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Avix Supercharger 60, Operator'S Manual

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Operator Manual, Supercharger 60 

R3.0 

 

Page 1 of 62 

 

TABLE OF CONTENTS 

 

 

1.

 

INTRODUCTION AND SYSTEM DESCRIPTION .................................................................. 5

 

2.

 

CONDENSED OPERATING INSTRUCTIONS ....................................................................... 8

 

2.1

 

Constant Current Charge (normal mode) ............................................................................................... 8

 

2.2

 

Constant Voltage ........................................................................................................................................ 9

 

2.3

 

Peak Voltage Charge ............................................................................................................................... 10

 

2.4

 

Discharge .................................................................................................................................................. 11

 

3.

 

SPECIFICATIONS ................................................................................................................ 12

 

3.1

 

CHARGE .................................................................................................................................................. 12

 

3.2

 

DISCHARGE ........................................................................................................................................... 14

 

3.3

 

TIMER ...................................................................................................................................................... 15

 

3.4

 

LINE INPUT VOLTAGE: ...................................................................................................................... 16

 

3.5

 

DIGITAL PANEL METERS .................................................................................................................. 17

 

3.6

 

FUSES and BREAKERS (Other than charge and discharge current limiters) ................................. 17

 

4.

 

CONTROLS AND DISPLAYS .............................................................................................. 18

 

4.1

 

M1 - Ammeter .......................................................................................................................................... 18

 

4.2

 

M1 - Voltmeter ......................................................................................................................................... 18

 

4.3

 

R1 - Main Charge Current Selector ....................................................................................................... 18

 

4.4

 

R2 - Topping/Discharge Current Selector ............................................................................................. 18

 

4.5

 

SW1 - Main Time selector switch ........................................................................................................... 18

 

4.6

 

SW2 - Total Time selector switch ........................................................................................................... 18

 

4.7

 

SW3 – Keypad .......................................................................................................................................... 18

 

4.8

 

SW4 - CELL SELECTOR: ..................................................................................................................... 19

 

4.9

 

SW5 - DIGITAL VOLTMETER INPUT SELECTOR: ...................................................................... 19

 

4.10

 

SW6 - VOLTAGE MODE SELECTOR:............................................................................................... 19

 

4.11

 

SW7 - TIMER SPEED SELECTOR: .................................................................................................... 19

 

4.12

 

DS1A - RESET:........................................................................................................................................ 21

 

4.13

 

DS1B - CYC END: ................................................................................................................................... 21

 

4.14

 

DS2A - DUAL: ......................................................................................................................................... 21

 

4.15

 

DS2B - MAIN: .......................................................................................................................................... 21

 

4.16

 

DS3A - SINGLE: ...................................................................................................................................... 21

 

4.17

 

DS3B - TOP: ............................................................................................................................................. 21

 

4.18

 

DS4A - AUTO: ......................................................................................................................................... 21

 

4.19

 

DS4B - DISCH: ........................................................................................................................................ 21

 

Summary of Contents for Supercharger 60

Page 1: ...BREAKERS Other than charge and discharge current limiters 17 4 CONTROLS AND DISPLAYS 18 4 1 M1 Ammeter 18 4 2 M1 Voltmeter 18 4 3 R1 Main Charge Current Selector 18 4 4 R2 Topping Discharge Current Selector 18 4 5 SW1 Main Time selector switch 18 4 6 SW2 Total Time selector switch 18 4 7 SW3 Keypad 18 4 8 SW4 CELL SELECTOR 19 4 9 SW5 DIGITAL VOLTMETER INPUT SELECTOR 19 4 10 SW6 VOLTAGE MODE SELECT...

Page 2: ...HARGE 24 5 3 PEAK CHARGE 25 5 4 DISCHARGE 26 6 OPERATING INSTRUCTIONS 27 6 1 GENERAL 27 6 2 CONSTANT CURRENT CHARGE 28 6 3 CONSTANT VOLTAGE CHARGE 28 6 4 PEAK VOLTAGE CHARGE 29 6 5 DISCHARGE 30 6 6 Float Peak Voltage Chart 31 6 7 OPERATING NOTES AND PRECAUTIONS 32 7 INSTALLATION 33 7 1 BENCH SPACE 33 7 2 LINE VOLTAGE 33 8 VERIFICATION OF PERFORMANCE 35 8 1 REQUIRED TEST EQUIPMENT AND ACCESSORIES 3...

Page 3: ...K VOLTAGE 40 8 14 METERS 41 9 CALIBRATION 42 9 1 CIRCUIT BOARD ADJUSTMENTS AND CALIBRATION 42 9 2 DIGITAL METERS see Figure 6 42 10 TROUBLESHOOTING AND REPAIRS 53 10 1 TROUBLESHOOTING 53 10 2 FINDING A SHORTED DISCHARGE TRANSISTOR 55 11 REPLACEABLE MODULES AND PARTS 59 11 1 CIRCUIT BOARDS 59 11 2 PARTS 59 11 3 OTHER 59 12 BATTERY TESTING NOTES 60 13 DISCLAIMER 61 14 REVISION INDEX 62 ...

Page 4: ...Board Adjustments 44 Figure 7 Control Switch Board Adjustments 45 Figure 8 Current Control Board Adjustments 47 Figure 9 Monitor Board Adjustments 48 Figure 10 Voltage Control Board Adjustments 50 Figure 11 Circuit Board Sequence 52 Figure 12 Measuring for a shorted transistor 56 Figure 13 Location of Current Limiters 57 Figure 14 Power Block Diagram 58 TABLE OF TABLES Table 1 Constant Voltage and...

Page 5: ...o arc and burn A simple performance verification procedure is all it takes to determine if the instrument requires re calibration or repair This instrument is also protected against certain internal performance deviations and programming errors plus it is also designed to sense certain battery abnormalities to protect the instrument and battery from possible damage In the event that any malfunctio...

Page 6: ...ting the end of the discharge cycle It checks for polarity reversal at voltages as low as 25V as well as an absolute Overvoltage at 85 volts both generating a voltage malfunction indication that prevents any further operation of the unit It measures the temperature of the discharge heat dissipators and signals an overheat malfunction if the internal temperature exceeds 90o C as it could be caused ...

Page 7: ...Operator Manual Supercharger 60 R3 0 Page 7 of 62 Figure 1 Block Diagram ...

Page 8: ... SINGLE RATE mode 2 1 2 2 Verify that the Timer Speed is consistent with the required elapsed time hours or minutes 2 1 2 3 Enter the MAIN and TOPPING CHARGE CURRENTS if in the TWO RATE mode or enter the TOPPING CURRENT only if in the SINGLE RATE mode 2 1 2 4 Place batteries on the TEMP PLATE When working with only one battery connect the free plug into the shorted receptacle provided in the TEMP ...

Page 9: ...eed is consistent with the required elapsed time 2 2 1 4 Start the Charger Analyzer in the Single Rate mode The charger will begin to reduce the charging current when the battery voltage is within 0 5V of the float level 2 2 1 5 The charge will terminate automatically CYCLE END when the TOTAL TIME selected is reached 2 2 1 6 The charge will terminate as a FAULT if the MONITOR CIRCUIT detects that ...

Page 10: ...ns Verify that the Timer Speed is consistent with the required elapsed time 2 3 1 5 Start the Charger Analyzer in the Dual Rate mode The charger will transfer from Main to Topping charge when the battery reaches the peak voltage or Start in the Dual or Single Rate mode and the Charger Analyzer will stop on peak at any part of the cycle 2 3 1 6 The charge will terminate automatically CYCLE END when...

Page 11: ...rify that the Timer Speed is consistent with the required elapsed time 2 4 2 3 Enter the DISCHARGE CURRENT 2 4 2 4 Depress the Blue button for DISCHARGE with automatic cut off ANALYSIS or the RED button for FULL DISCHARGE DEEP CYCLE 2 4 2 5 DISCHARGE will terminate automatically CYCLE END when the TOTAL time selected is reached or CAPACITY FAILURE if the BATTERY voltage reaches the equivalent of O...

Page 12: ... voltage e g a 24V battery is entered as 24 on the Cell Selector Current reduction from within 0 5V of the float voltage with an accuracy of 0 5 0 1A 3 1 4 2 PEAK The reference voltage is set at the equivalent of 2 45V cell Lead Acid The Cell Selector provides the basic reference as nominal battery voltage e g a 24V battery is entered as 24 on the Cell Selector Voltage transfer or stop within 1 of...

Page 13: ...ermistors on the TEMP PLATE measure the battery temperature 3 1 7 2 The charge is terminated when the surface temperature of the TEMP PLATE reaches 39o C 102o F 3 1 8 OVER UNDER CURRENT PROTECTION 3 1 8 1 A Monitor circuit continuously compares the actual charge current with the programmed value 3 1 8 2 Operation is terminated if they differ by more than 1 AMP 3 1 9 OVERVOLTAGE PROTECTION 3 1 9 1 ...

Page 14: ... 2 1 60 AMPS Total power dissipation must not exceed 1 2KW 1200 watts the product of battery voltage and battery current 3 2 2 2 NOTE Discharge current is automatically limited to 30 AMPS for battery voltages in excess of 32 VOLTS A current fault will be generated if attempting to discharge at more than 30 AMPS 3 2 3 MINIMUM INCREMENT 3 2 3 1 0 1 AMP 3 2 4 ACCURACY and STABILITY of settings 3 2 4 ...

Page 15: ...tual discharge current with the programmed value 3 2 8 2 Operation is terminated if they differ by more than 1 AMP 3 2 8 3 NOTE Undercurrent monitoring is disabled in the full discharge mode for battery voltages below 2 5V 3 2 9 REVERSE POLARITY PROTECTION 3 2 9 1 Operation of the unit is inhibited for reverse voltages greater than 0 5V 3 2 10 FUSING 3 2 10 1 Aircraft type current limiter ANN 80 f...

Page 16: ... LIMITS 3 3 5 1 0 to 9 in Main 3 3 5 2 0 to 79 in Total 3 3 5 3 NOTE The time limit in Total is dependent on the type of Timer Newer instruments characterized by a Timer Speed Switch mounted on the Front Panel have a limit of 79 hours or minutes while older units have a limit of 60 3 4 LINE INPUT VOLTAGE 3 4 1 115V 208V 230V 245V Note For proper operation of this instrument power line voltages mus...

Page 17: ...Scale 2V 20V and 200V 1 999V 19 9V and 199 9V for external measurements and 20V and 200V for internal battery measurements 3 5 2 AMMETER 3 5 2 1 Accuracy system 0 5 of reading 0 1A 3 5 2 2 Scale 200A 199 9A 3 5 3 SHUNT 3 5 3 1 Accuracy 0 25 3 5 3 2 Output 1mV A 100mV 100A 3 6 FUSES and BREAKERS Other than charge and discharge current limiters 3 6 1 Mains Dual Magnetic Circuit Breaker 3 6 2 Electro...

Page 18: ...r with digital readout to program current 4 3 1 1 MAIN charge current 0 to 50 0 AMPS 4 4 R2 Topping Discharge Current Selector 4 4 1 Ten turn potentiometer with digital readout to program 4 4 1 1 TOPPING charge current 0 to 50 0 AMPS 4 4 1 2 DISCHARGE current 0 to 60 0 AMPS 4 5 SW1 Main Time selector switch 4 5 1 0 to 9 hours or minutes to determine the duration of the main charge 4 6 SW2 Total Ti...

Page 19: ...l for discharge 4 8 3 Used also in the Float and Peak Voltage modes to enter nominal battery voltage 4 9 SW5 DIGITAL VOLTMETER INPUT SELECTOR 4 9 1 External 2 20 200V scale 4 9 2 Internal 20 200V scale 4 10 SW6 VOLTAGE MODE SELECTOR 4 10 1 Four position switch to select Normal Float and Peak Voltage modes 4 11 SW7 TIMER SPEED SELECTOR 4 11 1 Three position switch to select 4 11 1 1 Normal HH MM 4 ...

Page 20: ...Operator Manual Supercharger 60 R3 0 Page 20 of 62 Figure 2 Front Panel ...

Page 21: ...tes that the unit is in TOPPING charge 4 18 DS4A AUTO 4 18 1 Indicates that the AUTO analysis mode is selected 4 19 DS4B DISCH 4 19 1 Indicates that the unit is in AUTO discharge 4 20 DS5A FULL 4 20 1 Indicates that the FULL deep cycle mode is selected 4 21 DS5B DISCH 4 21 1 Indicates that the unit is in FULL discharge 4 22 DS6A CAP FAIL 4 22 1 Indicates that the battery has failed to meet capacit...

Page 22: ...n excess of 85 volts or open circuit 4 27 DS8B CURR FLT 4 27 1 Indicates that the actual current differs from the programmed value by more than 1A 4 28 DS9 CC 4 28 1 Indicates that the charger is in the basic Constant Current mode 4 29 DS10 CV 4 29 1 Indicates that the charger is in the Constant Current Float mode 4 30 DS11 PEAK 4 30 1 Indicates that the charger is in the Constant Current Peak mod...

Page 23: ...xcess of 85V voltage fault Actual charging current differs from the programmed value by more than 1 AMP current fault 5 1 1 3 Charge operation may be terminated at any time by depressing the RESET green button 5 1 2 SINGLE RATE 5 1 2 1 The battery is charged at the topping rate for a preset time 5 1 2 2 Charging is automatically terminated at the end of the total time selected cycle end or as a fa...

Page 24: ...he battery at the selected float voltage 5 2 3 Charging is automatically terminated at the end of the total time selected cycle end or as a fault if Battery overtemperature is detected Overtemp fault Battery voltage is in excess of 85V voltage fault Actual charging current differs from the programmed value by more than 1 AMP current fault Note applicable only before the charger switches from const...

Page 25: ...ent differs from the programmed value by more than 1 AMP current fault NOTE Charge operation may be terminated at any time by depressing the green reset button 5 3 2 Stop on Peak Voltage 5 3 2 1 The battery is charged at the main rate for a preset time 5 3 2 2 When the battery voltage reaches the programmed peak voltage the charging current stops 5 3 2 3 Charging is automatically terminated at the...

Page 26: ...ammed or it is terminated as a fault if The actual discharge current differs from the programmed value by more than 1 AMP current fault Overheating of the transistor heat sinks is detected overheat fault NOTE Discharge operation can be terminated at any time by depressing the green reset button 5 4 2 DEEP CYCLE FULL DISCHARGE 5 4 2 1 The battery is discharged at the selected rate for a preset time...

Page 27: ...polarity is reversed a voltage fault condition will be indicated and further operation of the instrument will be inhibited 6 1 3 Verify Voltmeter 6 1 3 1 The digital voltmeter will read battery voltage if the selector switch is in the internal position 6 1 3 2 Select the scale consistent with the battery voltage 6 1 4 Program the number of cells 6 1 4 1 Enter the number of cells of the battery 6 1...

Page 28: ...cle per second 6 2 3 Single Rate Charge 6 2 3 1 For a single rate program the current using the Topping selector 6 2 3 2 Set the required total time and depress the single rate yellow control button 6 2 3 3 The SING and TOP indicators will turn on and battery current will rise to the set rate in about three to five seconds 6 3 CONSTANT VOLTAGE CHARGE 6 3 1 Nominal Battery Voltage 6 3 1 1 Enter the...

Page 29: ...ltage or stop on Peak Voltage 6 4 2 Charge Currents 6 4 2 1 Program the Main and Topping Charge currents as required 6 4 3 Time 6 4 3 1 Program the Main and Total Time selectors to allow the battery to reach the required charge level consult battery manufacturers specifications 6 4 3 2 Verify that the Timer Speed is consistent with the required elapsed time 6 4 4 RUN 6 4 4 1 Start the Charger Anal...

Page 30: ...s to one volt per cell 6 5 2 2 Depress full discharge RED control button for battery deep cycling 6 5 2 3 DISCHARGE will terminate automatically CYCLE END when the TOTAL time selected is reached or CAPACITY FAILURE if the BATTERY voltage reaches the equivalent of ONE VOLT per CELL prior to the selected time 6 5 2 4 NOTE Battery voltage is ignored during full discharge 6 5 2 5 Discharge will termin...

Page 31: ...specifications for optimum float and peak voltage charge levels Table 1 Constant Voltage and Peak Voltage Chart CELL SELECTOR FLOAT VOLTAGE PEAK VOLTAGE CELL SELECTOR FLOAT VOLTAGE PEAK VOLTAGE 1 25 29 1 30 6 2 2 3 2 5 26 30 3 31 9 3 3 5 3 7 27 31 5 33 1 4 4 7 4 9 28 32 6 34 3 5 5 8 6 1 29 33 8 35 5 6 6 7 7 4 30 35 0 36 8 7 8 2 8 6 31 36 1 38 0 8 9 3 9 8 32 37 3 39 2 9 10 5 11 0 33 38 4 40 4 10 11...

Page 32: ...ure to do so will result in serious damage to the control and power circuitry of the instrument 6 7 5 2 Failure to observe this requirement will void the warranty 6 7 6 Do not block air circulation A substantial amount of heat must be dissipated particularly in the discharge mode up to 1KW External heat removal circulating fan is required when operating in confined spaces or hot environments 6 7 7...

Page 33: ...onments will severely reduce the cooling capacity of the fans and lead to premature failure 7 2 LINE VOLTAGE 7 2 1 Connect the unit to a wall receptacle NEMA 6 30R 230V re wire the transformers input for 240V or 208V operation with a 30 AMP capacity This line must be a dedicated line originating at the breakers box and must be protected with a motor load rated circuit breaker Sharing of the line w...

Page 34: ...Operator Manual Supercharger 60 R3 0 Page 34 of 62 Figure 4 Line Voltage Wiring 208 230V Figure 5 Line Voltage Wiring 230 245V ...

Page 35: ... 100 Battery Charger Analyzer Calibrator provides all necessary functions to monitor verify and calibrate the Charger Analyzer NOTE 2 In the following tests make no connection to a battery unless specifically indicated Always start from reset and always reset at the conclusion of a test 8 1 REQUIRED TEST EQUIPMENT AND ACCESSORIES 8 1 1 CAL 100 Calibrator and one 20 to 50A Hr 20 cell battery 8 1 2 ...

Page 36: ... 8 3 3 Start the unit by depressing the two rate charge selector 8 3 3 1 The unit will go immediately into Cycle End 8 3 3 2 Reset 8 3 4 Set the total time to 01 and start 8 3 4 1 Unit will start in main charge and immediately transfer to topping going into cycle end after one second 8 3 4 2 Reset 8 3 5 Set the main time to 1 total time to 02 and start 8 3 5 1 The unit will start in the main mode ...

Page 37: ...8 4 2 3 The red light will turn off 8 4 3 Start in either of the charge modes 8 4 3 1 The unit will start and immediately go into Overtemp fault red light flashing and alarm on 8 4 3 2 Reset 8 4 4 Repeat the previous test by rotating the 16 5 K OHM resistor in all four positions 8 4 5 Repeat the first test using four 17 5 K OHM 1 resistors 8 4 5 1 The unit must not show Overtemp fault 8 5 VOLTAGE ...

Page 38: ...ime selectors to 1 01 Set the Cell selector to 20 8 7 2 Connect the battery cable to an adjustable voltage source CAL 100 or low current power supply set to approximately 34V and start the unit in either charge mode 8 7 3 Slowly increase the voltage Unit will stop and indicate a voltage fault at 35V 0 5V Reset 8 7 4 See 8 2 5 for adjustments 8 8 DISCHARGE VOLTAGE CUT OFF 8 8 1 Settings 8 8 1 1 Set...

Page 39: ...CKING 8 10 1 Settings 8 10 1 1 Set the Time selectors to 1 01 and the Cell selector consistent with the battery 8 10 1 2 Set the main charge current selector to 25 AMPS 250 8 10 1 3 Set the topping charge current selector to 1 AMP 010 8 10 2 Connect the Battery Cable to the battery 8 10 3 Start the unit in the two rate mode Current will rise to 25 0A 0 35A 8 10 4 Switch to the single rate mode Cur...

Page 40: ...ll start to decrease and will settle on a value of current to maintain the battery at 25 6 8 12 7 Depending on the condition of the battery a charge current higher than the initial 1A may be required for the battery to rise to the expected float voltage Conversely if the voltage rises too fast it will be necessary to select the next higher reading 23 for 26 8V and or a lower charge current 8 12 8 ...

Page 41: ...Page 41 of 62 8 14 METERS 8 14 1 Verify the battery voltage and charge discharge current readings by comparing against a CAL 100 Calibrator or a reference voltmeter and a reference ammeter or reference shunt 8 14 2 See 8 1 for adjustments ...

Page 42: ...any part of the circuitry becomes in contact with the chassis while a battery is connected NOTE Most adjustments are performed with no current no battery required and require the use of a voltage source to simulate battery voltages such as the CAL 100 Calibrator or a Power Supply A battery is required for the adjustments of current output 9 2 DIGITAL METERS see Figure 6 NOTE Digital meters are adj...

Page 43: ...f clamp on meters and moving magnet meters will yield erroneous readings Verify in discharge pure DC if better meters are not available 9 2 2 VOLTMETER 9 2 2 1 ZERO No zero adjustments 9 2 2 2 SCALE This meter has a full scale of 1 999 volts but an attenuator on the board converts it to a full scale of 1 999 19 99 or 199 9 volts as selected by the DPM selector switch Verify and calibrate using a v...

Page 44: ...Operator Manual Supercharger 60 R3 0 Page 44 of 62 Figure 6 Meters Board Adjustments ...

Page 45: ... as reference common 9 2 3 1 R10 AMPLIFIER ZERO Static test no battery or Calibrator Adjust a reading of 0 000V 0 003V at E3 on the CONTROL circuit board NOTE 2 Newer versions of this circuit board no longer have a zero adjustment NOTE 3 Modified versions of this circuit board may not have a zero adjustment not required 9 2 3 2 R11 DISCHARGE CELL CALIBRATE No battery is required for this test ...

Page 46: ...justments to perform 9 2 3 4 Blank 9 2 3 5 CURRENT CONTROL see fig 11 NOTE Use the hook at pin 14 as ground reference for voltage measurements test point E0 9 2 3 5 1 R29 10 VOLT ADJUSTMENT Static test no battery or Calibrator Adjust for a reading of 10 000V 0 003V at E7 NOTE Newer versions of this circuit board have a fixed 10V reference no adjustment Verify that it reads 10V 0 005V 9 2 3 5 2 R28...

Page 47: ... interactive Therefore It will be necessary to repeat the adjustments once or twice to achieve exact results The Voltage reading at E3 shunt amplifier output must correspond to the current as follows voltage at E3 0 1V A 2 Examples 40 A equals 4 00V 0 08V 20 A equals 2 00V 0 04V 10 A equals 1 00V 0 02V 5 A equals 0 50V 0 01V Figure 8 Current Control Board Adjustments ...

Page 48: ... the card connector or the Test Point E0 on the Control Board as ground reference for voltage measurements 9 2 4 1 U12 pin 1 BATTERY VOLTAGE This point corresponds to one tenth of the battery voltage present at the input terminals 9 2 4 2 U12 pin 7 CELL SELECTOR This point corresponds to one tenth volt per cell e g 2 00V 20 cells ...

Page 49: ...standard digital voltmeter referenced to pin 14 9 2 5 1 PIN VOLTAGE 10 to 11 36VAC 2V nominal line dependent NOTE 10 to 14 or 11 to 14 will read the total voltage 18V nominal 12 12V B 11 4V 0 6V NOTE This is a battery backed up source During a power failure the voltage will drop to the backup battery voltage minus 0 6V approximately 7 8V for a 7 cell battery or 9 0V for an 8 cell battery 13 COMMON...

Page 50: ... voltage is 1 10 of the simulated battery voltage Connect a battery to the Charger Analyzer Set the Voltage Control Mode Switch to CV Constant Voltage Program for 10A of Topping current Enter 24 in the cell selector nominal battery voltage Start the Charger Analyzer in Single rate The current will rise to the programmed 10A Increase the power supply voltage towards 2 8V and observe the current The...

Page 51: ...t in place of the battery Set the calibrator power supply to 28 5V Set the Voltage Control Mode to Peak Transfer Set both current selectors to zero Enter 24 in the cell selector nominal battery voltage Start the Charger Analyzer in Dual rate The current will rise to the programmed value Increase the power supply calibrator towards 29 4V The Charger Analyzer will switch from Main to Topping at a ba...

Page 52: ...Operator Manual Supercharger 60 R3 0 Page 52 of 62 Figure 11 Circuit Board Sequence ...

Page 53: ...efective Monitor board 10 1 5 THE UNIT CHARGES LOW CURRENT BELOW 10 AMPS PROPERLY BUT HUMS NOTICEABLY AT HIGHER CURRENTS One of the SCR s is inoperative or one of the rectifiers is open 10 1 6 UNIT CHARGES ON TOPPING AND DISCHARGES CORRECTLY BUT WILL NOT CHARGE IN MAIN Defective Main Current Selector or defective Control board 10 1 7 UNIT STARTS IN THE DISCHARGE MODE BUT GOES INTO CAPACITY FAILURE...

Page 54: ... in the Monitor board is set in the test position If the switch is in the correct position run turn power off and back on to clear the condition and resume operation without resetting 10 1 16 DIGITAL METERS DO NOT TURN ON Open fuse to digital panel meters 10 1 17 OPEN LIMITER SMALL CRACK Inconsequential opening Replace and resume operation 10 1 18 OPEN LIMITER BLOWN ELEMENT vaporized Discharge tra...

Page 55: ...tely 0 1V for a lamp drawing 5A indicates current flow due to a transistor with a collector to emitter short NOTE A non zero reading on all emitter resistors 0 02V approx for a lamp drawing 0 5A indicates a different failure mode collector to base short refer to step 7 10 2 2 6 Remove any shorted transistors and repeat steps 4 and 5 until a no short reading is obtained Replace defective devices on...

Page 56: ...Operator Manual Supercharger 60 R3 0 Page 56 of 62 Figure 12 Measuring for a shorted transistor ...

Page 57: ...Operator Manual Supercharger 60 R3 0 Page 57 of 62 Figure 13 Location of Current Limiters ...

Page 58: ...Operator Manual Supercharger 60 R3 0 Page 58 of 62 Figure 14 Power Block Diagram ...

Page 59: ...s 100mA Hr 4311R25SB0 FUSE W Slow Blow 4317ANL060 CURRENT LIMITER ANL 60 4317ANN080 CURRENT LIMITER ANN 80 47412D1R00 RESISTOR POWER 1 ohm 2W 5 47130E10R0 RESISTOR POWER 10 ohm 1W 5 474120F1010 RESISTOR POWER 100 ohm 1 2W 5 47413CR33F RESISTOR POWER 0 33 ohm 3W 5 flameproof 4755101031 POTENTIOMETER with DIAL 10 turn 47562H1030 CELL SELECTOR 4822J15001 POWER TRANSISTOR MJ15001 4822J15002 POWER TRAN...

Page 60: ...he float voltage is reached at which time the current will diminish to the level needed to maintain the float voltage Lead Acid batteries can also be charged in a manner in which it is possible to know much better the end of charge When a Lead Acid cell is charged with constant current at C 15 to C 10 the end voltage will rise rapidly at about 90 to 95 of charge which occurs at about 2 4 to 2 45V ...

Page 61: ...ent of any malfunctioning part of the system not responsible for any losses incurred from the usage of the system It is the user s responsibility to verify the performance of the instruments and to operate and maintain it in accordance with the above given instructions It is the user s responsibility to operate the Instrument within standard safety procedures applicable to the operation of a Batte...

Page 62: ...ns REVISION DATE NOTES 1 0 21 January 2001 Release 2 0 15 January 2003 New Clock Timer Board and additional Peak function 2 1 23 July 2003 Overvoltage is now set at 1 75V cell was 1 70 Numerous other text updates clarifications 3 0 4 October 2007 Reformatted Many text changes for clarification ...

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