INSTALLATION AND OPERATING INSTRUCTIONS
FerroCharge® INDUSTRIAL BATTERY CHARGERS
PM990-1897-00, ISSUE 5
Issue History ISSUE
PAGE(S)
DESCRIPTION
APP'D / DATE
1
All
Original Release
8/4/03
2
56
Correct 575v 3 –ph primary connection
4/16/04
3
53 to 60
Remove optional ammeter and reference to TB3 watering
2/15/05
4
5, 50-52
Add models, add French safety instructions
5/13/05
5
9,50-55, 59,62,65-82
Add Models, Cabinet B, and three transformer diagrams, add TVS to diagrams, MC4 photos SEE ECN 15704
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MCM 9/20/06
Table of Contents 1.
IMPORTANT SAFETY INSTRUCTIONS.......................................................................................................................... 7
2.
RECEIVING AND INSTALLATION .................................................................................................................................. 8 2.1. RECEIVING ......................................................................................................................................................................... 8 2.2. IDENTIFICATION ................................................................................................................................................................. 8 2.3. STORAGE ........................................................................................................................................................................... 9 2.4. LOCATION .......................................................................................................................................................................... 9 2.5. MECHANICAL INSTALLATION............................................................................................................................................. 9 2.6. ELECTRICAL CONNECTION ............................................................................................................................................... 10 2.6.1. AC Input voltage and voltage changeover .............................................................................................................. 10 2.6.2. AC input voltage cables .......................................................................................................................................... 11 2.6.3. Grounding ............................................................................................................................................................... 12 2.6.4. DC cables and cable connectors............................................................................................................................. 12 2.7. MAINTENANCE ................................................................................................................................................................ 12
3.
SCOUT CONTROL.............................................................................................................................................................. 13 3.1. DESCRIPTION ................................................................................................................................................................... 13 3.2. OPERATION ...................................................................................................................................................................... 14 3.2.1. Basic operation ....................................................................................................................................................... 14 3.3. BASIC SETTINGS ............................................................................................................................................................... 14 3.3.1. Setting the number of cells ...................................................................................................................................... 14 3.3.2. Changing the five-second factory-set delay ............................................................................................................ 15 3.3.3. Changing maximum charging time ......................................................................................................................... 16 3.3.4. Cold Storage Setting ............................................................................................................................................... 16 3.3.5. Manual equalizing................................................................................................................................................... 17 3.3.6. Automatic equalizing............................................................................................................................................... 17
4.
COMPUCHARGE 3 CONTROL........................................................................................................................................ 18 4.1. DESCRIPTION ................................................................................................................................................................... 18 4.2. OPERATION ...................................................................................................................................................................... 19 4.3. BASIC SETTINGS .............................................................................................................................................................. 19 4.3.1. Setting the precharge delay..................................................................................................................................... 19 4.3.2. Activating cold storage ........................................................................................................................................... 20 4.3.3. Setting the number of cells ...................................................................................................................................... 21 4.3.4. Automatic equalizing............................................................................................................................................... 22 4.3.5. Manual equalizing................................................................................................................................................... 22 4.3.6. Automatic watering ................................................................................................................................................. 22
5.
COMPUCHARGE 4............................................................................................................................................................. 23 5.1. DESCRIPTION ................................................................................................................................................................... 23 5.2. OPERATION ...................................................................................................................................................................... 24 5.3. BASIC SETTINGS .............................................................................................................................................................. 24 5.3.1. Setting the Precharge Delay ................................................................................................................................... 24 5.3.2. Setting the Automatic Equalizing Frequency .......................................................................................................... 25 5.3.3. Setting the Equalize Charge Duration .................................................................................................................... 25 5.3.4. Setting the Refresh Charge Interval ........................................................................................................................ 25 5.3.5. Setting the Number of Cells..................................................................................................................................... 25 5.3.6. Setting the Shunt Size .............................................................................................................................................. 26 5.3.7. Setting the Operating Temperature......................................................................................................................... 26 5.3.8. Setting the Gassing Voltage .................................................................................................................................... 26 5.3.9. Setting the Charge Profile....................................................................................................................................... 26 5.3.10. Setting the Hold Time for Opportunity Charging ................................................................................................... 27
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5.3.11. 5.3.12. 6.
Cooldown Timer at End of Charge ......................................................................................................................... 27 Automatic watering ................................................................................................................................................. 27
RANGER II CONTROL ...................................................................................................................................................... 28 6.1. DESCRIPTION ................................................................................................................................................................... 28 6.2. BASIC SETTINGS .............................................................................................................................................................. 29 6.2.1. Real-time or fixed increment starting...................................................................................................................... 29 6.2.2. Automatic equalizing............................................................................................................................................... 29 6.2.3. Automatic watering ................................................................................................................................................. 30 6.2.4. Setting cool time...................................................................................................................................................... 30 6.2.5. Monitoring water flow ............................................................................................................................................ 30 6.2.6. Main power override............................................................................................................................................... 31 6.2.7. Water control override............................................................................................................................................ 31 6.2.8. Setting the number of cells ...................................................................................................................................... 31 6.2.9. Selecting the shunt size ........................................................................................................................................... 31 6.2.10. Setting the rated output current .............................................................................................................................. 31 6.2.11. Setting the charge mode .......................................................................................................................................... 31 6.2.12. Setting the date........................................................................................................................................................ 32 6.2.13. Setting the correct time ........................................................................................................................................... 32 6.2.14. Setting the day of the week ...................................................................................................................................... 32 6.2.15. Activating daylight savings time ............................................................................................................................. 32 6.2.16. Activating and setting the address .......................................................................................................................... 32 6.2.17. Setting the baud rate ............................................................................................................................................... 33 6.3. OPERATION ...................................................................................................................................................................... 33 6.3.1. Manual starting....................................................................................................................................................... 33 6.3.2. Manual Stopping ..................................................................................................................................................... 33 6.3.3. Manual equalizing................................................................................................................................................... 33 6.3.4. Operation after loss of AC power (warm start) ...................................................................................................... 33 6.3.5. Charge data retrieval.............................................................................................................................................. 34 6.4. SPECIAL FEATURES WITH A COMPATIBLE BATTERY MODULE ........................................................................................... 34 6.4.1. Installing a compatible battery module communications board ............................................................................. 34 6.4.2. Retrieving data from a compatible battery module................................................................................................. 34 6.5. COMMUNICATIONS PORT ................................................................................................................................................. 35
7.
CHARGER OPERATION ................................................................................................................................................... 36 7.1. 7.2.
8.
RECOMMENDED CHARGING PROCEDURES ........................................................................................................................ 36 OPERATING CHARACTERISTICS ........................................................................................................................................ 37
TROUBLESHOOTING ....................................................................................................................................................... 39 8.1. 8.2. 8.3. 8.4.
9. 10.
GENERAL TROUBLESHOOTING GUIDELINES..................................................................................................................... 39 PROCEDURE ..................................................................................................................................................................... 39 COMPONENT TESTING ...................................................................................................................................................... 44 REPLACING COMPONENTS ................................................................................................................................................ 45
MODELS, RATINGS, AND PARTS LISTS ...................................................................................................................... 46 SCHEMATICS AND WIRING DIAGRAMS ................................................................................................................ 52 SCHEMATIC DIAGRAM – 208/240/480 VAC 1- PHASE....................................................................................................................53 SCHEMATIC DIAGRAM – 120/208/240 VAC 1- PHASE....................................................................................................................54 SCHEMATIC DIAGRAM – 208/240/480 VAC 3-PHASE.....................................................................................................................55 SCHEMATIC DIAGRAM – 208/240/480 VAC 3-PHASE THREE TRANSFORMERS.......................................................................56 SCHEMATIC DIAGRAM –480 VAC 3-PHASE THREE TRANSFORMERS......................................................................................57 SCHEMATIC DIAGRAM – 575 VAC 1- PHASE..................................................................................................................................58 SCHEMATIC DIAGRAM – 575 VAC 3- PHASE..................................................................................................................................59 SCHEMATIC DIAGRAM – 575 VAC 3- PHASE THREE TRANSFORMERS....................................................................................60 WIRING DIAGRAM - 1 PHASE - 208/240/480 VAC ...........................................................................................................................61 WIRING DIAGRAM - 1 PHASE - 120/208/240 VAC ...........................................................................................................................62
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WIRING DIAGRAM - 3 PHASE - 208/240/480 VAC ...........................................................................................................................63 WIRING DIAGRAM - 3 PHASE - THREE TRANSFORMERS - 208/240/480 VAC ...........................................................................64 WIRING DIAGRAM - 3 PHASE - THREE TRANSFORMERS - 480 VAC .........................................................................................65 WIRING DIAGRAM - 1 PHASE - 575 VAC .........................................................................................................................................66 WIRING DIAGRAM - 3 PHASE - 575 VAC .........................................................................................................................................67 WIRING DIAGRAM - 3 PHASE - THREE TRANSFORMERS - 575 VAC .........................................................................................68
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Figures and Tables Content FIGURE 2.1 NAMEPLATE .............................................................................................................................................................. 8 TABLE 2.1 AC INPUT VOLTAGE CODES...................................................................................................................................... 8 FIGURE 2.2 CABINET DIMENSIONS............................................................................................................................................. 9 FIGURE 2.3 AC VOLTAGE RATING LABEL (VOLTAGE CIRCLED) ......................................................................................... 11 FIGURE 2.4 AC FUSE RATING CHART. CIRCLES INDICATE THE PROPER FUSES FOR EACH VOLTAGE....................... 11 TABLE 2.2 ALLOWABLE AC INPUT RANGE............................................................................................................................... 12 FIGURE 3.1 SCOUT CONTROL BOARD...................................................................................................................................... 13 FIGURE 3.2 SCOUT CONTROL BOARD JUMPERS ................................................................................................................... 15 FIGURE 3.3 JUMPERS FOR CHANGING CELLS ....................................................................................................................... 15 FIGURE 3.4 JUMPERS FOR SETTING TURN ON DELAY.......................................................................................................... 16 FIGURE 3.5 JUMPERS FOR SETTING MAXIMUM CHARGING TIME ..................................................................................... 16 FIGURE 3.6 JUMPERS FOR SETTING AUTOMATIC EQUALIZE ............................................................................................. 17 FIGURE 4.1 COMPUCHARGE 3 CONTROL ............................................................................................................................... 18 FIGURE 4.2 JUMPERS FOR SETTING TURN ON DELAY.......................................................................................................... 20 FIGURE 4.3 JUMPERS FOR SETTING COLD STORAGE........................................................................................................... 20 FIGURE 4.4 JUMPERS FOR SETTING THE NUMBER OF CELLS ............................................................................................ 21 FIGURE 4.5 JUMPERS FOR SETTING AUTOMATIC EQUALIZE ............................................................................................. 22 FIGURE 5.1 COMPUCHARGE 4 CONTROL (L) AND INTERFACE (R) BOARDS..................................................................... 23 FIGURE 6.1 RANGER II CONTROL WITH COMMUNICATIONS BOARD................................................................................. 28 FIGURE 7.1 TYPICAL FERRORESONANT CHARGER CURVES............................................................................................... 37 TABLE 8.1 TEST INSTRUMENTS AND TOOLS FOR TROUBLESHOOTING ............................................................................. 39 TABLE 8.2 DIODE CONNECTION TORQUE VALUES ............................................................................................................... 45
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1. IMPORTANT SAFETY INSTRUCTIONS INSTRUCTIONS IMPORTANTES CONCERNANT LA SÉCURITIÉ a. b. c. d. e. f. g. h.
i. j.
k.
l. m.
Read the instruction manual and all warning labels on the charger and battery before using the charger. Familiarize yourself with the locations of hazardous voltages within the cabinet. Danger: To prevent electric shock do not touch uninsulated live parts of the charger or battery. Danger: risque de chocs électriques. Ne pas toucher les parties non isolées du connecteur de sortie ou les bornes non isolées de l’accumulateur. Shut off the charger before connecting or disconnecting the battery. Press the STOP key before disconnecting the battery. The charger must be operated or serviced only by qualified personnel. De-energize the ac input and disconnect the battery before servicing the charger. Do not operate the charger outside its ratings as specified on the data nameplate. FerroCharge chargers are intended for charging lead acid batteries only. Attention : utiliser pour charger uniquement les accumulateurs du type au plomb. D’autres types d’accumulateurs pourraient éclater et causer des blessures ou dommages. Do not expose the charger to water or other liquids. FerroCharge chargers are intended for indoor use only. CAUTION: DO NOT EXPOSE TO RAIN. ATTENTION: NE PAS EXPOSER À LA PLUIE. Chargers are equipped from the factory with a tag describing the ac input Voltage. If the tag does not match the available ac line the input must be reconnected and the fuse values changed following the instructions in this manual. CAUTION – DISCONNECT SUPPLY BEFORE CHANGING FUSES. ATTENTION - COUPER L’ALIMENTATION AVANT DE REMPLACER LES FUSIBLES. FerroCharge chargers are not intended for use in hazardous locations. Even if equipped with an explosion proof connector to match the battery, the charger must be located in a non-hazardous location. Check for wear on the dc cables and connector. Replace cables that have cracked insulation. Replace connectors that overheat, are melted, or with pitted contacts. Legal Disclaimer
Any data, descriptions or specifications presented herein are subject to revision by C&D Technologies, Inc. without notice. While such information is believed to be accurate as indicated herein, C&D Technologies makes no warranty and hereby disclaims all warranties, express or implied, with regard to the accuracy or completeness of such information. Further, because the product(s) featured herein may be used under conditions beyond its control, C&D Technologies hereby disclaims all warranties, either express or implied, concerning the fitness or suitability of such product(s) for any particular use or in any specific application or arising from any course of dealing or usage trade. The user is solely responsible for determining the suitability of the product(s) featured herein for the user’s intended purpose and in user’s specific application. Seller’s liability for any breach of warranty is limited as set forth in seller’s standard warranty applicable to the product (“the warranty”). The warranty is exclusive and offered in lieu of all other express, implied or statutory warranties including, without limitation, implied warranties of merchantability and fitness for a particular purpose. In no event shall the seller’s liability for any damages arising out of any sale of products to buyer, and regardless of the legal theory on which such damages may be based, exceed the amount that supplier has received as payment for such products and under no circumstances shall supplier be subject to any consequential, incidental, indirect, special or contingent damages whatsoever, including but not limited to damages for lost profits or goodwill, even if supplier was advised of the possibility of such damages.
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2. RECEIVING AND INSTALLATION 2.1. Receiving Inspect the charger for any shipping and handling damage as soon as it arrives. Describe any damage on the receiving slip and immediately notify the shipper. Verify the model and serial numbers printed on the packing list against the nameplate (Figure 2.1). If they disagree, contact your representative before proceeding with installation. Use caution when moving chargers. Use the proper moving equipment. Do not drop or otherwise abuse the charger.
MODEL: IFR18HK1000 SPEC: XXXXXX SERIAL NUMBER: XXX000000 DC OUTPUT: 36 VOLTS 190 AMPS 18 CELLS LA RATED 8 HOUR CAPACITY: 1000 (100D6C8) AH AC INPUT: 208/240/480 VOLTS 3 PHASE 28/24/12 AMPS 60 HERTZ RECOMMENDED LINE FUSES: 40/40/20
FIGURE 2.1 NAMEPLATE 2.2. Identification A six-element model number identifies each charger. Each element describes a different charger performance characteristic. The model number of a FerroCharge charger describes its basic operating characteristics. A typical model number is: IFR 12 HK 1000
Code
-
Product Family Number of (Lead-Acid) Cells in Battery to be charged AC Input Voltage Code, See Table 2.1 Ampere-Hour Rating for 8-Hour Charge
AC INPUT VOLTAGE CODES Input (VAC) and Phase
AC CE HK M K L
120/208/240, 1-Phase 208/240/480, 1-Phase 208/240/480, 3-Phase 575, 1-Phase 480, 3-phase 575, 3-Phase
TABLE 2.1 AC INPUT VOLTAGE CODES
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Frequency (Hz) 60 Hz 60 Hz 60 Hz 60 Hz 60 Hz 60 Hz
2.3. Storage Keep the charger in its original shipping container until it is ready to be installed. The unit can be safely stored in any clean, dry area where temperatures remain between 40°F and 120°F (5°C and 50°C).
2.4. Location Battery charging produces heat and a potentially explosive mixture of odorless oxygen and hydrogen gases. Safe charging requires a clean, dry, well-ventilated area. For long battery life the room temperature should be between 60°F and 90°F (16°C and 32°C). Refer to the battery manufacturer’s recommendations. The charger is rated to operate in ambient temperatures between 60°F and 104°F (16°C and 40°C). The charger may be operated for limited periods (up to 4 hours) at ambient temperatures between 104°F and 122°F (40°C to 50°C). FerroCharge chargers are natural convection-cooled. Chargers require a MINIMUM of four inches of clearance between the floor, walls, chargers, and other obstructions for adequate air circulation. EXPLOSIVE, COMBUSTIBLE or FLAMMABLE MATERIALS SHOULD NOT BE PERMITTED IN THE CHARGING ROOM. NEVER MOUNT A CHARGER ON OR ABOVE COMBUSTIBLE MATERIALS. NE PAS INSTALLER SUR DES SURFACES COMBUSTIBLES OU AU-DESSUS DE TELLES SURFACES. To prevent the accumulation of explosive concentrations of hydrogen and oxygen, the charging area should have sufficient ventilation to prevent formation of one percent, by volume, of hydrogen. It is important to note hydrogen is generated at different rates during various times in the charger cycle. Most of the gas forms during the last two to three hours of the charge when the average cell potential exceeds 2.37 volts. Every pint of water dissociated during recharge releases 23 cubic feet of hydrogen gas to the atmosphere. To calculate hydrogen formation, multiply the number of pints of water needed to correctly re-level cells after charging then multiply the number by 23. Thus, a lead-acid motive power battery that requires 1.5 pints of water to re-level, will produce 34.5 cubic (1.5 X 23) feet of hydrogen. An approximation technique may be used to estimate hydrogen production from batteries charged by chargers equipped with CompuCharge and Ranger controls. It is estimated a total of 0.24 cubic feet of hydrogen gas will evolve from each cell per 100 ampere-hours of capacity. For example, an 18-cell battery rated at 720 ampere-hours: Cells x Capacity x 0.24/100 = Cubic feet of hydrogen/charge cycle 18 x 720 x 0.24/100 = 31.1 Cubic feet of hydrogen/charge cycle
2.5. Mechanical installation Chargers can be bolted to noncombustible floors or steel benches. Consult Figure 2.2 for charger cabinet dimensions. Wall mounting requires optional brackets, part number KBC05889A, quantity 2.
Cabinet A A B B
Height 26.062 In 662 mm 26.062 In 662 mm
Width 21.75 In 552 mm 32 In 813 mm
FIGURE 2.2 CABINET DIMENSIONS
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Depth 22.75 In 578 mm 22.75 In 578 mm
2.6. Electrical connection Each charger requires a fused safety disconnect switch or a circuit breaker. Use a line protection device rated for the recommended line fuse value shown on the charger nameplate (Figure 2.1). Electrical installations must be performed by a qualified electrician and satisfy all local, national and federal electrical codes. Proper grounding is required both for safety and to ensure optimum noise and transient immunity of the control board. Refer to the following sections for more specific information. CAUTION Electrical connections can work loose during shipping. Check all connections for tightness before connecting the charger to the AC supply voltage.
2.6.1.
AC Input voltage and voltage changeover
The voltage circled on the input voltage rating label (Figure 2.3} must match the available line voltage. If the voltages are different, it will be necessary to change the AC line fuses, the control transformer fuse, and the connection terminals on both the ferroresonant power transformer and the control transformer. Consult the voltage changeover instruction label inside the cabinet door and the schematics or wiring diagrams at the back of this manual. BE SURE THE CHARGER IS DISCONNECTED FROM ITS AC POWER SUPPLY AND THE BATTERY BEFORE ATTEMPTING THIS MODIFICATION. CAUTION – DISCONNECT SUPPLY BEFORE CHANGING FUSES. ATTENTION - COUPER L’ALIMENTATION AVANT DE REMPLACER LES FUSIBLES. NOTE: AC voltage changeover must be made at the terminals of both the ferroresonant power transformer and the control transformer. Input voltage changeover CANNOT BE PERFORMED on chargers manufactured for 575 VAC only operation.
CAUTION DO NOT ATTEMPT TO RECONNECT VOLTAGE WITHOUT READING INSTRUCTIONS
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THIS CHARGER CONNECTED FOR 120V-208V-240V 480V-575V OTHER
FIGURE 2.3 AC VOLTAGE RATING LABEL (VOLTAGE CIRCLED)
CAUTION AC FUSE RATING USE TYPES NOS, NLS, OR OTS ONLY 208V
240V
480V
575V
3 4 5
3 4 5
3 4 5
3 4 5
6 7 8
6 7 8
6 7 8
6 7 8
10 12 15
10 12 15
10 12 15
10 12
20 25 30
20 25 30
20 25 30
15 20
35 40 45
35 40 45
35 40 45
25 30
50 60
50 60
50 60
35 40
FIGURE 2.4 AC FUSE RATING CHART. CIRCLES INDICATE THE PROPER FUSES FOR EACH VOLTAGE.
2.6.2.
AC input voltage cables
Customers or electrical contractors must furnish the AC connection. Cables should be sized for the recommended line fuse values shown on the charger nameplate. Allowable variations from nominal AC line voltages appear in Table 2.2. Route the AC conduit through the knockout provided in the charger cabinet. Connect the cables to the fuseblock terminals. CAUTION – USE MINIMUM 75°C WIRING. USE COPPER CONDUCTORS. ATTENTION - EMPLOYER DES FILS POUR AU MOINS 75 DEG C
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TABLE 2.2 ALLOWABLE AC INPUT RANGE Nominal AC Voltage AC Voltage Range 120 106-127 208 184-220 240 212-254 480 424-508 575 508-600* *The charger will operate up to 632 VAC, but certain kinds of control and protective equipment have a maximum voltage limit of 600V. The manufacturer or power supplier or both should be consulted to assure proper application.
2.6.3.
Grounding
The charger chassis must be grounded to the AC power source per the requirements of the National Electrical Code and applicable local codes. In order to assure dependable operation, it is imperative that the charger be provided a reliable earth ground. A solderless connector (lug) is provided on the floor of the cabinet near the AC fuseblock. WARNING – THERE IS RISK OF ELECTRICAL SHOCK IF THE CHARGER IS NOT PROPERLY GROUNDED
2.6.4.
DC cables and cable connectors
Each charger ships with a standard, eight-foot long cable that terminates with an appropriate connector. As an option, other lengths are available. If it is necessary to install longer cables, they must be properly sized to prevent overheating and ensure compliance with electrical codes. When specifying replacement DC output connectors, it is important to remember single-phase chargers produce higher peak currents than similarly rated three-phase systems. The maximum DC current flowing from a single-phase charger is typically 1.3 times the ammeter reading. Higher capacity SB-350 connectors are recommended as retrofit equipment for all singlephase chargers rated at over 135 amperes. DC CABLE LENGTHS FROM 15 TO 25 FEET SHOULD BE ONE CABLE SIZE LARGER THAN THE STANDARD CABLE. CABLE LENGTHS FROM 25 TO 35 FEET SHOULD BE TWO CABLE SIZES LARGER. DC CABLE LENGTHS SHOULD NOT EXCEED 35 FEET. CAUTION Be sure the charger positive terminal is connected to the charger connector terminal marked (+) and the negative terminal to the one marked (-).
2.7. Maintenance Battery chargers work most efficiently and deliver better service life with good heat dissipation. Periodic cleaning with dry, low-pressure air will remove accumulated dust to assure good heat transfer to the surrounding air. At least twice a year, check input and output circuit connections and ground connections to make sure they are tight. The DC cables and DC connector require periodic maintenance. Inspect the DC cables and DC connector to verify a sound, low-resistance connection, that there is no exposed metal, and that the connector is mechanically intact. Dirty or pitted contacts should be cleaned and lubricated or replaced following the manufacturer’s recommendations. Cables should be replaced if the insulation is cut or cracked, or if the copper is exposed. There are no other maintenance adjustments to the FerroCharge chargers. CAUTION: Disconnect charger from AC voltage supply before servicing or dismantling.
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3. SCOUT CONTROL 3.1. Description The SCOUT CONTROL is a microprocessor-based controller that minimizes overcharging by continually monitoring battery voltage. Other STANDARD features include: • Automatic start-helps prevent operator errors • dV/dt termination • Adjustable start delay • Automatic equalization • Safety features-checks for correct battery before charge begins • Maximum charge time-helps prevent overheating • Abort feature-when the control senses a problem, the red LED flashes twice every second
FIGURE 3.1 SCOUT CONTROL BOARD
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3.2. Operation
3.2.1.
Basic operation
SERIES chargers equipped with the SCOUT control have an LED display and keypad for operator interface. One LED indicates the charger is ready to operate, another LED indicates the battery is being charged and a third LED indicates when gassing voltage is reached. The Equal key activates the equalization charge mode and the Stop key allows the charger to be turned off during a charge. Chargers equipped with the SCOUT control do not have start switches. Charging automatically begins five seconds after the operator connects the battery, unless the user specifies another delay (refer to Section 3.3.2). When no battery is connected, the green LED will flash briefly every four seconds to indicate the charger is ready to begin charge. Once a battery is connected, the red LED will flash and glow steadily when the charge is in progress. When the battery is 80 percent charged, the yellow LED is lit, and the red LED will be extinguished. When the charge is complete, the green LED will glow. If equalize is selected, the charge is extended by three hours. The red LED will flash when the battery is connected and during the charge. During equalization, the yellow LED will flash and will continue to do so throughout the equalize cycle. When the charge is complete, the green LED will flash. If a battery with a number of cells that do not match the charger rating is connected, the charger will not start. Refer to Section 8, Troubleshooting. If AC power is interrupted, charging will restart after a randomly timed start-up delay, not exceeding three minutes, thirty seconds. The random delay prevents a large inrush from the ac line if all chargers were to start at the same time. In the event of an accidental battery disconnect, the system will shut down automatically, protecting charger components. WARNING If it is necessary to disconnect the battery during the charge, press the stop key before disconnecting the battery. FAILURE TO TAKE THIS PRECAUTION CAN CAUSE A SERIOUS ARC HAZARD AND A POTENTIALLY SERIOUS INJURY.
3.3. Basic settings
3.3.1.
Setting the number of cells
The SCOUT control has jumpers to set the number of cells, 6, 12, 18, 24 or 36, to match the charger rating. The SCOUT is shipped from the factory matched to the charger. ADJUSTMENT OF THIS FEATURE IS NEEDED ONLY WHEN THE PRINTED CIRCUIT BOARD HAS BEEN REPLACED. To change the number of cells: 1) Disconnect the ac power supply at the circuit breaker or fused safety-disconnect. 2) Open the instrument panel and locate the printed circuit board mounted directly behind it. 3) Locate the configuration jumpers as shown in Figure 3.2. 4) Move the jumpers to the desired number of cells, as shown in Figure 3.3. 5) Close the cabinet and reconnect the AC power supply.
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FIGURE 3.2 SCOUT CONTROL BOARD JUMPERS
FIGURE 3.3 JUMPERS FOR CHANGING CELLS
3.3.2.
Changing the five-second factory-set delay
The SCOUT control is shipped with a preset, five-second safety-delay. The delay can be changed to 30 seconds, one hour, or four hours. To lengthen the factory-set delay: 1) 2) 3) 4) 5) 6)
Disconnect the battery and disconnect the ac power supply at the circuit breaker or fused disconnect. Open the cabinet door. Remove the screws at the bottom of the instrument panel. Swing out the instrument panel. Locate the bank of configuration jumpers on the control board as shown in Figure 3.2. Move the jumpers to the desired time pattern: 30 seconds, one hour, or four hours. Refer to Figure 3.4. Close all the panels and doors. Reconnect the ac power supply.
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FIGURE 3.4 JUMPERS FOR SETTING TURN ON DELAY 3.3.3.
Changing maximum charging time
The maximum charging time is factory-set at 12 hours. This feature should not need adjustment.
FIGURE 3.5 JUMPERS FOR SETTING MAXIMUM CHARGING TIME 3.3.4.
Cold Storage Setting
The SCOUT control may be set to extend the charge by 30 minutes for cold storage or similar applications. A special combination of the override timer settings is used for this feature. Place jumpers on both positions 13 and 14, 12hr max and 24hr max, to add 30 minutes of charging time with a 12-hour maximum charge time. Refer to Figure 3.5.
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3.3.5.
Manual equalizing
To initiate an equalization charge the operator connects the battery, waits for the red LED to flash or glow, and then presses the Equal key on the keypad. At the conclusion of an equalize charge the system automatically returns to the daily charge mode. The operator may initiate or terminate an equalize charge by pressing the Equal key while the charger is charging. If the charger is in the equalize part of the charge it will stop when the Equal key is pressed.
3.3.6.
Automatic equalizing
The SCOUT control can be set to automatically equalize never, every seventh cycle, or every tenth cycle. To set the automatic equalization: 1) 2) 3) 4) 5) 6)
Disconnect the AC power supply at the circuit breaker or fused disconnect panel. Open the cabinet door. Remove the screws at the bottom of the instrument panel. Swing out the instrument panel. Locate the bank of configuration jumpers on the control board as shown in Figure 3.2. Move the jumpers to the desired equalize cycle. The factory setting is 7 cycles. Refer to Figure 3.6. Close all the panels and doors. Reconnect the ac power supply.
FIGURE 3.6 JUMPERS FOR SETTING AUTOMATIC EQUALIZE
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4. COMPUCHARGE 3 CONTROL 4.1. Description The COMPUCHARGE 3 CONTROL is a microprocessor-based controller that reduces the chance for overcharging by continually monitoring battery voltage and current. Other COMPUCHARGE 3 control features include: • Automatic start-helps prevent operator errors • dV/dt and dI/dt termination • Turn-on time delay – Five seconds to seven hours, 45 minutes in 15 minute increments • Automatic equalize – Never, every seven days, 1, 2, 3, 4, 5, 6, or 7 cycles • Safety features-checks for correct battery before charge begins • Maximum charge time-helps prevent overheating • 4-digit, seven segment easy to read LED display • Fully charged battery detector – won’t start if detected • Hot battery detector will terminate charge and resume after 8 hours cooling • Automatic watering control output
FIGURE 4.1 COMPUCHARGE 3 CONTROL
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4.2. Operation The operating panel of the COMPUCHARGE 3 control is a sealed membrane with a four character, ½ inch LED display, a Stop key, an Equal key, and a Scroll key. The charging cycle is initiated when the battery is connected. The COMPUCHARGE 3 control checks for a battery of the proper voltage. If the match is correct, the display will show a count down until the charge starts. If a mismatch is detected, an error code (“bU E”) will appear. (Refer to the troubleshooting section for more information.) If an equalize charge is selected either automatically or by pressing the Equal key, a dot will appear on the display after the last character on the right. If automatic equalize is selected it will flash. If manual equalize is selected it will not flash. A manual equalize may be canceled by pressing the Equal key again. After the user-selected start up delay the charge cycle begins. (For safety reasons the minimum delay is factory set at five seconds.) The charge current is displayed during the charge. The COMPUCHARGE 3 control monitors the change in voltage and current to determine when the charge should be terminated. When the charge is greater than 80% completed, the last digit on the display will flash. Pressing the Scroll key at any time during the charge cycle will display the battery voltage (“99.9U”). Pressing the Scroll key twice displays the Ampere-hours returned (“999r”). The display will return to the charging current after 60 seconds, or if the Scroll key is pressed a third time. Charging continues until the battery is fully charged and the cell electrolyte is mixed. If the battery remains connected to the charger for three days, a refresh charge will be initiated automatically. Cells nearing the end of their operating life or mistreated batteries may be unable to accept a complete charge. If the charge termination criteria have not been met after 12 hours, the charge cycle is stopped and an error message is displayed (“12hE”). When ac power is interrupted during a charge, charging will restart after a randomly timed startup delay not exceeding two minutes. The random delay prevents a large inrush from the ac line if a group of chargers were to start at the same time. If a fully charged battery is inadvertently connected to the charger it will be detected and the charge terminated within three minutes. A hot battery that goes into thermal runaway will be detected. The charger will stop for 8 hours, and then resume in the state where it left off. Typically thermal runaway only occurs as the battery approaches full charge.
4.3. Basic Settings 4.3.1.
Setting the precharge delay
The precharge delay may be set to take advantage of lower utility rates. To change the precharge delay, follow these steps: 1) 2) 3) 4)
Disconnect the battery and disconnect the ac power supply at the circuit breaker or fused disconnect. Open the cabinet door. Remove the screws at the bottom of the instrument panel. Swing out the instrument panel. Locate the bank of configuration jumpers on the control board as shown in Figure 4.2. Move the jumpers to the desired setting. When multiple jumpers are used the delay times are additive. For example, placing jumpers on 15 minutes, 2 hours, and 4 hours will set the delay to 6 hours and 15 minutes. Refer to Figure 4.2. Extra jumpers are located on the upper right hand corner of the board. 5) Close all the panels and doors. 6) Reconnect the ac power supply.
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FIGURE 4.2 JUMPERS FOR SETTING TURN ON DELAY 4.3.2.
Activating cold storage
Users with a cold storage application can set the COMPUCHARGE 3 control to adjust its charge termination. Battery starting temperatures of below 55°F are considered cold storage. To select this option, place jumpers on both the “temp norm” and “temp cold” pins (use two jumpers). Refer to figure 4.3.
FIGURE 4.3 JUMPERS FOR SETTING COLD STORAGE
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4.3.3.
Setting the number of cells
The COMPUCHARGE 3 control is set up to match the charger. It has adjustments for a variable number of cells – 6, 9, 12, 15, 16, 18, 20, 24, 32, 36, and 40. To change the number of cells: 1) 2) 3) 4)
Disconnect the battery and disconnect the ac power supply at the circuit breaker or fused disconnect. Open the cabinet door. Remove the screws at the bottom of the instrument panel. Swing out the instrument panel. Locate the bank of configuration jumpers on the control board as shown in Figure 4.4. Move the jumpers to the desired number of cells. Refer to Figure 4.4. For 9, 15, 16, 20, 32, and 40 cells multiple jumpers are required as shown in the following table: Cells 9 15 16 20 32 40
Jumpers on 6 and 12 cell 12 and 18 cell 6, 12, and 18 cell 18 and 24 cell 24 and 36 cell 6 and 24 cell
5) Close all the panels and doors. 6) Reconnect the ac power supply.
FIGURE 4.4 JUMPERS FOR SETTING THE NUMBER OF CELLS
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4.3.4.
Automatic equalizing
The COMPUCHARGE 3 control can be set to automatically equalize never, every 7 days, or every 1, 2, 3, 4, 5, 6, or 7 cycles. To change the automatic equalize setting: 1) 2) 3) 4) 5) 6)
Disconnect the battery and disconnect the ac power supply at the circuit breaker or fused disconnect. Open the cabinet door. Remove the screws at the bottom of the instrument panel. Swing out the instrument panel. Locate the bank of configuration jumpers on the control board as shown in Figure 4.1 that start with “EQU”. Move the jumpers to the desired equalize setting. The factory setting is 7 days. Refer to Figure 4.5. Close all the panels and doors. Reconnect the ac power supply.
Note: The equalize cycles are designed for maximum flexibility, so multiple jumpers placed in the banks ending in “cyc” are additive. For example, a jumper on the pin marked “EQU 1 cyc” and a jumper on the pin marked “EQU 2 cyc” would result in an equalize charge every three cycles. A single jumper on the pin marked “EQU 1 cyc” results in equalize every cycle. “NEVER” takes precedence over all other jumpers. Spare jumpers are located on the control board.
FIGURE 4.5 JUMPERS FOR SETTING AUTOMATIC EQUALIZE 4.3.5.
Manual equalizing
To begin manual equalize, connect the battery and press the Equal key. Press the Equal key again to take the charger out of equalize.
4.3.6.
Automatic watering
The COMPUCHARGE 3 control has a 24 VAC output to power a solenoid for automatic watering. One side of the solenoid connects to pin 5 of the control board and the other side of the solenoid connects to X4 on the control transformer (CXF). Refer to the schematics at the back of this manual. The watering cycle lasts for 3 minutes at the end of charge. If equalize is set, the watering cycle precedes the equalize cycle. If the charger is equipped with a watering module, watering is automatic; there are no settings required. Refer to the instructions supplied with the water module for installation and connections to the charger, and for connections to the water supply. Refer to the instructions supplied with the battery filling system for installation on the battery.
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5. COMPUCHARGE 4 5.1. Description The CompuCharge 4 is a microprocessor-based controller that reduces the chance for overcharging by continually monitoring battery voltage and current. The settings are menu driven and accessible from the front panel membrane switches. Other CompuCharge 4 features include: • Automatic start-helps prevent operator errors • dV/dt and dI/dt termination • Turn-on time delay – 5, 10, 30, 60 seconds; 0.1, 0.2, 0.5, 1, 2, 5, 8, and 12 hours • Manual or automatic equalize – None, 1 to 7 cycles, 7 days, or 14 days. Default is 7 cycles. Equalize duration of 1 to 6 hours, default is 3 hours. Equalize is indicated when the decimal point after the rightmost digit flashes. • Checks for correct battery voltage before charge begins • Maximum charge time of 12 hours helps prevent overheating. • 4-digit, seven segment easy to read LED display for menu setup, current, Voltage, and accumulated Ampere-hours • Gassing voltage set points of 2.37 or 2.40 Volts per cell • Operating environment setting for normal or cold temperature • Refresh charge mode settable for intervals of 3, 6, 8, 12, 15, 20, 24, 30, 40, 48, 60, or 72 hours. The default is 72 hours. • 100 hour cooldown timer after end of charge helps to select the next battery to use • Opportunity charging mode that Stops charge at gassing voltage. Settable hold time until full charge commences of 3, 6, 8, or 12 hours • Fully charged battery detector – won’t continue to charge if detected • Hot battery detector will terminate charge and resume after 8 hours cooling • Automatic watering control output • All display segments light before start of charge to indicate proper operation
FIGURE 5.1 COMPUCHARGE 4 CONTROL (L) AND INTERFACE (R) BOARDS
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5.2. Operation The operating panel of the CompuCharge 4 control is a sealed membrane with a four character, ½ inch 7-segment LED display. There are three membrane switches, Stop, Equalize, and Scroll (curved arrow) used to enter the setup menu and select the setup parameters or to display Volts or Ampere-hours accumulated during the charge cycle. The 7-segment display shows the number of cells during the idle mode. The charging cycle is initiated when the battery is connected. The CompuCharge 4 control checks for a battery of the proper voltage. If the match is correct, the display will show a count down until the charge starts. If a mismatch is detected, the display will show “bV E”. (Refer to the troubleshooting section for more information.) After the user-selected start up delay the charge cycle begins. (For safety reasons the minimum delay is factory set at five seconds.) The charge current is displayed during the charge. The CompuCharge 4 control monitors the change in voltage and current to determine when the charge should be terminated. When the charge is greater than 80% completed, the last digit on the display will flash. Pressing the scroll key at any time during the charge cycle will display the battery Volts per cell (“XX.XV”). Pressing the key twice displays the Ampere-hours returned (“999r”). The display will return to the charging current after 60 seconds, or if the key is pressed a third time. Charging continues until the battery is fully charged and the cell electrolyte is mixed. If the battery remains connected to the charger, a refresh charge will be initiated automatically after a selected interval. The CompuCharge 4 has an automatic equalize feature that extends the charge to mix the battery electrolyte and equalize the cell voltages. The decimal point to the right of the rightmost digit flashes to indicate the charger is in the equalize mode. Cells nearing the end of their operating life or mistreated batteries may be unable to accept a complete charge. If the battery is not charged in 12 hours the charger will Stop and the display will show “12hE”. When ac power is interrupted during a charge, charging will restart after a randomly timed startup delay not exceeding two minutes. The random delay prevents a large inrush from the ac line if a group of chargers were to start at the same time. A battery that is mostly charged may show as fully charged after restarting. If a fully charged battery is inadvertently connected to the charger it will be detected and the charge terminated within three minutes. A hot battery that goes into thermal runaway will be detected. The charger will Stop for 8 hours, then resume in the state where it left off. Typically thermal runaway only occurs as the battery approaches full charge. If the Stop key is pressed the display will show “StPE”. The battery must be disconnected to clear the display.
5.3. Basic Settings 5.3.1.
Setting the Precharge Delay
The precharge delay may be set to take advantage of lower utility rates. To change the precharge delay, follow these steps: 1) Press the Stop key and disconnect the battery to return to the idle mode. 2) Press and hold both the Equalize and Scroll keys for 5 seconds until the display goes to the setup menu. The first menu item is the delay. 3) Press the Equalize key until the desired setting of 5S (seconds), 10S, 30S, 60S; 0.1, 0.2H (hours), 0.5H, 1H, 2H, 5H, 8H, or 12H is reached 4) Press the Stop key to exit the menu or press the Scroll key to go to the next setting.
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5.3.2.
Setting the Automatic Equalizing Frequency
The CompuCharge 4 can be set to automatically equalize none, every 1, 2, 3, 4, 5, 6, or 7 cycles, or every 7 or 14 days. The decimal point to the right of the rightmost digit flashes to indicate the charger is in the equalize mode. To change the automatic equalize setting: 1) Press the Stop key and disconnect the battery to go to the idle mode. 2) Press and hold both the Equalize and Scroll keys for 5 seconds until the display goes to the setup menu. The second menu item is the delay. 3) Press the Scroll key until the display shows “E no”, “E XC”, or “EXXd”. 4) Press the Equalize key until the desired setting of None, 1 to 7 cycles, 7 days, or 14 days is reached. Default is 7 cycles. 5) Press the Stop key to exit the menu or press the Scroll key to go to the next setting.
5.3.3.
Setting the Equalize Charge Duration
To change the automatic equalize setting: 1) Press the Stop key and disconnect the battery to return to the idle mode. 2) Press and hold both the Equalize and Scroll keys for 5 seconds until the display goes to the setup menu. The third menu item is the equalize duration. 3) Press the Scroll key until the display shows “EdXh”. 4) Press the Equalize key until the desired setting of 1, 2, 3, 4, 5, or 6 hours is reached. Default is 3 hours. 5) Press the Stop key to exit the menu or press the Scroll key to go to the next setting.
5.3.4.
Setting the Refresh Charge Interval
The CompuCharge 4 can be set to perform a refresh charge if the battery remains connected for 3, 6, 8, 12, 15, 20, 24, 30, 40, 48, 60, 72, or 80 hours. To change the refresh charge interval: 1) Press the Stop key and disconnect the battery to return to the idle mode. 2) Press and hold both the Equalize and Scroll keys for 5 seconds until the display goes to the setup menu. The fourth menu item is the refresh interval. 3) Press the Scroll key until the display shows “rXXh”. 4) Press the Equalize key until the desired setting of 3, 6, 8, 12, 15, 20, 24, 30, 40, 48, 60, 72 or 80 hours. The default is 12 hours. 5) Press the Stop key to exit the menu or press the Scroll key to go to the next setting.
5.3.5.
Setting the Number of Cells
The CompuCharge 4 must be set to match the rating of the charger in which it is installed. To set the number of cells: 1) Press the Stop key and disconnect the battery to return to the idle mode. 2) Press and hold both the Equalize and Scroll keys for 5 seconds until the display goes to the setup menu. The fifth menu item is the number of cells. 3) Press the Scroll key until the display shows “C XX”. 4) Press the Equalize key until the desired setting of 6, 9, 12, 15, 16, 18, 20, 24, 32, 36, or 40 is reached. 5) Press the Stop key to exit the menu or press the Scroll key to go to the next setting.
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5.3.6.
Setting the Shunt Size
The CompuCharge 4 must be set to match the rating of the charger in which it is installed. To set the shunt size: 1) Press the Stop key and disconnect the battery to return to the idle mode. 2) Press and hold both the Equalize and Scroll keys for 5 seconds until the display goes to the setup menu. The sixth menu item is the shunt size. 3) Press the Scroll key until the display shows “S XXX”. 4) Press the Equalize key until the desired setting of 100A, 200A, 300A, 500A, or 600A is reached. 5) Press the Stop key to exit the menu or press the Scroll key to go to the next setting.
5.3.7.
Setting the Operating Temperature
The default setting is normal or “Tnor”. Users with a cold storage application can set the CompuCharge 4 control to adjust its charge termination. Battery starting temperatures of below 55°F are considered cold storage. To set the operating temperature and extend the charge time: 1) Press the Stop key and disconnect the battery to return to the idle mode. 2) Press and hold both the Equalize and Scroll keys for 5 seconds until the display goes to the setup menu. The seventh menu item is the operating temperature. 3) Press the Scroll key until the display shows “Tnor” or “Tcol”. 4) Press the Equalize key to select normal, Tnor, or cold, Tcol. 5) Press the Stop key to exit the menu or press the Scroll key to go to the next setting.
5.3.8.
Setting the Gassing Voltage
The CompuCharge 4 control may be set to detect a gassing point Voltage of 2.37 or 2.40 Volts per cell. To set the gassing voltage detector: 1) Press the Stop key and disconnect the battery to return to the idle mode. 2) Press and hold both the Equalize and Scroll keys for 5 seconds until the display goes to the setup menu. The eighth menu item is the gassing voltage limit. 3) Press the Scroll key until the display shows “G2.37” or “G2.40”. 4) Press the Equalize key to select 2.37 or 2.40. 5) Press the Stop key to exit the menu or press the Scroll key to go to the next setting.
5.3.9.
Setting the Charge Profile
The CompuCharge 4 control may be set for either a conventional or opportunity charging profile. In the opportunity charging mode the charger will Stop when the voltage reaches the gassing point. If the battery remains connected beyond a selected interval, a complete charge cycle will be performed. To set the charge profile: 1) Press the Stop key and disconnect the battery to return to the idle mode. 2) Press and hold both the Equalize and Scroll keys for 5 seconds until the display goes to the setup menu. The ninth menu item is the charge profile mode 3) Press the Scroll key until the display shows “PrCV” or “PrOP”. 4) Press the Equalize key to select conventional mode, “PrCV” or opportunity mode, “PrOP”. 5) Press the Stop key to exit the menu or press the Scroll key to return to the beginning of the menu settings.
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5.3.10.
Setting the Hold Time for Opportunity Charging
In the opportunity charging mode the CompuCharge 4 control may be set to wait for 3, 6, 8, or 12 hours after the charger Stops after reaching the gassing point to begin a full conventional charge cycle. To set the hold time: 1) Press the Stop key and disconnect the battery to return to the idle mode. 2) Press and hold both the Equalize and Scroll keys for 5 seconds until the display goes to the setup menu. The ninth menu item is the charge profile mode 3) Press the Scroll key until the display shows “PrCV” or “PrOP”. 4) Press the Equalize key to select the opportunity charging mode, “PrOP”. 5) Press the Scroll key to display “HXXh”, the hold time. 6) Press the Equalize key to select 3, 6, 8, or 12 hours. 7) Press the Stop key to exit the menu or press the Scroll key to go to the next setting.
5.3.11.
Cooldown Timer at End of Charge
The CompuCharge 4 control displays the hours and minutes, “H.MMC” or hours and tenths of hours, “HH.HC” since the charge ended up to 100 hours. This feature may be used to select the next battery to place back into use. The rate of change of the last two digits on the clock determines if they are seconds or minutes. After 100 hours the display will show “COOL”.
5.3.12.
Automatic watering
The CompuCharge 4 control has a 24 VAC output to power a solenoid for automatic watering. One side of the solenoid connects to pin 5 of the control board and the other side of the solenoid connects to X4 on the control transformer (CXF). Refer to the schematics at the back of this manual. The watering cycle lasts for 3 minutes at the end of charge. If equalize is set, the watering cycle precedes the equalize cycle. If the charger is equipped with a watering module, watering is automatic; there are no settings required. Refer to the instructions supplied with the water module for installation and connections to the charger, and for connections to the water supply. Refer to the instructions supplied with the battery filling system for installation on the battery.
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6. RANGER II CONTROL 6.1. Description The RANGER II control uses a “plain-English,” menu-driven display program. When the charger is idle, the display shows the number of cells, the current date and the time. Features of the RANGER II control include: • Bright, two-line vacuum fluorescent display–visible in ambient light • “Plain English,” menu-driven display–for fast set-up, preview and change of equalize, delayed start and other charge parameters • Delayed start–turn-on time delay is selectable from five seconds to 12 hours in one second intervals and time of day start • Real-time 24-hour clock–with automatic adjustment for daylight savings time. • Automatic or manual equalize–automatic equalize selectable from one to 50 cycles or day of the week; manual equalize selectable from front panel • Automatic three-day refresh cycle- if battery is connected for more than 72 hours, a brief boost charge is provided to maintain battery in fully charged condition • Automatic charge termination– when voltages stabilize indicating full charge or if battery overheats • User programmable cool down step • A variety of cell and shunt sizes–selectable for six through 36-cell batteries and four shunt sizes • Output for optional automatic watering device • Advanced features with compatible battery module: o Equalize by battery cycles o Watering by cycles • Manual equalize and charger reports can be accessed by pressing the Scroll key (curved arrow). Refer to sections 6.3.3 for specific information.
FIGURE 6.1 RANGER II CONTROL WITH COMMUNICATIONS BOARD
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6.2. Basic Settings Basic control settings such as number of cells, shunt size, delay before starting, etc. are set from the front panel using a “hidden” menu with restricted access. Before operating your charger, check to be sure these initial settings have not been changed. Should you need to change any of these settings, you may access them through the RANGER II control panel. The battery must be disconnected in order to enter the parameters menu. To access this menu, press both Arrow keys at the same time when the seconds portion of the time display indicates :01 changing to :02. The Scroll key is used to move from selection to selection, and the Arrow keys are used to enter information. Begin by using the Arrow key to select “parameters,” then press the Scroll key to view the first parameter. To return to the idle display, press the Stop key. All parameters are automatically saved and overwrite existing parameters. NOTE: An internal, non-rechargeable lithium battery permits the RANGER II control to retain programmed operating parameters in memory even when the charger is disconnected from an AC line. This battery has an expected service life of more than 10 years, and, when required, should be replaced by C&D. In the event of battery malfunction, contact your local C&D representative.
6.2.1.
Real-time or fixed increment starting
IMPORTANT: When using real-time starting or fixed increment delay starting, be sure to allow for at least eight hours of charging before the battery is used again. Delayed starting lets you delay the time when the charge begins in order to take advantage of lower, off-peak after the preset start time has passed, the battery will still be charged after a short delay. This allows for unusual situations, such as extended-shift where the battery would not be available until after the preset time. NOTE: When using real-time start, if you connect a battery within four hours after the preset time has passed, the battery will still be charged after a short delay. Real-time or fixed delay starts can be selected from the programmable parameters menu. Use the Arrow keys to select either “Start at real time” or “Fixed delay mode.” If you have selected “Start at real time” press the scroll key and use the arrow keys to enter the start time in HH:MM. If you have selected “Start after delay,” press the Scroll key, and use the Arrow keys to enter the delay in HH:MM:SS. PP: Delay mode [↑↓] PP: Delay [↑↓]
6.2.2.
Automatic equalizing
The RANGER II control can be set to automatically equalize every 1 to 50 cycles or to equalize all batteries charged on a particular day of the week. Automatic equalize can be set through the programmable parameters (see Section 6.2). Use the scroll key until the display reads: PP: Equlz mode [↑↓] Press the Arrow keys to select either the number of cycles, the day of the week, never, or always. Depending on your selection the following displays will appear: PP: Equlz cycl [↑↓] or PP: Equlz mode [↑↓]
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If you have selected never or always, the next menu will be: PP: Water Mode [↑↓] To return to the idle display, press the Stop key or the Scroll key to continue entering parameters. When equalization is scheduled, “C:(E)” is displayed. If you have selected number of cycles or day of the week, press the Scroll key and use the Arrow keys to enter the appropriate information. Equalizing cycles can be programmed for two to 50 cycles NOTE: When a RANGER II charger programmed to equalize by cycles is connected to the optional compatible battery module it will equalize by battery cycles. Otherwise, it will equalize by charger cycles.
6.2.3.
Automatic watering
Provisions for automatic watering have been made within the RANGER II control. NOTE: If a charge mode other than conventional has been selected, these do not apply and the menus will not appear. It can be set to always, never, and if a communications board has been added for a compatible battery module, every 5 cycles or every 10 cycles. To select automatic watering, scroll through the programmable parameters until the display shows: PP: Water mode [↑↓] Use the Arrow keys to select watering options. NOTE: If the automatic watering parameter is set to every 5 cycles or every 10 cycles and a battery without a compatible battery module is connected, the RANGER II will always water the battery. Once watering has been activated, it is important that it remain activated long enough to ensure all cells have been fully watered. In order to limit possible overflow due to damage or malfunction, the RANGER II only maintains water flow for a limited duration. This time is factory set at one minute, but can be adjusted. To adjust automatic watering time, press the Scroll key until the display reads: PP: Set WTR tm [↑↓] Use the Arrow keys to set the length of the watering cycle. The watering cycle can last from 15 seconds to three minutes.
6.2.4.
Setting cool time
After the charge is completed, the charger will pause for a preset period of time to allow the battery to cool. Select a time from one minute to eight hours. PP: Set cool time [↑↓]
6.2.5.
Monitoring water flow
To monitor the flow of water during a watering cycle, use the Arrow keys to select “enable.” PP: Flow check [↑↓] When the flow check is enabled, the water flow is checked soon after the watering triac is turned on. If no flow is detected, the triac is turned off and a fault appears “(- Flo)”. The flow is also checked at the end of the watering cycle, and if flow is still detected, the fault will appear “(+ Flo)”. All flow faults appear after the postcharge display. Disconnecting the battery clears the fault.
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6.2.6.
Main power override
Under certain conditions, such as troubleshooting or recovery of an overdischarged battery, it is useful to be able to override the logic of the main control board and force the charger to turn on. Press the Arrow key to activate this feature. When activated, this feature energizes the main contactor and only checks for a connected battery. The contactor will be energized for a maximum of three minutes to preclude damage to a charger or battery caused by excessive charging with defective or mismatched equipment. PP: ctl MAIN [↑↓]
6.2.7.
Water control override
The water control override feature allows the watering output to be forced on for an indefinite period for troubleshooting. It should not be left in the ON position for an extended period of time. Use the Arrow keys to turn it on and off. PP: CTL WATER [↑↓] If the charge mode is set for other than conventional, the CTL water display will be replaced by the following: P: CTL STAGE 2 [↑↓] Use the Arrow keys to turn the second stage ON or OFF for troubleshooting purposes. Watering mode functions, including flow check, are not available in non-conventional modes.
6.2.8.
Setting the number of cells
The number of cells for the charger and the RANGER II control are designed to match. After entering the programming menu, as explained above, scroll through the selections until the above display appears. Use the Arrow keys to set the number of cells to match the charger nameplate rating. You may enter from six to 36 cells in 1-cell increments. PP: Set CELLS [↑↓]
6.2.9.
Selecting the shunt size
The RANGER II control is matched to its shunt size at the factory. There should be no need to change the shunt size unless a replacement control board is installed. Should you need to change the shunt size, refer to the parts lists on pages 50 & 51 (section 9). Use the Arrow keys to set the shunt at 100 mV to 100, 200, 300, or 500 amperes. Press the Scroll key to set the shunt size. PP: Set SHUNT [↑↓]
6.2.10.
Setting the rated output current
Set the rated current of the charger as it is indicated on the charger nameplate. Use the Arrow keys to enter rated current from 0 to 500 amperes in 5-ampere increments. Press the Scroll key to set rated output current. PP: Rated AMPS [↑↓]
6.2.11.
Setting the charge mode
Use the arrow keys to select ”conventional mode”. The FerroCharge charger can only charge conventional flooded batteries. The other settings are for battery types that are not compatible with this charger. PP: Charge Mode [↑↓]
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The ready screen will indicate the mode in use. If the charger is set for conventional mode it will display: READY (STD): ## cells Important: If the charger displays any mode other than (STD) the setting must be changed. If the charger is set for low maintenance battery mode it will display: READY (LM): ## cells If the charger is set for sealed battery mode it will display: READY (VR): ## cells
6.2.12.
Setting the date
Set the current date by pressing the Arrow keys until the current date is displayed. The display is in MM/DD/YY format. Press the Scroll key to set the current date. PP: Set DATE [↑↓]
6.2.13.
Setting the correct time
The RANGER II charger has a 24-hour clock, which allows charger operation to begin at a preset time or at a fixed delay from time of connection. It also allows the charger to report the actual time, date and when the charge was begun and completed. The 24-hour clock is set when it leaves the factory; however it may need to be adjusted if you live in a different time zone than the factory. The correct time must be set before placing the charger in operation. Set the current time HH:MM:SS by pressing the Arrow keys until the current time is shown. Press the Scroll key to set the correct time. PP: Set TIME [↑↓]
6.2.14.
Setting the day of the week
By keeping track of weekdays, RANGER II can perform equalizing charges on the day most convenient for the user. For example, you can program the RANGER II so all Friday charges include an equalizing charge. Using the Arrow keys set the current day of the week. Press the Scroll key to set the day of the week. PP: Set DAY [↑↓]
6.2.15.
Activating daylight savings time
If the charger will be operated in an area using Daylight Savings Time, the automatic daylight savings time feature can be activated to automatically adjust the clock to daylight savings time and back to standard time on the proper days. To activate this feature, press an Arrow key until “Auto daylight time” appears on the display. If you do not need daylight savings time, press an Arrow key until “Always STD time” appears on the display. To activate daylight savings time, press the Scroll key. PP: Set DST [↑↓]
6.2.16.
Activating and setting the address
If the Asset Management System (AMS) is in use, set the address for this charger. If the AMS is not in use set to net inactive. PP: Set NET [↑↓]
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6.2.17.
Setting the baud rate
If the network is activated, set the baud rate per the instructions for the AMS. PP: Set Baud [↑↓]
6.3. Operation 6.3.1.
Manual starting 1.
CONNECT THE CHARGER TO THE AC SUPPLY LINE. The digital display will show the number of cells for which the charger has been set as well as the charge mode selected and the time of day.
2.
CONNECT THE BATTERY. The charge cycle will begin within five seconds, if no other delay time has been selected. The RANGER II control display will show the time remaining until the start of charge. If the battery is fully charged, the charger will move from charging to post-charge, or if manual equalize is selected, to equalize. When the charge begins, the display will show the elapsed time charging, voltage and current in amperes. When the battery is 80 percent charged, an “(80%)” will appear after the elapsed time display. If manual or automatic equalize is selected, an “(E)” will appear in the upper left hand corner. When voltage and current have stabilized “(EXT)” will appear after the elapsed time display. When equalization has begun, an “(EQU)” will appear on the display after the elapsed time. When the charge is complete, the RANGER II will show the ampere-hours and kilowatt-hours returned to the battery.
In the event of a charging problem or error, an error message will be displayed. Refer to Section 8, Troubleshooting, for more information on error messages. NOTE: This error message will clear if the battery is disconnected. This information and other charge parameters are also available during the charge and can be accessed by pressing the Scroll key twice.
6.3.2.
Manual Stopping
To interrupt the charge before it is complete, press the Stop button. CAUTION: Always be sure charger is turned off—either manually or automatically—before disconnecting the battery from the charger. Otherwise, hazardous arcing will occur.
6.3.3.
Manual equalizing
In the course of the normal charge/discharge cycle, a motive power battery develops inequalities of voltage and specific gravity among its cells. Equalizing batteries at regular intervals will restore cell equality, assuring rated performance. Activate manual equalizing by pressing the Scroll key anytime before or during a charge. The normal equalization program is overridden, and so this feature can be used to equalize a fully charged battery. To activate manual equalize, press an Arrow key. To deactivate manual equalize, press an Arrow key again. After 60 seconds, the display will return to the idle charger display. MNU: Manual EQU [↑↓]
6.3.4.
Operation after loss of AC power (warm start)
If the charger has been started manually, it will return to its previous operating mode as soon as power is restored and continue charging the battery until the charge cycle is completed. If the charger is set for real-time start and the power is discontinued and then restored before the selected start time, charger operation is unaffected. If the charger is set for real-time start and the power loss occurs 1) after start or 2) before start and extends into the preselected charge period, the charger will resume operation as soon as power is restored and continue the charging sequence until the charge cycle is completed. An exception to this would be if the power outage lasted into the next day (beyond 24:00, midnight), in
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which case the charger would not restart until the preset hour that day. To reduce the possibility of tripping a breaker in multiple charger installations, the RANGER II control distributes charger starts randomly. The minimum delay time is 15 seconds and the maximum delay time is 3 minutes and 30 seconds.
6.3.5.
Charge data retrieval
When a charge is completed, the RANGER II control can display the ampere-hours and kilowatt-hours required for the charge, followed by the word “complete.” Pressing the Scroll key will enable the user to access information about starting time and date, open circuit battery voltage, starting and ending battery voltage, starting and ending battery current, ampere-hours and kilowatt-hours of charge, length of charge, ending time and date, and the number of nonequalized cycles. If the battery being charged has a compatible battery module installed and the charger is equipped for a compatible battery module communications, additional removed data will be available: ampere-hours moved on discharge and on charge temperatures. Press the Scroll key until the display reads: MNU: Charge rpt [↑↓] This data can be retrieved and shown on the display during or after the charge cycle. In the event of an error during the charge cycle, a “plain English” error message is displayed. Refer to Section 8, Troubleshooting.
6.4. Special features with a compatible battery module A RANGER II charger connected with a compatible battery module will operate in the same manner as described in Sections 6.2 through 6.3, except for the enhancements noted below. While the charger is charging a battery with a compatible battery module connected, the RANGER II control checks the battery module to see that the last charge was full and the battery is discharged. It then calculates and displays the percent charged. If the battery module indicates the battery is already fully charged, the charge cycle is terminated within two minutes. The display will indicate the percent charge. The charger may enter a cooling cycle if the battery module indicates temperatures within a certain range; if it does so it is indicated on the display as C:Cooling xx°F, with the hours, minutes and seconds. When the battery temperature is less than 105°F, the RANGER II resumes the charge cycle and will enter the equalize mode, if necessary. After equalization or watering, the RANGER II checks the battery module again for temperature. It may enter the cooling stage again, indicating it on the display. Because the battery module keeps track of battery cycles, you can equalize and water by battery cycles, not charger cycles. If equalization is selected, the display will show “C:E.” During equalization, the percent charge is displayed. You may specify equalizing parameters as indicated in Section 6.3. When a compatible battery module is connected to a RANGER II charger, the watering options are always, never, every five battery cycles or every 10 battery cycles. NOTE: A battery module capable RANGER II control programmed for watering by battery cycles will always perform the watering cycle if connected to a battery without a battery module. Changing watering parameters is also described in Section 6.2.3.
6.4.1.
Installing a compatible battery module communications board
The RANGER II control is designed to interface with a compatible battery module, enabling you to get data such as depth of discharge information, start and end of charge temperatures, minimum volts per cell, low volts per cell and more. In order for a RANGER II control to interface with a battery module, the charger must have a communications board installed. The communications board is installed by inserting it into the RANGER II board at expansion slot A. Firmly seat the communications board onto the RANGER II board. (Be sure to disconnect both AC power and the battery during this procedure.)
6.4.2.
Retrieving data from a compatible battery module
When entering the programmable parameters, a choice is given between the programmable parameters and the battery module menu. The battery module terminal menu is used to retrieve information from a compatible battery module
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attached to a RANGER II control. If the RANGER II cannot communicate with the battery module, COMerr is displayed on the interface. If COMerr is displayed, contact your local C&D Technologies Manufacturing representative. The following information is displayed; the Scroll key is used to move through the menu items. Menu display BT: Present T [C] 87 °F
Description The current temperature of the battery.
BT: Dischrg data [C] 2.37V 329AH 14.21
Shows minimum volts per cell, ampere-hours removed and time in discharge. When this information is retrieved, the equivalent information in the charge summary report is replaced with this new data.
BT: Discharges [C] 1000 cycles
The number of discharge cycles from a compatible battery module. When this information is retrieved, the equivalent information in the charge summary report is replaced with this new data.
BT: Low VPC [C] 25 cycles 2.5%
The number of low volts per cell cycles and the percent of the total.
BT: Lo DOD cycls [C] < 250, 30-70% 700
The number of low depth of discharge cycles for 30% (indicated by “ 5
The number of high depth of discharge cycles for 70-90% and > 90% (indicated by “>”).
BT: SOC T cycls [C] < 250, 500, > 250
The number of cycles in each of three start of charge temperature categories: < 60°F (indicated by “ 100°F (indicated by “>”).
BT: EOC T cycls [C] < 250, 500, > 250
The number of cycles in each of the three end of charge temperature categories: < 60°F (indicated by “ 100°F (indicated by “>”).
BT: Power cycls [C] 2
The number of times the power to the battery module has been cycled.
BT: Status [C] SW Version 1.00
The version of the compatible battery module software.
6.5. Communications port RANGER II controls are designed to be able to interface with a computerized asset management system (AMS). The unique fiber optic communications bus establishes a link with the AMS, enabling a user to have complete charging information on a fleet of FerroCharge chargers with RANGER II controls. The network address should be set to inactive unless there is an AMS. This will hide the baud rate menu. For information on setup and using an AMS, see the AMS operating manual. For more information on the available asset management systems, ask your local C&D representative for a brochure.
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7. CHARGER OPERATION 7.1. Recommended charging procedures Chargers require little attention beyond periodic removal of dust buildup and inspection for loose connections. Refer to section 2.7, Maintenance. Proper charging procedures are important to prevent damage to chargers, batteries and operators. Proper charging procedures require lead-acid batteries receive: • • • •
Watering at the end of charge, as needed, to maintain proper electrolyte level and concentration; An equalizing charge approximately every seventh charge to correct voltage imbalances among cells; Periodic cleaning to remove corrosive spills; Freshening charges if batteries remain out of service for three or more days.
Operators should only connect batteries to chargers with matching voltage and sufficient power output. The charger must be OFF before batteries are connected or disconnected. Motive power batteries are designed to be discharged daily but should not be discharged by more than 80 percent of their capacity during an 8-hour work shift. This allows sufficient time for them to charge and cool before they are returned to service and extends cycle life. Charging shallow-discharged cells can also lessen battery life. Batteries discharged less than 20 percent should remain in service for another shift in light duty before being placed on the charger. High resistance connections can reduce the charger’s ability to properly charge the battery as well as reduce charging efficiency. Dirty or pitted contact surfaces on either the charger or battery connector should be cleaned and lubricated, or replaced with the identical part following the manufacturer’s instructions and using the recommended tooling. Discolored contacts may also indicate loose crimps to the cable. Contacts should also be replaced if this is the case.
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7.2. Operating characteristics As a battery is placed on charge, there is an inrush of current to the battery. Charging increases battery voltage, and as the difference between the applied voltage and the battery voltage decreases, the flow of the charger current also decreases. During the final hours of the charge cycle, the charging rate is significantly reduced. Figure 7.1 shows typical ferroresonant charging characteristics.
Volts per Cell
IFR12HK510 Regulation 2.60 2.55 2.50 2.45 2.40 2.35 2.30 2.25 2.20 2.15 2.10 2.05 2.00 0
1
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16 17 18 19 20 21 22
Amperes per 100 Ampere-Hours Charger Rating
25
2.60
20
2.50
15
2.40
10
2.30
5
2.20
0
2.10 0
1
2
3
4
5
6
Hours
FIGURE 7.1 TYPICAL FERRORESONANT CHARGER CURVES
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7
Volts per Cell
Amps per 100 Ah Charger Rating
IFR12HK510 w/12D85-13 98% DoD, 108% Ah Return
As with all electrical apparatus, FerroCharge operating economics are influenced by electric utility rates, the user's choice of single phase or three-phase power, and the electrical efficiency and power factor of the charger. Electric utility rates are significantly lower during off-peak periods. However, to take advantage of these rates you may need a separate electric meter for the off-peak service connection. Your local utility representative can help you determine the type of off-peak program that best fits your application. Efficiency is the measure of the useful energy the charger makes available to the cell, as measured at the charger output. It is calculated by the equation: Percent efficiency = Output power (kW)/ Input power (kW) x 100 The power factor is the ratio of the true power (Watts) and the apparent power (Volts x Amps) a charger actually requires to operate. The equation for determining power factor is: Power factor (PF) = True power/Apparent power = Watts AC/(Volts AC) x (Current AC)
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8. TROUBLESHOOTING 8.1. General Troubleshooting Guidelines 1.
2.
3. 4. 5. 6. 7.
Safety is a prime consideration. a. Think before acting; plan your actions and troubleshooting strategy b. Wear safety glasses c. Remove watches, rings, and jewelry before reaching into the cabinet d. After recording the way you find the charger, press the Stop key, disconnect the battery and disconnect the ac supply unless a test requires otherwise. Keep a detailed record of the initial charger condition and the control board displays in case you need to request help later. By referring to the troubleshooting chart for the control board you can probably determine the problem from the display. Record the charger and battery model numbers and serial numbers. This information will be required when requesting service or warranty support. Visually inspect the charger displays and condition such as burn marks, smells, etc. Determine the symptoms. Take measurements as required. Diagnose the problem using the troubleshooting charts as a reference. Make the repairs.
TABLE 8.1 TEST INSTRUMENTS AND TOOLS FOR TROUBLESHOOTING Troubleshooting Equipment 0 to 200-mV scale VOM that reads up to 600 VAC and 250 VDC with minimum accuracy of 0.5 percent Clamp-on ammeter SB-175 or SB-350 shorting connector Wrench set Screwdriver set Jumper cables with alligator clips Note: Diode replacement requires a supply of thermal joint compound and a torque wrench capable of achieving the values in Table 8.2.
8.2. Procedure The following charts are designed to help a qualified technician diagnose and remedy malfunctions in the SCOUT, COMPUCHARGE, and RANGER II controls. In all cases, after recording the error message acknowledge the error message by pressing the Stop key. The first two charts cover the control; troubleshooting instructions for the charger are presented in the third chart. Sections 8.3 through 8.4 provide information on testing and replacing components. Also refer to the wiring diagrams in Section 10. IMPORTANT: Qualified personnel familiar with both local and national electrical codes must service this equipment. WARNING: Line voltages are present within the battery charger cabinet. When performing the following troubleshooting procedures, be sure to observe all appropriate safety precautions. ALWAYS BE SURE THE CHARGER IS TURNED OFF BEFORE DISCONNECTING A BATTERY.
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SCOUT CONTROL TROUBLESHOOTING CHART DISPLAY STATUS Yellow LED is lit and red LED is flashing rapidly
CAUSE 1. The wrong size battery has been connected
2. Battery is over-discharged
3. Battery has bad cells Green LED is lit and red LED is flashing rapidly
1. The maximum charging time has been exceeded
Both yellow and green LEDs are lit and red LED is flashing rapidly All LEDs are lit constantly
1. The Stop key has been pressed
All LEDs flashing
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1. Watchdog timer has reset
1. Low vpc early in the charge cycle due low charger output power.
40
ACTION a. Disconnect the battery and check that the number of cells in the battery matches the nameplate rating of the charger. b. Disconnect the battery and check that the control board’s jumper setting configuration for the number of cells matches the nameplate rating of the charger. If necessary, change the number of cells (see Section 3.3.1) by moving the jumpers and then restoring the power to the charger. a. Press the Equal key to force the charger on. While the key is pressed, the charger will remain on. After battery voltage rises, release Equal key, disconnect and reconnect the battery. The charger should start automatically in the normal manner. a. Check the battery for defective cells. a. Disconnect the battery to reset the charger. b. Check that the charger Amperehour rating matches the battery rating. c. Check the charger for low dc output. d. Check the battery for defective cells. a. Disconnect the battery. a. Disconnect AC power from the charger, wait 30 seconds and reapply. If problem persists, call for service. a. Check AC line and AC fuses to all phases. b. Check the charger for proper output voltage and current.
COMPUCHARGE CONTROL TROUBLESHOOTING CHART ERROR CODE bU E
DESCRIPTION 1. Battery voltage does not match the number of cells programmed (The wrong size battery has been connected.)
2. Battery is over-discharged
3. Battery has bad cells
ACTION a. Disconnect the battery and check that the number of cells in the battery matches the nameplate rating of the charger. b. Disconnect the battery and check that the control board’s jumper setting configuration for the number of cells matches the nameplate rating of the charger. If necessary, change the number of cells (see Section 4.3.3) by moving the jumpers and then restoring the power to the charger. a. Press the Equal key to force the charger on. While the key is pressed, the charger will remain on. After the battery voltage rises, release the Equal key, disconnect and reconnect the battery. The charger should start automatically in the normal manner. a. Check the battery for defective cells. a. Charger will reset after five seconds. It will begin from the Ready state.
uS E -or -uT E
1. The charger microprocessor needs to reset itself
bd E
1. During charge, the battery was disconnected
a. Charger will reset itself after five seconds. It will begin from the Ready state.
hotE
1. The battery temperature is too high
a. The charger will stop for 8 hours, then resume automatically. To clear the message, disconnect the battery. Let the battery cool down before using it.
StPE
1. During the charge, user pressed the Stop key
a. To clear this message, disconnect the battery.
12hE
1. The battery has been on charge more than 12 hours
a. To clear this message, disconnect the battery. b. Check that the charger Amperehour rating matches the battery rating. c. Check the charger for low dc output. d. Check the battery for defective cells.
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RANGER II CONTROL TROUBLESHOOTING CHART DISPLAY ABORT: discnect bat Wrong battery size
ABORT: discnect bat Charge > 12 hrs ABORT: discnect bat Hot battery ABORT: discnect PWR OFF, but charging ABORT: discnect bat Operator STOP ABORT: discnect bat Zero current flt ABORT: press {Stop} NVRAM is trashed WDT RST: Restarting ABORT: press [Stop] Replace RTC (lobat) ABORT: press [Stop] State machine flt
CAUSE 1. Battery not matched to charger (wrong number of cells) 2. Battery has short-circuited cells or overdischarged 3. Control board not matched to charger 1. Battery is too large for charger 2. Control board failure
ACTION a. Verify battery and charger match. a. The charger can be “forced” on from this condition by holding the “up” arrow until the voltage reads an acceptable level. a. Check and reset board settings to match charger output voltage. Verify other settings. a. Place battery on charger of proper size. a. If problem is repeated, contact C&D
1. Hot battery
a. Allow several hours for cool-down before flt restarting charge.
1. DC current continued to flow after contactor turned off
a. Check line contactor and replace if necessary.
1. Charge terminated by operator
a. Resume charge if necessary.
1. Operator disconnected battery
a. Reconnect battery and resume charge.
2. Charger problem 1. Charger parameters lost
a. Refer to flowcharts on next page. a. Remove and then restore AC power; re-enter parameters. If problem recurs, call your local C&D REPRESENTATIVE. a. If problem recurs, call your local C&D REPRESENTATIVE.
1. Watchdog timer reset has occurred. The charger will automatically restart. 1. Real-time clock must be replaced
1. Control program found in an unknown state
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a. Call your local C&D REPRESENTATIVE.
a. Disconnect and reconnect charger. If problem persists, contact C&D.
POWERTRAIN AND OTHER CHARGER PROBLEM-TROUBLESHOOTING CHART Problem Charger has no display
Possible Cause Loss of AC
AC fuses or breaker blow
Charger ac input recently reconnected for a different voltage
Wrong fuse or breaker size
Charger will not start charging
Loss of AC Over-discharged battery
Wrong battery or board set wrong
Defective control transformer (CXF) Defective Line contactor (LC) Defective control board Charger has no DC output
Blown output fuse (DCF)
Charger does not stop
Defective control board
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Solution Check AC supply fuses or breakers Check AC fuses in charger Check control fuse F3 (1-phase) or F4 (3-phase) Check control transformer CXF Check that power transformer and control transformer primary connections were both changed correctly. Refer to schematics. Check that ac fuses were changed for new line voltage Check label in charger for internal fuses and recommended line fuses on nameplate for external fuses. Check AC fuses or breakers Check charger AC fuses Check for correct number of cells. On Scout and CompuCharge controls press Equal key to force on the charger to raise battery voltage. Check that battery matches cells on charger nameplate Check that jumpers on control board are set to match cells on charger nameplate. Check primary voltage and secondary voltages Check for 24 Vac on coil Check for 24 Vac on line contactor coil Check for reverse polarity battery. Were the charger or battery connectors replaced recently? Shorted Diode Press Stop. If charger keeps running, turn off ac. Restart ac. If charger starts immediately replace control board. If charger goes to delay before starting the control board may have “hung up”. Resetting the ac may correct the problem, but if the problem persists it may be necessary to replace the board.
Low DC output, 3-phase charger
Low DC output, 1-phase charger
Override timer shuts down charger
Flashing lights on Scout control Error code displayed on CompuCharge control Utility power loss and restoration during the charge cycle
One of the power transformers is not working properly
Diode is open in rectifier Loose connection in output wiring Power transformer is not working properly
Diode is open in rectifier Loose connection in output wiring Battery is over-discharged or has bad cells Charger has low dc output Look at section 8.2
Check ac fuses (F1-F3) Check transformer input and output voltages. Defective or disconnected resonant capacitor Check diodes Tighten all connections Defective or disconnected resonant capacitor Check transformer input and output voltages Check diodes Tighten all connections Check battery
See chart entry for low output Record display before calling for service support Look at section 8.2 Record display before calling for service support Both the Scout and CompuCharge controls will restart the charge after a random time delay. The Scout control delay is up to 3-1/2 minutes and the CompuCharge control delay is up to 2 minutes.
8.3. Component testing Many problems can often be revealed by a visual inspection. In new chargers, look for connections that may have loosened during shipment. In previously operating systems, look for the whitish powder residue created by burning varnish, or a broken, melted or discolored wire. When troubleshooting three-phase chargers, be sure to test both sets of components. Always read and follow all warning labels and turn off the charger before touching, removing or installing components.
C&D supports FerroCharge chargers with prompt field service and overnight delivery of most components. If you do not know the name of your nearest representative contact: C&D Technologies, Inc. Integrated Power Systems, Motive Power Division 65 Industrial Park Road, Dunlap, TN 37327 Customer Service, Voice: (800) 440-3504 Customer Service, Fax: (423) 949-3647 Field Service: (800) 299-3907 Web site – http://www.cdpowercom.com
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Device and Procedure
Device and Procedure
CAPACITORS: Before starting, be sure the capacitor is discharged. Before testing, disconnect both leads to isolate the capacitor from the charger circuit. Test capacitors with a calibrated ohmmeter. Different sizes of capacitors require different ohmmeter range settings. Begin with the highest setting. Be sure to reverse the leads for each check. • A good capacitor deflects the ohmmeter needle toward zero then steadily rises toward infinite resistance. • An open capacitor immediately shows Infinite resistance. A short capacitor remains at zero resistance.
DIODES: Test diodes with the ohmmeter set at either the 1OX or 1OOX scale. Before testing, disconnect one lead to isolate the diode from the charger. • A good diode shows low resistance when tested in one direction and high resistance when the ohmmeter probes are reversed. • An open diode shows very high resistance in both directions. • A shorted diode shows zero or low resistance in both directions.
CONTROL TRANSFORMER: Output should be between 22 and 26 VAC across the full secondary winding.
FUSES: Remove the fuse from the fuse holder and test it with an ohmmeter set to any scale. • A good fuse shows zero resistance. • An open or "blown" fuse shows infinite resistance.
8.4. Replacing components Ammeter shunts, capacitors, fuses, control boards, control transformers, line contactors, and power transformers can be userreplaced. Simply mate the leads of the replacement component with their appropriate connectors. Printed circuit boards in the controls do not contain user-repairable parts. The entire printed circuit board must be replaced. It is recommended that the entire rectifier be replaced rather than individual diodes. Users attempting diode replacement MUST observe the following procedure: 1) Disconnect the charger from the AC line and battery. 2) Remove the rectifier assembly. 3) Clamp the heat sink portion of the assembly in a vise. 4) Remove the faulty diode. 5) Coat the mating surfaces of the diode and the heat sink with a suitable thermal joint compound. 6) Place the diode on the heat sink and hand tighten the diode connection hardware. 7) Torque diode connections to values shown In Table 8.2. 8) Remove excess thermal joint compound. 9) Reinstall the assembly and reconnect leads.
TABLE 8.2 DIODE CONNECTION TORQUE VALUES DIODE CONNECTION TORQUE VALUES 1/4" studs 25 +2/-2 in- lb. 3/8" studs 112 +4/-3 in- lb. 1/2" studs 137 +4/-4 in- lb. 3/4" studs 260 +5/-3 in- lb.
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9.
MODELS, RATINGS, AND PARTS LISTS Model
Input Voltage (V)
IFR6CE450 IFR6CE510 IFR6CE600 IFR6CE750 IFR6CE875 IFR6HK875 IFR6HK1000 IFR6HK1200
208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480
1 1 1 1 1 3 3 3
1 1 1 1 1 2 2 2
8.5/7.5/4 10.5/9/4.5 14/12/6 15/13.5/7 16/14/7 9.5/8/4 11.5/10/5 16/14/7
85 96 108 143 158 158 190 228
6 6 6 6 6 6 6 6
Battery Ah Capacity for 8 h Charge, 100% DOD 450 510 600 750 875 875 1000 1200
IFR12AC255 IFR12CE255 IFR12CE450 IFR12CE510 IFR12CE600 IFR12CE750 IFR12CE875 IFR12HK510 IFR12HK600 IFR12HK750 IFR12HK875 IFR12HK1000 IFR12HK1200
120/208/240 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480
1 1 1 1 1 1 1 3 3 3 3 3 3
1 1 1 1 1 1 1 2 2 2 2 2 2
18/9/8 9/8/4 18/16/8 20.5/18/9 24/21/10.5 30/26/13.5 35/28/14 10/9/4.5 12/10.5/5.5 15.5/13.5/7 18/15.5/8 20/17/8.5 23/20/10
46 46 85 96 108 135 166 96 108 135 158 190 228
12 12 12 12 12 12 12 12 12 12 12 12 12
255 255 450 510 600 750 875 510 600 750 875 1000 1200
A A A A A A A A A A A A A
IFR18CE450 IFR18CE510 IFR18CE650 IFR18CE750 IFR18HK510 IFR18HK650 IFR18HK750 IFR18HK875 IFR18HK935 IFR18HK1000 IFR18HK1100 IFR18HK1200 IFR18HK1250 IFR18HK1400
208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480
1 1 1 1 3 3 3 3 3 3 3 3 3 3
1 1 1 1 2 2 2 2 2 2 2 2 3 3
22/19/9.5 25/22/11 35.5/31.5/15.5 41/36/18 15/13.5/7 20/17/8.5 23/20/10 26/23/11.5 28.5/24.5/12 30.5/26.5/13.5 32/28/14 32/28/14 36/32/16 40/35/17.5
85 96 117 135 96 117 135 158 168 190 198 198 238 266
18 18 18 18 18 18 18 18 18 18 18 18 18 18
450 510 650 750 510 650 750 875 935 1000 1100 1200 1250 1400
A A A A A A A A A A A A B B
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No. Of No. Of Phases Xfmrs
46
Input Current (A)
Output Current (A)
Cells
Cabinet
A A A A A A A A
Model
Input Voltage (V)
IFR24CE450 IFR24CE510 IFR24CE600 IFR24CE680 IFR24HK450 IFR24HK510 IFR24HK600 IFR24HK680 IFR24HK765 IFR24HK850 IFR24HK900 IFR24HK1100 IFR24HK1250 IFR24K1360
208/240/480 208/240/480 208/240/480 240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 208/240/480 480
1 1 1 1 3 3 3 3 3 3 3 3 3 3
IFR36HK450 IFR36HK510 IFR36HK600 IFR36HK680
208/240/480 208/240/480 208/240/480 208/240/480
IFR40HK510
208/240/480
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No. Of No. Of Phases Xfmrs
Input Current (A)
Output Current (A)
Cells
1 1 1 1 2 2 2 2 2 2 2 3 3 3
31/27/13.5 38/33/17 44/38/19 46/23 19.5/17/8.5 23/20/10 24/21/10.5 27.5/24/12 31/27/13.5 35/30/15 36/32/16 40/35/17.5 48/42/21 23.5
85 96 114 129 85 96 114 129 138 153 162 198 228 258
3 3 3 3
2 3 3 3
26.5/23/11.5 31/27/13.5 35/31/15.5 39/34/17
3
3
35/30/15
47
Cabinet
24 24 24 24 24 24 24 24 24 24 24 24 24 24
Battery Ah Capacity for 8 h Charge, 100% DOD 450 510 600 680 450 510 600 680 765 850 900 1100 1200 1360
85 96 114 129
36 36 36 36
450 510 600 680
A B B B
96
40
510
B
A A A A A A A A A A A B B B
Model
Input Voltage (V)
IFR6M450 IFR6M510 IFR6M600 IFR6M750 IFR6M875 IFR6L875 IFR6L1000 IFR6L1200
575 575 575 575 575 575 575 575
1 1 1 1 1 3 3 3
1 1 1 1 1 2 2 2
4 4.5 6 6.5 7.5 3.5 4 5.5
85 96 108 143 166 166 190 228
6 6 6 6 6 6 6 6
Battery Ah Capacity for 8 h Charge, 100% DOD 450 510 600 750 875 875 1000 1200
IFR12M255 IFR12M450 IFR12M510 IFR12M600 IFR12M750 IFR12M875 IFR12L510 IFR12L600 IFR12L750 IFR12L875 IFR12L1000 IFR12L1200
575 575 575 575 575 575 575 575 575 575 575 575
1 1 1 1 1 1 3 3 3 3 3 3
1 1 1 1 1 1 2 2 2 2 2 2
3.5 7 7.5 9 11 13 4 4.5 6 7 7 8
46 85 96 108 135 166 96 108 135 158 190 228
12 12 12 12 12 12 12 12 12 12 12 12
255 450 510 600 750 875 510 600 750 875 1000 1200
A A A A A A A A A A A A
IFR18M450 IFR18M510 IFR18M650 IFR18M750 IFR18L510 IFR18L650 IFR18L750 IFR18L875 IFR18L935 IFR18L1000 IFR18L1100 IFR18L1200 IFR18L1250 IFR18L1400
575 575 575 575 575 575 575 575 575 575 575 575 575 575
1 1 1 1 3 3 3 3 3 3 3 3 3 3
1 1 1 1 2 2 2 2 2 2 2 2 3 3
8 9 13.5 15 5.5 7.5 8.5 9.5 10.5 11 12 12 13 14.5
85 96 117 135 96 117 135 158 168 180 198 198 238 266
18 18 18 18 18 18 18 18 18 18 18 18 18 18
450 510 650 750 510 650 750 875 935 1000 1100 1200 1250 1400
A A A A A A A A A A A A B B
PM990-1897-00, ISSU E 5
No. of No. of Input Phases Xfmrs Current (A)
48
Output Current (A)
Cells
Cabinet
A A A A A A A A
Model
Input Voltage (V)
IFR24M450 IFR24M510 IFR24M600 IFR24M680 IFR24L450 IFR24L510 IFR24L600 IFR24L680 IFR24L765 IFR24L850 IFR24L900 IFR24L1100 IFR24L1250 IFR24L1360
575 575 575 575 575 575 575 575 575 575 575 575 575 575
1 1 1 1 3 3 3 3 3 3 3 3 3 3
1 1 1 1 2 2 2 2 2 2 2 3 3 3
11.5 14 15.5 19 7 8 9 10 11.5 12 13.5 14.5 17.5 20
85 96 114 129 85 96 114 129 138 153 162 198 228 258
24 24 24 24 24 24 24 24 24 24 24 24 24 24
Battery Ah Capacity for 8 h Charge, 100% DOD 450 510 600 680 450 510 600 680 765 850 900 1100 1200 1360
IFR36L450 IFR36L510 IFR36L600 IFR36L680
575 575 575 575
3 3 3 3
2 3 3 3
9.5 11.5 13 14
85 96 114 129
36 36 36 36
450 510 600 680
A B B B
IFR40L510
575
3
3
12
96
40
510
B
PM990-1897-00, ISSU E 5
No. of No. of Input Phases Xfmrs Current (A)
49
Output Current (A)
Cells
Cabinet
A A A A A A A A A A A B B B
Model
IFR6CE450 IFR6CE510 IFR6CE600 IFR6CE750 IFR6CE875 IFR6HK875 IFR6HK1000 IFR6HK1200
NA NA NA NA NA NA NA NA
12 15 20 20 20 12 15 20
10 12 15 20 20 12 15 20
6 6 8 10 10 6 7 10
4 6 7 8 8 5 6 8
Output (DC) Fuse Rating Amperes 200 200 200 200 200 200 325 325
IFR12AC255 IFR12CE255 IFR12CE450 IFR12CE510 IFR12CE600 IFR12CE750 IFR12CE875 IFR12HK510 IFR12HK600 IFR12HK750 IFR12HK875 IFR12HK1000 IFR12HK1200
20 NA NA NA NA NA NA NA NA NA NA NA NA
12 12 25 30 30 40 40 15 15 20 25 30 30
12 10 20 25 30 35 35 12 15 10 20 25 30
NA 6 10 12 15 20 20 6 8 10 10 12 15
NA 5 10 10 12 15 15 6 6 8 10 10 12
100 100 200 200 200 200 200 200 200 200 200 325 325
100 100 200 200 200 200 200 200 200 200 200 300 300
IFR18CE450 NA 30 25 IFR18CE510 NA 35 30 IFR18CE650 NA 45 40 IFR18CE750 NA 60 50 IFR18HK510 NA 20 20 IFR18HK650 NA 25 25 IFR18HK750 NA 30 25 IFR18HK875 NA 35 30 IFR18HK935 NA 40 35 IFR18HK1000 NA 40 35 IFR18HK1100 NA 45 40 IFR18HK1200 NA 45 40 IFR18HK1250 NA 50 45 IFR18HK1400 NA 50 50 * Models with M or L input voltage code only
12 15 20 25 10 12 15 15 15 20 20 20 20 25
10 12 20 20 8 10 12 12 15 15 15 15 20 20
200 200 200 200 200 200 200 200 325 325 325 325 325 500
200 200 200 200 200 200 200 200 300 300 300 300 300 500
120 V
PM990-1897-00, ISSU E 5
Input (AC) Fuse Rating – Amperes 208 V 240 V 480 V 575 V *
50
Shunt Amperes
200 200 200 200 200 200 300 300
Model
IFR24CE450 IFR24CE510 IFR24CE600 IFR24CE680 IFR24HK450 IFR24HK510 IFR24HK600 IFR24HK680 IFR24HK765 IFR24HK850 IFR24HK900 IFR24HK1100 IFR24HK1250 IFR24K1360
NA NA NA NA NA NA NA NA NA NA NA NA NA NA
40 50 60 NA 25 30 30 35 40 45 50 50 60 NA
35 45 50 60 25 30 30 30 35 40 45 50 60 NA
20 20 25 30 12 15 15 15 20 20 20 25 30 30
15 20 20 25 10 12 12 15 15 15 20 20 25 25
Output (DC) Fuse Rating Amperes 200 200 200 200 200 200 200 200 200 200 325 325 325 500
IFR36HK450 IFR36HK510 IFR36HK600 IFR36HK680
NA NA NA NA
35 40 50 50
30 40 40 50
15 20 20 25
12 15 20 20
200 200 200 200
200 200 200 200
IFR40HK510 NA 50 40 * Models with M or L input voltage code only
20
15
200
200
120 V
PM990-1897-00, ISSU E 5
Input (AC) Fuse Rating – Amperes 208 V 240 V 480 V 575 V *
51
Shunt Amperes
200 200 200 200 200 200 200 200 200 200 300 300 300 500
10. SCHEMATICS AND WIRING DIAGRAMS
PM990-1897-00, ISSU E 5
52
PXF1
TB1
(SHOWN)
YEL
3
GRN
4 L2
T2
NAT
6
LCC
C1
C2 POS
BLU
5
F2
RES
{
RED
2
T1
PRI
240VAC
L1
F1
SEC
AC INPUT
BLK
1
LC
D1
SP
CA
7
D2
OPTIONAL AS
DCF
1
2 3
NEG
4
}
DC OUTPUT
LEGEND RB
}
DC CONNECTOR AUX. CONTACTS
CXF X1
H4
X2
H2
X3 H3 H1
X4 1
F3
4
5
7
9
11
12
15
18
K1
} JUMPER CONNECTIONS FOR 208V
JUMPER CONNECTIONS FOR 480V
TB1 1 2 3 4 5 6
TO OPTIONAL WATER MODULE DEVICE
TB1 BLK
CXF
RED L2 YEL
NAT
7
L1
BLK
2
RED
H2
3
YEL
H3
4
H1
5
BLU
6
NAT
GRN BLU
1
H4
CXF L2
H4 H2
GRN
H3 L1
H1
7
SCHEMATIC DIAGRAM – 208/240/480 VAC 1- PHASE PM990-1897-00, ISSU E 5
53
AS CA C1 & C2 CXF D1 & D2 DCF F1-F2 F3 K1 LC LCC PXF1 RB SP TB1 TVS
SHUNT (OPTION) CATHODE CAPACITOR (C2 OPTIONAL) CONTROL TRANSFORMER DIODE DC FUSE AC FUSE CONTROL FUSE BOARD CONNECTOR LINE CONTACTOR LINE CONTACTOR COIL POWER TRANSFORMER AUX. CONNECTOR BOARD (OPTIONAL) SURGE PROTECTOR TERMINAL BLOCK, AC CHANGEOVER TRANSIENT VOLTAGE SUPPRESSOR
PXF1
TB1
(SHOWN)
YEL
3
GRN
4 L2
T2
C2
C1
POS
BLU
5
F2
RES
{
RED
2
T1
PRI
120VAC
L1
F1
NAT
6
SEC
AC INPUT
BLK
1
LC
D1
SP
CA
LCC 7
D2
OPTIONAL AS
DCF
1
2 3
4
NEG
}
DC OUTPUT
LEGEND RB
}
DC CONNECTOR AUX. CONTACTS
CXF X1
H4
X2
H2
X3 H3 H1
X4 1
F3
4
5
7
9
11
12
15
18
K1
} JUMPER CONNECTIONS FOR 208V
JUMPER CONNECTIONS FOR 240V
TB1 1 2 3 4 5 6
TO OPTIONAL WATER MODULE DEVICE
TB1 BLK
CXF
RED L2 YEL
NAT
7
L1
BLK
2
RED
H2
3
YEL
H3
4
H1
5
BLU
6
NAT
GRN BLU
1
H4
CXF L2
H4 H2
GRN H3 L1
H1
7
SCHEMATIC DIAGRAM – 120/208/240 VAC 1- PHASE PM990-1897-00, ISSU E 5
54
AS CA C1 & C2 CXF D1 & D2 DCF F1-F2 F3 K1 LC LCC PXF1 RB SP TB1 TVS
SHUNT (OPTION) CATHODE CAPACITOR (C2 OPTIONAL) CONTROL TRANSFORMER DIODE DC FUSE AC FUSE CONTROL FUSE BOARD CONNECTOR LINE CONTACTOR LINE CONTACTOR COIL POWER TRANSFORMER AUX. CONNECTOR BOARD (OPTIONAL) SURGE PROTECTOR TERMINAL BLOCK, AC CHANGEOVER TRANSIENT VOLTAGE SUPPRESSOR
PX F2
240V S HO W N
L3
T3
2 3
F2
4 5 6
F3
7 8 9
LC C
10
RES
T2
F1
B LK RED
C1
C3
RED RED
PRI
{
L2
1
CA SEC
A C IN PUT
TB2 T1
YEL
PO S
D4
O PTIO N AL
G RN
AS
2 DCF 1
B LU
1
S P1
2 3
B LU
SEC
LC L1
B LU
4
NE G
}
D C O U TPU T
NAT
D3 PX F1
D C C O N N EC TO R
RB
3
A UX . CO NTA C TS
4 5
C2
C4
YEL G RN
D2
B LU
S P2
NAT
SEC
6
B LK RED
SEC
2
PRI
1
RES
TB1
D1 CXF H4 H2 H3 H1
X1 X2 X3 X4 1
4
5
7
9
11
12
15
18
F4 K1
LE G E ND
JUM PE R C O N NE C TIO N S FO R 208V
JU M P ER CO NN EC TIO NS FO R 480V
T B2
T B2
1
1
2
TB1
3
1
4
CXF L3
2
TB1 CXF
3
1
4
2
5
3
6
4
7
5
8
6
H4
2
L3
H2 5
3
6
4
7
5
8
6
H2
H3 L1
H4
H3
H1
9
9
10
10
L1
H1
SCHEMATIC DIAGRAM – 208/240/480 VAC 3-PHASE
PM990-1897-00, ISSU E 5
55
AS CA C 1-C 4 C XF D 1-D 4 D CF F1-F3 F4 K1 LC LC C P X F1 & PX F2 RB S P 1 & SP 2 TB 1 & TB2 TV S
S HU N T (O P TIO N) C ATH O D E C AP A C ITO R (C 3 & C 4 O P TIO N AL) C O N TR O L TRA N S FO R M E R D IO D E D C FUS E A C FUS E C O N TR O L FU SE B O A R D C O N N E CTO R LIN E C O N TAC TO R LIN E C O N TAC TO R C O IL P O W ER TRA N S FO R M ER A UX . CO N N EC TO R BO A R D (O PTIO NA L) S UR G E P R O TEC TO R TER M INA L BLO C K TR A NS IE NT V O LTA G E S U P P RE SS O R
PXF1
4 5 6
C1
C4
YEL
CA
GRN
SEC
3
BLK RED
PRI
2
D1
BLU
SP1
NAT
SEC
1
RES
TB1
7
D2
LC
T2
F1
1 2
L3
T3
3
F3
4 5 6
LCC
RES
TB2
F2
BLK
C2
C5 POS
RED
SEC
{
L2
PXF2
YEL GRN
PRI
240V SH O W N
T1
D3 2 DCF 1
BLU
SP2
NAT
AS 1
2 3
NEG
4
SEC
A C IN P U T
L1
7
}
D C O U TPUT
D4 PXF3
3 4 5 6 7
YEL
C3
C6
GRN
SEC
RB
AUX. CO NTACTS
BLK RED
PRI
2
D5
BLU
SP3
NAT
SEC
1
DC CO NN ECTO R
RES
TB3
D6 CXF H4 H2 H3 H1
X1 X2 X3 X4 1
4
5
7
9
11
12
15
18
F4
LEG END
K1
J U M P E R C O N N E C T IO N S F O R 2 0 8 V
J U M P E R C O N N E C T IO N S F O R 4 8 0 V
T B 1 /T B 2 /T B 3
T B 1 /T B 2 /T B 3 CXF
1 2
L3
3 4 5
L1
CXF
1
H4
2
H2
3
H3
4
H1
5
6
6
7
7
L3
H4 H2 H3
L1
H1
AS CA C 1 -C 4 CXF D 1 -D 4 DCF F 1 -F 3 F4 K1 LC LCC PXF1 & PXF2 RB SP1 & SP2 TB1 & TB2 TVS
S H U N T (O P T IO N ) CATHO DE C A P A C IT O R (C 3 & C 4 O P T IO N A L ) CO NTROL TR ANSFO RM ER D IO D E DC FUSE AC FUSE CO NTRO L FUSE BOARD CO NNECTOR L IN E C O N T A C T O R L IN E C O N T A C T O R C O IL POW ER TRAN SFO RM ER A U X . C O N N E C T O R B O A R D (O P T IO N A L ) SURG E PROTECTOR T E R M IN A L B L O C K T R A N S IE N T V O L T A G E S U P P R E S S O R
SCHEMATIC DIAGRAM – 208/240/480 VAC 3-PHASE THREE TRANSFORMERS PM990-1897-00, ISSU E 5
56
PXF1
B LK
PRI
2 3 4
YEL
C1
C4 CA
SEC
1
RES
TB1
D1
SEC
SP1
D2
LC
T2
F1
TB2 1
F2
B LK
T3
3
F3
4
C2
C5 POS
2 L3
RES
{
L2
PXF2
PRI
480V
T1
YEL
SEC
A C IN P U T
L1
D3 2 DCF 1 SP2
AS 1
NEG
2 3
4
SEC
LCC
}
D C O UTPUT
D4 PXF3
B LK
RB
PRI
2
DC CO NNECTOR
3
AUX. CO NTACTS
4
YEL
C3
C6
SEC
1
RES
TB3
D5
SP3 SEC
LEG END
D6 CXF H4 H2 H3 H1
X1 X2 X3 X4 1
4
5
7
9
11
F4 K1
12
15
18
AS CA C 1 -C 6 CXF D 1 -D 6 DCF F 1 -F 3 F4 K1 LC LCC PXF1 - PXF3 RB SP1 - SP3 TB1 - TB3 TVS
SCHEMATIC DIAGRAM –480 VAC 3-PHASE THREE TRANSFORMERS
PM990-1897-00, ISSU E 5
57
S H U N T (O P T IO N ) CATHODE C A P A C IT O R (C 4 - C 6 O P T IO N A L ) CONTRO L TRANSFORM ER D IO D E DC FUSE AC FUSE CONTRO L FUSE BO ARD C O NNECTO R L IN E C O N T A C T O R L IN E C O N T A C T O R C O IL PO W ER TR AN SFO RM ER A U X . C O N N E C T O R B O A R D (O P T IO N A L ) SURG E PROTECTOR T E R M IN A L B L O C K T R A N S IE N T V O L T A G E S U P P R E S S O R
PXF1
TB1
{
3 4 L2
YEL
C1
C2 POS
T2
F2
SEC
575VAC
2
T1
F1
PRI
A C IN P U T
D1
SP
CA
LCC D2
O P T IO N A L AS
DCF
RB
CXF H 3 575
X1
H 2 480
X2 X3
H1
X4 1
F3
4
5
7
9
11
12
15
18
K1
T O O P T IO N A L W ATER M O DULE D E V IC E
LEG END
AS CA C1 & C2 CXF D1 & D2 DCF F 1 -F 2 F3 K1 LC LC C PXF1 RB SP TB1 TVS
S H U N T (O P T IO N ) CATHODE C A P A C IT O R (C 2 O P T IO N A L ) CONTROL TRANSFORM ER D IO D E DC FUSE AC FUSE CONTROL FUSE BOARD CONNECTOR L IN E C O N N E C T O R L IN E C O N N E C T O R C O IL POW ER TRANSFORM ER A U X . C O N N E C T O R B O A R D (O P T IO N A L ) SURG E PROTECTOR T E R M IN A L B L O C K , A C C H A N G E O V E R T R A N S IE N T V O L T A G E S U P P R E S S O R
SCHEMATIC DIAGRAM – 575 VAC 1- PHASE PM990-1897-00, ISSU E 5
58
NEG
}
DC OUTPUT
LC L1
BLK
RES
1
PXF2
3
F2
4
CA
YEL
5
O P T IO N A L DCF
6
F3
POS
D4
AS
NEG
SP1 SEC
7
LC C D3
RES
PXF1
DC CO NNECTO R
YEL
RB
PRI
AUX. CO NTACTS
C4
C2
SEC
B LK
D2
SEC
SP2
D1 CXF X1 H3 X2 H2 X3 H1 X4
F4
1
4
5
7
9
K1
11
12
15
18
LEG END AM AS CA C 1 -C 4 CXF D 1 -D 4 DCF F 1 -F 3 F4 K1 LC LC C PXF1 & PXF2 RB SP1 & SP2 TB1 TVS
T O O P T IO N A L W ATER M O DULE D E V IC E
SCHEMATIC DIAGRAM – 575 VAC 3- PHASE
PM990-1897-00, ISSU E 5
59
A M M E T E R (O P T IO N A L ) S H U N T ( O P T IO N ) CATHODE C A P A C IT O R ( C 3 & C 4 O P T I O N A L ) CONTROL TRANSFORM ER D IO D E DC FUSE AC FUSE CONTROL FUSE BOARD CONNECTOR L IN E C O N T A C T O R L IN E C O N T A C T O R C O IL POW ER TRANSFORM ER A U X . C O N N E C T O R B O A R D ( O P T IO N A L ) SURGE PRO TECTOR T E R M IN A L B L O C K T R A N S IE N T V O L T A G E S U P P R E S S O R
}
DC
C3
RED
OUTPUT
C1
2
SEC
{
B LK
1
F1
PRI
AC IN P U T
TB1 RES
LC
PXF1
B LK
PRI
2 3 4
YEL
C1
C4 CA
SEC
1
RES
TB1
D1
SEC
SP1
D2
LC
T2
L3
T3
F1
TB2 1
F2
B LK
3 4
C2
C5 POS
2
F3
RES
{
L2
PXF2
PRI
57 5V
T1
YEL
SEC
A C IN P U T
L1
D3 2 DCF 1 SP2
AS 1
NEG
2 3
4
SEC
LCC
}
D C O U TP U T
D4 PXF3
B LK
DC CONNECTOR
RB
PRI
2 3
A U X . C O N TA C TS
4
YEL
C3
C6
SEC
1
RES
TB3
D5
SP3 SEC
LEG END
D6 CXF H 3 575 H 2 480
X1 X2 X3
H1
X4 1
4
5
7
9
F4 K1
11
12
15
18
AS CA C 1-C 6 CXF D 1-D 6 DCF F 1-F3 F4 K1 LC LCC P X F 1 - P X F3 RB SP1 - SP3 TB1 - TB3 TVS
SCHEMATIC DIAGRAM – 575 VAC 3- PHASE THREE TRANSFORMERS
PM990-1897-00, ISSU E 5
60
S H U N T (O P TIO N ) CATHODE C A P A C IT O R (C 4 - C 6 O P T IO N A L) CONTRO L TRANSFORM ER D IO D E DC FUSE AC FUSE CONTRO L FUSE BOARD CO NNECTOR LIN E C O N T A C T O R LIN E C O N T A C TO R C O IL P O W E R T R A N S FO R M E R A U X . C O N N E C TO R B O A R D (O P T IO N A L) S U R G E P R O T E C TO R T E R M IN A L B L O C K T R A N S IE N T V O LT A G E S U P P R E S S O R
NOTE: 1 . W IR E N U M B E R S F O R C H A R G E R W IT H O U T A S H U N T : 1 , 2 , 4 , 5 , 7 -1 4 , 2 3 , 2 5 , 3 9 & 4 2 . 2 . W H E N S H U N T IS U S E D M O V E W IR E 2 5 , A D D B U S - B A R , A N D C O N N E C T W IR E S 7 5 & 7 6 .
DCF
23
3 . W H E N C A P 2 IS U S E D A D D W IR E S : 6 0 & 6 1 . 4 . W H E N A M M E T E R IS U S E D C O N N E C T W IR E S : 7 0 t h r u 7 1 .
D1
5 . W H E N W A T E R M O D U L E IS U S E D A D D W IR E S : 7 4 & 7 7 .
D2
R1
R E C T I F IE R
PXF1-S2 #4 BLK
X 2 # 1 8 V IO X1 #18 O R N LCC 1 #18 YEL A S -4 # 1 8 B L K A S -3 # 1 8 W H T
11
30
9
5
75
4
76
1
D C O U TPUT BLK
SHUNT CATHODE
CAP1 & CAP2 CXF D1 & D2 DCF
C A P A C IT O R CONTROL TRANSFORM ER D IO D E DC FUSE
BLK
BUS-BAR
WATER
#18 BLU 77
LCC2
K1-12
#18 BLU 32
76
AS
T V S ( A L T E R N A T E L O C A T IO N )
RED
YEL
GRN
BLU
NAT
P3
P4
P5
P6
VO LTAG E C H AN G EO VER TABLE IN P U T VOLTAG E 208 VAC
FUSE
STEP 2CO NTRO L FUSE BO ARD CONNECTO R L IN E C O N T A C T O R L IN E C O N T A C T O R C O IL PO W ER TR ANSFO R M ER AUX. CONNECTOR BOARD T E R M IN A L B L O C K T R A N S IE N T V O L T A G E S U P P R E S S O R
WIRING DIAGRAM - 1 PHASE - 208/240/480 VAC
PM990-1897-00, ISSU E 5
2
TB1
STEP 1-
F 1 -F 2 F3 K1 LC LC C PXF1 RB TB1 TVS
4
75
BLK
L2 #18
K 1 -4 #18 BLK
1 3
12
11
7
34
33
LC-T2
BLK 5
51 10
8
6
K 1 -1 #18 W HT
H1
P2
D C C O NN EC TO R AUX. CO NTACTS
5
X4
BLK
}
4
#18 BRN
25 79
3
H3
P1
80
2
78
7
1
9
F 3 -1 # 1 8 B L K
52
X3
TVS
CXF
50
RB
AS CA
TVS K1
DC OUTPUT
H2
F3-2 #18
33
LC C 1 #18 YEL K 1 -7 # 1 8 Y E L O P T IO N A L
LEG END
DC O UTPUT
7
74
72
K1-11 X2
H4
RED
H 4 #18 RED
K 1 -7 # 1 8 Y E L
78
29
30 32
WHT
BLK
X4 #18 LC C2 BLU
L2 42
X1
JUM PER L2
#18 VIO
C X F -H 1 BLK
34
K1-9
2
F3
#18 ORN
1
42
LC-T1
2
12
29
K1-5
X4 BLK
TB1-7
L C -L 1 BLK
4
F2
L1
72
}
BLK
28
T2
WHT
1
31
AC INPUT
{
F1
15
RED
DCF
LC L1
26
K 1 -1 8
5
WHT
TB1-1 4 T1
18
3 1 /7 8
T B 3 -2 # 1 8 Y E L
23
#18 YEL
74
77
12
}
NAT
X3 #18 BRN
CA
27
28
AS-2
C A #18 RED
TO W ATER M O D U LE ( O P T IO N A L )
C2
LCC1
26
D CF #18 W HT
TB1-6
11
TB1-5
9
P6
BLU
GRN
P5
10
YEL
P4
TB1-4
TB1-3
BLK
RED
7
P3
#18 BLU
C1
TB1-2
TB1-1
61 CAP2
8
36
35
C2
60
C1
P2
BLK
K 1 -1 5 # 1 8 R E D P1
6 . W H E N A U X . C O N N E C T O R B O A R D IS U S E D R E M O V E W IR E 3 1 A N D A D D W IR E S 7 8 th r u 8 0 .
25
R2
CAP1
CA
61
240 VAC (S H O W N ) 480 VAC
T E R M IN A L B L O C K JU M P ER S #10 G A
T B 1 -1 T B 1 -2 T B 1 -5 T B 1 -1 T B 1 -3 T B 1 -6
TO TO TO TO TO TO
CO NTRO L TRANS. (C X F ) JU M P E R C O N N .
T B 1 -4 , T B 1 -5 , T B 1 -7 T B 1 -4 , T B 1 -6 , T B 1 -7
H 1 -H 3 H 2 -H 4
T B 1 -3 T O T B 1 -4 , T B 1 -6 T O T B 1 -7
H 2 -H 3
H 1 -H 3 H 2 -H 4
NOTE: 1 . W IR E N U M B E R S F O R C H A R G E R W IT H O U T A S H U N T : 1 , 2 , 4 , 5 , 7 -1 4 , 2 3 , 2 5 , 3 9 & 4 2 . 2 . W H E N S H U N T IS U S E D M O V E W IR E 2 5 , A D D B U S -B A R , A N D C O N N E C T W IR E S 7 5 & 7 6 .
DCF
23
3 . W H E N C A P 2 IS U S E D A D D W IR E S : 6 0 & 6 1 . 4 . W H E N A M M E T E R IS U S E D C O N N E C T W IR E S : 7 0 th ru 7 1 .
D1
5 . W H E N W A T E R M O D U L E IS U S E D A D D W IR E S : 7 4 & 7 7 .
D2
R1
R E C T IF IE R
PXF1-S2 #4 BLK
LC C 1 #18 YEL A S -4 # 1 8 B L K A S -3 # 1 8 W H T
6
RED
GRN
BLU
NAT
P4
P5
P6
FUSE
C A P A C IT O R
BOARD CONNECTOR L IN E C O N T A C T O R L IN E C O N T A C T O R C O IL
CONTROL TRANSFO RM ER
PXF1
P O W E R TR ANSFO R M ER
D1 & D2
D IO D E DC FUSE
RB TB1 TVS
AUX. CO NNECTO R BOARD
DCF
4
76
1
D C O U TPUT BLK
4 2
75
76
34
BLK
F3-2 #18
RED
K 1 -4 #18 B LK
1 3
AS
K 1 -1 #18 W HT
H1
BLK
BUS-BAR
WATER
#18 BLU 77
LCC2
#18 BLU 32
K1-12
#18 BRN
TVS
X4
33
L2 #18
BLK
LC-T2 7
X3
H3
T V S ( A L T E R N A T E L O C A T IO N )
TB1
IN P U T VOLTAGE
T E R M IN A L B L O C K T R A N S IE N T V O L T A G E S U P P R E S S O R
62
T E R M IN A L B L O C K JU M P E R S #10 G A
CONTROL TRANS. (C X F ) JU M PER CONN.
120 VAC (S H O W N )
T B 1 -1 T O T B 1 -4 , H 1 - H 3 T B 1 -3 T O T B 1 -6 , H 2 - H 4 T B 1 -6 T O T B 1 -7
208 VAC
T B 1 -2 T O T B 1 -4 , H 2 - H 3 T B 1 -5 T O T B 1 -7
240 VAC
T B 1 -3 T O T B 1 -4 , H 2 - H 3 T B 1 -6 T O T B 1 -7
S TEP 2-
C O N TR O L FU SE
WIRING DIAGRAM - 1 PHASE - 120/208/240 VAC
PM990-1897-00, ISSU E 5
5
75
V O LT A G E C H A N G EO V ER TA B LE DC CONNECTOR AUX. CO NTACTS
K1 LC LC C
CXF
7
74
12
5
11
4
10
8
3
YEL
BLK
}
F 1 -F 2 F3
CAP1 & CAP2
DC OUTPUT
TVS K1
DC OUTPUT
H2
S TEP 1-
SHUNT CATHODE
}
25 79
P1
80
2
7
1
78
LC C 1 #18 YEL K 1 -7 # 1 8 Y E L O P T IO N A L
LEG END
9
CXF
5
51
52
9
F 3 -1 # 1 8 B L K
RB
AS CA
11
30
72
K1-11 X2
H4
50
P3
33
P2
H 4 #18 RED
WHT
32
K 1 -7 # 1 8 Y E L
78
29
30
5
BLK
X4 #18 LCC2 BLU
L2 42
X1
JUM PER L2
#18 VIO
C X F -H 1 B LK
34
K1-9
2
F3
LC-T1
2
12
29
28
#18 ORN
1
42
4
F2
L1
72
BLK
K 1 -1 8
T2
WHT
1
31
AC INPUT
{
F1
15
RED
DCF
LC L1
26
K1-5
X4 L C -L 1 BLK
BLK
TB1-7
TB1-1
WHT 4
T1
18
3 1 /7 8
T B 3 -2 # 1 8 Y E L
23
#18 YEL
74
77
X 2 # 1 8 V IO X 1 #18 O RN
CA
27
28
AS-2
X 3 #18 BR N
}
NAT 12
11
C A #18 RED
TO W ATER M O D U LE ( O P T IO N A L )
C2
LCC1
26
D C F #18 W H T
TB1-6
TB1-5
9
P6
BLU
GRN
P5
10
YEL
P4
TB1-4
TB1-3
BLK
RED
7
P3
#18 BLU
C1
TB1-2
TB1-1
61 CAP2
8
36
35
C2
60
C1
P2
BLK
K 1 -1 5 # 1 8 R E D P1
6 . W H E N A U X . C O N N E C T O R B O A R D IS U S E D R E M O V E W IR E 3 1 A N D A D D W IR E S 7 8 th ru 8 0 .
25
R2
CAP1
CA
NOTE: 1 . W IR E N U M B E R S F O R C H A R G E R W IT H O U T A S H U N T : 1 -3 8 , 4 2 , 5 0 -5 5 , 7 2 . 2 . W H E N S H U N T IS U S E D M O V E W IR E 2 5 , A D D B U S -B A R , A N D C O N N E C T W IR E S 7 5 & 7 6 .
DCF 23
24
3. W HE N CA P3 & CAP4 ARE USED A D D W IR E S : 6 0 th ru 6 3 . 4 . W H E N A M M E T E R IS U S E D C O N N E C T W IR E S : 7 0 th ru 7 1 . 5 . W H E N W A T E R M O D U L E IS U S E D A D D W IR E S : 7 4 & 7 7 .
P1
P4
P5
P6
P7
P8
P9
P10
D C F #18 W HT
X 2 # 1 8 V IO X1 #18 O R N
74
77
#18 BLU
LC C 1 #18 YEL
#18 YEL
NAT TB2-10
TB2-9
X3 #18 BR N
}
16
15
14
BLU-6
13
BLU-5 TB2-8
12
BLU-4 TB2-7
C X F -H 1 B LK
A S -4 # 1 8 B LK A S -3 # 1 8 W H T
11
30
9
K1
7
74
5
75
4
1
4
5
6
7
8
9
10
8
9
10
11
12
13
14
15
16
52
K 1 -4 #18 B LK
76
34
75
BLK
50
55
RED
54
F4-2 #18
F 4 -1 # 1 8 B L K
L3 #18
51
53
YEL
GRN
P5
P6
P10 NAT
RED-3 P4
P9 BLU-3
RED-2 P3
P8 BLU-2
RED-1 P2
P7 BLU-1
BLK
18
19
20
21
22
TB2
P1
6
P16 NAT
DC CONNECTOR AUX. CONTACTS
5
P15 BLU
}
4
P14 GRN
79
3
P13 YEL
80
P11 BLK
RB
2
P12 RED
78
78
LC C 1 #18 Y EL K 1 -7 # 1 8 Y E L O P T IO N A L
1
17
K 1-7 # 1 8 Y E L TB1
T3 B LK 2 4 0 /4 8 0 U N IT
TVS
BLK
DC OUTPUT
BUS-BAR
25 6
3
WATER
K 1 -1 #18 W H T
H1
33 6 2
7
5 1
#18 BLU
X4
4
33
77
LCC2
#18 BLU
32
K1-12
#18 BRN
72
K1-11
#18 VIO X3
L C -T 1 W H T L C -T 2 RED
1 3
4 2
T V S (A L T . L O C A T IO N ) A C F U S E S M U S T B E C H A N G E D W H E N C H A N G IN G V O L T A G E . S E E L A B E L S IN C H A R G E R . S TE P 1- R E M O V E A LL C H A N G EO V ER JU M P ER S A N D C O N T R O L T R A N S F O R M E R P R IM A R Y J U M P E R S . STEP 2- FO LLO W TABLE BELO W FO R C O R RECT VO LTAG E C H ANG EO VER .
T3 BLK 2 0 8 U N IT
VO LTA G E C H AN G EO VER TABLE
IN P U T V O LT AG E 208 V AC
AC INPUT
LEG END
{
F1
1
F2
2
F3
3
F 1 -F 3 F4 K1 LC LC C 1 & 2 P X F 1 -P X F 2 RB TB1 & TB2 TVS
L C -L 1 W H T L C -L 2 R E D L C -L 3 B L K
AS CA C A P 1 -C A P 4 CXF D 1 -D 4 DCF
SHUNT C ATHODE C A P A C IT O R C ON TROL TRANSFORM ER D IO D E D C FUSE
FUSE CONTR OL FUSE BOARD CON NECTOR L IN E C O N T A C T O R L IN E C O N T A C T O R C O IL POW ER TRANSFORM ER AUX. C ON NECTOR BOARD T E R M IN A L B L O C K T R A N S IE N T V O L T A G E S U P P R E S S O R
WIRING DIAGRAM - 3 PHASE - 208/240/480 VAC
PM990-1897-00, ISSU E 5
63
DC OUTPUT
AS
32
H 4 #18 RED
X2
H4 H2 H3
3
2
F3 BLK
F2 RED
42
F1 WHT 1
31
12
29
CXF
JUM PER
X4 #18 LCC2 BLU
LC C 1
72
76
29
K1-9
X1 L3
15
DCF
#18 ORN
T3
L2
26
}
27
28
30 T2
LC L1
18
3 1 /7 8
T B 3 -2 # 1 8 Y E L
BLK 6
T1
RED
TVS
28
K1-5
34
GRN
11
TB2-5
YEL
RED-3
RED-2 2
F4
C A #18 R ED
TO W ATER M O D U LE (O P T IO N A L )
X4
1
42
TB2-4
C2
TB2-3
C1
TB2-1
C AP4
TB2-6
9
10
8
7
BLK
63
C2
62
21
22
NAT
BLU TB1-5
TB1-4
C1
TB1-6
20
19
GRN
18
YEL TB1-3
17
TB1-1
P3
C AP2
L C -L1 BLK
5
4
WHT TB2-1
RED SEE TABLE
C2
TB1-1
C1
RED
61 CAP3
TB1-2
C2
60
C1
BLK
CAP1
P2
26
BLK
P16
RED-1
P15
TB2-2
P14
38
P13
38
P12
36
35
P11
CA
R E C T IF IE R K 1 -15 # 1 8 R E D
6 . W H E N A U X . C O N N E C T O R B O A R D IS U S E D R E M O V E W IR E 3 1 A N D A D D W IR E S 7 8 th ru 8 0 .
AS-2
R2
D4
25
R1
R4
D3
DC OUTPUT
R3
D2
BLK
D1
240 V AC (S H O W N )
480 V AC
T E R M IN A L B L O C K JU M PE R S #10 G A
T B 2 -1 T B 2 -2 T B 2 -4 T B 2 -7 T B 1 -1 T B 1 -2 T B 2 -1 T B 2 -3 T B 2 -5 T B 2 -8 T B 1 -1 T B 1 -3 T B 2 -5 T B 2 -6 T B 1 -3
TO TO TO TO TO TO TO TO TO TO TO TO TO TO TO
T B 2 -6 , T B 2 -7 , T B 2 -9 , T B 1 -5 , T B 1 -4 , T B 1 -5 T B 2 -6 , T B 2 -8 , T B 2 -1 0 , T B 1 -6 , T B 1 -4 , T B 1 -6 T B 2 -6 , T B 1 -6 , T B 1 -4
S P E C IA L C O N N . T O T E R M IN A L BLO CK
CO NTRO L TRANS. (C X F ) JUM PE R CO NN.
F3 TO T B 2 -9
H 1 -H 3 H 2 -H 4
F3 TO T B 2 -1 0
H 1 -H 3 H 2 -H 4
F3 TO T B 2 -1 0
H 2 -H 3
NOTE: 1 . W IR E N U M B E R S FO R C H A R G E R W IT H O U T A S H U N T : 1 -4 6, 7 2. 2 . W H E N S H U N T IS U S E D M O V E W IR E 30 , A D D B U S -B A R , A N D C O N N E C T W IR E S 7 5 & 76. 27
28
3. W HE N CA P4 TO CA P6 ARE USED A D D W IR E S : 6 0 th ru 65. 4 . W H E N W A TE R M O D U LE IS U S E D A D D W IR E S 7 4 & 77
23
24
25
26
X 3 # 18 B R N
77
74
}
X 2 # 1 8 V IO X1 #18 ORN LCC1 #18 YEL
#18 YEL
#18 BLU
C X F -H 1 BLK
A S -4 # 1 8 B LK A S -3 # 1 8 W H T
K1
7
74
5
75
4
1
AC INPUT
{
1
F2
2
F3
3
BLK
L C -L 1 W H T L C -L 2 R E D L C -L 3 B LK
AS CA CAP1 - CAP6 CXF D1 - D6 DCF
SHUNT C A T H O D E (R E C T IF IE R + O U TP U T) C A P A C ITO R C O N T R O L T R A N S FO R M E R R E C T IF IE R D IO D E DC FUSE
64
BLK
BUS-BAR
AS 2
T V S (A L T . L O C A T IO N )
C A U T IO N A C F U S E S M U S T B E C H A N G E D W H E N C H A N G IN G V O LT A G E . S E E LA B E L S IN C H A R G E R .
S T E P 2 - F O LLO W T A B L E B E L O W F O R C O R R E C T V O L TA G E C H A N G E O V E R .
IN P U T VO LTAG E
F 1-F3 F4 K1 LC LCC1 & 2 P X F1 - P X F3 RB T B 1 - TB 3 TVS
AC FUSE C O N T R O L FU S E B O A R D C O N N E C TO R L IN E C O N TA C TO R L IN E C O N T A C TO R C O IL P O W E R T R A N S FO R M E R AU X. CO NNECTOR BO ARD T E R M IN A L B L O C K T R A N S IE N T V O L T A G E S U P P R E S S O R
WIRING DIAGRAM - 3 PHASE - THREE TRANSFORMERS - 208/240/480 VAC
PM990-1897-00, ISSU E 5
1 3
4
VO LTAG E C H AN G EO VER TABLE
LEG END F1
TV S
S T E P 1 - R E M O V E A L L C H A N G E O V E R JU M P E R S A N D C O N T R O L T R A N S FO R M E R P R IM A R Y JU M P E R S .
27
WHT LC-T1
4
7
TB1-1
26
6
P18 NAT
25
24
5
P17 BLU
23
4
P16 GRN
3
P15 YEL
20
2
22
21
1
P14 RED
BLK TB2-7
6
BLK
20
BLK
TB3-1
P12 NAT
TB3
P13 BLK
7
19
6
LC-T3
18
17
16
5
P11 BLU
15
YEL
4
P10 GRN
P9
14
RED P8
13
BLK
3
BLK
TB1-7
2
P7
BLK TB2-1
13
RED
5
1
TB2
LC-T2
12
NAT P6
9
BLU
11
GRN
P5
10
YEL
P4
8
7
27
7
6
P3
D C C O N N ECTOR AU X. C O NTACTS
5
RED
}
4
P2
BLK 79
TB3-7
80
3
BLK
RB
2
P1
78
78
L C C 1 #1 8 Y E L K 1-7 # 1 8 Y E L O P T IO N A L
1
DC OUTPUT
WATER
75
K 1-7 #1 8 Y E L TB1
#18 BLU
77
LCC2
#18 BLU
37
K1-12
#18 BRN
72 39
K 1 -4 # 18 B L K
76
BLK
3
F 4-1 #1 8 B LK
F4-2 #18
L3 #18
38
K 1 -1 # 18 W H T
H1
38
H 4 #1 8 RED
RED
F3 BLK
9
X3 X4
H4 H2 H3
37
2
F2 RED
46
F1 WHT 1
36
11
35
CXF
JU M P E R
X 4 #1 8 B LU
LCC2
#18 VIO
K1-11
X1 X2 L3
L CC 1
12
34
76
34
K1-9
T3
L2
72
DC OUTPUT
DCF
#18 ORN
T2
15
33
LC L1
32
3 6/78
T B 3-2 # 18 Y E L
35
6
T1
18
}
31
TVS
33
30
39
C A # 18 R E D
K1-5
NAT TB3-6
TB3-5
C2
RED
32
D C F # 18 W H T TO W ATER M O D ULE (O P T IO N A L)
X4
2
F4
TB3-1
TB2-6
CAP6
C1
BLU
BLK
65
C2
64
C1
GRN
19
NAT
CAP3
TB3-4
18
P 18
22
17
BLU
P 17
YEL
16
GRN
YEL
P 16
TB3-3
15
1
P 15
21
14
46
P 14
BLK
RED TB3-1
WHT TB2-1 5
4
TB1-1
L C -L 1 B LK
TB2-5
C2
TB2-4
C1
TB2-1
CAP5
TB2-3
63
C2
62
C1
RED
CAP2
P13
RED
P12
TB3-2
P11
45
P10
44
P9
BLK
12
P8
TB2-2
11
NAT
BLU TB1-5
TB1-6
GRN
YEL
TB1-4
C2
TB1-3
TB1-1
C1
RED
60
CAP4
TB1-2
C2
61
C1
BLK
CAP1
P7
43
P6
42
P5
9
8
P4
10
7
P3
41
40
P2
CA
R E C T IF IE R K 1-1 5 # 1 8 R E D
P1
5 . W H E N A U X . C O N N E C T O R B O A R D IS U S E D R E M O V E W IR E 36 A N D A D D W IR E S 7 8 th ru 80.
D6
BLK
R6
D5
D4
30
R4
D3
AS-2
R2
D2
BLK
R5
DC OUTPUT
R3
29
D1 R1
T E R M IN A L B L O C K JUM PERS #10 G A
CO N TR O L TRANS. (C X F ) JU M P ER CO NN.
208 V AC
T B 1: 1 -4, 2-5 , 5 -7 T B 2: 1 -4, 2-5 , 5 -7 T B 3: 1 -4, 2-5 , 5 -7
H 1 -H 3
240 V AC (S H O W N )
T B 1: 1 -4, 3-6 , 6 -7 T B 2: 1 -4, 3-6 , 6 -7 T B 3: 1 -4, 3-6 , 6 -7
H 1 -H 3 H 2 -H 4
480 V AC
T B 1: 3 -4, 6-7 T B 2: 3 -4, 6-7 T B 3: 3 -4, 6-7
H 2 -H 3
H 2 -H 4
D1 R1
R3
R5
R2
R4
R6
P1
P2
P3
P5
C AP 2
C AP 3
C AP 4
C AP 5
C AP 6
D3
D4
D5
D6
R EC TIFIER
P4
C AP 1
D2
DC O UT PU T
P6
TO W ATER M O D ULE (O P TION AL)
K1
D CF
TB3-1
F4
T1
T2
T3
X 1 X2 L2
L3
AC INPUT
TB 1
1
2
3
4
TB 2
1
2
3
4
T B3
F1
LEG EN D
F2
AS CA C A P1 - C A P6 CXF D1 - D6 DCF F 1-F3 F4
F3
1
2
3
4
N O T E: 1. W IR E N U M B ER S FO R C H A R G ER W IT H O U T A S H U N T : 1-15, 27-46, 72. 2. W H E N SH U N T IS U SE D M O V E W IR E 30 , A D D B U S -B AR , AN D C O N N E C T W IR ES 75 & 76. 3. W H E N C A P4 T O C A P6 AR E U S ED A D D W IR E S : 60 thru 65. 4. W H E N W A TE R M O D U LE IS U SED A D D W IR E S 74 & 77 5. W H E N AU X. C O N N E C TO R B O AR D IS U SE D R E M O VE W IR E 36 AN D AD D W IR E S 78 thru 80.
SHUNT C AT H O D E (R E C TIFIE R + O U TP U T) C AP AC ITO R C O N TR O L TR A N S FO R M ER R EC TIFIER D IO D E D C FU SE A C FU SE C O N TR O L FU S E
K1 LC LC C 1 & 2 P XF1 - PXF3 RB TB1 - T B3 TVS
WIRING DIAGRAM - 3 PHASE - THREE TRANSFORMERS - 480 VAC
PM990-1897-00, ISSU E 5
65
X3 X4
C XF H4 H2 H3 H1
AS
LC L1
B O A R D C O N N EC TO R LIN E C O N TAC TO R LIN E C O N TAC TO R C O IL P O W E R T R A N S FO R M ER A U X . C O N N EC TO R BO AR D TE R M IN A L BLO C K TR AN SIE N T VO LTAG E S U PP R E SSO R
NOTE: 1 . W IR E N U M B E R S F O R C H A R G E R W IT H O U T A S H U N T : 1 , 2 , 4 , 5 , 7 , 9 , 1 3 -1 4 , 2 3 , 2 5 , 3 9 & 4 2 . 2 . W H E N S H U N T IS U S E D M O V E W IR E 2 5 , A D D B U S - B A R , A N D C O N N E C T W IR E S 7 5 & 7 6 .
DCF
3 . W H E N C A P 2 IS U S E D A D D W IR E S : 6 0 & 6 1 .
23
4 . W H E N A M M E T E R IS U S E D C O N N E C T W IR E S : 7 0 th r u 7 1 . 5 . W H E N W A T E R M O D U L E IS U S E D A D D W IR E S : 7 4 & 7 7 . 6 . W H E N A U X . C O N N E C T O R B O A R D IS U S E D R E M O V E W IR E 3 1 A N D A D D W IR E S 7 8 th r u 8 0 .
D2
R1
LC C 1 #18 YEL A S -4 # 1 8 B L K A S -3 # 1 8 W H T
23
C A P A C IT O R
CXF
CONTROL TRANSFORMER
D1 & D2
D IO D E
DCF
DC FUSE
H3
H2
3
X3
D C OUTPUT B LK
BLK
YEL P3
D C C O N NECTO R AU X. CO NTACTS
F 1 -F 2 F3
FUSE
K1 LC LCC
BOARD CON NECTOR L IN E C O N T A C T O R L IN E C O N T A C T O R C O IL
PXF1
POW ER TRANSFORM ER
RB
AUX. CO NNECTOR BOARD
TB1
T E R M IN A L B L O C K
TVS
T R A N S IE N T V O L T A G E S U P P R E S S O R
K 1 -4 #18 B LK
BLK
1 3
4 2
75
BLK
76
34
CONTROL FUSE
66
K 1 -1 #18 W HT
H1
F3-2 #18
RED
TB1
BUS-BAR
WATER
#18 BLU 77
LCC2
#18 BLU 32
K1-12
#18 BRN
X4
33
L2 #18
BLK 4
P1
}
2
7
1
WIRING DIAGRAM - 1 PHASE - 575 VAC PM990-1897-00, ISSU E 5
1
25 79
CAP1 & CAP2
4
76
DC OUTPUT
X2
480
78
78
80
LC-T2
4
F 3 -1 # 1 8 B L K
5
33
RB
SHUNT C ATH ODE
5
75
AS
X1
575
9
H 3 #18 RED
WHT
32
LC-T1
X 4 #18 LCC2 B LU
LC C 1 #18 YEL K 1 -7 # 1 8 Y E L O P T IO N A L
LEG END
TVS
K1
7
74
72
30
K1-11
C X F -H 1 B LK
#18 VIO
34
29
2
F3
K1-9
1
42
K 1 -7 # 1 8 Y E L
AS CA
9
28
#18 ORN
BLK
TB1-7 BLK
WHT 42
11
30
K1-5
X4 2
F2
12
29
}
DCF
5
WHT
TB1-1 4
L C -L 1 B LK
L2 31
575 VAC INPUT
{
L1
1
F1
72
RED B LK
CXF
L2
L1
15
K 1 -1 8
LC LCC1
26
3 1 /7 8
T B 3 -2 # 1 8 Y E L
T2
T1
18
25
PXF1-S2 #4 BLK
74
77
#18 YEL
C2
X 2 # 1 8 V IO X1 #18 O RN
CA
27
28
AS-2
X3 #18 BRN
}
YEL
#18 BLU
CAP2
9
BLK TB1-1
61
60
C2
C A #18 RED
TO W ATER M O D ULE (O P T IO N A L )
TB1-4
7
CAP1
C1
26
D C F #18 W H T
36
35
K 1 -1 5 # 1 8 R E D
C1
CA
R E C T I F IE R
R2
BLK
D1
T V S ( A L T E R N A T E L O C A T IO N )
DC OUTPUT
DCF 24
D1 R4
D2
D3
9
}
X3 #18 BRN X 2 # 1 8 V IO X1 #18 ORN
74
YEL
RED
BLK
TO W ATER M O D U LE ( O P T IO N A L )
77
7
10
41
LC C 1 #18 YEL
#18 YEL
#18 BLU
A S -4 # 1 8 B L K A S -3 # 1 8 W H T
SHUNT C ATH ODE C A P A C IT O R C ON TR OL TRANSFORM ER D IO D E DC FUSE
4
1
DC OUTPUT B LK
F 1 -F 3 F4 K1 LC LCC1 & 2 P X F 1 -P X F 2 RB TB1 TVS
19
6
76
AS
7
BLK
RED
YEL
YEL
1 . W IR E N U M B E R S F O R C H A R G E R W IT H O U T A S H U N T : 1 -7 , 9 , 1 0 , 1 7 , 1 9 , 2 3 - 3 5 , 3 8 -4 2 , 7 2 .
P3
N O TE:
2 . W H E N S H U N T IS U S E D M O V E W IR E 2 5 , A D D B U S - B A R , A N D C O N N E C T W IR E S 7 5 & 7 6 .
FUSE C ON TR OL FUSE BOARD C ON NECTOR L IN E C O N T A C T O R L IN E C O N T A C T O R C O IL POW ER TRANSFO RM ER AUX. CO NNECTOR BOARD T E R M IN A L B L O C K T R A N S IE N T V O L T A G E S U P P R E S S O R
67
BLK
DC OUTPUT
BUS-BAR
WATER
#18 BLU
77
LCC2
#18 BLU
32
K1-12
#18 BRN
72
75
2
BLK
F4-2 #18
RED
4
10
5
9
7
4
K 1 -4 #18 B LK
1
W HT
3
P12
D C CO NN EC TO R AU X. C O NTA CTS
3
K 1 -1 #18 W H T
H1
34
H2
P2
}
X4
P11
RB
2
17
1
TB1
LC C 1 #18 YEL K 1 -7 # 1 8 Y E L O P T IO N A L
X3
33
6
4
35
L3 #18
BLK
LC-T3
LC-T2
RED BLK
5
3
F3
2
1
F1
LC-T1
33
WHT
H 3 #18 RED
H3
WIRING DIAGRAM - 3 PHASE - 575 VAC
PM990-1897-00, ISSU E 5
#18 VIO
K1-11
30
X2
K 1 -7 # 1 8 Y E L
79
LEG END
32
F 4 -1 # 1 8 B LK
80
AS CA C A P 1 -C A P 4 CXF D 1 -D 4 DCF
5
75
BLK
B LK
7
74
P1
3
L C -L 3
9
76
29
C X F -H 1 B LK
K1-9
34
BLK
LC-L1
2
F4
78
F3
2
42
11
30
CXF
X 4 #18 B LU
LCC2
F2
31
{
F2
L C -L 2 RED 78
AC INPUT
F1
L C -L 1 W HT
29
CA
RED BLK
K1
T3
L3
LCC1
1
72
12
DCF
X1 L2
15
28
LC L1
26
25
X4 BLK
TB1-9
RED
T2
1
42
6
TB1-3 5
WHT
TB1-1 4 T1
18
K1-5
TB1-7
C2
TB1-4
C1
TB1-1
TB1-5
C2
27
28
3 1 /7 8
T B 3 -2 # 18 Y E L
#18 ORN
40 19
CA #18 RED
CAP4
TB1-3
C AP3
C1
C2
63
60
C1
62
BLK
C2
61
C1
CA
26
D C F #18 W H T
CAP2
YEL
17
39
38
K 1 -1 5 # 1 8 R E D
C AP1
D4
R E C T IF IE R
AS-2
R3
R2
25
R1
BLK
23
3. W HEN CAP3 & C AP4 AR E USED A D D W IR E S : 6 0 th ru 6 3 . 4 . W H E N A M M E T E R IS U S E D C O N N E C T W IR E S : 7 0 th ru 7 1 . 5 . W H E N W A T E R M O D U L E IS U S E D A D D W IR E S : 7 4 & 7 7 . 6 . W H E N A U X . C O N N E C T O R B O A R D IS U S E D R E M O V E W IR E 3 1 A N D A D D W IR E S 7 8 th ru 8 0 .
B LK
}
DC OUTPUT
28
D2
D3
D5
D4
K1-15 #18 RED
X2 #18 VIO X1 #18 ORN
74
#18 YEL
LCC1 #18 YEL AS-4 #18 BLK AS-3 #18 WHT
72
12
34
11
35
9
K1
7
74
5
75
4
76
1
CXF
2
3
4
TB3
1
2
3
4
3. WHEN CAP4 TO CAP6 ARE USED ADD WIRES: 60 thru 65. 4. WHEN WATER MODULE IS USED ADD WIRES 74 & 77
AC INPUT
{
1
F2
2
F3
3
YEL
BLK
P4
P5
YEL
BLK P3
LC-L1 W HT LC-L2 RED
LC-L3 BLK
AS CA CAP1 - CAP6 CXF D1 - D6 DCF
SHUNT CATHODE (RECTIFIER + OUTPUT) CAPACITOR CONTROL TRANSFORMER RECTIFIER DIODE DC FUSE
F1-F3 F4 K1 LC LCC1 & 2 PXF1 - PXF3 RB TB1 - TB3 TVS
39
AS
75
76
BLK
38
F4-2 #18
2
AC FUSE CONTROL FUSE BOARD CONNECTOR LINE CONTACTOR LINE CONTACTOR COIL POWER TRANSFORMER AUX. CONNECTOR BOARD TERMINAL BLOCK TRANSIENT VOLTAGE SUPPRESSOR
WIRING DIAGRAM - 3 PHASE - THREE TRANSFORMERS - 575 VAC
PM990-1897-00, ISSU E 5
4
5. WHEN AUX. CONNECTOR BOARD IS USED REMOVE WIRE 36 AND ADD WIRES 78 thru 80.
LEGEND F1
K1-4 #18 BLK
1 3
P6
YEL P2
}
BLK 79
DC CONNECTOR AUX. CONTACTS
P1
RB 80
2. WHEN SHUNT IS USED MOVE WIRE 30 , ADD BUS-BAR, AND CONNECT WIRES 75 & 76.
12
4
11
3
10
2
8
1
7
78
78
TB1
9
K1-7 #18 YEL LCC1 #18 YEL K1-7 #18 YEL OPTIONAL
1. WIRE NUMBERS FOR CHARGER WITHOUT A SHUNT: 1-15, 27-46, 72.
L3 #18
TB1-1 BLK 15
TB2-4 BLK
LC-T3 BLK 6
1
14
TB3-1 BLK
TB2
14
5
TB1-4 BLK
LC-T2 RED
13
F4-1 #18 BLK
TB2-1 BLK
38
13
TB3-4 BLK
H4 #18 RED
K1-1 #18 WHT
H1
NOTE:
LC-T1 WHT
F3 BLK
H3 H2
3
F1 WHT
F2 RED 2
1
46
36
LCC1
37
RED
X4 #18 LCC2 BLU
4
L3
15
L2
68
DC OUTPUT BLK
BUS-BAR
WATER
#18 BLU
77
LCC2
#18 BLU
37
K1-12
#18 BRN
72
K1-11
#18 VIO
34
X1 X2 X3 X4
LC L1
31
DCF
K1-9
T3
15
33
#18 ORN
T2
32
36/78
TB3-2 #18 YEL
35
6
T1
18
30
39
#18 BLU
77
CXF-H1 BLK
X3 #18 BRN
}
12
NAT
11 65
64
2
F4
C2
RED
33
K1-5
1
C1
CA #18 RED
TO WATER MODULE (OPTIONAL)
X4
46
BLK
NAT
CAP6
CA
32
DCF #18 WHT
BLK
RED TB3-1
WHT TB2-1
5
4
TB1-1
LC-L1 BLK
C2
TB3-6
C2
C1
TB3-1
C1
P6
45
44
CAP5
CAP3
TB2-6
BLK
63
C2
62
C1
10
43 CAP2
TB2-1
C2
P5
P4
9
8
TB1-1
CAP4
TB1-4
61
60
C2
C1
NAT
7
BLK
CAP1
C1
P3
42
P2
41
40
P1
D6
RECTIFIER
BLK
R6
30
R5
R4
AS-2
R3
R2
29
D1 R1
DC OUTPUT BLK
27
}
DC OUTPUT
