SCR SERIES CHARGERS I & O MANUALS Section 93.
SCR/SCRF SERIES BATTERY CHARGER SPECIFICATIONS 1 MODEL No. INPUT VOLTAGE Vac SERIAL No. FLOAT VOLTAGE Vdc EQUALIZE VOLTAGE Vdc SMART PART No. (items A-F req’d) Pos.
IMPORTANT SAFETY INSTRUCTIONS 1) Before using the battery charger, read all instruction and cautionary markings on: A) battery charger, B) battery, C) equipment connected to charger and battery 2) This manual contains important safety and operating instructions, and therefore should be filed for easy access. 3) Do not touch any insulated parts of the battery charger, especially the input and output connections, as there is the possibility of electric shock.
TABLE OF CONTENTS Page No. SCR/SCRF BATTERY CHARGER SPECIFICATIONS (JF0026-00).......................... (inside front cover) IMPORTANT SAFETY INSTRUCTIONS ................................................................................................ i TABLE OF CONTENTS......................................................................................................................ii-iii SECTION II - INSTALLATION AND OPERATION 1. Safety Notice ..........................................................
Page No. SECTION V - CUSTOMER OPTIONS 1. Ground Detection Circuits (EJ0088 / EJ0089 / EJ0094 / EJ0086) .................................................................. 14 2. AC Power Failure Alarm Relay (EJ0085) ....................................................................................................... 15 3. Single Phase AC Input Voltmeter (EJ0095) / Single Phase AC Input Ammeter (EJ0134)............................. 15 4. High and Low DC Voltage Alarm Relays (EJ0083) .........................
SECTION II INSTALLATION AND OPERATION 1. SAFETY NOTICE CAUTION! READ “IMPORTANT SAFETY INSTRUCTIONS” ON PAGE i. There are dangerous voltages within the battery charger cabinet! a. Only qualified personnel should attempt to adjust or service this equipment. b. Refer to instruction manual for service procedures and CAUTION notes. 2. APPLICATION Specifications: The silicon controlled rectifier is designed to maintain a system voltage within + or 0.
4. PLACING CHARGER IN SERVICE a. With the AC and DC breakers OFF and the system in float mode, install the charger making AC and DC connections, as described in Section II, 3, and in accord with local regulations as they apply. b. After connecting the lead from the positive (+) battery terminal to the positive (+) terminal on the charger and the lead from the negative (-) battery terminal to the (-) terminal on the charger, observe the voltmeter.
7. MAINTENANCE a. This charger is designed to require a minimum of maintenance. There are no rotating parts except in the optional timer and all components have a nominally indefinite life with no expected aging effect. It should be kept clean, dry and checked periodically to make sure all connections are tight. If necessary, dry air may be used to blow dust out of the interior.
. DESCRIPTION OF OPERATION There are four major sections of the SCR single-phase charger, which work together to produce stable, regulated, filtered output. The functions of these four sections may be described as follows. a. The Power Transformer (T1): This section includes T1 and its associated input protection. Its purpose is basically to supply an AC voltage of the proper magnitude and capacity to the rectifier section. It also supplies various other voltages used by the control unit and accessories.
SECTION III TROUBLESHOOTING 1. CAUTION NOTICE Before troubleshooting, always isolate and de-energize the charger by opening the AC circuit breaker (CB1) and the DC circuit breaker (CB2). This avoids the possibility of high short circuit current damaging the charger, tools, test equipment, or injuring personnel.
b. Power Transformer (T1) 1. With the AC and DC circuit breakers open or "OFF", open the cabinet and carefully check the line voltage across the line terminals (TB1-L1 and TB1-L2). Refer to Section III, 2, a, 1 on page 6 if no AC voltage is indicated. Check the wiring connections to ascertain that unit has the proper primary tap connections for the line voltage indicated. Turn on the AC circuit breaker (CB1). Check that the voltage at the primary is the same as that of the line.
e. Rectifier Diodes (SCR1/SCR2) - (also see Section III, 2, f) 1. These diodes are a part of an SCR-diode module(s) in which the SCRs and diodes are contained in a module(s) mounted by an electrically insulated heat sink plate. Three connections (plus one SCR gate terminal) are available for checking. The diode portions should be checked by disconnecting one terminal and measuring their forward & reverse resistance, in either of two ways.
g. Control Module PC Board Assembly (A1) One preliminary note that should be kept in mind: The action of the overall feedback circuit controls the battery charger output voltage so that the feedback voltage from the slider of the "FLOAT ADJUST" potentiometer (R3) to the control module board matches the 6.4 Volt reference voltage on the module. Measure this voltage and if it is not approximately 6.4 Volts the feedback circuit or related circuits are not functioning.
k. DC Ammeter (M1) 1. The charger DC ammeter is connected in series between the charger output and battery. If open it will indicate zero, or if shorted, it will also indicate zero. First be certain the connections are tight. If still no indication, turn CB1 and CB2 breakers to OFF, disconnect the charger ammeter (and/or shunt) and substitute a precision ammeter of suitable range.
SECTION IV SYSTEM ADJUSTMENTS 1. VOLTAGE ADJUSTMENTS AND RESPONSE When abnormal output voltage exists (or no output current is present), and the previous checks in Table A on page 27 “VOLTAGE ADJUST INEFFECTIVE” have been made without locating the fault, switch the AC breaker (CB1) to OFF. Switch the DC breaker (CB2) to OFF or disconnect the battery and proceed as follows: Check the battery with a portable voltmeter of one percent accuracy to insure that it is not higher than the rated float voltage.
b. Equalize Adjustment 1. Since the equalize adjustment will not affect the float voltage adjustment and requires a higher voltage it should always be made after the float voltage is determined. Use a portable voltmeter of one percent accuracy as in the float adjustment. Set switch (SW1) to “EQUALIZE”. Close the DC (battery) breaker (CB2). Set the AC breaker (CB1) to "ON". 2. In attempting to set the equalize voltage, one thing must be kept in mind.
2. CURRENT LIMIT RESPONSE AND ADJUSTMENT a. Checks and Adjustments: Make certain the charger leads are connected to the battery and that the panel voltmeter indicates the proper polarity. Switch the DC breaker (CB2) to "ON" and AC breaker (CB1) to "ON". The "AC ON" indicating light (DS1) should illuminate, indicating power has been applied.
SECTION V SCR/SCRF SERIES BATTERY CHARGER CUSTOMER OPTIONS The following pages describe customer options available in SCR/SCRF Series battery chargers. The text describes the basic operational philosophy and theory of operation. Block diagrams (or schematics) for these options are shown in Section VIII, in numerical order of the "EJ####" specification number. 1.
2. AC POWER FAILURE ALARM RELAY (EJ0085) - WITH OPTIONAL INDICATOR LIGHT Purpose: The purpose of this alarm is to notify the user that the AC input power to the battery charger has been interrupted. A front panel "AC FAILURE" lamp is optional for local indication. Relay contacts are provided for remote monitoring. Description: The principle of operation utilizes the normally closed contacts of an AC relay (K1). K1 is powered from the AC line at the primary of the transformer (T1).
If it is necessary to adjust the LVA threshold in the field, the user must load the battery bank and allow the battery voltage to drop while decreasing the float voltage adjustment to the desired cut-off potential. The LVA potentiometer is then adjusted so that the LVA relay is activated into the low voltage alarm condition. Note that there is a delay time, up to 30 seconds before the relay operates once the threshold voltage is reached.
7. EQUALIZE TIMERS Purpose: Equalize Timers are used to switch the charger into equalize charging mode for a set period of time, when required by the batteries. "FLOAT" and "EQUALIZE" indicating lights mounted on the instrument panel can be included with all timers to indicate the charging mode. There are three basic timers described below. These Equalize Timers replace the standard "FLOAT/EQUALIZE" switch (SW1) featured in the charger mainframe and referenced elsewhere in this manual. Descriptions: a.
8. COMMON ALARM BUZZER (EJ0123) Purpose: The Common Alarm Buzzer is a charger mounted audible alarm, which is activated when any of several different alarm circuits goes into an alarm state. Description: This circuit simply utilizes a set of contacts on each separate alarm relay. All of the contacts are wired in parallel and connect the audible alarm (AU1) to the battery voltage. If any set of contacts closes the alarm sounds. A switch (SW13) is provided to turn off the audible alarm if desired. 9.
12. ZERO-CENTER DC AMMETER FOR BATTERY/LOAD MONITORING (EJ0138) Purpose and Description: The zero-center dc ammeter (M7) lies within the negative return lead of the battery. A current-sensing shunt (SH2) is provided when the range is greater than 50 Amperes. M7 indicates the direction and amount of the battery current. Indication on the ammeter is to the right of center when the charger is charging the battery and to the left when the battery is furnishing current to the load (discharging). 13.
15. CURRENT LIMIT ALARM RELAY W/INDICATOR LIGHT (EJ0137) Purpose: The Current Limit Alarm provides an alarm signal whenever the battery charger output reaches the maximum limit set by the current limit circuit. An indicator lamp (DS24) mounted on the instrument panel also lights when the current limit alarm is activated. Description: The CLA PC Board assembly (A18) continually monitors the output of the current limit circuit on the charger control module (A1).
19. COMBINED ALARM STATUS MONITOR "CASM" PC BOARD ASSEMBLY (EJ0837) Note: Refer to the Drawing (EJ0837-XX) on page 49 for additional information. Purpose: The Combined Alarm-Status Monitor (CASM) provides a comprehensive, cost-effective method to monitor the integrity of the battery charger and the dc bus.
SECTION VI COMPONENT DESCRIPTION SCR/SCRF SERIES BATTERY CHARGER - SINGLE PHASE MAIN FRAME Circuit Symbol (Note 2) Spare? (Note 1) A1 B Component Description Single Phase Input Main Control Module PC Board XA1 Holder for Control Module PC Board (A1) SO1 Socket for Control Module PC Board (A1) C1 B XC1 C2 Filter Capacitor (SCRF models only) Filter Capacitor Bracket (SCRF models only) B XC2 Battery Eliminator Filter Capacitor (SCRF-E models only) Battery Eliminator Filter Capacitor Bracket (SCR
Circuit Symbol (Note 2) Spare? (Note 2) Component Description R1 Bleeder / Feedback Resistor R2 Voltage Divider Resistor R3 B R4 Float Adjustment Potentiometer Voltage Divider Resistor R5 B Equalize Adjustment Potentiometer SCR1 B Silicon-Controlled Rectifier / Diode Module SCR2 B Silicon-Controlled Rectifier / Diode Module DC Ammeter Shunt (supplied with 50 Adc nominal dc output or greater) SH1 SS1 A, B DC Output Surge Suppressor SS2 A, B AC Input Surge Suppressor SW1 B T1 Stan
COMPONENT DESCRIPTION SCR/SCRF SERIES BATTERY CHARGER OPTIONS - SINGLE/THREE PHASE NOTES: 1) "B" indicates recommended operating spare part 2) For component placement of circuit symbols, refer to SCR/SCRF Series Option Schematics in Section VIII starting on Page 34 3) For option replacement parts, refer to Section IX starting on Page 57 Option Number Ref.
Option Number Ref.
Option Number Ref.
PILOT LIGHT 27 5 8 9 6 9 HIGH OUTPUT RIPPLE DOES NOT EQUALIZE DIODE/SCR FAILURE SURGE SUPPRESSORS 1 10 11 11 PC BOARD REG.
SCR/SCRF Series Battery Charger 29
Section VII 30
FIGURE 2 - TYPICAL WAVEFORMS OF SINGLE-PHASE CONTROL TRIGGER BOARD (GK0058-XX) (See Section III, 3, g) C D E F G H I 31
Option Schematics 34
SCR/SCRF Series Battery Charger 35
Option Schematics 36
SCR/SCRF Series Battery Charger 37
Option Schematics 38
SCR/SCRF Series Battery Charger 39
Option Schematics 40
SCR/SCRF Series Battery Charger 43
Option Schematics 44
SCR/SCRF Series Battery Charger 45
Option Schematics 46
SCR/SCRF Series Battery Charger 47
ELECTRICAL RATINGS AND REPLACEMENT PARTS SCR/SCRF Series Battery Charger (Single Phase Mainframe) PLEASE CONTACT YOUR SALES REPRESENTATIVE FOR DATA ON MODELS NOT LISTED. SCR/SCRF BATTERY CHARGER MODEL 12V-6A 12V-12A 12V-20A 12V-25A 24V-6A 24V-12A 24V-25A 24V-50A 24V-75A Enclosure Type Style-1A Style-1A Style-1A Style-1B Style-1A Style-1A Style-1B Style-1B Style-2 2.6 1.3 .7 3.8 1.9 .9 6.0 3.0 1.5 7.5 3.8 1.9 5.7 2.8 1.4 8.8 4.4 2.2 16 7.4 4.7 26 13 6.5 39 19 9.
ELECTRICAL RATINGS AND REPLACEMENT PARTS SCR/SCRF Series Battery Charger (Single Phase Mainframe) PLEASE CONTACT YOUR SALES REPRESENTATIVE FOR DATA ON MODELS NOT LISTED. SCR/SCRF BATTERY CHARGER MODEL 24V-100A Enclosure Type AC INPUT CURRENT (MAXIMUM) 120Vac 240Vac 480Vac 48V-6A 48V-12A 48V-16A 48V-25A 48V-35A 48V-50A 48V-75A 48V-100A Style-3 Style-1A Style-1A Style-1B Style-1B Style-1B Style-2 Style-2 Style-3 52 26 13 8.2 4.1 2.0 14 7.0 3.5 18 9.0 4.5 29 15 7.
ELECTRICAL RATINGS AND REPLACEMENT PARTS SCR/SCRF Series Battery Charger (Single Phase Mainframe) PLEASE CONTACT YOUR SALES REPRESENTATIVE FOR DATA ON MODELS NOT LISTED. SCR/SCRF BATTERY CHARGER MODEL 130V-6A 130V-12A 130V-16A 130V-20A 130V-25A 130V-35A 130V-50A 260V-6A 260V-16A Enclosure Type Style-1B Style-1B Style-1B Style-1B Style-1B Style-2 Style-2 Style-2 Style-2 19 9.5 4.8 31 16 7.8 42 21 10.5 50 25 13 58 29 15 81 40 20 115 57 29 28 14 7.
ELECTRICAL RATINGS AND REPLACEMENT PARTS SCR/SCRF Series Battery Charger (Single Phase Mainframe) PLEASE CONTACT YOUR SALES REPRESENTATIVE FOR DATA ON MODELS NOT LISTED.
REPLACEMENT PARTS SCR/SCRF Series Battery Charger Options (1PH/3PH) BATTERY CHARGER NOMINAL OUTPUT OPTION NUMBER CIRCUIT SYMBOL EJ0083 A2 EJ0084 EJ0086 HLVA Alarm Control PC Board RA0001-01 RA0001-01 RA0001-01 RA0001-06 RA0001-06 RA0001-06 RA0001-06 RA0001-06 R57 Power Supply Ballast Resistor n/a RJ0028-36 RJ0015-33 RJ0022-04 RJ0022-05 n/a n/a RJ0028-24 RJ0035-42 RJ0008-13 R75 DS3 Ballast Resistor SO2 Plug for A2 DS5 Float Indicating Light RA0001-05 RA0001-05 RA0001-05 RA
REPLACEMENT PARTS SCR/SCRF Series Battery Charger Options (1PH/3PH) BATTERY CHARGER NOMINAL OUTPUT OPTION NUMBER CIRCUIT SYMBOL EJ0120 A5 DS10 EJ0131 EJ0133 130 Vdc 260 Vdc MANUFACTURER'S PART NO.
REPLACEMENT PARTS SCR/SCRF Series Battery Charger Options (1PH/3PH) BATTERY CHARGER NOMINAL OUTPUT OPTION NUMBER CIRCUIT SYMBOL EJ0134 CT1 M3 DESCRIPTION AC Current Transformer AC Ammeter EJ0135 CT1 - CT3 M3 EJ0137 12 Vdc AC Current Transformer AC Ammeter 24 Vdc 48 Vdc 130 Vdc 260 Vdc MANUFACTURER'S PART NO.
REPLACEMENT PARTS SCR/SCRF Series Battery Charger Options (1PH/3PH) BATTERY CHARGER NOMINAL OUTPUT 12 Vdc 24 Vdc 48 Vdc 130 Vdc 260 Vdc OPTION NUMBER CIRCUIT SYMBOL EJ0141 AU1 Common Alarm Buzzer RA0004-00 RA0004-00 RA0004-00 RA0004-00 RA0004-00 EJ0143 EJ0155 K8 Common Alarm Relay RF0010-01 RF0010-03 RF0010-03 RF0010-06 RF0010-06 Ballast Resistor for AU1 n/a n/a n/a RJ0015-46 RJ0035-48 R63 Ballast Resistor for K8 n/a n/a RJ0015-33 n/a RJ0015-48 SW13 Buzzer ON/OFF Switc
REPLACEMENT PARTS SCR/SCRF Series Battery Charger Options (1PH/3PH) BATTERY CHARGER NOMINAL OUTPUT OPTION NUMBER EJ0837 EJ0862 EJ0869 CIRCUIT SYMBOL A24 24 Vdc EN0014-82 EN0014-83 EN0014-82 EN0014-83 EN0014-82 EN0014-83 EN0014-82 EN0014-83 EN0014-82 EN0014-83 RA0008-00 RA0008-00 RA0008-00 RA0008-00 RA0008-00 DESCRIPTION 48 Vdc 130 Vdc 260 Vdc MANUFACTURER'S PART NO.
SECTION X MANUAL SPECIFICATIONS DOCUMENT NUMBER: The internal text and graphics contained within this manual are controlled by the battery charger manufacturer's internal part number (JA5035-00). Revision level and dates for this part are listed below. These controls supercede all other available dates. The first two and last two pages of this manual are reserved for company-specific front and back cover artwork.
SCR/SCRF Series Battery Charger Preventive Maintenance Procedure JD5022-00 MAINTENANCE DATE PERFORMED BY Step (standard features) Clean battery charger Instructions • All vents clean and open. • Remove dust and debris from inside of unit. Check all electrical connections and wiring Check ac input voltage Check dc output voltage Check ripple voltage • TB1 and TB2 connections all tight. • Internal wiring connections tight, slip-on connectors fully seated. Wire and lug insulation in good condition.
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