model nrs-12/40 battery charger

model nrs-12/40 battery charger
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NATIONAL
RAILWAY
SUPPLY
Installing, Operating and
Service Instructions for the
NRS-12/40 Solid State Charger
MODEL NRS-12/40 BATTERY CHARGER
PLEASE SAVE THESE IMPORTANT SAFETY AND OPERATING INSTRUCTIONS
For correct operation of the equipment, it is important to read and be familiar
with this entire manual before installing and operating the charger.
DO NOT DISCARD THIS MANUAL AFTER READING.
LOOK FOR THIS SYMBOL TO POINT OUT SAFETY PRECAUTIONS. IT MEANS:
BECOME ALERT—YOUR SAFETY IS INVOLVED. IF YOU DO NOT FOLLOW THESE
SAFETY INSTRUCTIONS, INJURY OR PROPERTY DAMAGE CAN OCCUR.
g. De-energize all AC and DC power
connections before servicing this unit. If
injury does occur, apply standard treatment
for electric shock and, if necessary, consult
with a physician.
1. IMPORTANT SAFETY INSTRUCTIONS
a. Before using the battery charger, read all the
instructions and caution markings on the
battery charger, the battery, and all of the
products using the battery.
h. The charger is not for outdoor use. Do not
expose the charger to rain or snow.
b. Do not touch the uninsulated parts of the AC
input or the DC wires, the charger's binding
posts, or the battery terminals as there is a
possibility of electric shock.
c.
Batteries produce hydrogen gas while
operating, which can explode if ignited.
Never smoke, use an open flame, or create
sparks in the vicinity of the battery. Ventilate
the area well when the battery is charging in
an enclosed area.
d. Batteries contain caustic material which may
cause burns. Do not get in eyes, on skin, or
clothing. If the gelled or liquid content of the
batteries contacts the skin or clothing, wash
the area thoroughly with water. In the case
of contact with the eyes, flush immediately
with clean water for 15 minutes and obtain
medical attention.
j.
Do not disassemble the charger. Have the
charger examined by a NATIONAL
RAILWAY SUPPLY service agent or a local
qualified service center. If the charger is
reassembled incorrectly, damage to the
charger and the batteries or an electric shock
may result.
The NATIONAL RAILWAY SUPPLY charger, model
12/40, is a convection-cooled, solid state, SCR
regulated charger that provides either a constant
current or constant voltage output. The charger can
be set to charge batteries within a voltage range of
10.00 to 19.99 volts for gel-cell, liquid lead-acid,
nickel cadmium, nickel iron, and starved electrolytic
batteries.
Only qualified personnel should program or
service this equipment.
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Do not operate the charger if it has received
a sharp blow, been dropped, or otherwise
damaged.
2. DESCRIPTION
e. Connect or disconnect the battery plug only
when the charger output is off to prevent
arcing or burning.
f.
i.
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3. THEORY OF OPERATION
The control module has a temperature compensation
range between 32°F and 95°F (0°C and 35°C) that
does not allow charger voltage to increase or
decrease beyond the calculated values.
When the charger is connected to the desired AC
voltage source (115 or 230), the transformer creates
auxiliary voltages for the electronic control module.
The electronic control module controls and monitors
the charger so it will perform properly.
The
transformer also supplies the power output used for
charging the batteries and provides electrical
isolation between the charger's output and the AC
source.
Example 1:
If a 13.38 volt battery is charging and the
temperature increases to 95°F, then the output
voltage decreases to 13.06 volts.
13.38 - .018 (95°F - 77°F) = 13.06
Example 2:
The charger's output current flows through a shunt
and is sensed by the electronic control module along
with the charger's output voltage. These values are
converted into drive pulses for the SCRs by the
control module. This pulsating charge current (a
pulse occurs each time an SCR is on) is then filtered
by a large capacitor and the batteries to provide a
smooth output.
If a 14.50 volt battery is charging and the
temperature increases to 95°F, then the output
voltage decreases to 14.15 volts.
14.50 - .0195 (95°F - 77°F) = 14.15
Example 3:
If 15.61 volt batteries are charging and the
temperature decreases to 32°F, the output voltage
increases to 16.56 volts.
The charger is an "IE" profile which is: (a) High rate
constant current, and (b) Constant voltage. When
the charger is first started, the SCRs will conduct for
a certain portion of the sinusoidal anode voltage to
provide the required charging current at the low level
of battery voltage. In this start region, a constant
current is applied to the battery.
The SCR
conduction will then increase as the battery voltage
increases in order to provide a higher output voltage
while maintaining a constant charging current.
15.61 - .021 (32°F - 77°F) = 16.56
4. RECEIVING AND INSTALLING THE CHARGER
Proper installation of the charger is important in order
to achieve good charger performance and to prevent
damage to the charger and batteries. When a
charger is received, a check for possible in-transit
damage should be made. If any damage is found, it
should be reported as a claim to the carrier. To
permit free air flow for convention cooling, allow two
inches (2") minimum between the charger sides and
other equipment and four inches (4") minimum on top
of the charger.
When the battery voltage reaches the float voltage
(the voltage set with the switches), the SCRs will
start to decrease their output. This causes the
charger to automatically change from a constant
current charge region to a constant voltage charge
region. As the batteries become fully charged, the
output current decreases. A continuous constant
float voltage will be supplied to the batteries to
maintain their charge.
WARNING: NEVER PLACE ANYTHING ON
TOP OF THE CHARGER WHILE OPERATING.
DAMAGE TO THE CHARGER OR BATTERIES
COULD OCCUR.
Another feature of the charger is temperature
compensation, which keeps the batteries from getting
underor
over-charged.
TEMPERATURE
COMPENSATION ONLY OCCURS WHEN USING A
TEMPERATURE PROBE. The RED LED on the
front of the charger will be off when using a functional
temperature probe. If the LED is on, either a
temperature probe is not being used, or the
temperature probe is working improperly.
WARNING: THE CHARGER MUST BE SET UP
FOR THE PROPER USER SPECIFICATIONS
BEFORE STARTING THE INITIAL CHARGE.
5. AC ELECTRICAL SUPPLY
Temperature compensation uses a temperature
reference of 77°F (25°C), a voltage reference of 2.23
volts (the voltage of a standard gel-cell battery at
77°F), and a compensation value of 3.0 mV per °F,
or 5.4 mV per °C. The equivalent equation for the
compensated voltage is:
The charger must be connected to a single-phase,
50/60 Hertz AC power source, which can be either
115 or 230 VAC. Use 8 or 10 AWG wire for the AC
power input. Quarter-inch (¼") ring terminals are
required for proper connection to the AC input
binding posts (A.A.R.). Remove the small door cover
on the front of the charger by removing the two
retaining screws. On the panel behind the binding
posts is a diagram showing the proper jumper
connections for the different AC voltages.
Vcomp = V – k (t - 77°F)
Where V is the voltage of the battery at 77°F, t is
the temperature in °F, and k = V (.003 / 2.23).
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THE AC IS DISCONNECTED BECAUSE OF THE
ENERGY STORED IN THE CAPACITOR.
WARNING:
IMPROPER
JUMPER
CONNECTION MAY CAUSE SEVERE DAMAGE
TO THE CHARGER AND THE BATTERY.
7. TEMPERATURE PROBE
Configure the jumpers for your AC voltage source
(refer to the jumper diagram above). Place the AC
ring terminals on the binding posts and tighten the
post nuts.
The external temperature probe is an optional way of
extending battery life by using temperature
compensation. One end of the temperature probe
cable has a three-pin plug, which plugs into a
receptacle labeled TEMP PROBE on the front of the
charger. The other end of the cable has the
temperature sensor sealed either in a terminal or
small metal box.
WARNING:
FAILURE TO PROPERLY
CONNECT THE AC VOLTAGE CONDUCTORS
COULD CAUSE SERIOUS DAMAGE TO THE
CHARGER.
IMPROPER GROUNDING CAN
RESULT IN THE RISK OF AN ELECTRIC SHOCK.
DO NOT OPERATE THE CHARGER WITHOUT
PROPER GROUNDING.
WARNING: IT IS IMPORTANT TO MOUNT
THE
TEMPERATURE
PROBE
ON
THE
BATTERIES FOR PROPER TEMPERATURE
COMPENSATION. IF THIS CANNOT BE DONE,
LOCATE THE PROBE AS LOW AS POSSIBLE IN
THE BUNGALOW OR CABINET.
6. DC OUTPUT
The DC output wires, 6 AWG or larger, are
connected on the two right-most binding posts as
labeled on the panel behind the binding posts
(positive on the left and negative on the right). The
DC cables should have quarter-inch (¼") ring
terminals for connecting them to the binding posts.
Check to make sure the polarity of the DC output
wires is the same as those connected to the battery.
The charger will not operate in a reversed polarity
condition. WHEN CONNECTING THE DC WIRES
TO THE CHARGER WITH THE AC POWER
DISCONNECTED, A SPARK MAY OCCUR. This is
caused by the output capacitors being charged by
the batteries. If the DC polarity is reversed, a circuit
breaker will protect the charger from internal
damage. Correct the reversed wires and push the
circuit breaker button back in. Replace the door
cover on the front of the charger after tightening all of
the binding post nuts.
Terminal-Type Probe
The terminal-type probe should be attached to the
negative (-) battery post near the center of the battery
pack. If the threaded stud is long enough above the
battery jumper nut, attach the probe with another nut.
Torque this nut to proper speci-fications. If the stud
is too short, the nut holding the jumper wire will need
to be removed. Open or remove the load and
charging circuits to the batteries. Remove the nut
holding the jumper and add the probe, then torque
the nut to the proper specifications. Then close or
connect the load and charging circuits back to the
batteries.
Box-Type Probe
The metal box has a high performance contact
adhesive tape for attaching it to the battery. To
attach, clean a spot for the probe on the middle
battery about three inches (3") down from the top of
the battery. Make sure the spot is free of all dirt and
oil or the probe will not adhere properly. For proper
adhesion, the battery surface must be cleaned with
isopropyl alcohol.
Ideal application temperature
range is between 70 and 100°F. Initial application to
WARNING:
DO NOT TOUCH THE
CHARGER'S TERMINALS OR AN ELECTRIC
SHOCK COULD OCCUR.
A VOLTAGE IS
PRESENT ON THE DC TERMINALS EVEN AFTER
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9. MAINTENANCE
surfaces at temperatures below 50°F is not
recommended. Under cold conditions, the surface
should be warmed before application. Once properly
applied, low temperatures will not affect the bond
strength.
The battery charger requires minimal maintenance.
It should be kept clean and all connections are to be
periodically tightened. BE SURE THE CHASSIS IS
SECURELY GROUNDED. If any problem cannot be
resolved, consult the nearest NRS service agent.
Remove the adhesive's protective strip and press the
probe firmly against the battery to ensure good
adhesion.
10. SERVICING
Securely fasten the temperature probe cable to
protect the probe from being torn from the
battery. Secure the probe's cable to a fixed object to
ensure the probe will not be pulled loose. Use a
cable tie mount on the battery or on the adjacent
battery, if necessary.
If the battery charger operates improperly, follow the
steps below.
a. Begin by checking the voltage switches to
verify their settings against the specifications of the batteries.
b. Next, remove the small cover on the front of
the charger and make sure all of the binding
post nuts are tight. Also check the jumper
tap configuration for the AC voltage used.
8. OPERATION
The battery charger is adjustable with the three
rotary switches on the front of the charger. The
switches (settable between 10.00 and 19.99)
determine the float voltage for the batteries. SET
THE FLOAT VOLTAGE TO THE BATTERY
MANUFACTURER'S SPECIFIED VOLTAGE FOR
77°F. The charger will then electronically charge the
batteries to the voltage specified on the switches. To
set the switches, use a small screw-driver and turn
the switch so that the arrow head on the slot is
pointing to the desired number. Set the switches in
the following manner. If the desired battery voltage is
13.38 volts, set the top switch to 3, the middle switch
to 3, and the bottom switch to 8 (see the figure
below).
This will provide you with the proper
charging voltage. The tens digit is always a one (1)
and cannot be changed. BE SURE EACH SWITCH
IS SET ON A NUMBER AND NOT BETWEEN
NUMBERS. If a switch is set between numbers, the
output current will go to zero and the yellow charging
LED will flash.
c.
Check the fuses to make sure they have not
blown.
d. Check the circuit breaker to see if it has
opened and push it in to reset it, if
necessary.
e. Check the polarity between DC output and
the battery and make sure their connections
are tight.
f.
If the steps above do not solve the problem,
contact your local NRS service agent.
11. CHARGER SPECIFICATIONS
AC INPUT VOLTAGE:
115 VAC (100-128) or 230 VAC (200-256)
AC INPUT CURRENT:
12.4 amps for 115 VAC (full power)
6.2 amps for 230 VAC (full power)
AC INPUT FREQUENCY:
48 – 65 Hertz (single phase)
AC LINE REGULATION:
For a constant output current at 2.00 volts/cell
+8.7% for 10 cells
+24.4% for 8 cells
AC FUSES:
MDA 10 or equivalent
POWER FACTOR:
Percentage at 20.0 amps DC current
76% at 14.0 volts
The charger does not have a power switch. When
the AC power is applied to the charger, the DC
output will start and the yellow LED will be on. To
turn off the charger, disconnect the AC power
source.
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86% at 18.0 volts
DC OUTPUT:
Voltage range
Current maximum
4
10.00 – 19.99 + 0.1 volts
40.0 + 5 amps
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DC OUTPUT RIPPLE (at battery terminals):
WEIGHT, NET:
0.25V p-p at 40.0 amps, 12.0 volts
52.0 lbs.
0.1V p-p at 2.0 amps, 13.38 volts
DIMENSIONS:
TEMPERATURE COMPENSATION:
W = 18¼"
H = 11¼"
D = 9¾"
3 + .25mV per °F per cell
12. PARTS LIST
The following is a list of parts found in the NRS Model 12/40. When replacing a part, use only original factory
replacement parts of the correct size and rating.
PART NO.
QTY.
DESCRIPTION
21865S
17011S
18696S
14241S
29101S
14123S
14126S
29741S
29742S
04401S
15032S
14897S
22908S
14786S
14484S
03837S
12717S
15028S
14789S
14759S
14197S
31126B
22943S
27319S
22984S
23059S
15194S
1
2
1
2
1
1
1
1
1
1
2
1
1
2
1
2
1
2
1
2
4
1
1
1
1
1
1
TRANSFORMER ASSEMBLY
SCR ASSEMBLY
SHUNT ASSEMBLY
AC INPUT JUMPERS
CONTROL MODULE (W/ ELECTRONIC BOARD #21175)
TEMP TRANSDUCER, 10' (BOX W/ ADHESIVE)
TEMP TRANSDUCER, 30' (BOX W/ ADHESIVE)
TEMP TRANSDUCER, 10' (W/ TERMINAL)
TEMP TRANSDUCER, 30' (W/ TERMINAL)
TRANSFORMER CAP
OUTPUT CAP
CIRCUIT BREAKER ASSEMBLY
COVER ASSEMBLY
DIODE ASSEMBLY
TERMINAL TAP STRIP
FUSEHOLDER, ASSEMBLY
VARISTOR ASSEMBLY W/ CAP, VR1
FUSE
TAP STRIP ASSEMBLY, W/ I/O STUDS
VARISTOR ASSEMBLY, VR2
BUSHINGS, 1" DIA.
VARISTOR ASSEMBLY, AC, 320V, Lot size 10
AMMETER, 50 AMP, SNAP-IN
AMMETER, 50 AMP, CORNER MOUNT
BASE ASSEMBLY
CONTROL CABLE
HEATSINK ASSEMBLY W/SCR
The adhesive used on the temperature probes (#14123S and #14126S) is 3M Scotch #Y-9473 which is a
thermally conducting two-sided adhesive tape. If a replacement adhesive is needed, use this type of tape or an
equivalent adhesive.
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13. WIRING DIAGRAM
AC
LINE
SHUNT
SCR
AC FUSE
1
A
G
+
VR1
D
C
BLK
SCR
C
G
BLK
4
RED
AC FUSE
ORG
115V
JUMPER
SETTING
SHOWN
-BATTERY
CIRCUIT
BREAKER
3
AC
LINE
BLK
BLK
BLK
A
+BATTERY
VR2
BLK
2
BLK
A
BLK
C
J1-1
J1-7
J1-9
C1
YEL
BRN
BRN
GND
WHT
5
J1-8
ELECTRONIC
CONTROL
MODULE
J1-10
P1
J1-11
J1-3
J1-12
J1-4
J1-6
6
GRY
BLU
VLT
3
2
1
REMOTE
TEMPERATURE
PROBE
J1-5
7
WHT
8
J1-1
J1-2
J1-3
J1-4
J1-5
J1-6
J1-7
J1-8
J1-9
J1-10
J1-11
J1-12
-BATTERY
NOT USED
TMP PROBE (-)
GRAY
VIOLET TEMP PROBE (+)
WHITE
AC XFRMR #8
WHITE
AC XFRMR #5
RED
+BATTERY
YELLOW SHUNT+
ORANGE SHUNTBROWN SCR
BROWN SCR
BLUE
TEMP PROBE SENSE
BLACK
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CONNECTOR
DETAIL
P1
C
D
VR1
VR2
OUTPUT CAPACITOR
DIODE ASSEMBLY
VARISTOR WITH CAP
VARISTOR
3
2
1
AS VIEWED FROM OUTSIDE CHARGER
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