Eagle Eye Power Solutions | SCRF SERIES | Specifications | Eagle Eye Power Solutions SCRF SERIES Specifications

SCR/SCRF SERIES
Operating and Service Instructions
FLOAT BATTERY CHARGER
THREE PHASE INPUT
Eagle Eye Power Solutions
4230 N Oakland Ave #176, Milwaukee, WI 53211
Phone: 877-805-3377 | Web: www.eepowersolutions.com
JA5010-00
SCR/SCRF Series Battery Charger
Factory-Configured Specifications
JF0026-00
1
MODEL No.
INPUT VOLTAGE
Vac
SERIAL No.
FLOAT VOLTAGE
Vdc
EQUALIZE VOLTAGE
Vdc
SMART PART No.
(items A-F req’d)
Pos.
A
B
C
D
E
F
G
H
J
K
L
M
N
SMART
PART
CODE
U
F
E
1
2
3
4
5
6
7
0
F
B
C
1
2
3
4
5
6
0
2%
1%
SB
DM
CM
P
H
A
C
C1
C2
HL
ZC
HZ
S
L
R
F
H
R
B
C
D
D
D
D
D
1
CORE (BB####)
DWG#
EJ0450
EJ0093
EJ0097
EJ0869
EJ0131
EJ0096
EJ0895
CB0002
EJ0085
EJ0837
EJ0837
EJ0083
EJ0127
EJ0094
EJ0089
EJ0086
EJ0133
EJ0592
EJ0141
EJ0141
EJ0967
EI5030/31
EI5032
EI5033
EI5034
EI5035
A
B
C
D
E
F
G
H
DESCRIPTION
(X)
UNFILTERED DC OUTPUT
FILTERED DC OUTPUT
(30 mV RMS w/BATTERY)
BATTERY ELIMINATOR DC OUTPUT FILTERING
120 Vac - 60 Hz INPUT
(SINGLE PHASE ONLY)
208/240 Vac - 60 Hz INPUT
220/240 Vac - 50/60 Hz INPUT (SINGLE PHASE ONLY)
380/416 Vac - 50/60 Hz INPUT (THREE PHASE ONLY)
480 Vac - 60 Hz INPUT
120/208/240 Vac - 60 Hz INPUT (SINGLE PHASE ONLY)
208/240/480 Vac - 60 Hz INPUT
Vac
Hz INPUT
(CUSTOM)
REDUNDANT DC FUSE PROTECTION
(F1 / F2)
STANDARD DC CIRCUIT BREAKER
(F1 / CB2)
CUSTOM DC PROTECTION
MANUAL FLOAT / EQUALIZE SWITCH
MANUAL FLOAT / EQUALIZE SWITCH & IND. LIGHTS
0-72 HR. MANUAL EQUALIZE TIMER
MAN. EQUALIZE TIMER w/ F/E SWITCH & IND. LIGHTS
AC FAILURE AUTO-EQUALIZE TIMER & IND. LIGHTS
0-72 HR. MANUAL EQUALIZE TIMER & IND. LIGHTS
CUSTOM EQUALIZATION
2% ACCURACY 3.5in ANALOG DC METERS
1% ACCURACY 3.5in ANALOG DC METERS
1% ACCURACY 4.5in SWITCHBOARD DC METERS
0.1% ACCURACY 3.5in LED DIGITAL DC METERS
CUSTOM DC METERS
STANDARD (COLOR-CODED PVC) WIRING
SWITCHBOARD INSULATION SYS. (#-CODED) WIRING
AC POWER FAILURE ALARM & INDICATOR LIGHTS
CUSTOM AC FAILURE ALARM
CASM PC BOARD w/ ONE (1) FORM-C CONTACTS
CASM PC BOARD w/ TWO (2) FORM-C CONTACTS
HIGH / LOW DC VOLTAGE ALARM & IND. LIGHTS
CHARGER FAILURE ALARM (NO Adc) & IND. LIGHTS
HLVA / CFA & IND. LIGHTS (EJ0083 & EJ0127)
GND. DET. SWITCH FOR DC VOLTMETER INDICATION
GND. DET. IND. LIGHTS w/ GROUND & LAMP TEST
GND. DET. RELAYS w/ RESET SWITCH & IND. LIGHTS
PARALLEL CHGR OPERATION w/ 2% LOAD SHARING
HIGH DC VOLTAGE CHARGER SHUTDOWN
COMMON ALARM RELAY CONTACTS
COMMON ALARM RELAY CONTACTS w/ BUZZER
COMMON ALARM BUZZER FOR CASM PC BOARD
DRIP SHIELDS - STYLE-1A/1B CABINET (EB0220/221)
DRIP SHIELDS - STYLE-2 CABINET (EB0222)
DRIP SHIELDS - STYLE-3 CABINET (EB0123)
DRIP SHIELDS - STYLE-4 CABINET (EB0163)
DRIP SHIELDS - STYLE-5 CABINET (EB0198)
GENERAL SPECIFICATIONS:
Regulation: + or - 0.5%
Regulation: + or - 0.5%
Regulation: + or - 1%
Ambient Temperature Range:
Relative Humidity:
Altitude:
J
X
X
K
L
M
N
1 - Serial Number and Core (BB####) calculated by factory
DWG#
DESCRIPTION
EJ0088
EJ0095
EJ0120
EJ0121
EJ0123
EJ0134
EJ0135
EJ0137
EJ0138
EJ0143
EJ0145
EJ0155
EJ0439
EJ0615
EJ082X
EJ1123
EJ1165
EJ1234
EJ1247
EJ1303
EJ1398
EJ5005
EJ5012
EJ5087
GROUND DETECTION INDICATOR LIGHTS
2% ACCURACY 3.5in AC VOLTMETER (1PH)
BATTERY DISCHARGE ALARM & IND. LIGHT
2% ACCURACY 3.5in AC VOLTMETER (3PH)
COMMON ALARM BUZZER
2% ACCURACY 3.5in AC AMMETER (1PH)
2% ACCURACY 3.5in AC AMMETER (3PH)
CURRENT LIMIT ALARM & IND. LIGHT (1PH / 3PH)
0-CENTER DC AMMETER FOR BATT/LOAD MONITOR
END OF DISCHARGE ALARM & INDICATOR LIGHT
CABINET HEATER STRIPS
HIGH-LOW AC VOLTAGE ALARM & INDICATOR LIGHTS
OVER-TEMPERATURE ALARM w/ (BUZZER / IND.)
DC POWER ON INDICATOR LIGHT
INTERNAL TEMPERATURE COMPENSATION (PB/NICD)
4-20 mA TRANSDUCER
Adc
Vdc
HIGH AC RIPPLE ALARM w/ INDICATOR LIGHT
AC INPUT LIGHTNING ARRESTOR (1PH / 3PH)
VENT FAN CONTROL RELAY & IND. (FROM EQUALIZE)
BATTERY OPEN ALARM & IND LIGHT
EXTERNAL TEMP COMPENSATION PROBE (PB/NICD)
0-72 HR. MAN. EQ. TIMER & IND. w/ REMOTE EQ.
0-999 HR. MAN. EQUALIZE TIMER w/ SW & IND. LIGHTS
AUXILIARY CONTACTS (TB15-AUX) ON CASM (EJ0837)
SURGE WITHSTAND FILTER (SWC) PER IEEE-472
kAIC AC
kAIC DC CIRCUIT BREAKERS
200 kAIC AC FUSING
(1PH - 2-POLE / 3PH - 3-POLE)
AC
DC
CKT BKR AUX CONTACTS
COPPER GROUND BUS BAR
w/ LUG(S)
FUNGUS PROOFING PER CA0004-00
SPECIAL NEMA
CABINET TYPE
in RELAY RACK MOUNTING ASSY.
SPECIAL (FLOOR / WALL) MOUNTING ASSY.
CUSTOM TAG PLATE
ENGRAVED FUNCTIONAL NAMEPLATES
WHITE CHARACTERS ON BLACK BACKGROUND
BLACK CHARACTERS ON WHITE BACKGROUND
PARTS DATA PACKAGE PER MFG. SWITCHBOARD
COPY OF TEST DATA PER NEMA PE5-1985
EXTRA INSTRUCTION MANUALS
CUSTOM DRAWING PACKAGE
CAD DISK
CERTIFIED TEST DATA PER NEMA PE5-1985
CERTIFICATE OF CONFORMANCE
BURN-IN OR HEAT-RUN
HOURS
IN-HOUSE INSPECTION BY OUTSIDE PERSONNEL
EXPORT PACKING PER FS0001-00
CUSTOM PACKING
EXTENDED WARRANTY PER JF5001-00
EJ5007
EJ5007
JH0002
JH0002
-00
-10
-09
-07
JH0003
JH0002
JH0002
JH0002
JH0002
JH0004
JH0004
JH0004
-06
-03
-01
-00
-01
-05
-10
ADDITIONAL FEATURES / OPTIONS / NOTES:
no-load to full-load
for + or - 10% AC line variation
for combined load, line & temp. variations
0º C to 50º C
up to 95% without condensation
up to 1,000m above sea level
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.
4)
During normal operation, batteries may produce explosive gas. NEVER smoke, use an open flame,
or create arcs in the vicinity of the charger or battery.
5)
Maintain at least 1ft (0.3m) clearance from all obstructions on all sides of the battery charger.
6)
Keep area in front of battery charger clear for at least 4ft (1.3m).
7)
Connect or disconnect the battery only when the battery charger is off to prevent arcing or burning.
8)
De-energize all AC and DC inputs to the battery charger before servicing.
9)
Do not operate battery charger if it has been damaged in any way. Refer to qualified service
personnel only.
10) Do not disassemble battery charger. Only qualified service personnel should attempt repairs.
Incorrect reassembly may result in explosion, electrical shock, or fire.
11) Do not install the battery charger outdoors, or in wet or damp locations unless specifically ordered
for that environment.
12) Remove all jewelry, watches, rings, etc. before proceeding with installation.
PLEASE READ AND FOLLOW
ALL SAFETY INSTRUCTIONS
i
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 ......................................................................................................................................................2
2. Application .........................................................................................................................................................2
3. Installation..........................................................................................................................................................2
4. Placing Charger in Service .................................................................................................................................3
5. Adjustments of Float & Equalizing Charge .......................................................................................................3
6. Manual Equalize Timer ......................................................................................................................................3
7. Maintenance .......................................................................................................................................................4
8. Normal Performance ..........................................................................................................................................4
9. Description of Operation ....................................................................................................................................5
a. Power Transformer........................................................................................................................................5
b. Rectifier Section ............................................................................................................................................5
c. Control Module .............................................................................................................................................5
d. Filter Section .................................................................................................................................................5
SECTION III - TROUBLESHOOTING
1. CAUTION Notice .............................................................................................................................................6
2. Troubleshooting Procedure ................................................................................................................................6
3. Testing of Components ......................................................................................................................................6
a. External Circuit Wiring .................................................................................................................................6
b. Power Transformer (T1)................................................................................................................................7
c. Circuit Breakers (CB1 / CB2) .......................................................................................................................7
d. Surge Suppressors (SS1 / SS2 / SS3 / SS4)...................................................................................................7
e. Rectifier Diodes (CR4 / CR5 / CR6).............................................................................................................7
f. SCR Diodes (SCR1 / SCR2 / SCR3).............................................................................................................8
g. Control Module (A1).....................................................................................................................................8
h. Current Sensing Resistor (SH1) ....................................................................................................................9
j. DC Voltmeter (M2) .......................................................................................................................................9
k. DC Ammeter (M1) ......................................................................................................................................10
m. Filter Capacitors (C1 / C2) ..........................................................................................................................10
n. Internal Wiring ............................................................................................................................................10
SECTION IV - SYSTEM ADJUSTMENTS
1. Voltage Adjustments and Response .................................................................................................................11
a. Float Adjustment .........................................................................................................................................11
b. Equalize Adjustment ...................................................................................................................................12
2. Current Limit Response and Adjustment .........................................................................................................13
a. Checks and Adjustments .............................................................................................................................13
b. Checks to Make if Malfunctioning..............................................................................................................13
ii
Page No.
SECTION V - CUSTOMER OPTIONS
1. Ground Detection Circuits (EJ0088 / EJ0089 / EJ0094 / EJ0086) .................................................................. 14
2. AC Power Failure Alarm Relay (EJ0085) ....................................................................................................... 15
3. Three Phase AC Input Voltmeter (EJ0121) / Three Phase AC Input Ammeter (EJ0135)............................... 15
4. High and Low DC Voltage Alarm Relays (EJ0083) ..................................................................................15-16
5. Charger Failure Alarm Relay (EJ0127) ........................................................................................................... 16
6. Battery Discharging Alarm Relay (EJ0120) .................................................................................................... 16
7. Equalize Timers (EJ0097 / EJ0096 / EJ0869 / EJ0131 / EJ0084) ................................................................... 17
8. Common Alarm Buzzer (EJ0123) ................................................................................................................... 18
9. Common Alarm Relay (EJ0141) ..................................................................................................................... 18
10. Float and Equalize Indicating Lights (EJ0093) ............................................................................................... 18
11. Parallel Charger Operation with 2% Forced Load Sharing (EJ0133).............................................................. 18
12. Zero-Center DC Ammeter for Battery/Load Monitoring (EJ0138)................................................................. 19
13. High DC Voltage Charger Shutdown with Alarm Relay (EJ0592) ................................................................. 19
14. End of Discharge Alarm Relay (EJ0143) ........................................................................................................ 19
15. Current Limit Alarm Relay (EJ0137) .............................................................................................................. 20
16. Cabinet Heater Strips (EJ0145) ....................................................................................................................... 20
17. High and Low AC Voltage Alarm Relays (EJ0155) ....................................................................................... 20
18. Over-Temperature Alarm Relay (EJ0439)....................................................................................................... 20
19. Combined Alarm-Status Monitor "CASM" PC Board Assembly (EJ0837).................................................... 21
SECTION VI - COMPONENT DESCRIPTIONS
1. Component Description - SCR/SCRF Series Battery Charger Mainframe (Three Phase Input)................22-23
2. Component Description - SCR/SCRF Series Battery Charger Options (Single Phase / Three Phase).......24-26
SECTION VII - TABLES / DIAGRAMS / FIGURES
Table A - Troubleshooting Chart.......................................................................................................................... 27
Diagram - SCR/SCRF Series Battery Charger: Mainframe Schematic - 3PH Input (JE5078-00) ....................... 28
Figure 1 - Component Layout for Control Module - 3PH SCR/SCRF Battery Charger (GK0048)..................... 29
Diagram - Schematic: Control Module 3PH Battery Charger (EH0467) ............................................................. 30
Figure 2 - Typical Waveforms 3PH Control Module / 3PH Anode Firing PC Board Schematic (EH0617) ....... 31
Diagram - Power Transformer (T1) Schematics - 3PH SCR/SCRF Series (EH0553) ......................................... 32
Diagram - Remote Alarm Terminal Block Legend for TB3 and TB15 (EH0423-00).......................................... 33
SECTION VIII - OPTION SCHEMATICS
Option
Page No.
Option
Page No.
EJ0083 ...................... 34
EJ0096.......................38
EJ0084 ...................... 34
EJ0097.......................39
EJ0085 ...................... 35
EJ0120.......................39
EJ0086 ...................... 35
EJ0121.......................40
EJ0088 ...................... 36
EJ0123.......................40
EJ0089 ...................... 36
EJ0127.......................41
EJ0093 ...................... 37
EJ0131.......................41
EJ0094 ...................... 37
EJ0133 (schematic).......42
EJ0095 ...................... 38
EJ0133 (wiring) ...........42
Option
Page No.
EJ0134.......................43
EJ0135.......................43
EJ0137 (1PH) ..............44
EJ0137 (3PH) ..............44
EJ0138.......................45
EJ0141.......................45
EJ0141 (w/buzzer) ........46
EJ0143.......................46
EJ0145.......................47
Option
Page No.
EJ0155 ...................... 47
EJ0439 ...................... 48
EJ0592 ...................... 48
EJ0837 ...................... 49
EJ0826 ...................... 50
EJ1895 ...................... 50
EJ1234 ...................... 51
EJ1398 ...................... 51
SWC filter................. 52
SECTION IX - REPLACEMENT PARTS
Electrical Ratings and Replacement Parts - SCR/SCRF Series Battery Charger (3PH Mainframe)...............53-56
Replacement Parts - SCR/SCRF Series Battery Charger Options (1PH/3PH)................................................57-61
SECTION X - MANUAL SPECIFICATIONS (document control information)
Document Number / Revision Information .......................................................................................................... 62
On-Line Availability Note.................................................................................................................................... 62
Parts List / Drawing Notes.................................................................................................................................... 62
iii
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 0.5% of the set value without exceeding its rated output current. It will maintain + or - 0.5% with input
voltage variations 10% above or below the rated input AC voltage and with 5% frequency variations.
The charger is designed, primarily, to operate only when connected to a battery load. It can be
operated as a battery eliminator into a resistive load up to full rated output at increased ripple. Filtered type
chargers will have a ripple content less than 30 mV RMS under steady state conditions with the charger
connected to a battery having an 8-hour Amp-Hour rating of at least 4 times the full load current rating of
the charger. Other connected loads such as DC-to-DC power supplies or inverters, may put ripple on the
battery appreciably above 30 mV.
Unfiltered chargers should not be used with critical loads such as communication systems, amplifiers
and instrumentation systems, but should only be used for non-critical applications such as engine cranking.
This charger can be used on any number of lead-acid, nickel-cadmium, or nickel-iron cells as long as
the desired float and/or equalize voltages are within the range of the charger.
3. INSTALLATION
a. Location: Select a clean, dry location for the charger. It may be located in the battery room, but not
over the battery, and must be mounted upright. The openings for ventilation in the top, bottom and sides of
the cabinet should not be obstructed, as they provide convection cooling and ventilation. Ambient
temperatures between 32° F and 122° F, and elevations up to 3,300 feet above sea level, will not affect the
performance of the charger. Operation at higher temperatures, or at higher elevations, is possible if the
ampere output is de-rated in accordance with published information, and if the charger is custom ordered for
these operating ambient conditions.
b. Wire Sizes AC: Wire sizes for the AC wiring may be selected by consulting the data on the
nameplate for input amperage. Local electrical or NEMA standards should dictate appropriate wire size.
Most codes specify that the AC wiring size must match the current rating of the input circuit breaker or
fuses.
c. Wire Sizes DC: The size of the charger leads should be selected to (a) carry the charger (ampere)
current rating, and also (b) provide less than 0.5 volt total drop at rated current in the loop or leads between
the charger and battery terminals. Choose the larger wire size that meets conditions (a) and (b). Do not
undersize. It is good practice to keep the DC leads as short as possible and to keep them together as a pair to
obtain low inductance. Likewise, it is good practice to avoid sharp bends and to run both DC leads together
if run in conduit.
d. Input Power: These chargers are nominal 208V, 240V, 480V (60 Hz) or 380/416V (50 Hz) AC
three phase. If the AC input data as supplied with the charger does not agree with the AC supply voltage at
the installation site, do not connect the charger to the AC line. The AC voltage must be within +/- 10% of
the rated input voltage of the charger. If not, consult your power company or the battery charger
manufacturer. These three phase input power chargers are not phase rotation sensitive, and thus any
combination of three phase input AC wiring may be used.
2
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. It should read the correct polarity and be approximately the battery open circuit voltage (this is
2.0 volts per cell for lead-acid batteries and 1.2 volts per cell for nickel cadmium batteries). For example, a
60-cell lead-acid battery should read about 2 x 60 cells = 120 volts. This is a check to indicate that all cells
are in a true series (none connected in reverse). The open circuit voltage should be about 8% to 10% below
the rated float voltage.
c. The charger can now be energized, by first closing the DC breaker to supply voltage for the control
circuits then closing the AC breaker. Set the charger to “float”. The AC power ON pilot light should light,
and the ammeter should indicate charger output current. It is to be expected that the meter may show up to
110% current rating of the charger; the 110% being the factory setting of the current limit control.
d. The factory preset float voltage adjustment value is listed on the inside front cover. When this
value is reached, the charger ammeter should show a slow decrease in current, eventually down to a
stabilized value. Please note that whenever a charger is in a current limit condition, the output voltage is
automatically reduced to a value below the set float or equalize voltage. The voltage will not increase to
normal value until the battery’s state of charge increases, causing the charger current to decrease to a value
equal to or less than the rated current.
e. The factory preset equalize voltage value is also listed on the inside front cover. Assuming this is
as desired, the Float/Equalize switch may be switched to “Equalize”, to check the charger performance at
this voltage value. If a Manual Equalize Timer (option) has been included, turn it clockwise to activate the
equalize charger mode. The charger ammeter may again go up to current limit until the equalizing charger
voltage is reached. The length of time required to reach this level depends on the state of charge of the
battery, and the ampere rating of the charger versus the battery Ampere-hour rating.
f. With the charger operating at the desired float and equalizing voltage values, the system can be
considered installed and ready for service.
5. ADJUSTMENTS OF FLOAT & EQUALIZING CHARGE (also see Section IV, 1)
a. Each adjustment is made by means of a potentiometer with a slotted shaft for a screwdriver. The
potentiometers are front-panel mounted and appropriately marked. A lock nut on each potentiometer is
provided and should be tightened after the proper adjustment is completed. This prevents any accidental
mis-adjustments of the settings. The voltage response may be slow if a rise in voltage adjustment is desired,
because the battery state of charger and connected load must be considered. Turning the shaft clockwise will
raise the voltage, and turning counter-clockwise will lower the voltage.
b. Since accuracy of measurement is important when setting float and equalizing voltages, a
precision portable VoltOhmmeter with at least 1% accuracy is recommended for these DC measurements. A
conventional VoltOhmmeter or analyzer such as the Simpson Model 260 is also satisfactory, but is not as
accurate.
c. Any setting of the float voltage or equalizing charger voltage should not be considered final until
the ammeter shows less than charger rated current, and voltage does not change after several hours of
operation.
6. MANUAL EQUALIZE TIMER (OPTIONAL)
a. This timer is provided to obtain a charge up to 72 hours, at a slightly higher value than the
ordinary float voltage. The timer may be used for recharging older batteries, or for a freshening charge on
new batteries. For a detailed explanation of operation see Section V (Customer Options).
3
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. In the event of any irregular operation, examine, and tighten
if necessary, all internal and external connections and check circuits for continuity (see schematic diagram
on page 28). If the difficulty cannot be remedied, contact the manufacturer.
8. NORMAL PERFORMANCE
a. Assuming that the charger has been operating in the float position, an indication of normal
performance can be obtained by setting the FLOAT/EQUALIZE switch in the equalize position (turn timer
off zero). Increased charge current will show on charger ammeter until the battery reaches the equalize
voltage. At this point the current should slowly decrease.
b. If the charger has been operating in the equalize voltage position, turn SW1 to FLOAT (turn the
timer manually to zero). The charger will indicate zero or little output current until the float voltage is
reached. At this point, the current should increase slowly to the system load value, (the battery is now
“floating” across the line with approximately equal input and output currents).
c. When operating normally, the current limit control will limit the maximum charger output current
to approximately 110% of the rated charge current. In case of a high DC current demand, the current limit
control will keep the charger output within safe values without tripping the DC circuit breaker or the AC
breaker.
4
9. DESCRIPTION OF OPERATION
There are four major sections of the SCR three-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. It is
connected to an AC source by means of a circuit breaker.
b. The Rectifier Section: This section consists mainly of the voltage regulating silicon
controlled rectifiers and the power rectifier diodes. It accepts the AC voltage from the transformer, rectifies
this voltage to DC, and controls the voltage’s magnitude so that the charger output is regulated at all times.
The firing angle of the SCRs is controlled by the action of the control module. Both the SCRs and the diodes
are protected from AC and DC surge voltages by means of the metal-oxide varistor surge suppressors.
c. The Control Module: This printed circuit board generates the three-phase phase-fired gate
signals that turn on the SCR diodes in response to the charging requirements of the battery load. The output
voltage of the charger is monitored by the voltage feedback circuit and advances or retards the phase angle
of the trigger pulses so that the output voltage is maintained essentially constant. This is accomplished by
comparing a small portion of the output voltage to a stable voltage reference. An error signal is created
proportional to the differential voltage. This error signal is then used to alter the phase angle of the SCR gate
trigger pulses in order to correct the output voltage. The load current is also monitored by the circuit so that
when its value exceeds an arbitrary value (110% rated current) the system is “phased back” to limit the
output current to no more than 110% of its rated value.
d. The Filter Section:
(1). Depending on the application, the charger may be unfiltered. In this case, one
filter choke, L1, is utilized not for filtering but for phase correction of the highly leading current-voltage
condition created by the batteries during the charging pulses. The batteries represent a very large capacitor in
shunt with a resistive load. This creates out-of-phase current problems for the SCR diodes causing nonuniform triggering problems particularly at low load currents. The single filter choke corrects this condition
and also aids the ratio of average current to RMS current flowing in the circuit.
(2). For filtered units, the objective is to remove the charging ripple at the battery
terminals. To accomplish this a "T" or "double-L" section filter consisting of inductors L1 and L2 and
capacitors C1 and C2 are used. C1 and C2 may consist of one or more individual capacitors. The degree of
filtering required dictates whether the "T" or "double-L" configuration is used. The "double-L" section filter
is normally used to reduce the ripple to 0.06% of nominal output voltage when the charger is operated as a
filtered eliminator.
5
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. NOTE: Circuit breaker terminals (CBx), printed
circuit boards (Ax) and terminals/terminal blocks (TB1, TB2, TB3, TB5 & TB15) have dangerous voltage
across them, even when both circuit breakers are open. After isolating the charger, check that the voltage
across the filter capacitors (C1/C2) is zero. Once charged, they will take several minutes to discharge if
bleeder resistor (R1) is open. If DC circuit breaker (CB2) is not provided, remove the DC fuses (F1/F2) in
order to isolate the charger from the battery. AFTER LOCATING THE CHARGER PROBLEM,
ALWAYS DE-ENERGIZE ALL AC AND DC CHARGER INPUTS AT THE POWER SOURCE
BEFORE SERVICING.
2. TROUBLESHOOTING PROCEDURE
a. When a charger is not operating properly, the cause must be determined by checking various
components until the fault is located.
b. The major components do not have to be checked in the order as listed in Section II, 9, since a charger
may exhibit a number of difficulties, each with different symptoms. In many cases, failure of one
component may cause another component or part to fail. Therefore, the following paragraphs treat major
components, functional circuits and parts individually (or by symptom). Together with serviceability
measurements and tests, the faulty part or component should be located.
c. Most of the following checks can be performed with an oscilloscope, a VoltOhmmeter (similar to a
Simpson Model 260) and an SCR tester.
d. Consult the trouble-shooting chart in Table A on page 27. When using the table, first locate the fault
symptom observed (in the left hand column) then follow the sequence for checking components in the
numerical order listed (1, 2, 3 etc.) for that particular symptom. Follow this sequence until the trouble is
located. After correcting the trouble, check the charger for normal performance as described in Section II, 8.
e. In addition to those symptoms listed in Table A, the following procedure should be followed for any
condition:
• Check voltage of the AC supply to insure that it is within 10% of the value of the
specified input voltage.
• Examine charger for any evident loose or improper connections, particularly at the
control unit, transformer and input/output terminal board.
• Check continuity of battery circuit by comparing voltage at charger terminals with total
of cell voltages.
• Check accuracy of voltmeter and ammeter on the charger.
3. TESTING OF COMPONENTS
a. External Circuit Wiring
1. When no line voltage exists between TB1 input terminals (L1 to L2, L2 to L3 & L3 to L1), check
the AC line back to source.
2. With no output, or a low output, the external DC wiring may be at fault. Check the wiring
between charger and battery to see that it is properly installed. Make certain that terminals are tight and
clean, and that the DC wiring is free from grounds. The total operating voltage drop in the loop or leads
between the charger and battery terminals should never exceed 0.5 volt (at rated charge current), and
preferably should be kept considerably below this limit by using a sufficiently large wire size.
6
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 line terminals on TB1, terminals (L1 to L2, L2 to L3 & L3 to L1). If no AC voltage is indicated, refer to
Section III, 3, a, 1. Check the wiring connections to ascertain that the 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. If this is not the case, CB1 or the wiring between it and T1 is open. In this case, proceed with checks
under Section III, 3, c, 1.
2. Check AC secondary voltage on T1 (see Table B below for expected voltage values). If secondary voltages
are much less than indicated or not balanced, then either T1 is at fault or the power regulating devices (SCR1, SCR2
or SCR3) are faulty.
TABLE B - SECONDARY VOLTAGE OF TRANSFORMER T1
Expected Voltages (AC)
Leads or Locations
Approximately equal to float voltage X1 to X2, X2 to X3 and X3 to X1
120 Vac
Y1 to Y2, Y2 to Y3 and Y3 to Y1
Note: The "X" of Table B voltages should be measured as they terminate on the full-wave bridge
components. All other voltages may be measured at the end of the transformer leads. Where power
rectifier fuses are employed in the larger power chargers (see custom diagrams and parts list), these
fuses should also be checked, and replaced if unserviceable.
c. Circuit Breakers (CB1/CB2)
1. AC Circuit Breaker (CB1): When an AC voltmeter of suitable range is connected between leads L1-L2, L2L3 & L3-L1 and indicates line voltage, but does not indicate when connected to the output terminals of CB1 when
closed, the circuit breaker is probably defective. De-energize the AC supply to the charger and remove the leads to the
circuit breaker. Use a volt-ohmmeter to check for continuity between the circuit breaker terminals with breaker
manually closed. Zero resistance should be indicated if the unit is operative. If unit checks OK, check performance by
measuring the AC voltage drop across each pole of the breaker. This voltage should be under 0.1 volt when the load
current is normal. If a higher voltage drop is found, replace the breaker.
2. DC Circuit Breaker (CB2): When the DC circuit breaker is suspected of being inoperative or at fault, a
similar test to that made for the AC breaker will determine the operating condition of the breaker.
3. If the polarity protection diode (CR1) is shorted, the battery will discharge into CR1, which will trip the DC
circuit breaker (CB2). Check CR1 with an ohmmeter (both polarities) for a shorted condition and replace if required.
d. Surge Suppressors (SS1/SS2/SS3/SS4)
1. The metal-oxide varistor (MOV) type of surge suppressor is used throughout these battery chargers instead
of the older selenium type. This is done for personnel safety. When a selenium device fails and arcs or burns, toxic
selenium fumes are given off, which are very poisonous if inhaled. The MOV type has a much sharper limiting
“knee” characteristic, and performs a better protection function. If an MOV surge suppressor fails during a highenergy transient, it may explode. This is an obvious failure and the part must be replaced.
2. If the suppressor is shorted, an ohmmeter check will indicate continuity. When the suppressor shows an
infinite resistance in both directions measured with it disconnected from the charger and has a normal appearance it
can be presumed to be in good operating condition.
e. Rectifier Diodes (CR4/CR5/CR6) - also see Section III, 3, f
1. In lower current three phase chargers, these diodes are part of an SCR-diode module, in which the SCR and
diode of each leg are contained in an assembly mounted on an electrically insulated heatsink plate. Three connections
(plus one SCR gate terminal) are available for checking. In higher current three phase chargers, individual diodes and
SCRs are used instead of modules. Check the diode portion of each bridge leg by disconnecting one terminal and
measuring the forward and reverse resistance in either of two ways:
a) Using an ohmmeter, use the Rx1 scale for the forward resistance. This should show approximately 5 to
10 ohms. The reverse resistance should be up in the thousands of ohms (probably 50,000 or more) measured with a
higher scale of the meter.
b) Connect the diodes in series with a 6 or 12-volt lamp across a DC source of the same voltage. The lamp
must require at least one-quarter Ampere. The lamp should light with nearly full brilliance with current flowing in the
forward direction and not at all in reverse. If it lights in both directions, the diode is shorted. If in neither direction, the
diode is open.
7
2. Note that semiconductors usually short in pairs in bridge circuits, seldom as single units, and it is rare that
all six semiconductors in a bridge are found defective. When diodes fail it usually is because of surge voltages.
Therefore, surge suppressors (SS1, SS2, SS3 & SS4) should also be checked to determine that they are operative
(refer to Section III, 3, d).
f. SCR Diodes (SCR1/SCR2/SCR3) - also see Section III, 3, e
1. These devices are either part of the SCR-diode modules or are individual components as described in
Section III, 3, e above. Power regulating devices (SCR1, SCR2 & SCR3) are silicon-controlled rectifiers, which
cannot be checked using the same method as used with rectifier diodes by forward and reverse resistance checks,
since the SCR will always show a high resistance until triggered.
2. The operation of the SCR can be checked with an oscilloscope. The control module assembly (A1)
produces the gate-firing voltage signal. The oscilloscope should be GROUND ISOLATED for these tests. This is
normally done, using a line isolation transformer, in which the secondary that powers the oscilloscope is
UNGROUNDED. Alternatively, a battery-powered portable oscilloscope can be used. The gate signal may be
checked on the control module (see Section III, 3, g) or where the twisted-pair trigger leads terminate on the SCRdiode module. The same signal should appear at both points. Absence of the signal indicates that the control module is
defective, not the SCR (see Section III, 3, g).
3. If the charger AC input breaker (CB1) trips immediately, and a shorted SCR is suspected, a simple check
with an ohmmeter can be made. Turn off CB1 and CB2. Connect to the anode and to the cathode, and adjust to the
direct reading scale of the ohmmeter. If a low resistance is observed, reverse the leads and again check the resistance.
If this reading is also low, the SCR is shorted and should be replaced.
4. An SCR can also be checked for operation with a Simpson Model 260 volt-ohmmeter. With the black lead
in common and red lead in +, put polarity switch to + DC. Connect the red lead to the anode and the black lead to the
cathode. The meter should now indicate high resistance above 50,000 ohms (when on the R x 10,000 scale). With the
leads connected as above, set the function switch to R x 1 and touch the gate to the anode. This should fire the SCR
and give a reading of approximately 5-20 ohms. This shows the SCR has been turned on. On very small SCRs, this
reading will hold after removing the gate lead. This is latched-on and can be unlatched by opening the cathode lead.
Larger SCRs will not stay on with the current available with Simpson meter. The Simpson may not have enough
current to gate or turn on extremely large SCRs (400 amp and up).
5. If the charger output is too high, unplug the control module and turn on the charger. With no gate signals
the charger should have zero output. If there is still current output, one or both SCRs are defective.
6. The above checks can be used to confirm that a suspected SCR is indeed bad. However, occasionally an
SCR might check OK in all these tests and still break down or fail in the charger circuit during normal operation. Any
SCRs suspected should be replaced.
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 “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. Proceed as follows using the
GROUND ISOLATED oscilloscope described in Section III, 3, f, 2 above. Make the following tests in the order
shown.
1. If the gate signals were not checked as described in Section III, 3, f, 2, do so at this time. If one or more of
the gate signals are absent when attempting to operate the charger in a normal manner, make the following checks.
Refer to FIGURE 1 on page 29 for component layout and test point locations on the trigger board. See schematic on
page 30 for related circuit diagram.
2. Check DC voltages at test point P10 [+12 VDC, +/- 0.5V]. If zero, check input and output to miniature
transformer TR1 [120V:12V AC] and check DC voltage at IC7, pin 1 [18 VDC]. Replace defective components. If
OK, proceed as follows.
3. Check three phase input voltages at resistors (R1, R2 & R3). The voltage should be 120 VAC between any
two resistors in three phase relationship. If not present, check J1 plug connections and voltages appearing between
terminal pins 1, 3 and 5 (also 120V - three phase).
Note: The following wave form tests must be made using the oscilloscope set with vertical sensitivity set
at 5V/CM and the horizontal time base set at 5mS/CM. Compare the waveforms observed with those
shown in FIGURE 2 on page 31 for the various test points indicated.
8
4. Check square wave pattern at test points A1, A2 and A3. Note the 120-degree (5.5 mS) delay between the
three patterns (scope synchronized to the 60 Hz AC line). If A1 pattern is missing, replace IC3. If A2 or A3 is
missing, replace IC4.
5. Check ramp pattern at B1, B2 and B3. Compare with those shown in FIGURE 2. Note that the exact wave
shape depends on the phase angle of SCR gates. The steeper the ramp the earlier in each half cycle the SCR is fired
and the higher the output of the charger. If waveform at B1 or B2 is abnormal or missing replace IC2. If B3 waveform
is missing replace IC1.
6. Check waveform at test points C1, C2 and C3. This comparator pulse generator produces rectangular
waveforms of varying lengths with the leading edge varying in position to a fixed-in-time trailing edge. Compare with
FIGURE 2. If C1 or C2 is missing, replace IC2. If C3 is missing, replace IC1.
7. Check waveform at test point H. This waveform should be a continuous string of very short pulses with
approximately 10V amplitude. This is the picket fence generator output. If missing, replace IC3, IC5 or IC6.
8. Check bursts of picket fence signal at test points D1, D2 and E3. Compare with FIGURE 2. If D1 or D3 is
missing, replace IC4. If D2 is missing, replace IC3.
9. Check amplified picket fence pulse trains at test points E1, E2 and E3. These pulse trains are similar to
those at D1, D2 and D3 of FIGURE 2. If E1 is missing replace Q1 or Q2. If E2 is missing, replace Q3 or Q4. If E3 is
missing, replace Q5 or Q6.
Note: The following check should be made only after completing steps 1 through 9 above. Chargers with
output ratings higher than 150 Adc may be supplied with an Auxiliary Gate Drive PC Board (A14)
triggering the phase-controlled SCRs. The A14 board intercepts the SCR gate lead wiring from the
control module (A1) as shown in drawing EH0617 on page 31. The A14 board converts the “picket
fence” pulse train (waveform similar to D1) from the control module to a DC gating signal for the main
SCRs. The A14 output will be a square wave approximately 1.5 Vdc in amplitude.
10. If a main SCR fails to turn on, trace the gate signal from the control module to A14, and from A14 to the
appropriate SCR. The AC gate signal should be approximately the same magnitude at both input and output of A14. If
an input gate signal has no corresponding output signal, replace A14.
11. If a main SCR fails to turn off, resulting in a high charger output voltage, disconnect SO14 plug from A14
board. If the main SCR now turns off, replace A14. If the main SCR remains on, the main SCR is defective and must
be replaced.
12. Check ripple waveform symmetry of the charger by connecting the oscilloscope ahead of the filter choke
(L1). Connection may be made across the bleeder resistor (R1). With the unit adjusted for about 66% output current,
observe to determine that the 360 Hz ripple pulses are of uniform amplitude. If not, slowly adjust the two balance
adjust potentiometers (R24 & R32) on the trigger board (A1). Note that phase #1 is not adjustable and is used as a
reference. Adjust the two potentiometers for the most uniform pattern yielding the lowest ripple voltage at the output
terminals. This adjustment may also be made using a sensitive AC voltmeter at the charger output terminals, and
adjusting for minimum RMS voltage indication (less than 30 mV for a filtered charger).
h. Current Sensing Resistor (SH1)
1. In light current chargers, the current sensing signal is taken directly across the DC ammeter. In chargers
with 50 Amp or higher output current, the sensing resistor is a meter shunt, which also serves as the shunt for the
panel ammeter. Use a portable precision digital voltmeter and measure the voltage drop across the current sensing
resistor. With a rated current output indicated on the panel ammeter, a nominal voltage drop of approximately 30mV
(in proportion to rated current) should be observed. If the voltage drop is higher or lower than the nominal indication,
replace the ammeter or shunt and recheck the voltage drop.
j. DC Voltmeter (M2)
1. The DC voltmeter is of the 2 percent accuracy type. It is connected across the charger output to the battery
and should indicate regardless of whether or not the charger is operating or the DC breaker is ON. If it does not, use a
precision voltmeter of the 1% accuracy type connected across the meter terminals. An indication on the test meter will
show that the panel meter is open. Check the wiring for an open circuit, or replace meter if circuit wiring is complete.
2. A shorted voltmeter will show no indication. Battery current through a shorted meter will cause a visible
indication such as smoke from burning wire insulation. Disconnect the charger from the battery and AC source and
replace the meter and damaged wiring.
3. If the meter calibration is in doubt, checking against a precision meter will determine if the panel voltmeter
is off calibration more than two percent.
9
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. Be certain to make solid connections; clip contacts may not
carry sufficient current, or may make poor contact and cause the reading to be inaccurate.
2. A reverse-scale indication of the meter indicates the charger is inoperative or internally shorted,
and that the battery is discharging through the rectifier, or that the meter leads have been reversed. Turn
CB1 and CB2 to OFF and check wiring and meter connections. Then check meter operation, using a 1-1/2
Volt D-cell as the power source. Momentarily touch the D-cell terminals (with proper polarity) to meter
terminals and observe meter deflection.
m. Filter Capacitors (C1/C2) - (filtered chargers only)
NOTE: Capacitors C1 and C2 may consist of one or more parallel-connected capacitor units as
needed by the filtering requirements. C2 normally is used only in chargers with the filtered eliminator
option.
CAUTION: The filter capacitor is on the charger side of the blocking diode (CR2) and is NOT
charged by the battery when CB2 is turned ON. When the charger is turned "OFF" (CB1 opened) the
capacitor will hold a charge until discharged by bleeder resistor (R1). Capacitors C1 and C2 should always
be discharged before servicing in the event the R1 has opened and no longer serves as a bleeder.
1. Before attempting to check the output ripple, it should be determined that in all other respects the
charger is operating normally. Having determined this, the ripple may be checked as follows. Connect a
sensitive AC voltmeter (digital type preferred) to the battery terminals and measure the AC ripple voltage. If
it measures more than 30 milliVolts RMS check the following:
(a). That the battery connected to the output terminals of the charger has an Ampere-hour rating
of at least four times the rated capacity in amperes of the charger.
(b). The ripple is measured at the terminals of the battery.
(c). Check capacitors C1 and C2 as follows: Switch the VoltOhmmeter to the Rx100 scale and
connect the red lead to the capacitor plus terminal (marked by a red dot or plus sign) and the black lead to
the negative terminal. The meter should initially swing up scale toward zero Ohms then come back as the
capacitor charges. A reading of zero Ohms indicates a shorted capacitor while no initial swing means an
open capacitor. Either an open or shorted capacitor should be replaced.
n. Internal Wiring
1. Check internal wiring for obvious mechanical faults or wear. Follow the schematic diagram on
page 28 and check continuity with an ohmmeter to determine open connections. Check wiring against
ground also, and remove any grounds.
10
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. For proper operation, the open circuit voltage of the battery must be slightly
lower than the rated float voltage. If the battery voltage is higher than the float voltage range, check the
number and type of cells connected to the charger making certain the proper number and type of cells are
not exceeded. Close the DC breaker (CB2) or connect charger to battery. Close the AC breaker (CB1). If
battery voltage is now within the float voltage range or is slightly lower and some output current exists,
proceed with Section IV, 1, a, 2 below.
If the battery voltage is slightly lower or within the float voltage range, switch the charger to the
equalize mode. If still no output appears, or the potentiometer (R5) does not produce a rise from the
previous value, turn equalize charge control fully clockwise, and if still no voltage rise is obtained or no
output appears, proceed again with the check sequence in Table A trouble-shooting chart. If the voltage
increased or output was obtained when the charger switched, to evaluate proceed with the voltage
adjustments.
a. Float Adjustment
1. Since the charger must be operable for this adjustment, preceding checks in Section IV, 1
above must indicate a serviceable charger. Set switch (SW1) to “FLOAT”. Use a portable voltmeter of
one percent accuracy. Connect the battery supply leads to the battery and close the DC (battery) breaker
(CB2). Set the AC breaker (CB1) to "ON".
2. Since the EQUALIZE and FLOAT potentiometer control settings interact with each other, it is
always necessary to adjust the FLOAT control first and then the EQUALIZE control afterward. Never
finalize a voltage adjustment with the charger output in excess of 100% rated output current.
3. Turn the control clockwise, watching the response on the voltmeter. Clockwise rotation should
cause the charger output current to increase rapidly, while the voltage should rise slowly. The rate of
voltage rise depends upon whether the battery is fully charged, the size of any connected load, and the
size of the charger versus the size of the battery. After getting several volts response in battery voltage
rise, turn the FLOAT control counterclockwise. This should result in a rapid drop in charger output
current and eventually in a slow decrease in battery voltage. Now adjust the voltage for the desired float
setting and tighten the locknut on the potentiometer.
11
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. It will be impossible
to set the equalize voltage if the batteries are in a discharged condition. If fact, they must be at near fullcharge. This is to prevent the charger from going into a current limit condition. Current limit reduces the
charging voltage and no matter if the EQUALIZE potentiometer is increased to a full-clockwise position,
the charger voltage will not increase.
3. Therefore, it is suggested that the batteries be placed on equalize charge for several hours so
that the charger is no longer in current limit. This should be observed using the portable 1% accuracy
voltmeter and the charger panel ammeter. When the charging current falls below the 100% rated value of
charger current, observe the voltage and set carefully for the desired equalize voltage. If, upon
readjustment, the current again goes into current limit wait for the batteries to continue their charge
cycle. Continue this adjustment procedure until the desired voltage is reached and the current is less than
rated current. When the final setting is determined, tighten the lock nut on the EQUALIZE
potentiometer.
12
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. With the charger in float mode, a float voltage charge should be indicated on the panel
voltmeter and the ammeter should show either a charge current, or practically none at all, depending on
the state of battery charge.
1. If the batteries are in a discharged condition, switching to the equalize mode will cause the
charger to automatically go into a current limit condition. If, however, the batteries are fully charged they
probably will not draw current in the current limit range. In order to cause this condition, it will be
necessary to connect additional load to the battery charger or battery bank. This can be resistive elements
or turning on the normal load of the installation. When current limiting is encountered, observe that the
charger voltage will be reduced below its set value by the current limit feedback signal. Observe that as
the current limit condition continues, the voltage will slowly increase as the batteries take on a charge.
Eventually the current will begin to decrease below the current limit value and continue to decrease to a
value less than 100% of rated output current. As the current decreases below 100% of rated output
current, the voltage will become constant at the equalize value and remain so.
2. To check the system response, turn the AC breaker (CB1) to "OFF" to simulate line voltage
failure. Charging current will return to zero on the instrument panel ammeter (M1), and the voltage
should reduce slightly. Place a load on the battery and discharge it heavily for a short period of time until
the voltmeter drops to float value or slightly lower. Return the AC breaker (CB1) to "ON" and observe
that charge ammeter again reads 110% of charge rate and voltage is less than the equalizing level. If
current is greater than, or less than 110% of rated charge, open the cabinet and locate the CURRENT
LIMIT potentiometer on the control trigger PC board (A1). Reference the component layout on page 29
and schematic on page 30. The CURRENT LIMIT is labeled R11 on single-phase control PC boards
(GK0058) and R65 on three-phase control PC boards (GK0048). Adjust this control for 110% charge
current. Repeat the AC circuit breaker (CB1) ON-OFF sequence listed above. If charge rate is still 110%
rated value for which it was set, close the cabinet. Restore the charger to float mode.
b. Checks to Make if Malfunctioning: If all of the above adjustments were attempted and a high
current persists, the current limit circuit on the control trigger board or the ammeter or shunt used for
current sense may be defective. The interconnecting wiring may also be faulty. Make the following
checks to isolate the fault.
1. Turn the current limit control on the control trigger PC Board (A1) to determine if it has any
effect on the high output current reading. This control is the potentiometer labeled R11 on single-phase
control PC boards (GK0058) and R65 on three-phase control PC boards (GK0048). If it does have an
effect, make the adjustment for 110% rated current for a current limit setting as described in paragraph
IV, 2, a, 2 above.
2. If no effect is noted, IC1 on the control trigger PC board (A1) may be defective. If so, replace.
3. Check the voltage generated across the ammeter (M1), or ammeter shunt (SH1) to determine
that sufficient voltage is available at rated current to activate the current-limit feedback amplifier. See
Section III, 2, h. Use a sensitive DC voltmeter and measure the voltage across the ammeter (M1) or
ammeter shunt (SH1). Measure the voltage from the "current limit" pin to the "control circuit reference"
pin, on the plug (SO1) of the control trigger PC board (A1). These pins are respectively pins #1 and #10
on single-phase control boards (GK0058) and pins #6 and #9 on three-phase control boards (GK0048). If
the sense voltage is not present at the control trigger PC board (A1), check the wiring. If the wiring is
satisfactory, proceed with the check sequence listed in Table A trouble shooting chart on page 27.
13
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. GROUND DETECTION CIRCUITS
Purpose: The purpose of a ground detector circuit is to indicate to the user when either the positive (+)
or negative (-) output terminal of the battery charger (or its connected load) is grounded. This is important
for many applications where a full floating system is required for operation or safety reasons. There are
several methods of indicating a grounded output terminal. These will be outlined below with an explanation
of how each works.
Descriptions:
a. POSITIVE / NEGATIVE GROUND INDICATOR LIGHTS (EJ0088)
The simplest form of a ground detection system is the two-lamp method. This utilizes two lamps of
voltage equal to the battery charger output voltage connected from the positive terminal to ground and from
negative terminal to ground. Under normal conditions, each bulb will have half-voltage applied and glow
dimly at quarter-brilliance. Upon a ground, the lamp indicating the grounded terminal will glow at full
brilliance. The other lamp will go out.
b. POSITIVE / NEGATIVE GROUND INDICATOR LIGHTS W/TEST SWITCH (EJ0089)
This is a variation of “EJ0088” above, so that the two lamps are not continuously connected in the
circuit. A double-pole, double-throw momentary center off switch (SW12) is utilized. Activating the SW12
down will connect the two lamps in series across the battery, with the center attached to chassis ground. This
performs as the two-lamp system (EJ0088) as described above. Activating the SW12 up serves to test the
lamps.
c. GROUND DETECTION SWITCH FOR DC VOLTMETER INDICATION (EJ0094)
This method uses the existing panel DC voltmeter (M2) and two double-throw switches (SW8/SW9)
to utilize the voltmeter in both functions. SW8 establishes the meter function (output voltage or ground
detection) and SW9 switches the voltmeter between (+) or (-) terminals to chassis ground, reversing the
meter polarity to maintain up-scale indications. The voltmeter, used in the ground detection mode, will
indicate the DC voltage potential between the corresponding output terminal and chassis ground. For cases
of partial grounds, the voltmeter will indicate the difference of the terminal DC voltage and the voltage of
the partial ground.
d. GROUND DETECTION ALARM RELAYS (EJ0086) - W/OPTIONAL INDICATOR LIGHTS
This method utilizes two DC relays which monitor the (+) and (-) terminal voltage to chassis ground
and will energize if the opposite polarity terminal is grounded. To insure that the relays will not energize on
half-voltage, when there is no ground present, series resistances are used to reduce the relay pull-in
sensitivity. However, once pulled in by a ground condition, the relays will not drop out when the ground is
removed because the drop out voltage of a DC relay is always less than the pull-in voltage. As a result, a
momentary “RESET” switch (SW3) must be activated to open the relays returning them to the “ready”
condition. Schematic EJ0086 shows the circuit diagram of this method. The panel lamps shown are a user
option that is available for front panel indication. The relay coil voltages, and series resistances will depend
on the output voltage of the battery charger.
14
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). TM1, when energized, holds the normally
closed contacts open disabling the alarm indication. When the AC line fails or the AC circuit breaker (CB1)
is opened for any reason, the alarm contacts will close activating the alarm indicator. EJ0085 shows the
circuit with the optional panel indicator lamp and external relay connections for remote indication. The
indicator lamp must operate from the battery power since the AC line power is not available in an alarm
state. As a result, the indicator light operating voltage must match the battery DC voltage or must utilize a
series-dropping resistor to compensate for the difference in voltage between the battery and indicator lamp.
3. AC INPUT VOLTMETER (EJ0095/EJ0121) AND AMMETER (EJ0134/EJ0135) OPTIONS
Purpose: These options are to permit the user to monitor the input AC line voltage and line current to
the battery charger. This may be done for either single phase or three phase input power.
Descriptions:
a. Single phase AC: EJ0095 shows the connections to the ac voltmeter and EJ0134 shows the
connections to the AC ammeter. The ammeter is usually connected to the AC line via a current transformer
(CT1) if the line current is over 50 Amperes.
b. Three Phase AC: EJ0121 shows the connections to the ac voltmeter and EJ0135 and shows the
connections to the AC ammeter. Both show the connections utilizing a single meter, one to monitor the
three phase-to-phase voltages and one to monitor the three line currents. A two-pole, three position switch
(SW5) is used to switch the voltmeter from phase-to-phase to check all three input voltages. The ammeter
switch (SW6) is a special switch, which shorts all unused current transformer secondaries. Upon changing
switch position, it shorts the current transformer (CT1) secondary in use before transferring the ammeter to a
new position. This prevents very high voltage arcs when the secondary is open circuited.
CAUTION: NEVER OPERATE A CURRENT TRANSFORMER WITHOUT A SECONDARY
LOAD OR SHORT CIRCUIT ACROSS THE SECONDARY TERMINALS.
4. HIGH / LOW DC VOLTAGE ALARM RELAYS (EJ0083) - W/OPTIONAL INDICATOR LIGHTS
Purpose: The HIGH/LOW DC Voltage Alarm (HLVA) provides alarm indication for the DC system in
the event of a malfunction of the battery charger, which causes the battery voltage to rise or drop to a
dangerous level. Relay contacts and optional front panel lamps provide alarm indications.
Description: The HLVA printed circuit board consists of two independent operational amplifier circuits,
one monitoring the battery voltage for a high voltage condition and the other monitoring for a low voltage
condition.
The board obtains its operating voltage (12VDC) from the battery terminals and if required, an
externally mounted dropping resistor (R57).
There are two potentiometers on the HLVA PC board (A2). Viewed from the component side of the
board, the potentiometer near the top-left of the board is the LOW voltage alarm (LVA) threshold
adjustment. The right-hand potentiometer at the top of the board is the HIGH voltage alarm (HVA)
threshold adjustment.
15
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. It will be necessary to raise and lower the battery voltage several times to ascertain that the
potentiometer setting is correct.
Similarly the battery bank will have to be charged at a high equalize rate in order to set the HVA
threshold. At the equalize rate the charger may go into a current limit condition, depending on the state of
charge, and it may be impossible to reach the desired high voltage alarm voltage. If this is the case, it will be
necessary to substitute a resistive load bank with paralleled capacitance in place of the batteries. Adjust the
output voltage of the charger by using the "EQUALIZE" potentiometer (R5) and then set the HVA
potentiometer accordingly.
It will be noticed that there is an operational delay time and a hysteresis zone (dead zone) between the
drop out voltage and the pull-in voltage of the alarm circuits. This is natural and desirable to prevent
chattering of the relays when the threshold voltage is reached.
The factory preset thresholds for alarm conditions are as follows unless otherwise specified:
LVA 2.00 volts/cell for LEAD ACID
1.14 volts/cell for NICKEL CADMIUM
HVA 2.40 volts/cell for LEAD ACID
1.65 volts/cell for NICKEL CADMIUM
5. CHARGER FAILURE ALARM RELAY (EJ0127) - WITH OPTIONAL INDICATOR LIGHT
Purpose: The Charger Failure Alarm provides an alarm indication whenever the charger output current
decreases to below 2% of rated current for more than 30 seconds. Alarm contacts are wired to TB3 terminals
19, 20 & 21 and an optional front-panel indicator (DS7) is available.
Description: Charger output current is sensed by means of an auxiliary winding on the main inductor
(L1). The CFA PC Board assembly (A3) detects the voltage signal from L1. When the voltage signal
indicates that the current has dropped to below 2%, an on-board relay switches to provide the alarm
indication. When the output current is restored to a value above 2%, the alarm will be automatically reset.
6. BATTERY DISCHARGING ALARM RELAY WITH INDICATOR LIGHT (EJ0120)
Purpose: The Battery Discharging Alarm indicates the condition when the battery is no longer receiving
adequate charging current from the charger and has become a source of current for the load. Alarm
indication is provided by a front panel lamp (DS10) and relay contacts. Alarm contacts are wired to TB3
terminals 22, 23 & 24.
Description: This is accomplished by monitoring the direction of current flow in a DC meter shunt
(SH3) connected in the main battery lead. When this current polarity changes from negative to positive the
alarm circuit is activated.
EJ0120 shows the connection diagram of the alarms. An op-amp voltage comparator senses when the
input signal from SH3 changes from negative to positive polarity. The op-amp output goes “high” and
activates the alarm.
The alarm board derives its power from the battery terminals. If necessary, voltage-dropping resistors are
used to properly match the battery voltage.
16
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. MANUAL EQUALIZE TIMER (EJ0097), W/LIGHTS (EJ0096), W/LIGHTS & SW (EJ0869)
To operate this 0-72 hour timer, turn the timer control knob (TM1) clockwise to the number of charge
hours desired. This will start an AC clock, driving two cams, which operate two contacts. One contact
provides AC to the clock motor, the other changes the voltage-sensing network to the higher equalizing
voltage. Upon completion of the time period, when the timer control knob reaches "0", the clock motor is
stopped and the voltage-sensing network is returned automatically to the float voltage value. Option EJ0096
features the aforementioned manual equalize timer, along with "FLOAT" and "EQUALIZE" indicating
lights. Option EJ0896 features the aforementioned manual equalize timer and indicator lights, along with a
manual "FLOAT/EQUALIZE" switch.
b. AC LINE FAILURE AUTO-EQUALIZE TIMER WITH INDICATOR LIGHTS (EJ0131)
The Auto-Equalize timer is designed to automatically provide an equalizing cycle when the ac input has
been interrupted longer then 10 seconds. The operation of this equalize timer is as follows. Toggle switch
(SW1) to the "AUTO/EQUALIZE" position, and the battery charger in the "FLOAT" mode: When the AC
power is interrupted for a period longer than 10 seconds and returns, the battery charger is placed in the
"EQUALIZE" charge mode for a pre-selected period of time (0 to 999 hours). The timer, now energized,
displays time remaining and completes the equalize charge period. Once the timer reaches "0" the charger
will switch to the "FLOAT" mode. The timer will shut its self down and remains ready to repeat the
operation for the same number of preset hours. The charger may also be returned to the "FLOAT" mode by
pushing the "FLOAT RESET" switch (SW11).
The schematic diagram (EJ0131) shows the circuit details. Relay (TM2) is a 10-second time-delay relay,
which latches itself closed 10 seconds after the AC power fails. When the AC power returns, the timer
(TM1) operates. As long as TM2 is latched closed, the charger is in "EQUALIZE" mode. When TM1 times
out, it opens the latch circuit of TM2 and returns the charger to "FLOAT" mode. The timer clutch then
disengages, and the timer (TM1) returns to start position. Placing switch (SW1) in the "EQUALIZE"
position overrides the timer function and manually puts the charger into "EQUALIZE" mode. "FLOAT" and
"EQUALIZE" indicating lights mounted on the instrument panel are standard, to indicate the charging mode.
c. PERCENT EQUALIZE TIMER WITH INDICATOR LIGHTS (EJ0084)
The “PERCENT” Equalizing Timer is used for certain types of batteries that required a period of
equalizing charge every 72 hours. The timer is an electro-mechanical timer whose dial reads from 0 to
100%, and whose drive motor rotates internal cams once every 72 hours.
If the operator sets the “percent” dial for 10%, for example, the timer will operate the cams such that the
EQUALIZE charge contacts will be closed for 7.2 hours (10%) out of the 72 hour continuously cycling
rotation period.
There is a manual "FLOAT/AUTO-EQUALIZE" switch (SW4), which interrupts the motor circuit when
the batteries are to be left in "FLOAT" charge.
"FLOAT" and "EQUALIZE" indicating lights mounted on the instrument panel are standard, to indicate
the charging mode. The timer is used to drive a DP-DT relay (K6). One set of the relay’s contacts control
the float/equalize charging while the other set of contacts control the indicating lights.
17
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. COMMON ALARM RELAY (EJ0141) - WITH OPTIONAL BUZZER
Purpose: The Common Alarm Relay circuit provides an alarm indication via relay contacts and optional
buzzer when any one of the alarm circuits being monitored goes into its alarm state.
Description: The individual alarm contacts, that are closed when in the non-alarm condition, are wired
in a series loop configuration with the common alarm relay and its DC source. If one of the alarm circuits
activates, its relay contact will open and de-energize the common alarm relay providing a common alarm
condition. One set of contacts of the common alarm relay is connected to the remote alarm terminal strip
(TB3) at terminals 28, 29 & 30. If the optional buzzer (AU1) is required, an additional set of contacts is used
to activate it. A switch (SW13) is provided to turn off the optional audible alarm if desired.
10. MANUAL FLOAT / EQUALIZE SWITCH WITH INDICATOR LIGHTS (EJ0093)
Purpose: Front panel lights indicate whether the charger is in a FLOAT or EQUALIZE charging mode.
Description:
A double-pole, double-throw switch (SW7) is substituted for the normal
"FLOAT/EQUALIZE" switch (SW1). The second section of SW7 is wired to provide voltage to the proper
instrument panel light to denote the "FLOAT" or "EQUALIZE" position of SW7.
11. PARALLEL CHARGER OPERATION WITH 2% FORCED LOAD SHARING (EJ0133)
Installation: Using the interconnection cable supplied with the charger equipment, interconnect charger
"A" and charger "B" via the load share signal terminal block (TB4) as shown on EJ0133 on page 42. Also
refer to any instructions supplied with the manual for the option. DC load cables to be provided by the user.
Purpose: This option permits connecting two battery chargers in parallel to a common battery bank/load
in order to increase the total load capability or to provide redundancy for system reliability.
Description: The principle of operation is based on the ability to sense the current furnished by each
charger and to electronically force the two currents to be equal within a small percentage. Each individual
charger’s current is sensed by means of the shunt associated with the ammeter. The resultant voltages are
differentially amplified by the op-amp on each charger’s “paralleling” printed circuit board (A6). The output
of the op-amp in each charger is connected to the Control Module (A1) input. This output is combined with
the feedback signal from the front-panel "FLOAT" and "EQUALIZE" potentiometers (R3/R5). The net
effect is to adjust each charger so that the current furnished is sensed as being equal. The rectangular
potentiometer (R13) on the “paralleling” printed circuit board (A6) can be used to correct for any small
inequalities that may exist because of difference in shunts or system parameters.
Once the system is balanced, the two chargers will equally share any changes in the load. If either
charger is shut down or becomes inoperative, the other will assume the total load up to the point where its
current limit circuit operates. It is possible to operate each charger independently by setting the "LOAD
SHARE ON/OFF" switch (SW10) to the "OFF" position.
18
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. HIGH DC VOLTAGE CHARGER SHUTDOWN ALARM RELAY W/IND. LIGHT (EJ0592)
Purpose: The High DC Voltage Shutdown option functionally disables and locks-out the battery charger
whenever the output DC voltage exceeds the preset upper limit of charging voltage. This option is designed
to protect the batteries and/or load from an over-charge or over-voltage condition. In the case of parallel,
redundant chargers with charger shutdown, this option selectively detects and shuts down the faulty
charger/rectifier only. The option provides a front panel indicating light and alarm contacts wired to TB3
terminals 53, 54 & 55.
Description: The high DC voltage detector PC Board assembly (A13) is an HVA alarm module, which
closes a circuit on alarm and energizes the shutdown relay (K21). The shutdown relay disconnects the
Control Module (A1) from its AC supply thus removing the SCR trigger signals to the rectifier. This
disables the charger and output current goes to zero. After shutdown the circuit must be manually reset
before restarting the charger. A push-button “CHARGER RESET” momentary switch (SW14) is provided
on the front panel for this purpose. The high DC voltage detector circuit has a built-in, several second, timedelay to prevent charger shutdown due to transient voltage surges.
Adjustment for the shutdown circuit is provided by a potentiometer (R4) on the A13 assembly. It can be
field adjusted using the same procedure as for the HVA portion of the EJ0083 option on page 14.
The factory-preset thresholds for HDCV charger shutdown are as follows unless otherwise specified:
2.40 volts/cell for LEAD ACID
1.65 volts/cell for NICKEL CADMIUM
The above set points are the same as the High DC Voltage Alarm (HVA). If HVA and High DC Voltage
Shutdown options are ordered on the same charger, the shutdown thresholds are set as follows unless
otherwise specified:
2.45 volts/cell for LEAD ACID
1.70 volts/cell for NICKEL CADMIUM
14. END OF DISCHARGE ALARM RELAY (EJ0143) - WITH OPTIONAL INDICATOR LIGHT
Purpose and Description: The End of Discharge alarm option utilizes a printed circuit board assembly
(A8) to provide low-limit threshold voltage, set at the lowest safe voltage to which the batteries may be
discharged. Alarm contacts are wired to TB3 terminals 31, 32 & 33. These may be used to operate a system
load disconnect circuit by tripping a shunt trip DC load circuit breaker or opening a DC load contactor. An
optional "END OF DISCHARGE" front panel indicator lamp (DS12) may also be provided.
The factory-preset thresholds for alarm condition are as follows unless otherwise specified:
1.75 volts/cell for LEAD ACID
1.00 volts/cell for NICKEL CADMIUM
19
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). When the current limit circuit indicates that the charger output is
in current limit, the circuitry of A18 closes a relay (K24). This provides an alarm condition at terminals 25,
26 & 27 of TB3. A several second delay is built into A18 so that brief excursions into current limit caused
by load changes will not result in an erroneous alarm indication. When the battery charger comes out of
current limit, the alarm will be automatically reset.
16. CABINET HEATER STRIPS (EJ0145)
Purpose and Description: This option provides a method of maintaining a dry charger interior in high
humidity environments. Strip heaters (R68x), placed inside the charger cabinet, are physically shielded to
prevent accidental human contact. A customer-supplied 120 Volt single-phase source provides power for
this option, and is separate from the charger circuit. This customer power source, protected by circuit
breaker (CB6), is connected to terminal block (TB6) located inside the charger enclosure. The cabinet
heaters are "ON/OFF" type, and are controlled by a fixed thermostat (TH1). The thermostat opens on a rise
to approximately 80° F and resets (re-closes) at approximately 70° F.
17. HIGH / LOW AC VOLTAGE ALARM RELAYS WITH INDICATOR LIGHTS (EJ0155)
Purpose: The HLAC Alarm relay provides an indication whenever the AC input voltage deviates
beyond preset limits. The factory-set limits are 115% (high alarm) and 85% (low alarm) of the nominal AC
input voltage. Indicator lights on the battery charger front panel are provided for each condition.
Description: The HLAC Alarm relay operates similarly to the High-Low DC voltage alarm relay. An
AC Detector PC Board assembly (A11B) converts AC voltage to DC voltage. An Alarm PC Board assembly
(A11A) measures this filtered signal from A11B. If the measured signal is not within an acceptable range, an
alarm condition is provided at terminals 38, 39 & 40 (High ACV) and 41, 42 & 43 (Low ACV) of TB3.
Corresponding indicator lamps (DS18/DS17) are lighted on the instrument panel. A11A has a built-in delay
to prevent line voltage surges and sags from causing erroneous alarm indications. When the AC line returns
to within acceptable limits, the alarm indications will be reset.
18. OVER-TEMPERATURE ALARM RELAY (EJ0439) - WITH BUZZER OR INDICATOR LIGHT
Purpose: The Over-Temperature Alarm provides an alarm indication whenever the battery charger
internal components become overheated for any reason. This feature is standard on all battery chargers rated
over 300 ADC.
Description: A built-in audible alarm (DS19) is furnished, along with alarm contacts at TB3 terminals
47, 48 & 49. A normally open thermostat (TH2) is mounted on one or more of the heat-sensitive
components of the charger. If an over-temperature condition occurs, the thermostat closes the circuit to
DS19 and the alarm relay (K18). The audible alarm may be turned off with a switch (SW17) mounted inside
the charger enclosure. When the internal component temperature returns to an acceptable value, the alarm
relay is automatically reset. SW17 should then be returned to the normal position.
20
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.
Description: The CASM combines the monitoring and alarm functions of the High-Low AC Voltage
Alarm, High-Low DC Voltage Alarm, Ground Detection Relay Alarm, Charger Failure Alarm, and a
Common Alarm Relay into one printed circuit board assembly (A24). Each alarm in the CASM PC board
operates similarly to the alarms in the equivalent stand-alone option (see previous descriptions).
One or two form-C relay contacts are provided for each alarm function. These contacts (TB15-1 thru 18)
have a contact rating of 0.5A, 125 VAC/VDC resistive. Panel indicators (DS26-DS32) are provided for each
alarm function except the Common Alarm. In addition, a front-panel push-to-test switch (SW20) checks the
front panel indicators. SW20 tests only the CASM indicators. All relays reset automatically when the alarm
condition is corrected. All alarm relays have a 15 second time delay, except the Charger Failure Alarm.
You may operate the CASM Charger Failure Alarm in either of two modes:
1) True Charger Failure Alarm: In the True Charger Failure mode, the CASM PC board does not
report an alarm when the charger output current is zero, unless the charger actually has failed. The CASM
performs a periodic self-test to accomplish this.
2) Zero Current Alarm: In the Zero Current mode, the CASM reports an alarm whenever the charger
output current decreases to zero. In this mode, you may get false alarms if your normal load is very low, or if
you have two chargers connected in parallel.
To change the Charger Failure Alarm mode, set the switch (SW1) on A24 to the desired mode. To
change the interval of the self-test in True Charger Failure mode, move jumper (J11) on A24 to the desired
position (4 minutes or 8.5 minutes).
You can remove the Charger Failure Alarm from the Common Alarm circuit by moving jumper (J6) to
pins 2-3. This reduces the incidence of false common alarms, if your system has little or no continuous load
current, and you chose the Zero Current mode. This does not affect the operation of the Charger Failure
Alarm relay or panel indicator (DS30).
Installation: Remove the mating plug from the alarm terminal block (TB15). Wire remote alarm
indicators to contacts 1-18 on TB15 according to drawing EJ0837-XX. If you ordered two form-C contacts,
wire both plugs (TB15A & TB15B) according to the drawing. Be sure that your monitor, or other load, does
not exceed the relay contact rating on TB15.
Optional Wiring: The standard alarm terminal block
(TB15) supplied on the CASM features solder-less plug-in
terminals, accepting #18-14 AWG. wire. An optional
auxiliary alarm contact terminal block (TB15-AUX) or
blocks (TB15A-AUX & TB15B-AUX) may be supplied
external to the CASM PC Board assembly (A24). TB15AUX is supplied if the customer's remote alarm wiring
requirements exceed the specifications of the standard
terminal block (TB15). Contacts 1-18 on TB15-AUX are
wired directly to contacts 1-18 of TB15 on A24. TB15AUX terminal blocks feature 6-32 binder head screw
terminals, and will accept #22-16 AWG. wire.
If you have a grounded battery, disable the Ground Detection Alarm circuit by moving jumper (J7) to
pins 1-2, and by removing wire # 836/GR from R107 to “CHASSIS GROUND” (see EJ0837-XX). Putting
J7 on pins 2-3 enables the Ground Detection Alarm circuit.
21
SECTION VI
COMPONENT DESCRIPTION
SCR/SCRF SERIES BATTERY CHARGER - THREE PHASE MAIN FRAME
Circuit Symbol
(Note 2)
Spare?
(Note 1)
A1
B
Component Description
Three Phase Input Main Control Module PC Board
XA1
Holder for Control Module PC Board (A1)
SO1
Socket for Control Module PC Board (A1)
A14
B
Anode Firing Auxiliary Gate Drive Module PC Board
(supplied with 175 Adc nominal dc output or greater)
XA14
Holder for Gate Drive Module PC Board (A14)
SO14
Socket for Gate Drive Module PC Board (A14)
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 (SCRF-E models only)
C3
B
Snubber Capacitor
C6
B
EMI Suppression Capacitor
CB1
B
AC Input Circuit Breaker
CB2
B
DC Output Circuit Breaker
CR1
A, B
Polarity Diode
CR2
B
Blocking Diode
CR4
B
Rectifier Diode (may be part of SCR1)
CR5
B
Rectifier Diode (may be part of SCR2)
CR6
B
Rectifier Diode (may be part of SCR3)
DS1
B
"AC ON" Indicator Light
F1
A, B
XF1
F2
Main DC Fuse
Fuse Holder for F1
A, B
XF2
Redundant DC Fuse
(not supplied if dc breaker option is selected)
Fuse Holder for F2
L1
Main Inductor
L2
Filter Inductor (SCRF models only)
M1
B
DC Output Ammeter
M2
B
DC Output Voltmeter
22
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 (line 1)
SCR2
B
Silicon-Controlled Rectifier (line 2)
SCR3
B
Silicon-Controlled Rectifier (line 3)
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
Standard Manual Float/Equalize Switch
(not supplied when other equalize option provided)
Power Isolation Transformer
TB1
AC Input Terminal Block
TB2
DC Output Terminal Block
TB3
Remote Alarm Terminal Block
(supplied as-required with alarm relay options)
TB5
Internal (+/-) Signal Connection Terminal Block
TB15x
Remote Alarm Terminal Block
(supplied as-required with EJ0837 CASM option)
n/a
Wire Harness
n/a
Cabinet
n/a
Heat Sink(s)
NOTES:
1) "A" indicates recommended start-up spare part
"B" indicates recommended operating spare part
2) For component placement of circuit symbols, refer to Three Phase SCR/SCRF Series
Mainframe Schematic (JE5078-00) on Page 28
3) For mainframe replacement parts, refer to Section IX starting on Page 53
23
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.
Page
Circuit
Symbol
Spare?
(Note 1)
EJ0083
34
A2
SO2
DS3
DS4
R57
R75
TM4
SW4
K6
DS5
DS6
K1
DS2
R54
K2
K3
SW3
R59
R60
R83
R84
DS13
DS14
DS8
DS9
R50
R51
DS8
DS9
R50
R51
SW12
SW7
DS5
DS6
SW8
SW9
M4
B
EJ0084
34
EJ0085
35
EJ0086
35
EJ0088
36
EJ0089
36
EJ0093
37
EJ0094
37
EJ0095
38
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
Component Description
High/Low DC Voltage Alarm PC Board w/Relays
Socket for A2
Low Voltage Indicator Light
Hi Voltage Indicator Light
Voltage Dropping Resistor
Voltage Dropping Resistor
Percent Equalize Timer
Float/Auto Equalize Switch
Switching Relay
Float Indicator Light
Equalize Indicator Light
AC Failure Alarm Relay
AC Failure Indicator Light
Voltage Dropping Resistor
Positive Ground Detection Alarm Relay
Negative Ground Detection Alarm Relay
Reset Switch
Voltage Dropping Resistor
Voltage Dropping Resistor
Voltage Dropping Resistor
Voltage Dropping Resistor
Positive Ground Detection Indicator Light
Negative Ground Detection. Indicator Light
Positive Ground Detection Indicator Light
Negative Ground Detection Indicator Light
Voltage Dropping Resistor
Voltage Dropping Resistor
Positive Ground Detection Indicator Light
Negative Ground Detection Indicator Light
Voltage Dropping Resistor
Voltage Dropping Resistor
Test Switch
Float/Equalize Switch
Float Indicator Light
Equalize Indicator Light
Ground Detection/Ouput Switch
Ground Detection Positive/Negative Switch
Single Phase AC Voltmeter
24
Option
Number
Ref.
Page
Circuit
Symbol
Spare?
(Note 1)
EJ0096
38
EJ0097
EJ0120
39
39
TM3
DS5
DS6
TM3
A5
SO5
SH3
DS10
TB2
R71
R82
M4
SW5
AU1
SW13
R61
A3
SO3
R52
R85
DS7
K6
K7
TM1
TM2
R55
R56
CR52
SW11
DS5
DS6
A6
TB4
SW10
CT1
M3
CT1
CT2
CT3
SW6
M3
A18
SO18
K24
DS24
R77
M7
SH2
TB2
K8
R63
B
B
B
B
B
EJ0121
40
EJ0123
40
EJ0127
41
EJ0131
41
EJ0133
42
EJ0134
43
EJ0135
43
EJ0137
44
EJ0138
45
EJ0141
(w/o Buzzer)
45
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
Component Description
0-72 Hour Manual Timer
Float Indicator Light
Equalize Indicator Light
0-72 Hour Manual Timer
Battery Discharging Alarm PC Board w/Relay
Socket for A5
DC Current Shunt
Battery Discharging Indicator Light
3-Position DC Output Terminal Block (+batt/load, -load, -batt)
Voltage Dropping Resistor
Voltage Dropping Resistor
Three Phase AC Voltmeter
Phase Selector Switch
Common Alarm Buzzer
Buzzer ON/OFF Switch
Voltage Dropping Resistor
Charger Failure Alarm PC Board w/Relay
Socket for A3
Voltage Dropping Resistor
Voltage Dropping Resistor
Charger Failure Indicator Light
AC Failure Relay
Switching Relay
0-72 Hour Auto Timer
Time Delay Relay
Timing Resistor
Voltage Dropping Resistor
Zener Diode
Float Reset Switch
Float Indicator Light
Equalize Indicator Light
Load Sharing Control PC Board
Load Sharing Signal Terminal Block
Load Sharing ON/OFF Switch
AC Current Transformer
Single Phase AC Ammeter
AC Current Transformer (line 1)
AC Current Transformer (line 2)
AC Current Transformer (line 3)
Line Selector Switch
Three Phase AC Ammeter
Current Limit Alarm PC Board w/Relay
Socket for A18
Auxiliary Alarm Relay
Current Limit Indicator Light
Voltage Dropping Resistor
DC Zero-Center Ammeter
DC Current Shunt
3-Position DC Output Terminal Block (+batt/load, -load, -batt)
Common Alarm Relay
Voltage Dropping Resistor
25
Option
Number
Ref.
Page
Circuit
Symbol
Spare?
(Note 1)
EJ0141
(w/Buzzer)
46
B
EJ0143
46
EJ0145
47
EJ0155
47
K8
AU1
SW13
R61
R63
A8
SO8
R58
R76
DS12
CB6
TH1
TB6
TB14
R68x
A11A
A11B
SO11A
DS17
DS18
R78
R87
TH2
K18
DS19
SW17
A13
SO13
K21
DS20
SW14
R81
A24
SO12
DS26
DS27
DS28
DS29
DS30
DS31
DS32
R102
R103
R105
R104
R106
R107
SW20
TB15x
EJ0439
EJ0592
EJ0837
NOTES:
48
48
49
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
Component Description
Common Alarm Relay
Common Alarm Buzzer
Buzzer ON/OFF Switch
Voltage Dropping Resistor
Voltage Dropping Resistor
End of Discharge Alarm PC Board w/Relay
Socket for A8
Voltage Dropping Resistor
Voltage Dropping Resistor
End of Discharge Indicator Light
Heater Strip AC Input Circuit Breaker
Thermostat
Heater Strip Input Terminal Block
Interface Terminal Block
Heater Strip(s)
High-Low AC Voltage Alarm PC Board w/Relays
AC Detector PC Board
Socket for A11A
Low AC Voltage Indicator Light
High AC Voltage Indicator Light
Voltage Dropping Resistor
Voltage Dropping Resistor
Thermostat
Over Temperature Alarm Relay
Over Temperature Buzzer
Buzzer ON/OFF Switch
High DC Voltage Detector PC Board
Socket for A13
Charger Shutdown /Alarm Relay
Charger Shutdown Indicator Light
Charger Reset Switch
Voltage Dropping Resistor
Combined Alarm Status Monitor (CASM) PC Board
Socket for A24
High DC Voltage Alarm LED
Low DC Voltage Alarm LED
High AC Voltage Alarm LED
Low AC Voltage Alarm LED
Charger Failure Alarm LED
Positive Ground Detection LED
Negative Ground Detection LED
Voltage Dropping Resistor
Voltage Dropping Resistor
Voltage Dropping Resistor
Voltage Dropping Resistor
Voltage Dropping Resistor
Voltage Dropping Resistor
Lamp Test Switch
Remote Alarm Terminal Block(s)
1) "B" indicates recommended operating spare part
26
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. VOLTAGE
1
4
8
5
8
5
PC BOARD
WAVE FORMS
3
2
5
9
7
9
6
VOLTAGE
ADJUST
2
3
6
10
7
CURRENT
ADJUST
1
4
2
2
3
7
4
4
SHUNT OR
AMMETER
FLOAT / EQUALIZE
SWITCH OR TIMER
1
5
INTERNAL WIRING
3
3
7
11
7
10
4
4
3
2
2
5
EXTERNAL WIRING
REFER TO SECTION III FOR TROUBLE SHOOTING AND COMPONENT TESTING PROCEDURES
TABLE A
TROUBLE-SHOOTING CHART
4
4
4
5
8
VOLTAGE ADJ.
INEFFECTIVE
3
3
DC CIRCUIT
BREAKER
1
DIODES
6
2
AC CIRCUIT
BREKAER
1
SCRs
HIGH OUTPUT
CURRENT
1
LOW VOLTAGE
OR CURRENT
1
3
1
2
AC & LINE
TRANSFORMER
NO OUTPUT
AC BREAKER
TRIPPING
DC BREAKER
TRIPPING
PILOT LIGHT
DOES NOT LIGHT
DC VOLTMETER
5
DC AMMETER
2
6
5
3
FILTER CAPACITOR
1
12
FILTER INDUCTOR
2
13
SECTION VII
29
30
31
32
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 Chargers (Three Phase Mainframe)
PLEASE CONTACT YOUR SALES REPRESENTATIVE FOR DATA ON MODELS NOT LISTED.
SCR/SCRF BATTERY CHARGER MODEL
Enclosure Type
AC INPUT CURRENT
(MAXIMUM)
208Vac
240Vac
380Vac
480Vac
24V-50A
24V-75A
24V-100A
24V-125A
24V-150A
24V-175A
24V-200A
24V-250A
Style-2
Style-2
Style-3
Style-3
Style-3
Style-3
Style-3
Style-3
6.8
5.9
3.7
3.0
10.2
8.8
5.6
4.4
14
12
7.4
5.9
17
15
9.3
7.4
21
18
12
8.9
24
21
13
10
28
24
15
12
34
29
19
15
SYMBOL DESCRIPTION
C1/C2
C3
MANUFACTURER'S PART No.
FILTER CAPACITOR
RP0019-01
SNUBBER CAPACITOR
RP0023-00
CB1
AC INPUT
CIRCUIT BREAKER
CB2
DC OUTPUT
CIRCUIT BREAKER
CR1
POLARITY DIODE
RK0017-04
RK0017-04 RK0017-04
CR2
BLOCKING DIODE
RK0017-04
RK0028-00 RK0028-00
CR4 CR6
RECTIFIER DIODE
F1/F2
DC FUSE
RE0004-06 RE0004-09 RE0004-10 RE0004-11 RE0004-13 RE0004-13 RE0004-14 RE0004-15
XF1/
XF2
DC FUSE HOLDER
EI0068-00
L1
MAIN INDUCTOR
AP0481-00 AP0314-00
AP0339-00
AP0990-00
AP0572-00
AP0378-00
AP0762-00
AP0859-00
L2
FILTER INDUCTOR
AP0481-00 AP0314-00
AP0339-00
AP0990-00
AP0572-00
AP0378-00
AP0762-00
AP0859-00
M1
DC OUTPUT
AMMETER
RB0003-06 RB0003-07 RB0003-08 RB0003-09 RB0003-09 RB0003-10 RB0003-10 RB0003-10
M2
DC OUTPUT
VOLTMETER
RB0002-02
R1
BLEEDER /
FEEDBACK RESISTOR
RJ0022-02
R2
VOLTAGE DIVIDER
RESISTOR
RJ0004-12
SCR1 SCR3
208/240Vac
380/480Vac
RE0016-03 RE0016-04 RE0016-05 RE0016-05 RE0016-06 RE0016-07 RE0016-08 RE0016-09
RE0016-03 RE0016-03 RE0016-03 RE0016-04 RE0016-04 RE0016-05 RE0016-05 RE0016-06
RE0015-34 RE0015-36 RE0217-03 RE0217-04 RE0217-05 RE0217-07 RE0217-07 RE0038-07
part of SCR1-SCR3
RK0017-04 RK0017-04 RK0017-04
EI0068-00
part of I/O panel
SILICON-CONTROLLED
RECTIFIER
RM0001-00
SH1
DC AMMETER SHUNT
RB0008-01 RB0008-02 RB0008-03 RB0008-04 RB0008-04 RB0008-05 RB0008-05 RB0008-05
SS1
DC OUTPUT SURGE
SUPPRESSOR
SS2 SS4
AC INPUT SURGE
SUPPRESSOR
T1
POWER ISOLATION
TRANSFORMER
RM0001-01
RM0010-02 RM0010-02 RM0010-02
RK0031-00
208/240Vac
380/480Vac
208/240Vac
380/416Vac
480Vac
RK0038-00
RK0038-01
AH0682-00 AH0682-00 AH0685-00 AH0685-00 AH0685-00 AH0688-00 AH0688-00 AH0688-00
AH1029-00 AH0684-00 AH0687-00 AH0687-00 AH0687-00 AH0690-00 AH0690-00 AH0690-00
AH0683-00 AH0683-00 AH0686-00 AH0686-00 AH0686-00 AH0689-00 AH0689-00 AH0689-00
TB1
AC INPUT
TERMINAL BLOCK
RC0012-00 RC0012-00
RC0012-01 RC0012-01
part of I/O panel
TB2
DC OUTPUT
TERMINAL BLOCK
RC0014-00
FB0313-00
RC0014-01
part of I/O panel
PARTS COMMON TO ALL THREE PHASE SCR/SCRF SERIES CHARGERS
SYM
A1
A14
B5
C6
C6
DS1
R3
PART NO.
GK0048-82
EN0007-00
PJ0001-00
RP0043-20
RP0046-12
RA0001-05
RJ0014-06
DESCRIPTION
CONTROL MODULE PC BOARD
GATE DRIVE MODULE (=>175 ADC)
ENCLOSURE FAN (HIGHER RATED UNITS)
SUPPRESSION CAPACITOR (24/48/130 VDC)
SUPPRESSION CAPACITOR (260 VDC)
"AC ON" INDICATOR
FLOAT ADJUSTMENT POTENTIOMETER
SYM
R4
R5
SO1
SO14
SW1
XA#
XC#
PART NO.
RJ0003-84
RJ0014-06
EJ0617-00
EJ0617-00
RD0001-00
EJ0616-00
PE0068-00
TO ORDER PARTS, PLEASE CONTACT YOUR SALES REPRESENTATIVE.
PLEASE ORDER BY QUANTITY, PART NUMBER AND CIRCUIT SYMBOL FROM TABLES ABOVE.
HAVE YOUR BATTERY CHARGER MODEL NUMBER AND SERIAL NUMBER AVAILABLE.
53
DESCRIPTION
VOLTAGE DIVIDER RESISTOR
EQUALIZE ADJUSTMENT POTENTIOMETER
PLUG FOR A1 PC BOARD
PLUG FOR A14 PC BOARD
MANUAL FLOAT/EQUALIZE SWITCH
PC BOARD HOLDERS
FILTER CAPACITOR BRACKET
ELECTRICAL RATINGS AND REPLACEMENT PARTS
SCR/SCRF Series Battery Chargers (Three Phase Mainframe)
PLEASE CONTACT YOUR SALES REPRESENTATIVE FOR DATA ON MODELS NOT LISTED.
SCR/SCRF BATTERY CHARGER MODEL
Enclosure Type
AC INPUT CURRENT
(MAXIMUM)
208Vac
240Vac
380Vac
480Vac
48V-50A
48V-75A
48V-100A
48V-125A
48V-150A
48V-175A
48V-200A
48V-250A
Style-2
Style-2
Style-3
Style-3
Style-3
Style-3
Style-3
Style-4
14
12
7.7
6.1
19
16
10.4
8.2
25
22
14
11
31
27
17
13
37
32
20
16
44
38
24
19
50
43
27
22
62
54
34
27
SYMBOL DESCRIPTION
C1/C2
C3
MANUFACTURER'S PART No.
FILTER CAPACITOR
RP0019-01
SNUBBER CAPACITOR
RP0023-00
CB1
AC INPUT
CIRCUIT BREAKER
CB2
DC OUTPUT
CIRCUIT BREAKER
CR1
POLARITY DIODE
RK0017-04
RK0017-04 RK0017-04
CR2
BLOCKING DIODE
RK0017-04
RK0028-02 RK0028-02
CR4 CR6
RECTIFIER DIODE
F1/F2
DC FUSE
RE0004-06 RE0004-09 RE0004-10 RE0004-11 RE0004-13 RE0004-13 RE0004-14 RE0004-15
XF1/
XF2
DC FUSE HOLDER
EI0068-00
L1
MAIN INDUCTOR
AP0481-00 AP0314-00
AP0339-00
AP0572-00
AP0572-00
AP0378-00
AP0762-00
AP0619-00
L2
FILTER INDUCTOR
AP0481-00 AP0314-00
AP0339-00
AP0572-00
AP0572-00
AP0378-00
AP0762-00
AP0619-00
M1
DC OUTPUT
AMMETER
RB0003-06 RB0003-07 RB0003-08 RB0003-09 RB0003-09 RB0003-10 RB0003-10 RB0003-16
M2
DC OUTPUT
VOLTMETER
RB0002-03
R1
BLEEDER /
FEEDBACK RESISTOR
RJ0022-03
R2
VOLTAGE DIVIDER
RESISTOR
RJ0008-21
SCR1 SCR3
208/240Vac
380/480Vac
RE0016-05 RE0016-07 RE0016-07 RE0016-09 RE0016-09 RE0016-11 RE0016-11 RE0016-13
RE0016-03 RE0016-04 RE0016-05 RE0016-05 RE0016-05 RE0016-07 RE0016-08 RE0016-09
RE0015-34 RE0015-36 RE0217-03 RE0217-04 RE0217-05 RE0217-07 RE0217-07 RE0038-07
part of SCR1 - SCR3
RK0017-04 RK0017-04 RK0017-04
EI0068-00
part of I/O panel
SILICON-CONTROLLED
RECTIFIER
RM0001-00 RM0001-01 RM0001-01 RM0001-01 RM0001-01 RM0010-06 RM0010-06 RM0010-06
SH1
DC AMMETER SHUNT
RB0008-01 RB0008-02 RB0008-03 RB0008-04 RB0008-04 RB0008-05 RB0008-05 RB0008-10
SS1
DC OUTPUT SURGE
SUPPRESSOR
SS2 SS4
AC INPUT SURGE
SUPPRESSOR
T1
POWER ISOLATION
TRANSFORMER
RK0031-00
208/240Vac
380/480Vac
208/240Vac
380/416Vac
480Vac
RK0038-00
RK0038-01
AH0694-00 AH0694-00 AH0697-00 AH0697-00 AH0697-00 AH0700-00 AH0700-00
AH0696-00 AH0696-00 AH0699-00 AH0699-00 AH0699-00 AH0702-00 AH0702-00
AH0695-00 AH0695-00 AH0698-00 AH0698-00 AH0698-00 AH0701-00 AH0701-00
TB1
AC INPUT
TERMINAL BLOCK
RC0012-00 RC0014-00
RC0012-01 RC0014-01
part of I/O panel
TB2
DC OUTPUT
TERMINAL BLOCK
RC0014-00
FB0313-00
RC0014-01
part of I/O panel
AI0762-00
AI0764-00
AI0763-00
PARTS COMMON TO ALL THREE PHASE SCR/SCRF SERIES CHARGERS
SYM
A1
A14
B5
C6
C6
DS1
R3
PART NO.
GK0048-82
EN0007-00
PJ0001-00
RP0043-20
RP0046-12
RA0001-05
RJ0014-06
DESCRIPTION
CONTROL MODULE PC BOARD
GATE DRIVE MODULE (=>175 ADC)
ENCLOSURE FAN (HIGHER RATED UNITS)
SUPPRESSION CAPACITOR (24/48/130 VDC)
SUPPRESSION CAPACITOR (260 VDC)
"AC ON" INDICATOR
FLOAT ADJUSTMENT POTENTIOMETER
SYM
R4
R5
SO1
SO14
SW1
XA#
XC#
PART NO.
RJ0003-84
RJ0014-06
EJ0617-00
EJ0617-00
RD0001-00
EJ0616-00
PE0068-00
TO ORDER PARTS, PLEASE CONTACT YOUR SALES REPRESENTATIVE.
PLEASE ORDER BY QUANTITY, PART NUMBER AND CIRCUIT SYMBOL FROM TABLES ABOVE.
HAVE YOUR BATTERY CHARGER MODEL NUMBER AND SERIAL NUMBER AVAILABLE.
54
DESCRIPTION
VOLTAGE DIVIDER RESISTOR
EQUALIZE ADJUSTMENT POTENTIOMETER
PLUG FOR A1 PC BOARD
PLUG FOR A14 PC BOARD
MANUAL FLOAT/EQUALIZE SWITCH
PC BOARD HOLDERS
FILTER CAPACITOR BRACKET
ELECTRICAL RATINGS AND REPLACEMENT PARTS
SCR/SCRF Series Battery Chargers (Three Phase Mainframe)
PLEASE CONTACT YOUR SALES REPRESENTATIVE FOR DATA ON MODELS NOT LISTED.
SCR/SCRF BATTERY CHARGER MODEL 130V-25A
Enclosure Type
AC INPUT CURRENT
(MAXIMUM)
208Vac
240Vac
380Vac
480Vac
130V-35A
130V-50A
130V-75A
130V-100A
130V-125A
130V-150A
130V-200A
130V-250A
Style-2
Style-2
Style-3
Style-3
Style-3
Style-3
Style-4
Style-4
Style-5
18
16
9.6
7.8
27
23
15
12
33
29
18
14
47
41
26
20
64
55
35
28
80
69
44
35
94
81
51
41
126
109
69
55
155
134
85
67
SYMBOL DESCRIPTION
C1/C2
C3
MANUFACTURER'S PART No.
FILTER CAPACITOR
RP0019-03
SNUBBER CAPACITOR
RP0023-00
CB1
AC INPUT
CIRCUIT BREAKER
CB2
DC OUTPUT
CIRCUIT BREAKER
RE0015-28 RE0015-31 RE0015-34 RE0015-36 RE0217-03 RE0217-04 RE0217-05 RE0217-07 RE0038-07
CR1
POLARITY DIODE
RK0009-04 RK0013-04
RK0017-04
RK0017-04
CR2
BLOCKING DIODE
RK0013-04 RK0014-04
RK0017-04
RK0028-02
CR4 CR6
RECTIFIER DIODE
F1/F2
DC FUSE
RE0003-01 RE0003-04 RE0004-06 RE0004-09 RE0004-10 RE0004-11 RE0004-13 RE0004-14 RE0004-15
XF1/
XF2
DC FUSE HOLDER
EI0053-00
L1
MAIN INDUCTOR
AP0604-00 AP0379-01
AP0481-00
AP0377-00
AP0827-00
AP0572-00
AP0572-00
AP0516-00
AP0806-00
L2
FILTER INDUCTOR
AP0604-00 AP0604-00
AP0481-00
AP0377-00
AP0827-00
AP0572-00
AP0572-00
AP0516-00
AP0806-00
M1
DC OUTPUT
AMMETER
RB0003-04 RB0003-05 RB0003-06 RB0003-07 RB0003-08 RB0003-09 RB0003-09 RB0003-10 RB0003-10
M2
DC OUTPUT
VOLTMETER
RB0002-04
R1
BLEEDER /
FEEDBACK RESISTOR
RJ0023-02
R2
VOLTAGE DIVIDER
RESISTOR
RJ0008-32
SCR1 SCR3
RE0016-06 RE0016-08 RE0016-09 RE0016-11 RE0016-13 RE0016-15 RE0190-06 RE0190-07 RE0218-06
RE0016-04 RE0016-05 RE0016-06 RE0016-08 RE0016-10 RE0016-11 RE0016-14 RE0016-15 RE0190-05
part of SCR1 - SCR3
SILICON-CONTROLLED
RECTIFIER
SH1
DC AMMETER SHUNT
SS1
DC OUTPUT SURGE
SUPPRESSOR
SS2 SS4
AC INPUT SURGE
SUPPRESSOR
T1
208/240Vac
380/480Vac
POWER ISOLATION
TRANSFORMER
EI0053-00
part of I/O panel
RM0001-00
n/a
n/a
RK0017-05
RM0001-01
RM0010-06
RB0008-01 RB0008-02 RB0008-03 RB0008-04 RB0008-04 RB0008-05 RB0008-05
RK0038-00
208/240Vac
380/480Vac
208/240Vac
380/416Vac
480Vac
RK0038-00
RK0038-01
AH1018-00 AH0706-00 AH0706-00 AH0709-00 AI0738-00
AH1019-00 AH0708-00 AH0708-00 AH0711-00 AI0740-00
AH0770-00 AH0707-00 AH0707-00 AH0710-00 AI0739-00
AI0843-00
AI0845-00
AI0844-00
TB1
AC INPUT
TERMINAL BLOCK
RC0012-00 RC0012-00
RC0012-01 RC0012-01
part of I/O panel
TB2
DC OUTPUT
TERMINAL BLOCK
RC0012-00 RC0014-00
RC0012-01 RC0014-01
part of I/O panel
AI0843-00
AI0845-00
AI0844-00
AI0744-00
AI0746-00
AI0745-00
AI0744-00
AI0746-00
AI0745-00
PARTS COMMON TO ALL THREE PHASE SCR/SCRF SERIES CHARGERS
SYM
A1
A14
B5
C6
C6
DS1
R3
PART NO.
GK0048-82
EN0007-00
PJ0001-00
RP0043-20
RP0046-12
RA0001-05
RJ0014-06
DESCRIPTION
CONTROL MODULE PC BOARD
GATE DRIVE MODULE (=>175 ADC)
ENCLOSURE FAN (HIGHER RATED UNITS)
SUPPRESSION CAPACITOR (24/48/130 VDC)
SUPPRESSION CAPACITOR (260 VDC)
"AC ON" INDICATOR
FLOAT ADJUSTMENT POTENTIOMETER
SYM
R4
R5
SO1
SO14
SW1
XA#
XC#
PART NO.
RJ0003-84
RJ0014-06
EJ0617-00
EJ0617-00
RD0001-00
EJ0616-00
PE0068-00
TO ORDER PARTS, PLEASE CONTACT YOUR SALES REPRESENTATIVE.
PLEASE ORDER BY QUANTITY, PART NUMBER AND CIRCUIT SYMBOL FROM TABLES ABOVE.
HAVE YOUR BATTERY CHARGER MODEL NUMBER AND SERIAL NUMBER AVAILABLE.
55
DESCRIPTION
VOLTAGE DIVIDER RESISTOR
EQUALIZE ADJUSTMENT POTENTIOMETER
PLUG FOR A1 PC BOARD
PLUG FOR A14 PC BOARD
MANUAL FLOAT/EQUALIZE SWITCH
PC BOARD HOLDERS
FILTER CAPACITOR BRACKET
ELECTRICAL RATINGS AND REPLACEMENT PARTS
SCR/SCRF Series Battery Chargers (Three Phase Mainframe)
PLEASE CONTACT YOUR SALES REPRESENTATIVE FOR DATA ON MODELS NOT LISTED.
SCR/SCRF BATTERY CHARGER MODEL 130V-300A 130V-400A
Enclosure Type
AC INPUT CURRENT
(MAXIMUM)
208Vac
240Vac
380Vac
480Vac
130V-600A
260V-25A
260V-50A
260V-75A
260V-100A
260V-150A
260V-200A
Style-5
Style-5
Style-5
Style-3
Style-3
Style-4
Style-4
Style-5
Style-5
187
162
102
81
249
216
136
108
372
322
204
161
31
27
17
13
61
53
33
26
92
80
50
40
122
106
67
53
184
159
101
80
245
212
134
106
SYMBOL DESCRIPTION
C1/C2
C3
MANUFACTURER'S PART No.
FILTER CAPACITOR
RP0019-03
SNUBBER CAPACITOR
208/240Vac
380/480Vac
RP0019-05
RP0023-00
RP0023-00
RE0218-06 RE0223-02 RE0064-10
RE0190-06 RE0190-08 RE0190-10
RE0016-09 RE0016-13 RE0218-03 RE0218-04 RE0218-06 RE0223-02
RE0016-06 RE0016-10 RE0016-13 RE0016-15 RE0190-06 RE0190-08
RE0038-08 RE0052-11 RE0052-13
RE0015-28 RE0015-34 RE0015-36 RE0217-03 RE0217-05 RE0217-07
CB1
AC INPUT
CIRCUIT BREAKER
CB2
DC OUTPUT
CIRCUIT BREAKER
CR1
POLARITY DIODE
RK0017-04
RK0028-02
RK0009-05
RK0017-05
CR2
BLOCKING DIODE
RK0028-02
PM0003-00 RK0013-05
RK0017-05
CR4 CR6
RECTIFIER DIODE
RK0017-05
F1/F2
DC FUSE
XF1/
XF2
DC FUSE HOLDER
part of
SCR1-3
part of SCR1 - SCR3
RK0017-06
RE0004-18 RE0004-19 RE0004-21
RE0006-07 RE0006-11 RE0006-14 RE0006-15 RE0006-18 RE0006-20
part of I/O panel
part of I/O panel
L1
MAIN INDUCTOR
AP0942-00 AP0727-00
AP0816-00
AP0305-00 AP0377-00
AP0803-00
AP0876-00
AP0730-01
AP0913-00
L2
FILTER INDUCTOR
AP0942-00 AP0727-00
AP0816-00
AP0305-00 AP0377-00
AP0803-00
AP0876-00
AP0730-01
AP0913-00
M1
DC OUTPUT
AMMETER
RB0003-16 RB0003-16 RB0003-11
RB0003-04 RB0003-06 RB0003-07 RB0003-08 RB0003-09 RB0003-10
M2
DC OUTPUT
VOLTMETER
RB0002-04
RB0002-05
R1
BLEEDER /
FEEDBACK RESISTOR
RJ0023-02
RJ0024-01
R2
VOLTAGE DIVIDER
RESISTOR
RJ0008-32
RJ0008-32
RJ0008-40
SCR1 SCR3
SILICON-CONTROLLED
RECTIFIER
RM0008-02
PM0002-00
SH1
DC AMMETER SHUNT
RB0008-10
RB0008-06
SS1
DC OUTPUT SURGE
SUPPRESSOR
SS2 SS4
AC INPUT SURGE
SUPPRESSOR
T1
POWER ISOLATION
TRANSFORMER
208/240Vac
380/480Vac
208/240Vac
380/416Vac
480Vac
AI0873-00
AI0899-00
AI0815-00
RM0001-00
n/a
RB0008-01 RB0008-02 RB0008-03 RB0008-04 RB0008-05
RK0038-00
RK0038-01
RK0038-00
RK0038-01
consult
factory
AI0814-00
RK0038-00
RK0038-01
AI0753-00 AI0753-00
AI0755-00 AI0755-00
AI0754-00 AI0754-00
AI0914-00
AI0916-00
AI0915-00
AH0712-00
AH0714-00
AH0713-00
RM0010-08
AI0750-00
AI0752-00
AI0850-00
TB1
AC INPUT
TERMINAL BLOCK
part of I/O panel
part of I/O panel
TB2
DC OUTPUT
TERMINAL BLOCK
part of I/O panel
part of I/O panel
AI1119-00
AI1121-00
AI1120-00
AI1090-00
AI1092-00
AI1091-00
PARTS COMMON TO ALL THREE PHASE SCR/SCRF SERIES CHARGERS
SYM
A1
A14
B5
C6
C6
DS1
R3
PART NO.
GK0048-82
EN0007-00
PJ0001-00
RP0043-20
RP0046-12
RA0001-05
RJ0014-06
DESCRIPTION
CONTROL MODULE PC BOARD
GATE DRIVE MODULE (=>175 ADC)
ENCLOSURE FAN (HIGHER RATED UNITS)
SUPPRESSION CAPACITOR (24/48/130 VDC)
SUPPRESSION CAPACITOR (260 VDC)
"AC ON" INDICATOR
FLOAT ADJUSTMENT POTENTIOMETER
SYM
R4
R5
SO1
SO14
SW1
XA#
XC#
PART NO.
RJ0003-84
RJ0014-06
EJ0617-00
EJ0617-00
RD0001-00
EJ0616-00
PE0068-00
TO ORDER PARTS, PLEASE CONTACT YOUR SALES REPRESENTATIVE.
PLEASE ORDER BY QUANTITY, PART NUMBER AND CIRCUIT SYMBOL FROM TABLES ABOVE.
HAVE YOUR BATTERY CHARGER MODEL NUMBER AND SERIAL NUMBER AVAILABLE.
56
DESCRIPTION
VOLTAGE DIVIDER RESISTOR
EQUALIZE ADJUSTMENT POTENTIOMETER
PLUG FOR A1 PC BOARD
PLUG FOR A14 PC BOARD
MANUAL FLOAT/EQUALIZE SWITCH
PC BOARD HOLDERS
FILTER CAPACITOR BRACKET
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
RA0001-05
RA0001-05
DS6
Equalize Indicating Light
RA0001-04
RA0001-04
RA0001-04
RA0001-04
RA0001-04
EJ0617-00
Switching Relay
RF0010-00
RF0010-00
RF0010-00
RF0010-00
RF0010-00
SW4
Float/Auto Equalize Switch
RD0001-01
RD0001-01
RD0001-01
RD0001-01
RD0001-01
TM4
Percent Equalize Timer (0-72 hour)
RF0005-01
RF0005-01
RF0005-01
RF0005-01
RF0005-01
DS2
AC Failure Indicating Light
RA0001-00
RA0001-01
RA0001-01
RA0001-06
RA0001-06
K1
AC Failure Alarm Relay
RF0010-00
RF0010-00
RF0010-00
RF0010-00
RF0010-00
R54
Voltage Dropping Resistor
n/a
n/a
RJ0028-24
n/a
RJ0008-13
DS13
Ground Detection Indicating Light
RA0001-00
RA0001-01
RA0001-01
RA0001-06
RA0001-06
DS14
Ground Detection Indicating Light
RA0001-00
RA0001-01
RA0001-01
RA0001-06
RA0001-06
K2
Positive Ground Detection Relay
RF0010-01
RF0010-03
RF0010-05
RF0010-06
RF0010-06
K3
Negative Ground Detection Relay
RF0010-01
RF0010-03
RF0010-05
RF0010-06
RF0010-06
Relay Ballast Resistors
RJ0003-44
RJ0005-58
RJ0007-67
RJ0007-89
RJ0015-48
n/a
n/a
RJ0028-24
n/a
RJ0008-13
Relay Reset Switch
RD0001-02
RD0001-02
RD0001-02
RD0001-02
RD0001-02
DS8, DS9
Ground Detection Indicating Lights
RA0001-00
RA0001-01
RA0001-01
RA0001-01
RA0001-01
R50, R51
Lamp Ballast Resistors
RJ0007-34
RJ0005-55
RJ0007-72
RJ0035-42
RJ0035-45
DS8, DS9
Ground Detection Indicating Lights
RA0001-00
RA0001-01
RA0001-01
RA0001-01
RA0001-01
R50, R51
Lamp Ballast Resistors
RJ0007-34
RJ0005-55
RJ0007-72
RJ0035-42
RJ0035-45
Lamp/Ground Test Switch
RD0001-08
RD0001-08
RD0001-08
RD0001-08
RD0001-08
Float Indicating Light
RA0001-05
RA0001-05
RA0001-05
RA0001-05
RA0001-05
DS5
Lamp Ballast Resistors
DS6
Equalize Indicating Light
RA0001-04
RA0001-04
RA0001-04
RA0001-04
RA0001-04
SW7
Float/Equalize Switch
RD0001-01
RD0001-01
RD0001-01
RD0001-01
RD0001-01
SW8
Ground Detection/Output Switch
RD0001-04
RD0001-04
RD0001-04
RD0001-04
RD0001-04
SW9
Ground Detection Positive/Negative Switch
RD0001-01
RD0001-01
RD0001-01
RD0001-01
RD0001-01
M4
EJ0097
GK0045-01 (specify dc voltage)
RA0001-06
EJ0095
EJ0096
MANUFACTURER'S PART NO.
RA0001-00
SW12
EJ0094
260 Vdc
High Voltage Indicating Light
SW3
EJ0093
130 Vdc
Low Voltage Indicating Light
R83, R84
EJ0089
48 Vdc
DS4
R59, R60
EJ0088
DESCRIPTION
24 Vdc
DS3
K6
EJ0085
12 Vdc
AC Voltmeter
120 Vac
RB0006-04
RB0006-04
RB0006-04
RB0006-04
RB0006-04
208 - 240 Vac
RB0006-05
RB0006-05
RB0006-05
RB0006-05
RB0006-05
380 - 480 Vac
RB0006-21
RB0006-21
RB0006-21
RB0006-21
RB0006-21
DS5
Float Indicating Light
RA0001-05
RA0001-05
RA0001-05
RA0001-05
RA0001-05
DS6
Equalize Indicating Light
RA0001-04
RA0001-04
RA0001-04
RA0001-04
RA0001-04
TM3
Manual Equalize Timer (0-72 hour)
RF0003-02
RF0003-02
RF0003-02
RF0003-02
RF0003-02
TM3
Manual Equalize Timer (0-72 hour)
RF0003-02
RF0003-02
RF0003-02
RF0003-02
RF0003-02
TO ORDER PARTS, PLEASE CONTACT YOUR SALES REPRESENTATIVE.
PLEASE ORDER BY QUANTITY, PART NUMBER AND CIRCUIT SYMBOL FROM TABLES ABOVE.
HAVE YOUR BATTERY CHARGER MODEL NUMBER AND SERIAL NUMBER AVAILABLE.
57
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.
Battery Discharging Alarm PC Board
GK0052-01
GK0052-02
GK0052-05
GK0052-06
GK0052-07
Battery Discharging Alarm Indicating Light
RA0001-00
RA0001-02
RA0001-02
RA0001-04
RA0001-04
n/a
RJ0007-52
RJ0035-34
RJ0022-04
RJ0023-04
R82
Ballast Resistor for DS10
n/a
n/a
RJ0007-72
n/a
RJ0008-13
25 - 40 Adc
RB0008-00
RB0008-00
RB0008-00
RB0008-00
RB0008-00
50 - 60 Adc
RB0008-01
RB0008-01
RB0008-01
RB0008-01
RB0008-01
TB2
EJ0127
48 Vdc
Ballast Resistor for A5
SO5
EJ0123
DESCRIPTION
24 Vdc
R71
SH3
EJ0121
12 Vdc
M4
DC Current Shunt
75 Adc
RB0008-02
RB0008-02
RB0008-02
RB0008-02
RB0008-02
100 - 150 Adc
RB0008-04
RB0008-04
RB0008-04
RB0008-04
RB0008-04
175 - 250 Adc
RB0008-05
RB0008-05
RB0008-05
RB0008-05
RB0008-05
300 - 400 Adc
RB0008-10
RB0008-10
RB0008-10
RB0008-10
RB0008-10
6 - 20 Adc
RC0006-01
RC0006-01
RC0006-01
RC0012-00
RC0012-00
25 - 30 Adc
RC0012-00
RC0012-00
RC0012-00
RC0012-00
RC0012-00
35 - 60 Adc
RC0014-00
RC0014-00
RC0014-00
RC0014-00
RC0014-00
75 Adc
FB0314-00
FB0314-00
FB0314-00
208 - 240 Vac
RB0006-05
RB0006-05
RB0006-05
RB0006-05
RB0006-05
380 - 480 Vac
RB0006-21
RB0006-21
RB0006-21
RB0006-21
RB0006-21
Plug for A5
EJ0617-00
DC Output Terminal
AC Voltmeter
part of I/O Panel
SW5
Phase Selector Switch
RD0005-00
RD0005-00
RD0005-00
RD0005-00
RD0005-00
AU1
Common Alarm Buzzer
RA0004-00
RA0004-00
RA0004-00
RA0004-00
RA0004-00
R61
Buzzer Ballast Resistor
n/a
n/a
n/a
RJ0015-46
RJ0035-48
SW13
Buzzer ON/OFF Switch
RD0001-00
RD0001-00
RD0001-00
RD0001-00
RD0001-00
Charger Failure Alarm Control PC Board
GK0055-01
GK0055-01
GK0055-01
GK0055-01
GK0055-01
DS7
Charger Failure Alarm Indicating Light
RA0001-00
RA0001-01
RA0001-01
RA0001-06
RA0001-06
R52
Ballast Resistor for A3
n/a
RJ0028-37
RJ0015-33
RJ0022-04
RJ0022-05
n/a
n/a
RJ0028-24
n/a
RJ0008-13
A3
R85
Ballast Resistor for DS7
SO3
Plug for A3
CR52
Zener Diode
n/a
RK0005-22
RK0005-22
RK0005-22
DS5
Float Indicating Light
RA0001-05
RA0001-05
RA0001-05
RA0001-05
DS6
EJ0617-00
Equzlize Indicating Light
RA0001-04
RA0001-04
RA0001-04
RA0001-04
K6
AC Failure Relay
RF0010-00
RF0010-00
RF0010-00
RF0010-00
K7
Switching Relay
RF0010-00
RF0010-00
RF0010-00
RF0010-00
R55
Timing Resistor
RJ0004-40
RJ0004-40
RJ0004-40
RJ0004-40
R56
Ballast Resistor for TM2
n/a
RJ0015-30
RJ0020-03
RJ0022-06
SW1
Equalize / Auto-Equalize Switch
RD0001-00
RD0001-00
RD0001-00
RD0001-00
SW11
Float Reset Switch
RD0001-02
RD0001-02
RD0001-02
RD0001-02
TM1
Auto-Equalize Timer (0-72 hour)
RF0034-00
RF0034-00
RF0034-00
RF0034-00
TM2
Time Delay Relay
RF0007-00
RF0007-00
RF0007-00
RF0007-00
A6
SW10
TB4
n/a
Load Sharing Control PC Board
EJ0144-00
EJ0144-00
EJ0144-00
EJ0144-00
EJ0144-00
Load Sharing ON/OFF Switch
RD0001-00
RD0001-00
RD0001-00
RD0001-00
RD0001-00
Load Sharing Signal Terminal Block
RC0005-02
RC0005-02
RC0005-02
RC0005-02
RC0005-02
TO ORDER PARTS, PLEASE CONTACT YOUR SALES REPRESENTATIVE.
PLEASE ORDER BY QUANTITY, PART NUMBER AND CIRCUIT SYMBOL FROM TABLES ABOVE.
HAVE YOUR BATTERY CHARGER MODEL NUMBER AND SERIAL NUMBER AVAILABLE.
58
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.
75 Aac max
AT0057-01
AT0057-01
AT0057-01
AT0057-01
AT0057-01
100 Aac max
AT0057-02
AT0057-02
AT0057-02
AT0057-02
AT0057-02
10 Aac max
RB0006-00
RB0006-00
RB0006-00
RB0006-00
RB0006-00
15 Aac max
RB0006-17
RB0006-17
RB0006-17
RB0006-17
RB0006-17
20 Aac max
RB0006-01
RB0006-01
RB0006-01
RB0006-01
RB0006-01
30 Aac max
RB0006-19
RB0006-19
RB0006-19
RB0006-19
RB0006-19
50 Aac max
RB0006-02
RB0006-02
RB0006-02
RB0006-02
RB0006-02
75 Aac max
RB0006-22
RB0006-22
RB0006-22
RB0006-22
RB0006-22
100 Aac max
RB0006-06
RB0006-06
RB0006-06
RB0006-06
RB0006-06
60:5 ratio
AT0057-00
AT0057-00
AT0057-00
AT0057-00
AT0057-00
75:5 ratio
AT0057-01
AT0057-01
AT0057-01
AT0057-01
AT0057-01
100:5 ratio
AT0057-02
AT0057-02
AT0057-02
AT0057-02
AT0057-02
10 Aac max
RB0006-23
RB0006-23
RB0006-23
RB0006-23
RB0006-23
20 Aac max
RB0006-25
RB0006-25
RB0006-25
RB0006-25
RB0006-25
30 Aac max
RB0006-26
RB0006-26
RB0006-26
RB0006-26
RB0006-26
50 Aac max
RB0006-27
RB0006-27
RB0006-27
RB0006-27
RB0006-27
75 Aac max
RB0006-22
RB0006-22
RB0006-22
RB0006-22
RB0006-22
100 Aac max
RB0006-06
RB0006-06
RB0006-06
RB0006-06
RB0006-06
SW6
Phase Selector Switch
RD0006-01
RD0006-01
RD0006-01
RD0006-01
RD0006-01
A18
Current Limit Alarm PC Board
GK0045-05
GK0045-05
GK0045-05
GK0045-05
GK0045-05
Current Limit Alarm Indicating Light
RA0001-06
RA0001-06
RA0001-06
RA0001-06
RA0001-06
K24
Auxiliary Alarm Relay
RF0010-00
RF0010-00
RF0010-00
RF0010-00
RF0010-00
R77
Ballast Resistor for A18
n/a
RJ0028-36
RJ0015-32
RJ0022-04
RJ0022-05
DS24
SO18
Plug for A18
EJ0138
M7
SH2
TB2
DC Ammeter
DC Current Shunt
DC Output Terminal
EJ0617-00
6 - 15 Adc
RB0003-19
RB0003-19
RB0003-19
RB0003-19
RB0003-19
16 - 25 Adc
RB0003-17
RB0003-17
RB0003-17
RB0003-17
RB0003-17
26 - 50 Adc
RB0003-22
RB0003-22
RB0003-22
RB0003-22
RB0003-22
51 - 75 Adc
RB0003-18
RB0003-18
RB0003-18
RB0003-18
RB0003-18
76 - 100 Adc
RB0003-13
RB0003-13
RB0003-13
RB0003-13
RB0003-13
101 - 200 Adc
RB0003-15
RB0003-15
RB0003-15
RB0003-15
RB0003-15
201 - 300 Adc
RB0003-20
RB0003-20
RB0003-20
RB0003-20
RB0003-20
301 - 500 Adc
RB0003-21
RB0003-21
RB0003-21
RB0003-21
RB0003-21
51 - 75 Adc
RB0008-01
RB0008-01
RB0008-01
RB0008-01
RB0008-01
76 - 100 Adc
RB0008-02
RB0008-02
RB0008-02
RB0008-02
RB0008-02
101 - 200 Adc
RB0008-04
RB0008-04
RB0008-04
RB0008-04
RB0008-04
201 - 300 Adc
RB0008-05
RB0008-05
RB0008-05
RB0008-05
RB0008-05
301 - 500 Adc
RB0008-10
RB0008-10
RB0008-10
RB0008-10
RB0008-10
6 - 20 Adc
RC0006-01
RC0006-01
RC0006-01
RC0006-01
RC0006-01
25 - 35 Adc
RC0012-00
RC0012-00
RC0012-00
RC0012-00
RC0012-00
40 - 60 Adc
RC0014-00
RC0014-00
RC0014-00
RC0014-00
RC0014-00
75 Adc
FB0314-00
FB0314-00
FB0314-00
FB0314-00
FB0314-00
TO ORDER PARTS, PLEASE CONTACT YOUR SALES REPRESENTATIVE.
PLEASE ORDER BY QUANTITY, PART NUMBER AND CIRCUIT SYMBOL FROM TABLES ABOVE.
HAVE YOUR BATTERY CHARGER MODEL NUMBER AND SERIAL NUMBER AVAILABLE.
59
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 Switch
RA0001-00
RA0001-00
RA0001-00
RA0001-00
RA0001-00
RA0001-00
RA0001-01
A8
GK0045-01 (specify dc voltage)
RA0001-01
RA0001-01
RA0001-06
Ballast Resistor for A8
n/a
RJ0028-36
RJ0015-33
RJ0022-04
RJ0022-05
End of Discharge Alarm Indicating Light
n/a
n/a
RJ0028-24
RJ0035-42
RJ0008-13
R76
Ballast Resistor for DS12
SO8
Plug for A8
CB6
Cabinet Heater AC Input Circuit Breaker
RE0015-05
R68
Cabinet Heater Strip(s)
RG0003-00
EJ0617-00
TB6
Heater Strip AC Input Terminal Block
RC0006-00
TB14
Interface Terminal Block
RC0006-00
TH1
Cabinet Heater Control Thermostat
A11A
High/Low AC Voltage Alarm Control PC Board
A11B
High/Low AC Voltage Alarm Detector PC Board
DS17
Low AC Voltage Alarm Indicating Light
RA0001-00
RA0001-01
RA0001-01
RA0001-01
RA0001-06
RG0002-01
High AC Voltage Alarm Indicating Light
GK0045-01 (12 Vdc)
EN0003-00
RA0001-06
RA0001-06
RA0001-06
RA0001-06
RA0001-06
R78
Ballast Resistor for A11A
n/a
RJ0028-36
RJ0015-33
RJ0022-04
RJ0022-05
R87
Ballast Resistor for DS17
n/a
n/a
RJ0028-24
RJ0035-42
RJ0008-13
SO11A
Plug for A11A
EJ0617-00
DS19
Over-Temperature Alarm Buzzer
RA0004-01
RA0004-01
RA0004-01
RA0004-01
RA0004-01
DS23
Over-Temperature Alarm Indicating Light
RA0001-06
RA0001-06
RA0001-06
RA0001-06
RA0001-06
K18
Over-Temperature Alarm Relay
RF0010-00
RF0010-00
RF0010-00
RF0010-00
RF0010-00
Buzzer ON/OFF Switch
RD0001-00
RD0001-00
RD0001-00
RD0001-00
RD0001-00
TH2
Over-Temperature Thermostat
RG0002-05
RG0002-05
RG0002-05
RG0002-05
RG0002-05
A13
Hight DC Voltage Shutdown Control PC Board
SW17
EJ0592
End of Discharge Alarm Control PC Board
R58
DS18
EJ0439
MANUFACTURER'S PART NO.
R61
DS12
EJ0145
DESCRIPTION
DS20
GK0045-01 (specify dc voltage)
High DC Voltage Shutdown Indicating Light
RA0001-06
RA0001-06
RA0001-06
RA0001-06
RA0001-06
K21
High DC Voltage Shutdown Control Relay
RF0010-08
RF0010-08
RF0010-08
RF0010-08
RF0010-08
R81
Ballast Resistor for A13
n/a
RJ0028-36
RJ0015-33
RJ0022-04
RJ0022-05
SO13
Plug for A13
EJ0617-00
EJ0617-00
EJ0617-00
EJ0617-00
EJ0617-00
SW14
Hight DC Voltage Shutdown Reset Switch
RD0002-01
RD0002-01
RD0002-01
RD0002-01
RD0002-01
EJ0803
K32
AC Failure Time Delay Relay (5 second)
EJ0826
R6
Temperature Comp. Series Resistor (Lead Acid)
RJ0062-90
RJ0063-57
RJ0064-00
RJ0064-46
RJ0076-77
R7
Temperature Compensation Parallel Resistor
RJ0063-05
RJ0063-34
RJ0060-58
RJ0064-04
RJ0064-29
R8
Temperature Compensation Thermistor
RG0010-04
RG0010-03
RG0010-01
RG0010-01
(2) RG0010-01
RF0016-00
TO ORDER PARTS, PLEASE CONTACT YOUR SALES REPRESENTATIVE.
PLEASE ORDER BY QUANTITY, PART NUMBER AND CIRCUIT SYMBOL FROM TABLES ABOVE.
HAVE YOUR BATTERY CHARGER MODEL NUMBER AND SERIAL NUMBER AVAILABLE.
60
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.
Combined Alarm-Status Monitor
Control PC Board
1 Form-C
2 Form-C
DS26
High DCVoltage Alarm Indicating Light
DS27
Low DC Voltage Alarm Indicating Lights
RA0008-00
RA0008-00
RA0008-00
RA0008-00
RA0008-00
DS28
High AC Voltage Alarm Indicating Light
RA0008-00
RA0008-00
RA0008-00
RA0008-00
RA0008-00
DS29
Low AC Voltage Alarm Indicating Lights
RA0008-00
RA0008-00
RA0008-00
RA0008-00
RA0008-00
DS30
Charger Failure Alarm Indicating Light
RA0008-00
RA0008-00
RA0008-00
RA0008-00
RA0008-00
DS31
Positive Ground Detection Indicating Light
RA0008-00
RA0008-00
RA0008-00
RA0008-00
RA0008-00
DS32
Negative Ground Detection Indicating Light
RA0008-00
RA0008-00
RA0008-00
RA0008-00
RA0008-00
R102
Ballast Resistor for A24
RJ0007-32
RJ0035-25
RJ0035-32
RJ0023-03
RJ0024-02
R103
Prescaler Network Resistor
RJ0003-90
RJ0004-07
RJ0004-16
RJ0004-26
RJ0004-34
R105
Prescaler Network Resistor
RJ0003-90
RJ0004-04
RJ0004-14
RJ0004-25
RJ0004-32
R104
Prescaler Network Resistor
RJ0003-98
RJ0003-98
RJ0003-98
RJ0003-98
RJ0003-98
R106
Prescaler Network Resistor
RJ0003-98
RJ0003-98
RJ0003-98
RJ0004-00
RJ0003-98
n/a
n/a
n/a
n/a
n/a
R107
Ground Detection Scaling Resistor
SO12
Plug for A24
SW20
Lamp Test Switch
RD0002-00
RD0002-00
RD0002-00
RD0002-00
RD0002-00
TB15
Remote Alarm Terminal Block(s)
RC0108-16
RC0108-16
RC0108-16
RC0108-16
RC0108-16
CR9
AC Failure Time Delay Relay Regulator Diode
n/a
n/a
n/a
n/a
RK0005-38
DS2
AC Failure Alarm Indicating Light
RA0001-00
RA0001-01
RA0001-01
RA0001-06
RA0001-06
RC0035-01
K1
Line Sensing Relay
RF0010-00
RF0010-00
RF0010-00
RF0010-00
RF0010-00
K30
AC Failure Time Delay Relay
RF0015-05
RF0015-09
RF0015-13
RF0015-01
RF0015-01
R46
Ballast Resistor for K30
n/a
n/a
n/a
n/a
RJ0007-96
R54
Ballast Resistor for DS2
n/a
n/a
RJ0028-24
n/a
RJ0008-13
DS5
Float Indicating Light
RA0001-05
RA0001-05
RA0001-05
RA0001-05
RA0001-05
DS6
Equalize Indicating Light
RA0001-04
RA0001-04
RA0001-04
RA0001-04
RA0001-04
SW7
Equalize / Timer Switch
RD0001-04
RD0001-04
RD0001-04
RD0001-04
RD0001-04
TM3
Manual Equalize Timer (0-72 hour)
RF0003-02
RF0003-02
RF0003-02
RF0003-02
RF0003-02
EJ0895
M1
M2
SH1
EJ0967
12 Vdc
Digital DC Ammeter
6 - 16 Adc
RB0025-10
20 - 40 Adc
RB0025-12
50 - 125 Adc
RB0025-14
150 - 250 Adc
RB0025-16
300 - 600 Adc
RB0025-19
6 - 16 Adc
RB0008-17
Digital DC Voltmeter
DC Ammeter Shunt
RB0025-00
20 - 40 Adc
RB0008-00
50 - 125 Adc
RB0008-03
150 - 250 Adc
RB0008-05
300 - 600 Adc
RB0008-18
DS43
Common Alarm Buzzer for CASM (EJ0837)
RA0004-00
SW13
Buzzer Control Switch
RD0001-00
TO ORDER PARTS, PLEASE CONTACT YOUR SALES REPRESENTATIVE.
PLEASE ORDER BY QUANTITY, PART NUMBER AND CIRCUIT SYMBOL FROM TABLES ABOVE.
HAVE YOUR BATTERY CHARGER MODEL NUMBER AND SERIAL NUMBER AVAILABLE.
61
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 (JA5036-00). 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. Any document numbers, revision levels, or revision dates featured
on the first two or last two pages of this manual refer to the cover artwork only.
DOCUMENT INFORMATION:
Document Number:
Revision Level:
Engineering Change Number:
Electronic Filename:
Last Date Saved:
Last Date Printed:
JA5036-00
1
20053
[JA5036-00.pdf]
[12/27/2005 3:41 PM]
[12/27/2005 3:42 PM]
ON-LINE AVAILABILITY:
Electronic versions of this SCR/SCRF Series Battery Charger manual, saved in Adobe Acrobat Portable
Document Format (PDF), are readily available online for downloading and printing. Please contact your sales
representative for document availability, or visit the manufacturer's web site listed on the back cover of this manual.
STANDARD DRAWINGS:
Standard drawings for the SCR/SCRF Series Battery Charger, saved in Adobe Acrobat Portable Document
Format (PDF), are readily available online for downloading and printing. Please contact your sales representative for
standard drawing availability, or visit the manufacturer's web site listed on the back cover of this manual.
PARTS DATA PACKAGE:
Any job-specific custom Parts Data Package supplied with this battery charger and/or this manual, supercede
the standard parts listed on pages 53-61.
CUSTOM DRAWINGS:
A customized record drawing package is available for your SCR/SCRF Series battery charger, featuring an
itemized internal component layout, electrical schematic with component ratings, and a full connection diagram. If
the standard drawings featured in this manual are not sufficient, please contact your sales representative for drawing
availability from the battery charger manufacturer.
Any job-specific custom drawings supplied with this battery charger and/or this manual, supercede the
standard drawings featured on pages 28 and 32-52. The standard drawings and corresponding page numbers featured
in these sections may not be included with custom printed manuals, when job-specific custom drawings are supplied.
62
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.
¨ OK
¨ OK
¨ OK
¨ OK
• Terminations at battery or bus are tight and corrosion free.
¨ OK
• Measure at TB1-L1, TB1-L2 & TB1-L3 (3 Phase only) using ac
voltmeter. Value must be within +10%, -12% of nominal.
Input
• Measure at TB2(+) and TB2(-) using dc voltmeter. Value should agree
with front panel voltmeter within 2%, and must be correct values for
your battery. If the charger is using a temperature compensation probe,
see the curve in Section VII of user's manual to determine correct
battery voltage.
• Measure at battery terminals using ac voltmeter set to milliVolts scale.
• Check against specification listed on charger's Data Nameplate.
Exercise front panel
controls
Results
Vac
Float
Vdc
Equalize
Vdc
Ripple
mVac
• Switch from Float to Equalize, then back to Float.
¨ OK
• Verify front panel meters functional
¨ Volts OK
¨ Amps OK
• Verify adjustment capabilities of float and equalize potentiometers.
¨ Float OK
¨ Equalize OK
Check voltage settings
Final checks
• Verify voltage setting per battery manufacturer recommendations.
• Utilize float and equalize potentiometers to make any required
adjustments. See Section IV of user's manual.
¨ Float OK
¨ Equalize OK
• Close and latch front panel door.
¨ OK
¨ OK
• Restore charger to normal operation.
Step (optional features)
Instructions
Results
Check alarm settings
• See Section V of SCR/SCRF Series battery charger user’s manual for
calibration of alarms.
Combined Alarm Status
Monitor (CASM)
• See service instruction JD0036-00 for CASM alarm adjustments
• Test integrity of LEDs by pressing "lamp test" button on front panel.
¨ OK
Check integrity of
remote wiring
• Internal temperature compensation network wiring. See instruction
JA5022-00 and Section VII of user's manual.
¨ OK
• Temperature compensation remote probe. See instruction JA5022-00
and Section VII of user's manual.
¨ OK
Step (10-year repair)
Instructions
Replace capacitors
• See supplied Parts Data Package report or standard replacement parts
table for battery charger manufacturer's part number of optional dc
filtering electrolytic capacitors (C1/C2).
• Order and replace capacitors
¨ HVDC OK
¨ LVDC OK
Results
¨ OK
SCR/SCRF SERIES
BASIC START-UP AND
SHUT DOWN INSTRUCTIONS
START UP
Switch "ON" DC Circuit Breaker.
Switch "ON" AC Circuit Breaker.
SHUT DOWN
Switch "OFF" AC Circuit Breaker.
DC Circuit Breaker may be left "ON" or "OFF".
NOTE
If Circuit Breakers are not installed, use external devices to
remove power to and from the battery charger.
WARNING
AC and DC Circuit Breakers do not remove power to some
components within the battery charger enclosure.
Wait one minute after all external power is removed before
accessing internal components.
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