using

minimum test equipment):

(a) Connect a dc ammeter in series with one of the

wires connecting the battery bank to the battery charger, observing the polarity of the ammeter terminals.

(b) Turn on ac power at service entrance and set the

battery charger's

POWER switch to ON.

during the eight second charge periods

(d) The current reading should be a maximum of

three amperes when charging a deeply discharged battery bank, reducing to a nominal two amperes as the battery bank approaches its fully charged condition.

(e) Simulate a deeply discharged condition by

lowering the terminal voltage of the battery bank. (remove some of the series connected cells, noting the terminal voltage must not be less than 36 volts using this technique).

NOTE

Ensure the battery charger is turned off when opening

and closing connections.

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48 VOLT BATTERY CHARGER NAB05E

(f) Observing ammeter, adjust

CHARGE CURRENT

potentiometer A1R18 for the maximum allowable charge current (not to exceed 3.0 amperes) as determined in step (b) of paragraph

5.3.2.

(g) If cells were disconnected to simulate a

discharged state in step (e), restore battery bank by reconnecting them.

(h) Wait until battery bank is fully charged (inter-

vals in excess of 60 seconds between charge periods).

(i) Measure the specific gravity and/or terminal

voltage of all battery cells.

- Specific gravity should be as specified by

battery manufacturer for a fully charged battery.

- The terminal voltage for each cell shall be the

voltage specified by the battery manufacturer.

(j) If charge level is too low, make a small

adjustment to

CHARGE VOLTAGE potentiometer

A1R24 in a clockwise direction then repeat steps (h) and (i).

(k) If charge level is too high, make a small

adjustment to

CHARGE VOLTAGE potentiometer

A1R24 in a counter clockwise direction and then partially discharge the batteries until charging resumes. Repeat steps (h) and (i).

5.3.4 ADJUSTMENT METHOD 2 (Using all test equipment listed in table 1-2):

(a) Verify requirements of paragraph 5.3.2 have

been completed and battery charger is turned off (it's

POWER switch is set to OFF).

(b) Interface ac power source and the battery

charger with a variac that will accommodate changing the ac voltage being applied to the battery charger ±10% from nominal. Preset the output of the variac to 230 V ac or 115 V ac depending on the ac source.

by disconnecting the interconnecting wiring from TB2-2 and TB2-1. Ensure disconnected wires are not shorted.

(d) Disconnect the power transformer's 75-0-75 vac

secondary voltage from the battery charger's switched full wave rectifier. Disconnect wire #4 from T1-5 and wire #5 from T1-7.

(e) Connect a variable dc power supply, that has

been precisely preset to the battery bank's fully charged, open circuit, terminal voltage [determined in step (a) of paragraph 5.3.2]; between TB2-1 (-) and TB2-2 (+) of the battery charger.

(f) Connect an oscilloscope's test probe between the

junction of resistors A1R26/R27 and the dc reference level (either side of A1R27).

NOTE

The dc reference level is not at ground potential. Use

isolated oscilloscope probes.

(g) Turn on the battery charger (set its

switch

ON and verify POWER lamp turns on).

POWER

(h) Set

CHARGE VOLTAGE potentiometer A1R24

fully clockwise. The oscilloscope waveform should be a nominal 0.0 V dc trace.

(i) Slowly adjust

CHARGE VOLTAGE potentiometer

A1R24 counter clockwise until oscilloscope waveform just switches to a nominal 12.0 V dc trace.

(j) Reduce output voltage of variable dc power

supply by minimum of 2.0 V dc. The oscilloscope waveform should be a nominal 0.0 V dc trace.

(k) Simulate a 10% increase in the ac power source.

Set the variac's output 10% above the nominal V ac (ac power source for battery charger).

(l) Slowly increase output voltage of variable dc

power supply until the oscilloscope waveform just switches to a nominal 12.0 V dc trace.

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48 VOLT BATTERY CHARGER NAB05E

(m) Output voltage of variable dc power supply

shall be within 0.5% of the battery bank's fully charged, open circuit, terminal voltage [determined in step (a) of paragraph 5.3.2].

(n) Repeat step (j), simulate a 10% decrease in the

ac power source by setting the variac's output to 10% below the nominal V ac and then repeat steps (l) and (m).

(o) Turn off the battery charger (set its

switch

OFF and verify POWER lamp turns off).

POWER

(p) Disconnect test leads of oscilloscope and

variable dc power supply.

(q) Reconnect the power transformer's 75-0-75 V ac

secondary to the battery charger's switched full wave rectifier. Connect wire #4 to T1-5 and wire #5 to T1-7.

(r) Reconnect negative lead from battery bank to

TB2-1 of the battery charger.

(s) Connect a 5 ampere dc ammeter between TB2-2

and the positive leads of the battery bank. Ensure positive terminal of ammeter is connected to TB2-2.

(t) Discharge the battery bank or simulate a deeply

discharged condition by reconfiguring the battery bank for a nominal 36 V dc terminal voltage (remove one 12 volt battery).

(u) Set the variac's output to 230 or 115 V ac (ac

power source for battery charger).

(v) Turn on the battery charger (set its

switch

ON and verify POWER lamp turns on).

POWER

(w) The ammeter reading shall be the desired charge

current (not to exceed 3.0 amperes) as determined in step (b) of paragraph 5.3.2.

(x) Simulate a 10% increase in the ac power source.

Set the variac's output to 10% above the nominal V ac and verify the ammeter reading does not increase by more than five percent.

(y) Simulate a 10% decrease in the ac power

source. Set the variac's output to 10% below the nominal V ac and verify the ammeter reading does not decrease by more than five percent.

(z) Turn off the battery charger (set its

switch

OFF and verify POWER lamp turns off).

POWER

(aa) Disconnect the variac and connect ac power

source wiring directly to the battery charger as detailed in step (d) of paragraph 3.8.3.

(ab) If battery bank was reconfigured to simulate a

discharged condition in step (t), restore it to its original (48 volt) configuration.

(ac) Partially discharge the battery bank to ensure it

will require a charging current when the battery charger is turned on.

(ad) Turn on the battery charger (set its

switch

ON and verify POWER lamp turns on).

POWER

(ae) Note the interval of time between charging

periods (ammeter current will drop to 0).

(af) Simulate an increase in temperature at the

battery bank by heating its temperature transducer with a controlled heat source (heat gun).

(ag) Verify the interval of time between charging

periods increases as the sensed temperature increases.

(ah) Discontinue heating battery bank's temperature

transducer.

(ai) When the battery bank is fully charged (inter-

vals between charging periods are in excess of 60 seconds), measure the specific gravity and/or terminal voltage of all battery cells.

- Specific gravity should be as specified by battery manufacturer for a fully charged battery.

- The terminal voltage for each cell shall be the voltage specified by the battery manufacturer.

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48 VOLT BATTERY CHARGER NAB05E

FUNCTIONAL TEST

5.4 The only practical functional test of the battery

charger is to place it in operation and monitor the battery charge state until the batteries are fully charged.

NOTE

If the batteries being charged have provision to check their electrolyte, periodically measure the specific gravity of the electrolyte to verify the battery charger is functioning normally.

If the batteries being charged do not have provision to check their electrolyte, periodically measure the battery terminal voltage during the periods of time the eight second charging current bursts are not being applied. Battery terminal voltage shall increase to the full charge, no load voltage for the batteries and the period of time between current bursts shall increase towards infinity as the batteries approach this voltage.

Page 5-4 01 September 2004

48 VOLT BATTERY CHARGER NAB05E

SECTION 6 MAINTENANCE

GENERAL

6.1 This section contains maintenance infor-

mation. Fault symptoms should be analyzed to determine corrective action required. Normally, a routine adjustment will resolve any out-of- tolerance condition. This section contains wiring information for each hard-wired assembly and references illustrations in the foldout section that depict the mechanical assembly of the transmitter components, and provide information regarding the location, marking of all controls and indicators.

SCHEMATICS/LOGIC DIAGRAMS

6.2 An electrical schematic for the battery

charger is provided in figure SD-2.

6.2.1 COMPONENT VALUES: Unless otherwise specified on the schematic:

- Resistor values are shown in ohms (K = 1 000 and M = 1 000 000).

- Capacitor values are shown in microfarads (uF).

- Unidentified diodes are part number 1N4938.

6.2.2 GRAPHIC SYMBOLS: The symbols used on electrical schematics are in accordance with American National Standard ANSI Y32.2 Graphic Symbols for Electrical and Electronic Diagrams.

6.2.3 LOGIC SYMBOLS: Logic symbols used on schematics/logic diagrams are in accordance with American National Standard ANSI Y32.14 Graphic Symbols for Logic Diagrams.

6.2.4 REFERENCE DESIGNATIONS: Reference designations have been assigned in accordance with American National Standard ANSI Y32.16 Reference Designations for Electrical and Electronic

WIRING INFORMATION

6.3 Point-to-point wiring information for the

battery charger is detailed in table 6-2.

MECHANICAL DRAWINGS

6.4 Mechanical drawings that depict the loca-

tion of electrical components and show assembly outline detail are provided in the foldout section. The assembly illustrations are presented in the order of their assigned reference designations.

TEST EQUIPMENT

6.5 The test equipment recommended for

maintenance of the battery charger is listed in table 1-2.

SCHEDULED MAINTENANCE

6.6 Establishment of an inspection schedule is

recommended to ensure long-term performance is maintained. Local operating and environmental conditions may dictate more frequent intervals and, in the case of remote sites, less frequent intervals may be acceptable. Experience and system reliability will determine the most practical schedule for a specific installation.

CORRECTIVE MAINTENANCE

6.7 Corrective maintenance procedures consist

of identifying and correcting defects or out-oftolerance conditions identified during a calibration procedure. The first step in any corrective maintenance procedure should be the calibration procedures detailed in paragraph 5.3. Table 6-1 provides additional troubleshooting assistance information.

Parts and Equipments. Each electrical symbol has been identified with its basic reference designation. To obtain the full reference designation for a specific part, this basic identifier must be prefixed with the reference designation assigned to all higher assemblies.

Page 6-1 01 September 2004

48 VOLT BATTERY CHARGER NAB05E

Table 6-1 System Troubleshooting Assistance Chart

SYMPTOM PROBABLE CAUSE CORRECTIVE MEASURE

System will not turn on a. Defective fuse F1. a. Replace defective fuse.

b. No ac line input. b. Check ac line at TB1-4/5.

c. Defective +23 volt supply. c. Check +23 volts at A1CR1 cathode.

No charge current to battery a. Defective fuse F2. a. Replace defective fuse F2.

b. No pulses to turn on b. Check pulses at gates of Q1/Q2.

c. Battery fully charged. c. No corrective action necessary.

Battery not charging a. to required voltage. A1R24 incorrectly adjusted.

Battery charge current a. not as required. A1R18 incorrectly adjusted.

CHARGE VOLTAGE potentiometer a. Adjust battery charger's CHARGE

VOLTAGE potentiometer A1R24 for

battery manufacturer's recommended fully charged, no-load terminal voltage.

CHARGE CURRENT potentiometer a. Adjust battery charger's CHARGE

CURRENT potentiometer A1R18 for

battery manufacturer's recommended charging current.

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48 VOLT BATTERY CHARGER NAB05E

Table 6-2 Wiring List - NAB05E Battery Charger

* SOURCE DESTINATION CODE SIZE REMARKS

TT1 TT2 Resistor 1000 ohms 5 Watt, 5% TT3 TT4 Resistor 0.075 ohms 5 Watt, 1% Front Panel Box - - Braid Jumper

- - 1 Not Used TB1-1 S1-1 2 Grey 16 S1-2 XF1-Centre 3 Grey 16 T1-5 Q1-Anode 4 White 16 T1-7 Q2-Anode 5 White 16 L1-2 CR1-Anode 6 White 16 CR1-Anode T1-6 7 White 16 L1-1 R2-02 8 White 16 R2-02 TB2-1 9 White 16 CR1-Cathode Q2-Cathode 10 White 16 Q2-Cathode Q1-Cathode 11 White 16 Q1-Cathode R1-03 12 White 16 TB2-2 XF2-Side 13 White 16 XF2-Centre R1-04 14 White 16 R1-04 C1-(-) 15 White 16 P1-1 Q2-Gate 16 White 22 P1-2 Q1-Gate 17 White 22 P1-3 XDS1-Cathode 18 White 22 P1-7 T1-9 19 White 22 P1-8 C1 (+) Cathode 20 White 22 P1-9 C1 (-) 21 White 22 P1-10 T1-8 22 White 22 P1-11 R1-03 23 White 22 P1-12 R2-01 24 White 22 XDS1-Anode C1 (+) 25 White 22 P1-4 TB2-3 26 White 22 P1-5 TB2-4 27 White 22 TB1-4 U2-3 28 Grey 16 TB1-5 U2-4 29 Grey 16 TB1-2 U2-1 30 Grey 16 TB1-1 U2-2 31 Grey 16 TB1-2 T1-4 32 Grey 16 XF1-Side T1-1 33 Grey 16 # T1-2 U2-01 34 Grey 16 * T1-3 XF1-Side 35 Grey 16 U1-White TB2-3 - - - Lead of U1 U1-Red TB2-4 - - - Lead of U1

* Denotes wire used when ac power source is 115 volts ac (NAB05E/01 variation). # Denotes wire used when ac power source is 230 volts ac (NAB05E/02 variation).

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48 VOLT BATTERY CHARGER NAB05E

RIPPLE VOLTAGE OUTPUT of 23 V DC POWER SUPPLY

Junction A1R2/CR1

5.0 Volts/division

5.0 Milliseconds/division

Centre line at +10 Volts

DIGITIZER OUTPUT

Junction A1R2/CR1

1.0 Volts/division

5.0 Milliseconds/division

Centre line at dc reference level

RAMP GENERATOR OUTPUT

Junction A1C4/R7

1.0 Volts/division

5.0 Milliseconds/division

Centre line at +2.0.Volts

Figure 6-1 Waveforms (Sheet 1)

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48 VOLT BATTERY CHARGER NAB05E

THYRISTOR TURN-ON CONTROL PULSES

Junction A1R2/CR1

5.0 Volts/Division

5.0 Milliseconds/division

Centre line at +10 Volts

Figure 6-1 Waveforms (Sheet 2)

Page 6-5 01 September 2004

48 VOLT BATTERY CHARGER NAB05E

SECTION 7

PARTS LIST

INTRODUCTION

7.1 This section contains reference designation

indexes which provide descriptive and provisioning information for all electrical and mechanical parts that have been assigned a reference designation and form a part of the battery charger.

FAMILY TREE

7.2 Not applicable.

MANUFACTURER'S INDEX

7.3 Table 7-1 provides a cross reference from

the original equipment manufacturers (OEM) codes to the manufacturer's name and address. The listing is sorted alpha/numerically by the manufacturers' codes.

HOW TO LOCATE INFORMATION FOR A SPECIFIC PART

7.4 To locate the information for a specific

part, the user must know the reference designation assigned to the part.

REFERENCE DESIGNATION INDEXES

7.5 The reference designation indexes is

divided into six columns as an aid to locating specific information. Refer to paragraph 7.6 for an explanation of column contents.

COLUMN CONTENT EXPLANATION

7.6 The following paragraphs provide an

explanation of the purpose and contents of each column in the reference designation indexes.

7.6.1 USE CODE COLUMN: This column contains a symbol/letter code which is part of a configuration control management system. When there is more than one variation of an assembly, each variation will be assigned a code in this column and the parts that are unique to a variation will be assigned the same code. Parts that are common to all variations will not have an entry in this column. Notes at the end of each table explain the code's significance.

7.6.2 REF DES COLUMN: This column con-

Page 7-1 01 September 2004

tains the reference designation for a specific part. These designations are assigned in accordance with the requirements of American National Standard Specification ANSI Y32.16. Each reference designation index is sorted and listed alpha/numerically according to the reference designations in this column.

7.6.3 NAME OF PART AND DESCRIPTION

COLUMN: This column contains the name and

descriptive information for each part. The key word or noun is presented first, followed by the adjective identifiers.

7.6.4 NAUTEL'S PART NO. COLUMN:

This column contains the Nautel part number assigned to each part. This number is Nautel's drawing number for Nautel manufactured parts, Nautel's configuration control number for assemblies that are under configuration control management or Nautel's inventory management number for purchased parts.

7.6.5 JAN, MIL OR MFR PART NO. COL-

UMN: This column contains an original equipment

manufacturer's part number for a part. A single part number is listed for each part, even though there may be more than one known manufacturer. The listed number is Nautel's usual or preferred choice. A JAN or MIL number has been assigned as the manufacturer's part number, where practical, to assist the user in finding a suitable replacement part. The use of this number does not restrict Nautel from selecting and using commercial equivalents, where their use will not degrade circuit operation or reliability, during manufacture.

48 VOLT BATTERY CHARGER NAB05E

7.6.6 OEM CODE COLUMN: This column contains a five digit coded group as the original equipment manufacturer's (OEM) identifier. The code was extracted from Cataloging Handbook H4/H8 - Commercial and Government Entity (Cage) Code. Manufacturers that were not listed in the

OEM code 37338 is listed for parts manufactured by Nautel or to a Nautel control drawing. United States of America customers should refer all replacement part orders to Nautel Maine Incorporated (OEM code

57655).

NOTE

catalog when this listing was compiled have been assigned a unique five letter code. This code is assigned arbitrarily and has no other significance. The manufacturers identified for parts that have JAN or MIL part numbers are Nautel's normal supply source for that part.

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48 VOLT BATTERY CHARGER NAB05E

Table 7-1 Manufacturers' Code to Address Index

00779 AMP Incorporated, 2800 Fulling Mill, P O Box 3608, Harrisburg, Pennsylvania 17105

00853 Sangamo Weston Incorporated, Sangamo Capacitor Division, PO Box 128, Route 3, Sangamo Road, Pickens, South Carolina 29671

04713 Motorola Incorporated, Semiconductor Products Group, 5005 East McDowell Road, Phoenix, Arizona 85008

08372 Cutler-Hammer Canada Limited, 45 Progress Avenue, Scarsborough, Ontario, Canada M1P 2T6 USA customers use - 55459

09482 AMP of Canada Limited, 20 Esna Park Drive, Markham, Ontario, Canada L3R 1E1 USA customers use - 00779

14552 Microsemi Corporation, 2830 South Fairview Street, Santa Ana, California 92704

15513 Data Display Products, P O Box 91072, 5428 West 104th St., Los Angeles, California 90009

24355 Analog Devices Incorporated, Route 1 Industrial Park, PO Box 280, Norwood, Massachusetts 02062

35005 Dale Electronics Canada Limited, 18 Howden Road, Scarsborough, Ontario, Canada M1R 3E6 USA customers use - 91637

37338 Nautel Limited, 10089 Peggy’s Cove Road Hackett's Cove, Nova Scotia, Canada B3Z 3J4 USA customers use - 57655

50434 Hewlett Packard Company, 640 Page Mill Road, Palo Alto, California 94304

55459 Eaton Corporation, Aerospace & Commercial Controls Div., JBT Products, 300 8th Avenue, Arab, Alabama 35016

57655 Nautel Maine Incorporated, 201 Target Industrial Circle Bangor, Maine 04401

56289 Sprague Electric Company, 87 Marshall Street, North Adams, Massachusetts 01247

63426 MKK Switches of America Incorporated 7850 East Gelding Drive Scottsdale, Arizona, 85260

71400 Bussman Manufacturing Division, McGraw-Edison Company, 502 Earth City Plaza, Earth City, Missouri 63045

73631 Curtis Instruments Inc., Helipot Division. 2500 Harbour Blvd., Fullerton, California 92634

75042 TRW Electronic Components, IRC Fixed Resistor Division, 401 North Broad Street, Philadelphia, Pennsylvania 19108

75915 Littlefuse Incorporated, 800 East Northwest Highway, Des Plaines, Illinois 60016

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48 VOLT BATTERY CHARGER NAB05E

Table 7-1 Manufacturers' Code to Address Index (Continued)

80294 Bourns Incorporated, Instrument Division, 6135 Magnolia Avenue, Riverside, California 92506

81483 International Rectifier, 9220 Sunset Boulevard, PO Box 2321, Terminal Annex, Los Angeles, California 90069

83003 VARO Incorporated, PO Box 401426, 2203 Walnut Street,

89473 General Electric Distributing Corp., 1 River Road, Schenactady, New York 12305

91506 Augat Incorporated, PO Box 779, 633 Perry Avenue, Attleboro, Massachusetts 02703

91637 Dale Electronics Incorporated, 2064 12th Avenue, Columbus, Nebraska 68601

Garland, Texas 75040

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48 VOLT BATTERY CHARGER NAB05E

Table 7-2 Ref Des Index - NAB05E 48 Volt Battery Charger

USE REF NAME OF PART NAUTEL'S JAN/MIL/OEM OEM

CODE DES AND DESCRIPTION PART NO. PART NO. CODE

♥ - Battery Charger, 48 V dc (115 V ac) NAB05E/01 147-1300-20 37338 ♦ - Battery Charger, 48 V dc (230 V ac) NAB05E/02 147-1300-21 37338 A1 Battery Charger PWB 147-1310-08 147-1310-08 37338 A1C1 Capacitor, Ceramic, 0.1uF 10% 100V CCG07 CKR06BX104KL 56289 A1C2 Capacitor, Ceramic, 0.1uF 10% 100V CCG07 CKR06BX104KL 56289 A1C3 Capacitor, Ceramic, 0.01uF 10% 100V CCG04 CKR05BX103KL 56289 A1C4 Capacitor, Ceramic, 0.33uF 10% 50V CCG22 CKR06BX334KR 96095 A1C5 Capacitor, Ceramic, 1.0uF 10% 50V CCG10 CKR06BX105KL 56289 A1C6 Capacitor, Ceramic, 1.0uF 10% 50V CCG10 CKR06BX105KL 56289 A1C7 Capacitor, Ceramic, 1.0uF 10% 50V CCG10 CKR06BX105KL 56289 A1C8 Capacitor, Ceramic, 0.01uF 10% 100V CCG04 CKR05BX103KL 56289 A1C9 Capacitor, Ceramic, 0.01uF 10% 100V CCG04 CKR05BX103KL 56289 A1C10 Capacitor, Ceramic, 0.001uF 10% 200V CCG01 CKR05BX102KL 56289 A1CR1 Diode, Power Rectifier, 200V, 3A QG31 1N5624 89473 A1CR2 Diode, Zener, 9V, 0.5W, Temp Compensated QL41 1N935A 14552 A1J1 MTA, Square Post Header Assembly, 12-pin JU21 1-640383-2 09482 A1Q1 Transistor, NPN, Switch/Amplifier QA03 2N2222A 04713 A1Q2 Transistor, NPN, Switch/Amplifier QA03 2N2222A 04713 A1Q3 Transistor, PNP, Switch/Amplifier QA23 2N2905A 04713 A1R1 Resistor, Metal Film, 1800 Ohms, 2% 1/2W RAP10 RL20S182G 35005 A1R2 Resistor, Metal Film, 1000 Ohms, 2% 1/2W RAP09 RL20S102G 35005 A1R3 Resistor, Metal Film, 100K Ohms, 2% 1/2W RAP17 RL20S104G 35005 A1R4 Resistor, Metal Film, 1200 Ohms, 2% 1/2W RC38 RL20S122G 35005 A1R5 Resistor, Metal Film, 10K Ohms, 2% 1/2W RAP13 RL20S103G 35005 A1R6 Resistor, Metal Film, 1000 Ohms, 2% 1/2W RAP09 RL20S102G 35005 A1R7 Resistor, Metal Film, 100K Ohms, 2% 1/2W RAP17 RL20S104G 35005 A1R8 Resistor, Metal Film, 10K Ohms, 2% 1/2W RAP13 RL20S103G 35005 A1R9 Resistor, Metal Film, 22K Ohms, 2% 1/2W RD11 RL20S223G 35005 A1R10 Resistor, Metal Film, 22K Ohms, 2% 1/2W RD11 RL20S223G 35005 A1R11 Resistor, Metal Film, 100 Ohms, 2% 1/2W RAP05 RL20S101G 35005 A1R12 Resistor, Metal Film, 10K Ohms, 2% 1/2W RAP13 RL20S103G 35005 A1R13 Resistor, Metal Film, 560 Ohms, 5% 2W RT14 GS-3, T0 5600J 75042 A1R14 Resistor, Metal Film, 560 Ohms, 5% 2W RT14 GS-3, T0 5600J 75042 A1R15 Resistor, Metal Film, 1000 Ohms, 2% 1/2W RAP09 RL20S102G 35005 A1R16 Resistor, Metal Film, 1000 Ohms, 2% 1/2W RAP09 RL20S102G 35005 A1R17 Resistor, Metal Film, 56K Ohms, 2% 1/2W RAP16 ML20563G 35005 A1R18 Resistor, Variable, Film, 1000 Ohms, 1/2W RV06 3339P-1-102 80924 A1R19 Resistor, Metal Film, 1000 Ohms, 2% 1/2W RAP09 RL20S102G 35005 A1R20 Resistor, Metal Film, 100K Ohms, 2% 1/2W RAP17 RL20S104G 35005 A1R21 Resistor, Metal Film, 22K Ohms, 2% 1/2W RD11 RL20S223G 35005 A1R22 Resistor, Metal Film, 1500 Ohms, 2% 1/2W RC39 RL20S152G 35005 A1R23 Resistor, Metal Film, 4700 Ohms, 2% 1/2W RD03 RL20S472G 35005 A1R24 Resistor, Variable, Film, 2000 ohms, 1/2W RW31 3339P-1-202 80294 A1R25 Resistor, Metal Film, 22K Ohms, 2% 1/2W RD11 RL20S223G 35005 A1R26 Resistor, Metal Film, 5600 Ohms, 2% 1/2W RAP12 RL20S562G 35005 A1R27 Resistor, Metal Film, 10K Ohms, 2% 1/2W RAP13 RL20S103G 35005 A1R28 Not Used

Page 7-5 01 September 2004

48 VOLT BATTERY CHARGER NAB05E

Table 7-2 Ref Des Index - NAB05EA 48 Volt Battery Charger (Continued)

USE REF NAME OF PART NAUTEL'S JAN/MIL/OEM OEM

CODE DES AND DESCRIPTION PART NO. PART NO. CODE

A1R29 Resistor, Metal Film, 1800 Ohms, 2% 1/2W RAP10 RL20S182G 35005 A1R30 Resistor, Metal Film, 1800 Ohms, 2% 1/2W RAP10 RL20S182G 35005 A1R31 Resistor, Metal Film, 1000 Ohms, 2% 1/2W RAP09 RL20S102G 35005 A1R32 Resistor, Metal Film, 390 Ohms, 5% 2W RBP33 GS-3 T0 3900J 35005 A1R32 Resistor, Metal Film, 390 Ohms, 5% 2W RBP33 GS-3 T0 3900J 35005 A1U1 Rect/Assy, Diode, Bridge 200V 2A UA27 VS247 83003 A1U2 IC, Voltage Regulator, +15V UT19 MC78M15CT 04713 A1U3 IC, Operational Amplifiers, Quad UC15 MC3403L 04713 A1U4 IC, CMOS, Oscillator/Timer UB12 MC14541BCP 04713 A1U5 IC, CMOS, Quad, 2-input NOR Gates UB01 MC14001BCP 04713 A1XU3 Socket, Integrated Circuit, 14-Pin UD41 1814AG111D 91506 A1XU4 Socket, Integrated Circuit, 14-Pin UD41 1814AG111D 91506 A1XU5 Socket, Integrated Circuit, 14-Pin UD41 1814AG111D 91506 C1 Capacitor, Electrolytic, 1100uF, 75V CYP01 500112U075AA2B 00853 CR1 Diode, Power Rectifier, 300V, 40A QK17 1N1187A 81483 DS1 Diode, Light Emitting, Green QK12 HLMP-3554 50434 /1 F1 Fuse, 5A, 250V, Slow, 3AB FB33 MDA5 71400 /2 F1 Fuse, 3A, 250V, Slow, 3AG FA10 313003 75915 F2 Fuse, 5A, 250V, Slow, 3AB FB33 MDA5 71400 L1 Inductor Assembly 147-1322 147-1322 37338 P1 MTA, Closed End Housing, 12-Pin, 22 AWG JU26 1-644463-2 00779 Q1 Thyristor, Power, 50A, 800V QM26 SLT24-/08C UNF SEMIK Q2 Thyristor, Power, 50A, 800V QM26 SLT24-/08C.UNF SEMIK R1 Resistor, Wirewound, 0.075 Ohms, +1% 5W RS14 LVR-5 0.075 35005 R2 Resistor, Wirewound, 1000 Ohms, 5% 5W RWP10 RS5-1000 Ohms-5% 35005 S1 Switch, Toggle, SPST, ac/dc/CSA Rated SCP43 S1A 63426 T1 Transformer Assembly 147-1321 147-1321 37338 TB1 Terminal Block, 6-pos, Single, 1 Sd JR03 GBS-6 73631 TB2 Terminal Block, 6-pos, Single, 1 Sd JR03 GBS-6 73631 U1 Probe Assembly 147-1318 147-1318 37338 U2 EMI Filter, Mod 139-8227 139-8227 37338 XDS1 Socket, LED QK25 PS-200-B 15513 XF1 Fuseholder, Panel, 20A, 250V, Type 3AG BAP30 342012 75915 XF2 Fuseholder, Panel, 20A, 250V, Type 3AG BAP30 342012 75915

NOTE ♥ - Denotes used when ac power source is 115 V ac (line-to-neutral, 50/60Hz) ♦ - Denotes used when ac power source is 230 V ac (line-to-neutral, 50/60Hz) /1 - Denotes used on NAB05E/01 variations /2 - Denotes used on NAB05E/02 variations

Page 7-6 01 September 2004