Onan 305-0856 Installation Manual

Model

Redistribution or publication of this document by any means, is strictly prohibited.

Onan

305-0856

Installation Manual

Number

901

-0604

9-90

Printed

in

USA.

Safetv

Redistribution or publication of this document by any means, is strictly prohibited.

This manual includes the following symbols to indicate

potentially dangerous conditions to the operator or equipment. Read the manual carefully and know when these conditions exist. Then take the necessary steps

protect personnel and the equipment.

.

I'

ards that will result in severe personal injury or

death.

1-1

safe practice that can result in severe personal in-

jury

or death.

1-1

safe practice that can result in personal injury or product or property damage.

This symbol warns of immediate haz-

This symbol refers

Precautions

to

a hazard or un-

to

a

hazard or un-

IMPORTANT SAFETY INSTRUCTIONS

1.

Save these instructions. This manual contains important safety instructions.

2.

Working in the vicinity

Batteries generate explosive gasses during normal battery operation. portance that you read all instructions and cautionary markings on the battery charger, the battery, and the generator set.

3.

To

reduce the risk of battery explosion, follow these instructions and those published by the battery manufacturer and the manufacturer of any equip-

ment that is used in the vicinity of the battery. Review and follow all cautionary markings on these products.

4.

To reduce riskof injury, only use the battery charger

to

charge lead-acid batteries. Other types of batteries (such as dry cell batteries) can burst, causing personal injury and property damage.

of

For

this reason,

a

battery is dangerous.

it

is

of

utmost im-

8.

Use

of

an attachment not recommended the battery charger manufacturer can result in a risk of fire, electric shock, or personal injury.

9.

Do

not operate the battery charger

a sharp blow, been dropped,

it

to

in any way; take

IO.

Do

not disassemble the battery charger; take it to a qualified service technician when service is required. Incorrect reassembly can result in a risk of electric shock or fire.

11.

To reduce the risk of electrical shock, disconnect the battery charger from AC power before performing any maintenance trols does NOT reduce this risk.

12.

If

it is necessary to remove the battery from the generator set battery tray grounded place it last. Make sure that erator set control panel are arc.

13.

Study all battery manufacturer's specific precautions, such as removing or not removing cell caps while charging, and recommended rates

14.

Do

voltage matches the output voltage rating of the charger. Refer ual to determine the battery voltage.

.

15.

Never place the charger directly above battery; gases and damage the charger. Locate the charger as far away from the battery as practical.

16.

Do

area

(-)

terminal from the battery first and re-

not use the battery charger unless the battery

not operate the battery charger in a closedin

or

restrict ventilation in any way.

a qualified service technician.

to

the generator set operator's man-

or

fluids from the battery can corrode

or

otherwise damaged

or

cleaning. Turning

to

charge, always remove the

all

switches on the gen-

off

in order to prevent an

or

sold by

if

it has received

or

repair

off

con-

of

charge.

or

below the

5.

Never smoke or allow an open spark, arding equip-

or

ment

tor set.

6.

Do

other precipitation.

7. Never charge a frozen battery.

flame in the vicinity

not expose the battery charger to rain, snow, or

of

the battery

or

genera-

17.

Grounding Instructions: This battery charger should be connected to ing system. An equipment-grounding conductor should connected minal on the battery charger. Wiring and connec tions

to

the battery charger must comply with the

National Electrical Code, and all local codes and dinances.

a

grounded, metal, permanent wir-

to

the equipment-grounding

ter-

or-

CHG-4

Table

Redistribution or publication of this document by any means, is strictly prohibited.

of

Contents

TITLE

SAFETY PRECAUTIONS INSTALLATION

General Location Mounting

Wiring

Float Voltage Adjustment

INCORRECT SERVICE SONAL INJURY, DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE

QUALIFIED

............................................................

..............................................................

.............................................................

...............................................................

TO

.....................................

Inside Front Cover

................................................

IAWARNlNGl

OR

PARTS REPLACEMENT CAN RESULT IN SEVERE

PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE.

PAGE

PER-

1

2

3

i

Redistribution or publication of this document by any means, is strictly prohibited.

Installation

Redistribution or publication of this document by any means, is strictly prohibited.

~ ~~

GENERAL

These instructions provide information necessary for installation of the battery charger. The charger is intended for use in a permanently wired, industrial application. Installation and service are to be performed only by technically qualified personnel.

This battery charger is fully automatic, and has a constant voltage, current limiting output. A manually-operated override switch (Override Reset) provides about one hour charged batteries. This operation mode is automatic when power is first applied to the charger.

During normal float-charge operation, as the battery approaches the preset voltage, charging current automatically tapers

If

there is a problem with operation, consult the Operator's Manual, or contact the and give the complete model and serial number of the charger.

of

straight-current-limit charging for deeply-dis-

to

a low value.

local

authorized distributor

LOCATION

The battery charger can be mounted vertically on a wall, or on a horizontal surface. The charger specifications are listed in Table

Choose a vibration-free mounting surface that will sup-

port

the weight

1.

of

the charger. Avoid locations that are

near flammable liquids or gases, are moist densation source, are hot (140"

are dusty.

TABLE

VAC

Nominal VDC Output (Refer to Nameplate)

Output, Continuous rating Weight, Height 6.2 in. Width 9.0 in. (229 Depth 10.6 in. (269 mm)

-1

the baffery, do orbelow

1.

CHARGER

Input 120 VAC

Max.

To

avoid damage

not

mounf,fhe

the

battery. Keep the chargeras faraway as

F

SPECIFICATIONS

13.2 or 26.4 VDC

35

10

to

charger dlrecfly above

practical from the explosivegases and corrosive

ids

given

off

by the baffery.

Do not mount the battery charger in a closed-in area, or restrict the ventilation in any way. Allow a minimum spaceof 6 inches (152mm) aboveand belowthecharger for ventilation.

or

near a con-

[60°

C] or above), or

or

17

Amps

Ibs (4.5 kg)

(157

mm) mm)

the charger and/or

flu-

FIGURE

1.

TYPICAL

BAQTERY

CHARGER

1

INSTALLATION

ESlQ63-lc

MOUNTING

Redistribution or publication of this document by any means, is strictly prohibited.

The battery charger has a mounting foot on each corner.

Vertical mounting on a wall with the connections down is

preferred for most efficient air flow as shown in Figure

Placement should be considered for efficient conduit

runs

to

the generator set and the alarm necessary bends. Agrounded 3-prong, 120-volt, 15-ampere AC receptacle must also be available near the charger for the power cord. the National Electrical code, local codes and ordinances.

1.

Check the mounting location ing, plumbing, gas or exhaust lines are located behind the wall. The charger ammeter should preferably be at about eye level.

2.

Hold

the charger in the mounting position and scribe

the mounting hole locations on the wall. Drill pilot holes

3.

with #10 mounting screws.

if

All

wiring must comply with

needed and secure the charger

to

eliminate un-

to

be sure that no wir-

1.

WIRING

1.

Connect 3/4-inch thin wall conduit between the charger DC Output connector and the generator battery case. See Figure 1.

2.

If

an alarm is used, connect 1/2-inch thin wall conduit between the charger Alarm Output connector and the alarm.

3.

Connect the grounding stud on the charger and the generator set frame (common ground). The stud will accept

4.

Remove the access cover from the battery charger. Pull battery leads (positive

a

#12 AWG

#8

AWG gauge wire maximum.

or

larger ground wire between

[+]

and negative

[-I)

through the 3/4 inch thin wall conduit. Use a wire size that will offer low resistance for the wire length required (refer to the National Electrical Code Handbook). The charger output lugs gauge wire maximum.

Pull alarm leads through the 112-inch thin wall con-

5. duit. Use are rated

6.

Connect the battery positive leads rect polarity (see Figure securely.

7.

Connect the alarm leads Select either the normally-open (NO) or normallyclosed (NC) terminals depending on the alarm system requirements. The designations shown below are for the relay not energized (power malfunction).

8.

Connect the DC output wires (negative

-1

can cause severe personal .injury. smoke or cause any spark, arc, or flame while servicing batteries.

9.

Replace the access cover on the battery charger. Plug the power cord into the AC receptacle and place the onloff switch in the On position. Observe charger operation. The DC ammeter should show a charge condition depending upon the battery stateof-charge.

16

AWG

or larger wire. The relay contacts

5

amperes at

to

the charger output terminals observing cor-

TB1-1 TB1-2 TB1-3

[-I

lead last).

/Snition

240

VAC.

(+)

2).

Tighten the lug screws

to

the terminal board TB1.

.

NO Contact

.

Common

. .

.

NC Contact

of

explosive battery gases

will

accept#6

and negative

off

or charger

to

the battery, the

Do

(-)

not

CONNECTOR

FIGURE

2.

BATTERY CHARGER WIRING CONNECTIONS

2

TERMINAL

STRIP

TB1

Es1964

FLOAT VOLTAGE ADJUSTMENT

Redistribution or publication of this document by any means, is strictly prohibited.

The float voltage is factory-set at the correct value and

it

is

should not require adjustment. However, tice to check the voltage output after completing the installation, and make adjustment for ambient temperature

if

necessary. Adjust potentiometer accessible through a hole in the top panel.

The adjustment procedure in the Operator's Manual is for voltage settings other than the nominal value that may be needed to keep the batteryfully charged. This adjustment accounts for factors of battery age, circuit resistance, and temperature.

r

$

To

adjust the float voltage, the charger must not be in current-limit mode of operation (Foldback Override indicator light on) while adjusting the output voltage, otherwise erroneous voltages Some tools required are asmall screwdriver, an accurate voltmeter ing specific gravity (if the battery is not a sealed, selfmaintenance type).

have a specificgravity of 1.260 at 77" following procedure:

It

can be changed

will

result under normal conditions.

(0.5%

accuracy), and a hydrometer for check-

A

fully-charged lead-acid battery

if

needed with the Output

F

good prac-

(25"

C). Use the

will

1-1

given sonal injury. arc, or flame while servicing batteries. Always

disconnect the negative

connect it last

dentally touches the frame or other grounded metal parts ing or connecting the positive

2. Connect the voltmeter directly to the battery terminals. The charger must not be of operation (Foldback Override indicator light on)

while adjusting the output voltage, or erroneous voltages

3.

Compare the battery voltage reading with the reo ommended nominal float value-13.2 for a 12-volt charger, 26.4 for a 24-volt charger. These float

ages are referenced at 77" F

is above or below, adjust per Step

4.

Use a small flat-blade screwdriver adjustment potentiometer counterclockwise crease the float voltage, or clockwise

the float voltage. Adjust in small increments

VDC ma), and allow battery charge level to stabilize before making further adjustment.

Ignition

off

by the battery can cause severe per-

Do

of

will

result

of

explosive hydrogen gas

not

smoke or cause any spark,

(-)

lead first, and

to

prevent arcing

the equipment while disconnect-

under normal conditions.

(25"

if

a

tool

(+)

cable.

in

current-limit mode

C).

If

the voltage

4.

to

turn the float

to

increase

re-

acci-

volt-

to

de-

(0.1

1-1

eye damage and burns to the skin. Wear goggles, rubber gloves and a protective apron when working

wlth batteries.

1. Remove all load from the battery. If connected to a standby generator set, disconnect the genset battery leads, the negative

Battery electrolyte can cause severe

(-)

lead first.

Reduce the voltage by

77"

F

above by

0.8%

ambient.

5.

If the battery is connected to a generator set, recon-

nect the battery leads. Connect the positive first, and the negative Step

(25"

for every 10" F

1).

0.8%

for every

C)

ambient. Increase the voltage

(5.5"

C) below 77" F (25"

(-)

lead last (see Warning in

IO"

F

(5.5"

(+)

C)

lead

3

Onan Corporation

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1400 73rd Avenue Minneapolis, MN 55432 612-574-5000 Telex: 275477 Fax: 612-574-8087

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of

Onan

Corporation

of

Cumrnins Engine Company