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Summary of Contents for Exide GNB ELEMENT Series
- Page 1 ELEMENT SERIES INDUSTRIAL BATTERY CHARGERS INSTALLATION & OPERATING INSTRUCTIONS...
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Page 3: Table Of Contents
TABLE OF CONTENTS 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 Precautions
SAFETY PRECAUTIONS BEFORE ATTEMPTING TO OPERATE THE CHARGER, PLEASE READ THIS GUIDE CAREFULLY. SAVE THESE INSTRUCTIONS – This guide contains important instructions for Element 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. - Page 5 Risk of electrical component failure due to improper installation. To prevent damage from overheating, proper airflow must be ensured. Do not restrict fan inlets or exhaust outlets. Do not mount the charger in a confined space or where the exhaust air will recirculate. There are no user serviceable parts within the charger enclosure.
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Page 6: Charger Specifications
CHARGER SPECIFICATIONS The Element system specifications are listed below. LMT-06kW-48-xxxS LMT-10kW-48- LMT-10kW-80- xxxT xxxT Nominal VA Ratings 48V / 150A 48V / 250A 80V / 120A Input Specs. Voltage 480VAC, 3-phase +10% Delta Connection with Earth Ground 13.8A rms / 13.8A rms / Current (nominal) 8.3A rms / phase... -
Page 7: Installation Procedure
INSTALLATION PROCEDURE Charger Inspection Upon receipt of the Element charger, verify that the shipping information (packing list) matches the charger rating (label on the side of the charger). Upon receipt of the Element charger, ensure that there is no physical damage to the chassis, the LCD/keypad, the E-Stop/Disconnect switches, or the AC/DC cables. - Page 8 CAUTION: When installing, do not lift the unit from the middle of the lower cover as this may damage the filter. To reduce potential for filter damage, lift the charger using the lifting handles mounted on either side of the charger chassis (see Figure 2). Lifting Handles Figure 2: Charger lifting instructions...
- Page 9 Air filter Filter Guides Figure 3: Installing / Replacing Air Filter Sales Service Recycling 888.563.6300 in the USA 800.268.2698 in Canada...
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Page 10: Charger Electrical Installation
Charger Electrical Installation 1. Verify proper AC line voltage and current ratings per the charger specifications as listed on the label on the side of the unit (see table below for proper AC line ratings). AC Line Ratings for Element Chargers Disconnect Circuit Charger Model AC Voltage... - Page 11 Figure 4: Removing top cover AC Knockouts 480VAC Figure 5: AC wire connections Sales Service Recycling 888.563.6300 in the USA 800.268.2698 in Canada...
- Page 12 Figure 6 : Making AC wire connections Figure 7: Connecting GND wire Sales Service Recycling 888.563.6300 in the USA 800.268.2698 in Canada...
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Page 13: Charger Controls And User Interface
Charger Controls and User Interface The charger main disconnect is located on the upper right side of charger. The user interface panel is located on the front of the charger (see Fig. 8). 1- Main 2 -LCD / Disconnect Keypad Power Switch Fig. - Page 14 The LCD/Keypad assembly shown in Figure 10 encompasses: o A 4x20 character LCD for operation and fault message display o A 1x6 push button keypad with separate START and STOP push button o Two status LEDs for run (OK) and Fault indication o A serial RS-232 connector and an IR window Status RS-232...
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Page 15: Operating Procedure
OPERATING PROCEDURE Turning on the Unit Connect charger to truck’s battery using DC connectors. Energize the AC Mains. Energize the side panel AC input main disconnect switch (RED). Verify that the LCD display is lit and displays the “Connect Battery” screen shown below. Battery Voltage Setting Charger Maximum Current If the LCD is not lit, if the above message is not displayed, or the fans are not operating,... - Page 16 Starting a Charge Cycle Connect the truck’s battery to the charger. Once the battery is detected, the LCD message will change to “Push Start to Begin Cycle”. If the above message is not displayed, the battery may not have been detected. Make sure that the battery cables are connected properly and verify that the auxiliary contacts are proper and making good contact.
- Page 17 Pressing the STOP button for the second time will stop the charger completely and the unit will default to the Charger Idle screen. If necessary, it is now safe to disconnect the 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.
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Page 18: Charger Menus
CHARGER MENUS Users can access various menus of the charger to view charge history, charger lifetime operational history, charger settings, charger model and serial number as well as activate a recovery cycle for a sulfated battery. The charger menus can be accessed when the charger is idle, i.e. when the “Connect Battery” or the “Push Start to Begin Cycle”... - Page 19 Pressing the left/right ( / ) keys will display the second screen of the charger history. The second screen lists additional relevant information about the charge cycle including: ACTIVATED PROFILES: Lists the profiles that were activated during that cycle. STATE: Shows whether the cycle completed successfully or interrupted by the user or due to a fault.
- Page 20 III. Charger Lifetime History While in the Main Menu, press the up/down ( / ) keys until the Lifetime Summary screen appears. Pressing the “ENTER” key will access the selected menu. The charger lifetime operational summary screen will then appear. The above variables allow users to verify charger usage since installation and compare usage of a specific charger versus others in the vicinity or in the plant.
- Page 21 Pressing the”ENTER” key will access the selected menu. The user will then be prompted to enter the battery voltage, charge current, and required cycle time. Pressing the up/down ( / ) keys will change the battery voltage setting (24V/36V/48V). Select the correct voltage then press the “ENTER”...
- Page 22 Select the correct value then press the “ENTER” key. The recovery charge start screen will then appear. 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.
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Page 23: Troubleshooting
TROUBLESHOOTING Under normal operation, the Status OK (green) is lit. In case of a fault, the Status FAULT (red) is lit. If that occurs, perform the following: 1. Note the fault message that appears on the screen. Make sure to note the second line of the fault message as it indicates the type of fault. - Page 24 II. Charger Faults 1. AC Fault Note that the drawer number that reported the fault is listed on the second line. Also note that the charging drawer that caused the fault is shown. Possible Causes: AC line voltage is below/above operational limits (±10%) Internal input stage failure Troubleshooting: 1.
- Page 25 Possible Causes: Worn DC cables (open or short) Improper DC cable connections Troubleshooting: 1. Press the STOP key to revert to the IDLE screen. 2. Verify that the output cables are in good working condition and are properly connected to the battery.
- Page 26 4. Restart the charge cycle by pressing the START key. 5. If the charger starts with no faults, the fault was likely caused by the build up of heat in the charger. 6. If the fault persists, verify that all fans are operational. If one or more fans are not operational, switch off the disconnect switch and contact GNB Industrial Power.
- Page 27 Possible Causes: Battery temperature exceeded preset limit Faulty (worn) thermistor Troubleshooting: 1. Press the STOP key to revert to the IDLE screen. 2. Measure the battery tray temperature. If an elevated battery temperature is detected, do not re-start the charge cycle. 3.
- Page 28 Internal to Charger Wire Loop in one Battery Aux. contact Charger Aux +Temp Sense Battery Aux Charger Aux -Temp Sense Battery Aux Thermistor in one Battery Aux. contact 8. Charger Timeout Faults XXXXXXXX: Total Charge Timer Trickle Charge Timer CC Charge Timer CV Charge Timer Finish Charge Timer Possible Causes:...
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Page 29: Appendix
Appendix Charging System Block Diagrams Sales Service Recycling 888.563.6300 in the USA 800.268.2698 in Canada... - Page 32 SALES – SERVICE – RECYCLING TOLL FREE 1-888-563-6300 in the USA 1-800-268-2698 in Canada...
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