Exide GNB ELEMENT LMT-06kW-48-S Series Installation & Operating Instructions Manual Download Page 4

Sales 

x

Service 

x

Recycling 888.563.6300 in the USA 800.268.2698 in Canada 

 

1

SAFETY PRECAUTIONS 

 

BEFORE ATTEMPTING TO OPERATE THE CHARGER, PLEASE READ THIS GUIDE CAREFULLY

.

SAVE THESE INSTRUCTIONS

 – This guide contains important instructions for Element

Š

High 

Frequency series product line that shall be followed during installation and maintenance of the charger. 

Only qualified personnel should install, operate, or service this equipment.  

WARNINGS: 

¾

WARNING Risk of High Voltages

 – Lethal voltages are present within the charger enclosure 

whenever the ac line is energized and/or the battery/load is connected.  The heatsinks and other 

internal components present the risk of electric shock. 

¾

WARNING Risk of Improper Grounding

 – The charger must be connected to an ac power supply 

incorporating an earth/ground. The grounding conductor must be of a size equal to or larger than 

the line (phase) conductors. 

¾

WARNING Risk of Explosive Gases

 – Working in the vicinity of a lead-acid battery is dangerous. 

Batteries generate explosive gases during charging and discharging. To reduce the risk of battery 

explosion, follow these safety instructions as well as those published by the battery manufacturer. 

¾

WARNING Protect Eye and Skin

 – Wear safety goggles and skin protection while installing your 

battery charger or working in the vicinity of lead-acid batteries.  

¾

To reduce the risk of injury, only charge rechargeable lead-acid batteries.  Charging other battery 

types may cause damage and result in personal injury. 

 

CAUTIONS: 

¾

Risk of electric shock from stored energy

. Wait at least two minutes after de-energizing the ac 

line and disconnecting the battery/load before removing the cover. 

¾

Risk of electric shock and/or electric energy

 - high current levels. Do not touch un-insulated 

battery, connectors or terminals.  All tools should be adequately insulated to avoid the possibility of 

shorting connections.  Inspect cables often for damage to the insulation. Replace cracked or worn 

cables immediately. 

¾

Risk of fire or explosion from gases vented by batteries

. Be sure to discharge static electricity 

from tools and technician by touching a grounded surface in the vicinity of the batteries. To prevent 

damage to the connectors and reduce the risk of explosion due to arcing, connect or disconnect the 

battery plug only when the charger output is off.  ALWAYS press the STOP pushbutton before 

unplugging the battery to prevent arcing. 

¾

Risk of electrical component failure due to improper connection.

  If the charger is incorrectly 

wired to input or output devices, or wiring is not in accordance with local safety codes and 

standards, the unit is at risk of being destroyed.   

Summary of Contents for ELEMENT LMT-06kW-48-S Series

Page 1: ...ELEMENT SERIES INDUSTRIAL BATTERY CHARGERS INSTALLATION OPERATING INSTRUCTIONS ...

Page 2: ......

Page 3: ...TS SAFETY PRECAUTIONS 1 CHARGER SPECIFICATIONS 3 INSTALLATION PROCEDURE 4 CHARGER ELECTRICAL INSTALLATION 7 CHARGER CONTROLS AND USER INTERFACE 10 OPERATING PROCEDURE 12 CHARGER MENUS 15 TROUBLESHOOTING 20 APPENDIX 26 ...

Page 4: ...safety goggles and skin protection while installing your battery charger or working in the vicinity of lead acid batteries To reduce the risk of injury only charge rechargeable lead acid batteries Charging other battery types may cause damage and result in personal injury CAUTIONS Risk of electric shock from stored energy Wait at least two minutes after de energizing the ac line and disconnecting ...

Page 5: ...ould be consulted for safe handling installation testing and maintaining deep cycle batteries Applicable state and local codes must be followed x NESC National Electric Safety Code ANSI C2 1993 or latest revision Copies may be obtained by writing The Institute of Electrical and Electronics Engineers Inc 345 East 47th Street New York NY 10017 USA x NEC National Electrical Code NFPA 70 or latest ver...

Page 6: ...x 10 kW Max Pk Pk Voltage Ripple 1 Efficiency typical 92 at Full Load Protection Input Under voltage Over Voltage Output Over Current Over Voltage Over temperature Battery reverse polarity protection Operating Conditions Ambient Temperature 0 40o C Humidity 10 90 RH non condensing Interface Communication Isolated RS 232 Ethernet optional User Interface LCD Keypad RS 232 IR with a PDA Palm Pilot Co...

Page 7: ...ceived a sharp blow been dropped or otherwise damaged II Charger Physical Installation 1 Ensure that the charging area is well ventilated dry and adequately clean 2 Do not restrict airflow to the bottom air filter or top cover Leave at least 1 ft spacing between the sides of the charger and any adjacent walls or barriers and 2 ft spacing between the bottom of the charger air filter and the floor a...

Page 8: ...sis see Figure 2 Figure 2 Charger lifting instructions III Installing Removing Air Filter The charger is equipped with an air filter located in the lower cover of the unit The air filter needs to be checked on a regular basis and cleaned if needed ATTENTION To clean the filter use soap and water dry thoroughly before installing To remove the filter hold the open end of the filter and slide out To ...

Page 9: ...Sales x Service x Recycling 888 563 6300 in the USA 800 268 2698 in Canada 6 Air filter Filter Guides Figure 3 Installing Replacing Air Filter ...

Page 10: ...hat the main power and emergency stop switches on the unit are in the off stop positions 3 Figure 4 then push out one of the knockouts on the top cover to pass the AC conduit through The AC GND wire connections are shown in 4 Figure 5 5 Connect the input 480VAC power cable to the three pole AC block terminals marked ABC Figure 6 Connect the GND wire to the terminal marked GND as shown in Figure 7 ...

Page 11: ...Figure 4 Removing top cover Figure 5 AC wire connections AC Knockouts 480VAC 3 GND Sales x Service x Recycling 888 563 6300 in the USA 800 268 2698 in Canada 8 ...

Page 12: ...Sales x Service x Recycling 888 563 6300 in the USA 800 268 2698 in Canada 9 Figure 6 Making AC wire connections Figure 7 Connecting GND wire ...

Page 13: ...uld be in the OFF position and padlocked before any panels or drawers are removed It disconnects AC power from all parts of the system 2 LCD Keypad Assembly The main user interface for viewing and displaying operation and fault messages as well as programming the charger The disconnect switch action is rotational where turning the switch clockwise will move the switch to the ON position arrow poin...

Page 14: ...RT and STOP push button o Two status LEDs for run OK and Fault indication o A serial RS 232 connector and an IR window Fig 10 LCD Keypad and User Interfaces The status LEDs indicate the charger status namely OK Green LED lit for normal operation Fault Red LED lit when a fault trips Fig 11 For faults and troubleshooting refer to the troubleshooting section of this manual Fig 11 Charger status LEDs ...

Page 15: ... T E R Y D I S P L A Y If the LCD is not lit if the above message is not displayed or the fans are not operating perform the following A Turn off the unit de energize the disconnect switch B Ensure proper AC wiring C Ensure the main AC disconnect wall is energized D Verify fuses in main AC junction box wall E If wiring and fan operation check OK proper and the problem persists contact GNB Industri...

Page 16: ... is connected the above message will be displayed 2 To start the charger press the START button A STARTING CHARGE screen will appear for few seconds as shown below S T A R T I N G C H A R G E E X I T 3 The charge cycle will start and the following screen showing the charging operation will be displayed M M C H A R G E H H M M S S V X X X X A X X X X T X X X F A H X X X X E F 5 2 MM indicates the a...

Page 17: ...charger from the battery Pressing the START button from the CHARGE CYCLE STOPPED screen will resume the charge cycle and the screen will again display the Charger Operation screen 5 Once the charge cycle has completed the following screen will be displayed C Y C L E H H M M S S C O M P L E T E T E M P X X X F A H R S X X X X E X I T The elapsed charging time the battery temperature in degrees F an...

Page 18: ...displayed push the function key F The Charge History menu will first appear M A I N M E N U C H A R G E H I S T O R Y E X I T E N T E R Pressing the EXIT key will exit the charger menus while pressing the ENTER key will access the selected menu 2 Push the ENTER key to access the charge cycle history The charger can hold up to 100 charge cycles which can be displayed Note that the first cycle will ...

Page 19: ...alize cycles on the preset days The STATE field lists the state of the charge when the cycle was terminated The following messages may appear COMPLETED Cycle completed successfully STOPPED Cycle stopped by user XX FAULT Y Charger fault with drawer Y If a fault took place the reference to the drawer number allows quick identification of a problem or faulty drawer 4 Pressing the up down q r keys all...

Page 20: ...f a specific charger versus others in the vicinity or in the plant IV CHARGER MODEL AND SERIAL NUMBER While in the Main Menu press the up down q r keys until the Charger Model screen appears M O D E L P C H G L V 6 0 0 4 8 M F G I D 2 0 0 5 0 1 0 0 0 1 M F G D A T E 0 7 1 9 2 0 0 7 R E V I S I O N 1 1 0 The charger model number ID manufacturing date and firmware revision are shown for reference V ...

Page 21: ...48V Select the correct voltage then press the ENTER key The recovery charge current setting screen will then appear R E C O V E R Y C H A R G E C U R R E N T 1 0 A E X I T E N T E R Pressing the up down q r keys will change the recovery charge current setting in 5 A increments Recommended recovery charge current rates are 3A 5A 100 Ahrs Select the correct value then press the ENTER key The recover...

Page 22: ...ecovery charge start screen will then appear P U S H S T A R T T O B E G I N R E C O V E R Y E X I T E N T E R Pressing the ENTER key will start the recovery cycle Once the cycle is completed the Cycle Complete message will appear Note that the recovery cycle is a separate cycle and activating it does not change the charger settings ...

Page 23: ...he charging drawer s with a RED LED is are the one s that initiated the fault I Charger Not Operational When the charger is first turned on with the main disconnect power switch in the ON CW position the LCD should be ON with the CHARGER IDLE message displayed If the problem persists perform the following A Turn off the unit Main disconnect power switch should be in the OFF CCW position B Ensure p...

Page 24: ... AC line voltage is below above operational limits 10 Internal input stage failure Troubleshooting 1 Press the STOP key to revert to the IDLE screen 2 Open the charger drawer and identify the drawer with a RED LED lit unit that initiated the fault 3 Verify the AC connections to the charger 4 Restart the charge cycle by pressing the START key 5 If the fault persists turn off the charger and contact...

Page 25: ...ition and are properly connected to the battery 3 Restart the charge cycle by pressing the START key 4 If the fault persists turn off the charger and contact the local GNB Industrial Power service representative 3 Over Temperature O V E R T E M P F A U L T E X I T Possible Causes Blocked air flow to the charger Failed fan Troubleshooting 1 Press the STOP key to revert to the IDLE screen 2 Allow th...

Page 26: ... cable was disconnected while the charger cycle is active The charger or battery cables are worn out The charger or battery connectors contacts are worn out Troubleshooting 1 If the battery was intentionally disconnected press the STOP key to clear the fault message 2 If the battery was not intentionally disconnected check the charger and battery cables as well as the charger and battery connector...

Page 27: ...auxiliary thermistor connections 4 Restart the charge cycle by pressing the START key 5 If the fault persists turn off the charger and contact GNB Industrial Power 6 Battery Fault Battery Not Detected When Battery is Connected 4 8 V 2 0 0 A 0 1 0 1 0 5 1 2 0 0 0 0 C O N N E C T B A T T E R Y D I S P L A Y Possible Causes Battery auxiliary wiring is damaged Charger auxiliary wiring is damaged Troub...

Page 28: ... to the IDLE screen 2 Using the provided Palm software start the PowerCharge program tap the Charge Timers button and tap the scan button on the Charge Timers screen 3 Verify that the programmed timer values are proper If not they may need to be reprogrammed 4 Verify battery is in good working condition no shorted cell 5 If the fault persists turn off the charger and contact GNB Industrial Power t...

Page 29: ...Sales x Service x Recycling 888 563 6300 in the USA 800 268 2698 in Canada 26 Appendix Charging System Block Diagrams ...

Page 30: ... 1 2 3 12V 30 AC2 1 2 3 4 5 6 FAN 1 1 2 3 4 5 6 Vout Boost Control 30 pin connector Fan Power 3 Phase Temp OC Fault AC1 Boost Control LCD VBAT Output Power Assembly 1 2 3 4 5 6 7 8 More Vout AC Fuses 25A 600V F Fan Power 1 2 3 4 5 6 7 8 OK DC Bus Temp OC Fault 1 2 3 4 5 6 AC3 1 2 Output Feedback 1 2 1 2 3 4 Fault 480VAC Disconnect Switch Charger Idle RS 232 1 2 3 4 5 6 Gate Drive Control L 12V Key...

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Page 32: ...SALES SERVICE RECYCLING TOLL FREE 1 888 563 6300 in the USA 1 800 268 2698 in Canada ...

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