ECF – SERIES Installation and Operation Manual Controlled Ferro-Resonant Sales – Service – Recycling Toll Free: U.S.A. 1-888-563-6300 Canada 1-800-268-2698 PN 047-0176 REV02 (GB4128 2009-04) Ferro Magnetics Corporation, St.
INDEX PAGE 34 1.0 4 1.1 4 1.2 5 6 6 6 1.6 6 6 SECTION 1.3 1.4 1.5 1.7 1.8 7 2.0 7 2.1 7 2.1.1 8 2.1.2 9 2.1.3 10 2.1.4 10 2.1.5 10 2.1.6 10 2.1.7 11 2.1.8 12 2.1.9 12 2.1.10 14 3.0 14 14 3.2 14 15 4.0 15 15 4.2 16 5.0 16 5.1 16 5.
SAFETY INSTRUCTIONS WARNING THIS EQUIPMENT CONTAINS LETHAL VOLTAGE LEVELS. INSTALLATION AND SERVICING MUST BE PERFORMED BY QUALIFIED PERSONNEL IMPORTANT: SAVE THESE INSTRUCTIONS! READ AND FOLLOW ALL INSTRUCTIONS BEFORE INSTALLING, OPERATING, OR SERVICING CHARGER. ANY DEVIATION CAN CAUSE SERIOUS AND PERMANENT DAMAGE. FAILURE TO FOLLOW THE INSTRUCTIONS VOIDS THE WARRANTY. 1. Install and ground the charger in accordance with the National Electric Code and your local electric code.
1. INSTALLATION 1.1. RECEIVING Immediately upon receipt of the charger, check it against the shipping invoice to ensure the shipment is complete and undamaged. Examine the outsid e of the packing for sign s of rou gh handli ng before a ccepting the cha rger from the carrier. If there is evid ence of damag e, the recei pt sho uld be signed, an d b oth copi es (carrier's an d receiving copies) marked "Shipment Received Damaged".
1.3. LINE VOLTAGE ADJUSTMENTS All chargers are shipp ed with the AC line voltage ju mper wires set for the AC voltage spe cified on the purchase order. Before connecting the charger to the AC service, it should be verified that the internal AC voltage connections match the available AC service voltage. If necessary, change the AC voltage jumper wires as shown in Figs. 1.3.1 through 1.3.2. CAUTION: It will be necessary in most cases to change the AC fuses when the AC voltage jumpers are changed.
1.4. AC SERVICE REQUIREMENTS Follow local code requirements if they are different than the in structions in this manual. After ch ecking the transformer connections as d escribed in Parag raph 1.3, refer to Table 1-1, to determine the corre ct ratings for the AC cable, AC fuses, and AC service disconnect switch for the line amperes as listed on the nameplate of the charger for the available AC voltage TABLE 1-1 Line Amperes Disconnect 000.0 - 02.5 003.0 - 04.5 005.0 - 07.5 008.0 - 11.0 011.5 - 15.5 016.
2. OPERATION 2.1. 046-0172 CONTROL The charger utilizes a controlled ferro-r esonant transformer , whi ch prov ides isolation fro m the AC service lin e and regulates the charging current. The transformer output is connected to a full- wave bridge of silicon diod es, which provides DC charging current to the battery. The starting charge amps and len gth of time requi red for a charge vary dep ending on the charger m odel, a nd si ze of batt ery. See th e data plate o n the cha rger for specific information.
2.1.2. NORMAL DAILY CHARGE When no battery is connected, the control display shows ‘OK 0 A’, and a ‘no bat’ message periodically if messaging is turned on. With the auto-start feature active, connecting a battery to the charger will cause it to begin a cha rge cy cle. The charger will first perform a self-diagnostic te st to verify the control is working prop erly. Du ring t his time a la mp test is p erformed cau sing all displa y segme nts t o light.
2.1.3. EQUALIZE CHARGE Over time b atteries can d evelop in equalities in cell charge. This can l ower th e effective capacity of the battery and shorten life. An equali zing charge re-bal ances the ch arge in the b attery cells. Perform a n equalize charge if any of the following conditions exist: 1. On flooded batteries the specific gravity of any cell at the end of charg e is 20 points less than the average of all the cells. 2.
2.1.4. TIME OF DAY START The time-of-day start feature allows the operator to delay the start of charge until a particular time of day. This might be desired to reduce peak energy surcharges if the charger were ready to start during a peak energy perio d. The time-o f-day st art co uld be set to keep the ch arger from st arting until af ter the pea k period ends. Press the ‘SET FUNC.’ key to enter the prog ramming mode. The DATA di splay will show ‘Set’. Pr ess ‘START TIME’.
2.1.8. CHARGE INDICATIONS The following indications are not necessarily a result of a charger problem. They are typically caused by external problems such as AC line, poor battery conditions, connections, etc. If abnormal charge conditions are detected, the charge is terminated, the MODE display shows ‘ER’ for error. The DATA display shows the code. Note: The letter V is displayed as ’U’. DISPLAY F0 SHrt CELL #.## F1 SHrt CELL #.## F2 HOt BAtt F3 LO ULts #.## F4 HI ULts #.
2.1.9. F3 (LOW BATTERY) OVERRIDE If battery volt age i s belo w 1.6 volt s pe r cell the charger will not start autom atically. If this i s du e to an overly discha rged battery of the corre ct volt age, t he F3 fault can be manu ally overrid den by pre ssing POWER ON while the F3 Fault message (Low Battery) displays. 2.1.10. DISPLAYING ADDITIONAL CHARGE INFORMATION The user can view m any different parameters associated with a charge.
2.1.10.10. DISPLAY TIME OF DAY To view the current time, press ‘CLO CK. The DATA display shows the time-of-day in 24-hour format. The UNITS display shows ‘HM’ for hours and minutes format. 2.1.10.11. DISPLAY COOL-DOWN TIME To view battery cool do wn time, p ress ‘CO OL DO WN’. The DA TA di splay shows th e cool do wn time setting in hours and minutes. The UNITS display will show ‘HM’ for hours and minutes format. 2.1.10.12.
3. OPTIONAL FEATURES 3.1. FUSIBLE DOOR-INTERLOCK SWITCH (JIC SWITCH) The door interlock switch assembly connects the AC service to the charger’s input fuses for each AC line. The switch is mechanically latched by the door so that it must be in the OFF position before the door can be opened. Operation of the charger is identical to that of the standard model, except the charger cannot be energized if the door is open. 3.2.
4. TROUBLESHOOTING & GENERAL MAINTENANCE Caution: There are lethal voltages exposed when the charger is energized with the door open. Always disconnect the AC service voltage to the charger before opening the door. The following chart lists the most probable cause of a malfunction. 4.1. SYMPTOMS AND POSSIBLE CAUSES SYMPTOM POSSIBLE CAUSE No charging current, the control has no display, contactor does not operate. Blown AC fuse. No AC service voltage. Incorrect AC voltage.
5. REPLACEABLE PARTS 5.1. ORDERING INFORMATION The following information must be supplied when ordering a replacement part from your service agent in order to ensure that the correct part is supplied: A. Model or Spec. number of charger (Located on charger data plate) B. Serial number of charger (Located on charger data plate) C. Schematic reference symbol or part D. Description of part 5.2. RECOMMENDED SPARES The quantity of spares stocked should be increased as the number of chargers increases.
5.3. SPARE PARTS LIST Part Number Description Capacitors 008-0002 008-0004 008-0006 008-0008 008-0010 008-0012 008-0015 008-0017 008-0020 008-0030 008-0040 2 MFD 440 Volt 4 MFD 440 Volt 6 MFD 440 Volt 8 MFD 440 Volt 10 MFD 440 Volt 12.5 MFD 440 Volt 15 MFD 440 Volt 17.5 MFD 440 Volt 20 MFD 440 Volt 30 MFD 440 Volt 40 MFD 440 Volt Resistors 037-0017 037-0018 037-0015 037-0010 1.25 1.25 2.50 2.
