INSTALLATION & OPERATING INSTRUCTIONS SCR FLX SERIES INDUSTRIAL BATTERY CHARGERS
PACIFIC CHLORIDE GNB Industrial Power Motive Power GNB Industrial Power Motive Power Exide Technologies Chloride Motive Power 829 Parkview Boulevard Lombard, IL 60148-3249 U.S.A. Tel: 877.GNB.INFO Fax: 630.691.7869 8301 Keele Street Maple, Ontario Canada L6A 1T2 Tel: 905.669.9326 Fax: 905.669.7688 P.O. Box 1, Salford Road Over Hulton, Bolton BL5 1DD United Kingdom Tel: 44.1204.661.230 Fax: 44.1204.652.100 GB-3889 RPT 11/01 Printed on recycled paper www.gnb.
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 Display and Fault Codes 8 7.2 Options 8 TABLE 2 - SINGLE PHASE RATINGS 9 TABLE 3 - THREE PHASE RATINGS 11 8.
SCRFLX 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 SCRFLX battery chargers are convection cooled, solid state, micro-processor controlled SCR regulated chargers designed to make battery charging simple. They are designed to charge flooded lead-acid batteries only. The charger has a comprehensive self-checking diagnostic program to control all charger functions, monitor the quality of charge and check its own safety conditions. Large easy to read LEDs, three button keypad and LED display report on charger and battery status. 3.
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 L2 L1 208 VAC CONFIGURATION (120/208/240V INPUT) BLK L1 240 VAC CONFIGURATION (208/240/480V INPUT) BRN BLK BRN L2 L1 L1 L2 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 L1 L3 240VAC CONFIGURATION (208/240/480V INPUT) L2 L1 L3 L2 L1 L3 480VAC CONFIGURATION (208/240/480V INPUT) L2 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) (SCRFLX- XX-XXXXT1Z ONLY) L1 L1 L3 L2 L3 L2 240VAC CONFIGURATION (208/240/480V INPUT) (SCRFLX -XX-XXXXT1Z ONLY) L1 L2 L1 L3 L2 L3 480VAC CONFIGURATION (208/240/480V INPUT) (SCRFLX -XX-XXXXT1Z ONLY) L1 L2 L3 L2 Instr.
5.3 AC VOLTAGE CONNECTIONS 6.0 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 SCRFLX-XX-XXXX-S1Z DC AC AMPS @ AC VOLTS AMPS SCRFLX-06-260S1Z SCRFLX-06-475S1Z (50 Hz) SCRFLX-06-600S1Z (50 Hz) SCRFLX-06-865S1Z SCRFLX-06-965S1Z SCRFLX-09-475S1Z SCRFLX-09-600S1Z SCRFLX-09-865S1Z SCRFLX-09-965S1Z SCRFLX-12-260S1Z (50 Hz) 40 74 74 93 93 134 150 74 93 134 150 40 40 SCRFLX-12-475S1Z 74 (50 Hz) SCRFLX-12-600S1Z (50 Hz) SCRFLX-12-750S1Z SCRFLX-12-865S1Z SCRFLX-12-965S1Z SCRFLX-18-260S1Z SCRFLX-18-475S1Z Instr.
TABLE 2 – SINGLE PHASE TECHNICAL DATA STANDARD MODEL SCRFLX-XX-XXXX-S1Z DC AC AMPS @ AC VOLTS AMPS SCRFLX-18-600S1Z 93 SCRFLX-18-750S1Z 116 SCRFLX-18-865S1Z 134 (50 Hz) 134 SCRFLX-24-260S1Z 40 SCRFLX-24-475S1Z 74 (50 Hz) 74 SCRFLX-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 SCRFLX-XX-XXXX-T1Z AMPS SCRFLX-06-475T1Z SCRFLX-06-600T1Z SCRFLX-06-750T1Z SCRFLX-06-865T1Z SCRFLX-06-965T1Z SCRFLX-06-1050T1Z 134 SCRFLX-12-475T1Z SCRFLX-12-600T1Z SCRFLX-12-750T1Z SCRFLX-12-865T1Z SCRFLX-12-965T1Z SCRFLX-12-1050T1Z SCRFLX-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 10 15 9 12 5 7 C.F.
TABLE 3 – THREE PHASE TECHNICAL DATA AC AMPS @ AC VOLTS STANDARD MODEL DC 60Hz SCRFLX-XX-XXXX-T1Z AMPS SCRFLX-18-1050T1Z SCRFLX-18-1200T1Z SCRFLX-18-1450T1Z SCRFLX-18-1700T1Z SCRFLX-24-475T1Z SCRFLX-24-600T1Z SCRFLX-24-1050T1Z SCRFLX-24-1200T1Z SCRFLX-24-1450T1Z SCRFLX-24-1700T1Z SCRFLX-36-475T1Z SCRFLX-36-600T1Z SCRFLX-36-750T1Z 480 380 415 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 SCRFLX CHARGER OPERATION LED DISPLAY DESCRIPTION (NONE) OFF FLd* PLUG IN THE BATTERY TO COMMENCE CHARGING CHARGER SET FOR FLOODED BATTERIES DELAY (Orange), dEL, then delay time remaining in Hours. minutes OFF dEL time DELAY MODE, PRESS “START” BUTTON TO OVERRIDE. (Section 9.1.
9.1.2 9.1 SCRFLX CHARGER FUNCTIONAL DESCRIPTION CHARGING 9.1.2.1 CHARGING LED This section gives a brief description of each LED, pushbutton, and the delay function on the SCRFLX type charger front control panel. 9.1.2.2 80 % CHARGED LED 9.1.1 DELAY STAGE 9.1.1.1 This LED indicates that the charger is ON. This LED indicates that the battery has reached 80% charge. DELAY CIRCUIT CAUTION: HAZARDOUS VOLTAGES INSIDE.
9.1.7 EQUALIZE STAGE 9.1.7.1 EQUALIZE PUSHBUTTON This pushbutton when pressed will extend the charge cycle by 3.5 hours in the equalize mode after the finish rate time has expired. If pressed a second time, it will cancel the equalize charge mode. CAUTION: DO NOT EQUALIZE MORE OFTEN THAN REQUIRED BY THE CONDITION OF THE BATTERY, AS SPECIFIED IN THE BATTERY MAINTENANCE INSTRUCTIONS. EXCESSIVE EQUALIZING MAY DAMAGE THE BATTERY. 9.1.7.
13.0 SCRFLX 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.
3.3 Charger’s DC fuse blown. Indication FdC and FAULT LED is on. 4. Symptom => Disconnect battery and AC power. Consult GNB technician. CHARGING LED DOES NOT LIGHT ON AFTER BATTERY CONNECTION Possible Cause Action 4.1 Connection between charger and battery open. Repair or clean battery lugs. Repair and/or change charger and /or battery DC cables and contacts of DC connectors. 4.2 Battery with wrong number of cells connected to a charger. Indication LO/rEJ or HI/rEJ and FAULT LED is on.
APPENDIX A: SCRFLX BATTERY CHARGERS. LIST OF DISPLAY INDICATIONS. Indication Abbreviation Interpretation 1.00 2.00 3.00 4.00 5.00 6.00 8.00 1 hour delay set 2 hour delay set 3 hour delay set 4 hour delay set 5 hour delay set 6 hour delay set 8 hour delay set Delay before charge starts Delay before charge starts Delay before charge starts Delay before charge starts Delay before charge starts Delay before charge starts Delay before charge starts CHP CHamPion Control board is set to 2.55VPC not 2.
Instr.
APPENDIX B: ELECTRICAL SCHEMATIC DRAWINGS Pages 21-31 Instr.
SALES • SERVICE • RECYCLING TOLL FREE 1-888-563-6300 Champion® is a registered trademark of Federal-Mogul Corporation GNB Industrial Power Motive Power GNB Industrial Power Motive Power Exide Technologies Chloride Motive Power 829 Parkview Boulevard Lombard, IL 60148-3249 U.S.A. Tel: 877.GNB.INFO Fax: 630.691.7869 8301 Keele Street Maple, Ontario Canada L6A 1T2 Tel: 905.669.9326 Fax: 905.669.7688 P.O. Box 1, Salford Road Over Hulton, Bolton BL5 1DD United Kingdom Tel: 44.1204.661.230 Fax: 44.1204.
