SBS PSC-SERIES User Manual

PSC-SERIES

BATTERY CHARGER

USER’S MANUAL

Storage Battery Systems, Inc. MANUAL PSC

Table of Contents

INTRODUCTION..........................................................................................................................................................................................4

IMPORTANT SAFETY INSTRUCTIONS................................................................................................................................................4

INSTALLATION...........................................................................................................................................................................................5

PLACEMENT :...............................................................................................................................................................................................5

V ENTILATION AND COOLING:..................................................................................................................................................................5

ELECTRICAL CONNECTION AND WIRING...............................................................................................................................................5

POWER UP ....................................................................................................................................................................................................6

SYSTEM POWER OFF PROCEDURE ......................................................................................................................................................6

THEORY OF OPERATION.........................................................................................................................................................................7

DISPLAY SCREEN AND K EYPAD...........................................................................................................................................................8

DISPLAY SCREEN........................................................................................................................................................................................8

Keypad:..................................................................................................................................................................................................8

Fixed charger mode: ............................................................................................................................................................................8

Display unit..........................................................................................................................................................................................8

ACCESSING MENU VIA KEYPAD; OVERVIEW:.........................................................................................................................................9

MENU STRUCTURE QUICK OVERVIEW:.................................................................................................................................................11

MENU DETAILED FUNCTIONS:.............................................................................................................................................................13

MAIN MENU: .............................................................................................................................................................................................13

Equalize:..............................................................................................................................................................................................13

LCD Contrast: .....................................................................................................................................................................................13

Reset alarms and relays:..................................................................................................................................................................14

Adjust:...................................................................................................................................................................................................14

Control:...............................................................................................................................................................................................14

Alarms:...............................................................................................................................................................................................15

Level 2:...............................................................................................................................................................................................17

Readings: .............................................................................................................................................................................................18

MODBUS: (OPTIONAL)..........................................................................................................................................................................19

MATERIAL CONFIGURATION : ...............................................................................................................................................................19

RAM MEMORY MAP:...............................................................................................................................................................................19

1.1 - Format for voltage and current values :...............................................................................................................................20

1.2- logic of alarms:...........................................................................................................................................................................21

1.3- Float/Equalize :..........................................................................................................................................................................21

1.4- Reset Alarm :...............................................................................................................................................................................21

RS-232 CONNECTIONS:............................................................................................................................................................................22

TROUBLE SHOOTING.............................................................................................................................................................................23

REGULAR PREVENTIVE M AINTENANCE...........................................................................................................................................24

CONTROL BOARD (PC) - ADJUSTMENT PROCEDURE................................................................................................................25

EXAMPLE:..................................................................................................................................................................................................25

Procedure............................................................................................................................................................................................25

ALARMS ADJUSTMENT PROCEDURE..............................................................................................................................................26

Storage Battery Systems, Inc. MANUAL PSC

Procedure............................................................................................................................................................................................26

WARRANTY...............................................................................................................................................................................................28

ANNEXES: ....................................................................................................................................................................................................29

ELECTRIC DIAGRAM.................................................................................................................................................................................29

PART LIST ..................................................................................................................................................................................................29

MECHANICAL DRAWINGS.......................................................................................................................................................................29

TEST REPORT ............................................................................................................................................................................................29

Storage Battery Systems, Inc. MANUAL PSC

Introduction

Thank you for having chosen Storage Battery Systems, Inc. The PSC-series battery charger is designed to provide quality DC power for many years.

This user's manual contains important technical instructions to be followed by qualified personnel responsible for the installation, start-up and maintenance of this unit. We recommend that this manual be read attentively to insure safe and reliable operation of this equipment.

Should you require any assistance, please call our service department at:

Storage Battery Systems, Inc.

N56 W16665 Ridgewood Dr.

Menomonee Falls, WI 53051

Tel: (262) 703-5800

Fax: (262) 703-3073

E-mail: sbs@sbsbattery.com

Web site : www.sbsbattery.com

IMPORTANT SAFETY INSTRUCTIONS

Keep these instructions in a safe place: this manual contains important safety and operating instructions

• AC and DC currents are present in this system even with indicators and breakers are on “OFF” position.

• Before performing any maintenance on this system make sure that the battery and the AC power are disconnected.

• Experienced and qualified personnel only must perform maintenance.

• Electrostatic sensitive components are used in this equipment. Proper ESD (electrostatic discharge)

procedures must be followed to prevent any severe damage to electronic components.

• Working in the vicinity of a lead acid battery is dangerous: batteries generate explosive gases during normal operation. Therefore never smoke or allow an open spark or flame in the vicinity of the battery or engine.

• To reduce risk of battery explosion, follow these instructions and those on the battery.

• Never charge a frozen battery.

Storage Battery Systems, Inc. MANUAL PSC

Installation

Placement:

FOR INSTALLATION, PLEASE REFER TO NATIONAL AND LOCAL ELECTRICAL CODES. The system is a very heavy equipment. To prevent personal injury or equipment damage, use lifts and extreme care when handling.

Ventilation and cooling:

The rectifier/charger is rated to better perform within 18°F (–10°C) and 122°F (+50°C) temperature range. To calculate the required air displacement (exchange) volume, please use the following equation: V = BTU x e

V = air flow: [cubic meter/hour] BTU: Total dissipated heat Tr: Maximum allowed room temperature [°K] {i.e. 50°C = 323°K]

(0.125 x H x Tk/To)

/ (Tr -Tk)

Tk= Temperature of input cooling air To= 273 °K H = Altitude [km]

Avoid placing the system in direct sunlight N.B. to insure adequa te ventilation and safe access make sure that the following clearances are respected:

• 3 in. (10 cm) on the sides and top

• 3 feet (1 meter) in front of the unit.

Should seismic conditions require a more secure installation the unit may be bolted to the floor. Four (4) holes are provided for this purpose.

Electrical Connection and wiring

Before Connecting the PSC battery charger make sure that:

• The battery is disconnected (if applicable)

• The circuit breakers are OFF

• The relays, fuses and circuit boards are installed

• The unit is wired in accordance with the instructions (refer to the wiring connections and electrical diagram)

Storage Battery Systems, Inc. MANUAL PSC

Wire size is very important, The nameplate provides the essential information regarding the input and output voltages and currents. Refer to your Local or National Electrical Code for WIRE GAUGE and GROUNDING instructions. Wire ampere capacity must be sized to the maximal correspondent current. Correct voltage and polarity are of critical importance. Check all connections for tightness and polarity. Connect battery (if applicable) to the output terminals observing its polarity.

Power up

After all wires installation is completed and has been double checked, the unit may be powered up as follow:

• Before to connect the load to the charger, compare the critical characteristics of the load with the critical characteristics of the charger (i.e. measure ondulation, line-neutral tension, positive -neutral tension).

• Keep a log of manipulations (i.e. V

FLOAT

and V

values entered, alarm messages, alarm and SCR

EQUALIZE

blinking leds).

• All input and output breakers must be on ”OFF” position

• Apply power to the equipment from the source panel

• Turn on AC breaker (”ON” position)

• Turn on DC breaker (if supplied) (”ON” position)

• Green LED must turn ON

• Wait 5 seconds till the indication Screen (LCD) indicates the system output voltage and status

• The system soft starts by rising the output current and the voltage

If readings or calibration of the unit is necessary, refer to the field programming section for more information.

System power Off procedure

• Open the AC breaker (OFF position)

• Open the DC breaker (if supplied) (OFF position)

• Open the source panel’s AC breaker (OFF position)

• If work inside the unit has to be performed, wait 5 minutes to discharge the filter capacitors or use bleeding

resistors of the correct rating to discharge the capacitors.

Now the system can be considered de-energized.

Storage Battery Systems, Inc. MANUAL PSC

t V IN AC t V

t V +

Theory of operation

MODE FLt Eq

Ok Exit

F1 F2 F3 F4

T1 : the AC supply is transformed and isolated.

MANUAL

INPUT

CONTROL BOARD PC 20/21///////

DISPLAY

SEQUENTIAL

ACCESS MSG

ALARMS

SCR: the transformer secondary voltage is rectified by a full-wave, half-controlled bridge.

L1, C1 (optional) : the rectified DC voltage is smoothed by lC filter section.

Shunt : current and voltage reading sent to the control board

I / P

MONITORING

V REG

A LIMIT

SCR

Shunt

O / P

MONITORING

OUT

F1 : a fuse protects the SCR's and diodes.

Control Board: the PC20/21 series control board provides automatic charge control, precise voltage regulation,

alarm status annunciation and display.

Storage Battery Systems, Inc. MANUAL PSC

Display Screen and Keypad

DESCRIBED IN

Display Screen

The PSC-series provides a very flexible and user friendly interface. The display supplied with the standard unit’s features a high visibility, back light LCD display.

Keypad:

The PSC used four (4) long life membrane switches.

TO CHOOSE

AC ON

FLOAT MODE OR ANOTHER MESSAGES

THIS MANUAL

MODE FLt Eq

Ok Exit

F1 F2 F3 F4

EACH KEY CORRESPONDS TO A FUNCTION

ALARMS ACTIVES

EQUALIZE MODE OR OTHER MESSAGES DESCRIBED

Fixed charger mode:

Display unit

Adjustable values are displayed on the higher row of the LCD, i.e. number of relays, alarm On/Off, voltage level. Keys function are displayed on the lower row, depending of the menu context. When an alarm is active on the charger exact failure message appears and the red led blinks to warn the user. In case of multiple alarms the PSC display unit shows sequentially all the warning messages. There is also an AC sector detection led (green led). The user is able to save his parameters individually. LCD power save feature shut down the display unit after 5 minutes of keyboard inactivity. When the PSC enter in power save mode it saves the latest values entered. Upon wake-up PSC return to main menu. The display accuracy is ± 2%, ± 1 digit

Storage Battery Systems, Inc. MANUAL PSC

Accessing menu via keypad; overview:

Exit

Equalize

On power-up the following readings appears on the screen (example):

From that point, if you press any key of F1 to F4, only once, you reach the menu screen:

F1 (Ok), gives you access to Float / Equalize menu. Press F4(Exit) to step back to the menu.

From the menu, you may reach the different functions by pressing F2(à):

131.4V 0.0A

MODE Flt ß à Eq

Storage Battery Systems, Inc. MANUAL PSC

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SBS PSC-SERIES User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual