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ELEMENT

SERIES

INDUSTRIAL BATTERY CHARGERS

INSTALLATION & OPERATING

INSTRUCTIONS

Содержание ELEMENT LMT-06kW-48-S Series

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

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Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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