INSTALLATION & OPERATING INSTRUCTIONS SCR 100 SERIES INDUSTRIAL BATTERY CHARGERS
SCR 100 CHARGER WARRANTY This Warranty Agreement entered into between GNB Technologies, "GNB", and the Original User in respect to GNB electric vehicle battery chargers for electric vehicle usage. 1.0 GENERAL GNB warrants that each new electric vehicle battery charger supplied by it, is of good workmanship and is free from any inherent mechanical defects, provided: 1.
TABLE OF CONTENTS TITLE PAGE 1.0 IMPORTANT OPERATING AND SAFETY INSTRUCTIONS 2 2.0 INTRODUCTION 3 3.0 RECEIVING CHARGER 3 4.0 LOCATION AND INSTALLATION OF CHARGER 3 4.1 Stacking 3 5.0 AC ELECTRICAL SUPPLY 3 5.1 AC Fuse Mounting 3 5.2 Input Voltage Change 3 5.3 AC Voltage Connections 7 5.4 Ground connection 7 6.0 DC OUTPUT 7 7.0 APPLICATION 8 7.1 Fault and Display Codes 8 7.2 Options 8 TABLE 2 - SINGLE PHASE RATINGS 9 TABLE 3 - THREE PHASE RATINGS 11 8.
SCR100 SERIES INDUSTRIAL BATTERY CHARGERS 1.0 IMPORTANT OPERATING AND SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS a) Before using the battery charger, read all the instructions in addition to the CAUTION, WARNING, and DANGER markings on the charger, battery and all the associated equipment. b) Do not touch uninsulated parts of the DC output connector or the battery terminals, as there is a possibility of electric shock.
2.0 INTRODUCTION The GNB SCR100 battery chargers are convection cooled, solid state, micro-processor controlled SCR regulated chargers designed to make battery charging simple. They are factory set to charge sealed lead-acid batteries but it may be configured by a GNB service representative to charge flooded lead-acid batteries. STONE, BRICK, CONCRETE OR METAL. IF THIS IS NOT AVAILABLE, A FLOOR PLATE OF AT LEAST 1.43mm GALVANIZED OR 1.
FIGURE 1: SINGLE PHASE INPUT WARNING: IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE DAMAGE TO THE CHARGER AND BATTERY 120 VAC CONFIGURATION (120/208/240V INPUT) BRN BLK L2 208 VAC CONFIGURATION (208/240/480V INPUT) BRN BLK L1 L2 208 VAC CONFIGURATION (120/208/240V INPUT) BLK L1 240 VAC CONFIGURATION (208/240/480V INPUT) BRN BLK BRN L2 L2 L1 L1 240 VAC CONFIGURATION (120/208/240V INPUT) 480 VAC CONFIGURATION (208/240/480V INPUT) BLK BLK BRN BRN L2 Instr.
FIGURE 2: THREE PHASE INPUT WARNING: IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE DAMAGE TO THE CHARGER AND BATTERY 208VAC CONFIGURATION (208/240/480V INPUT) L2 L1 L3 L2 380VAC CONFIGURATION L2 L1 L1 L3 L2 L1 L3 L3 415VAC CONFIGURATION 240VAC CONFIGURATION (208/240/480V INPUT) L2 L1 L3 L2 L1 L2 L3 480VAC CONFIGURATION (208/240/480V INPUT) L2 L1 L3 Instr.
FIGURE 3: THREE PHASE INPUT WARNING: IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE DAMAGE TO THE CHARGER AND BATTERY 208VAC CONFIGURATION (208/240/480V INPUT) (SCR100-XX-YYYT1Z ONLY) L1 L1 L3 L2 L3 L2 240VAC CONFIGURATION (208/240/480V INPUT) (SCR100-XX-YYYT1Z ONLY) L1 L2 L1 L3 L2 L3 480VAC CONFIGURATION (208/240/480V INPUT) (SCR100-XX-YYYT1Z ONLY) L1 L2 L3 L2 Instr.
5.3 6.0 AC VOLTAGE CONNECTIONS DC OUTPUT To connect the input AC voltage, route the AC conduit through the knockout hole provided. Continue the AC wiring to fuseholder terminals L1 (N) and L2 (L) (single phase input) or L1, L2, and L3 (three phase input), ensuring that the AC source phases match the phase rotation on the AC input. For proper connection, torque the screws to approximately 25 inch-pounds. The DC charging cable has a commonly used battery plug or receptacle.
7.0 APPLICATION The charger will automatically charge a battery per the Ah rating set at the factory. The charger can be re-set for anywhere between 65% to 200% of the nameplate Ah rating. Ensure that battery and charger are matched. Keep in mind if the charger is set for more than 100% of Ah of the charger rating the charging time will increase proportionately (up to 16 hours). For battery sizes not listed, contact your local GNB service representative. 7.
TABLE 2 – SINGLE PHASE TECHNICAL DATA STANDARD MODEL SCR100-XX-XXXX-S1Z DC AC AMPS @ AC VOLTS AMPS SCR100-06-260S1Z SCR100-06-475S1Z (50 Hz) SCR100-06-600S1Z (50 Hz) SCR100-06-865S1Z SCR100-06-965S1Z SCR100-09-475S1Z SCR100-09-600S1Z SCR100-09-865S1Z SCR100-09-965S1Z SCR100-12-260S1Z (50 Hz) 40 74 74 93 93 134 150 74 93 134 150 40 40 SCR100-12-475S1Z 74 (50 Hz) SCR100-12-600S1Z (50 Hz) SCR100-12-750S1Z SCR100-12-865S1Z SCR100-12-965S1Z SCR100-18-260S1Z SCR100-18-475S1Z Instr.
TABLE 2 – SINGLE PHASE TECHNICAL DATA STANDARD MODEL SCR100-XX-XXXX-S1Z DC AC AMPS @ AC VOLTS AMPS SCR100-18-600S1Z 93 SCR100-18-750S1Z 116 SCR100-18-865S1Z 134 (50 Hz) 134 SCR100-24-260S1Z 40 SCR100-24-475S1Z 74 (50 Hz) 74 SCR100-24-600S1Z 93 (50 Hz) 93 WEIGHT 480 CABINET TYPE LBS KGS B 260 118 C 260 118 C 325 147 C 340 155 B 300 135 C 315 143 C 340 155 C 380 172 C 400 182 120 208 240 C.F. - 36.5 50 31.5 16 FUSE 40 20 AMPS AMPS C.F.
TABLE 3 – THREE PHASE TECHNICAL DATA AC AMPS @ AC VOLTS STANDARD MODEL DC 60Hz SCR100-XX-XXXX-T1Z AMPS SCR100-06-475T1Z SCR100-06-600T1Z SCR100-06-750T1Z SCR100-06-865T1Z SCR100-06-965T1Z SCR100-06-1050T1Z 134 SCR100-12-475T1Z SCR100-12-600T1Z SCR100-12-750T1Z SCR100-12-865T1Z SCR100-12-965T1Z SCR100-12-1050T1Z SCR100-12-1200T1Z TYPE LBS KGS 5 7 4.5 6 2.2 3 C.F. - C.F. - B 170 77.1 7 10 6 8 3.5 5 C.F. - 3.5 5 B 190 86.2 9 12 8 12 4 6 C.F. - C.F. - B 220 99.
TABLE 3 – THREE PHASE TECHNICAL DATA STANDARD MODEL AC AMPS @ AC VOLTS 60Hz DC SCR100-XX-XXXX-T1Z AMPS SCR100-18-1050T1Z SCR100-18-1200T1Z SCR100-18-1450T1Z SCR100-18-1700T1Z SCR100-24-475T1Z SCR100-24-600T1Z SCR100-24-1050T1Z SCR100-24-1200T1Z SCR100-24-1450T1Z SCR100-24-1700T1Z SCR100-36-475T1Z SCR100-36-600T1Z SCR100-36-750T1Z 380 415 TYPE LBS KGS 28 40 24 35 12 15 19 25 17.5 25 C 380 163 37 50 32 45 16 20 26 35 C.F. - C 410 186 47.
8.0 CABINET OUTLINE/DIMENSIONS FOR –Z MODEL CHARGERS ONLY CABINET A B C D D (Mining) E (Mining) DIM. A 15.10” 22.70” 32.10” 24.30” 24.30” 24.30” DIM. B 20.65” 26.65” 26.65” 42.00” 42.00” 59.00” DIM. C 12.75” 22.25” 22.25” 23.65” 23.65” 31.50” NOTE: Mining chargers are equipped with a drip cap and four lifting eyebolts for sling lifting. Add an additional 5.000” to the height. (DIM.B) Instr.
9.0 SCR100 STANDARD CHARGER OPERATION LED (NONE) DISPLAY DESCRIPTION PLUG IN BATTERY TO COMMENCE CHARGING OFF/Fld* OFF/CHP* DELAY (Orange), dEL, then delay time remaining in Hours. minutes CHARGING (Orange) OFF dEL time CHARGER SET FOR FLOODED BATTERIES. CHARGER SET FOR SEALED CHAMPION® BATTERIES. DELAY MODE, PRESS “START” BUTTON TO OVERRIDE. (Section 9.1.1, page 15) SMART START (Section 9.1.
9.1 SCR100 CHARGER FUNCTIONAL DESCRIPTION 9.1.2.1 SMART START STAGE This section gives a brief description of each LED, pushbutton, and the delay function on the SCR100 type charger front control panel. 9.1.1 DELAY STAGE 9.1.1.1 DELAY CIRCUIT CAUTION: HAZARDOUS VOLTAGES INSIDE. DO NOT ATTEMPT TO CHANGE THE SLIDE SWITCHES ON THE CONTROL CARD UNTIL ALL AC POWER IS DISCONNECTED FROM THE UNIT AS WELL AS THE BATTERY IS UNPLUGGED FROM THE CHARGER. USE PROPER TOOL TO OPEN THE CABINET DOOR. 1.
occures, cooldown will not start until after Equalize charging is complete. 9.1.6 REFRESH CHARGE STAGE If the AC power fails during a charge cycle the charger will resume operation in progress as soon as the AC power is restored. Refresh Charge is only available on Z model chargers and replacement boards. If a battey is left connected to the charger after cooldown, the charger will go into a refresh charge mode.
14.0 SCR100 TROUBLESHOOTING 1.Symptom => NO DISPLAY INDICATION AFTER CONNECTION OF AC POWER Possible Cause Action Charger connected to low AC voltage. Verify AC voltage per nameplate of the charger and electrician’s tag. Verify connection of primary windings of power transformer and AC fuses of charger per connected AC voltage and electrician’s tag. Charger connected to high AC voltage. Verify AC voltage per nameplate of the charger and electrician’s tag.
4. Symptom => DISPLAY INDICATES FCD BEFORE CONNECTION OF BATTERY Possible Cause 4.1 Action Previous charge cycle was interrupted during Cool Down. 5. Symptom => Do not interrupt charge cycle until LED End is continuously on. Connect next battery – charger will start automatically. DISPLAY INDICATES FDC BEFORE CONNECTION OF BATTERY. Possible Cause 5.1 5.2 5.3 Action Charge cycle was interrupted during charge by DC cable disconnection with slow / bouncing disconnection of DC plug.
7. Symptom => DISPLAY INDICATES FCC OR F2 AT THE END OF CHARGE CYCLE Possible Cause Action 7.1 Battery failed to reach gassing voltage. Consult GNB technician. Check matching of charger and battery: Ah, type. 7.2 Battery failed to reach End Voltage (Stage 3 of OPC). Consult GNB technician. Check matching of charger and battery: Ah, type, etc. 8. Symptom => DISPLAY INDICATES FAC OR F3 DURING CHARGE CYCLE Possible Cause Action Complete or partial loss of AC power.
APPENDIX A: SCR100 BATTERY CHARGERS. LIST OF DISPLAY INDICATIONS. Indication Abbreviation Interpretation 1.00 2.00 3.00 4.00 5.00 6.00 8.
APPENDIX B: ELECTRICAL SCHEMATIC DRAWINGS Pages 21-31 Instr.
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