GNB SCR SERIES Installation & Operating Instructions Manual
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GNB SCR SERIES Installation & Operating Instructions Manual

GNB SCR SERIES Installation & Operating Instructions Manual

Scr series chargers with single phase input
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SCR SERIES CHARGERS
SCR SERIES CHARGERS
Section 93.20
2011-11
JA0132-00
INSTALLATION & OPERATING
INSTRUCTIONS
FOR
SCR & SCRF SERIES
BATTERY CHARGER
WITH
SINGLE PHASE INPUT

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  • Page 1 SCR SERIES CHARGERS SCR SERIES CHARGERS Section 93.20 2011-11 JA0132-00 INSTALLATION & OPERATING INSTRUCTIONS SCR & SCRF SERIES BATTERY CHARGER WITH SINGLE PHASE INPUT...
  • Page 2 JF0026-00 SCR/SCRF SERIES BATTERY CHARGER SPECIFICATIONS MODEL No. INPUT VOLTAGE SERIAL No. FLOAT VOLTAGE SMART PART No. EQUALIZE VOLTAGE (items A-F req’d) CORE (BB####) 1 - Serial Number and Core (BB####) calculated by factory SMART PART DWG# DESCRIPTION (X) DWG# DESCRIPTION Pos.

  • Page 3: Important Safety Instructions

    IMPORTANT SAFETY INSTRUCTIONS 1) Before using the battery charger, read all instruction and cautionary markings on: A) battery charger, B) battery, C) equipment connected to charger and battery 2) This manual contains important safety and operating instructions, and therefore should be filed for easy access.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Page No. SCR/SCRF BATTERY CHARGER SPECIFICATIONS (JF0026-00)......(inside front cover) IMPORTANT SAFETY INSTRUCTIONS ....................i TABLE OF CONTENTS........................ii-iii SECTION II - INSTALLATION AND OPERATION 1. Safety Notice ..............................2 2. Application .................................2 3. Installation................................2 4. Placing Charger in Service ..........................3 5.
  • Page 5 Page No. SECTION V - CUSTOMER OPTIONS 1. Ground Detection Circuits (EJ0088 / EJ0089 / EJ0094 / EJ0086) ..............14 2. AC Power Failure Alarm Relay (EJ0085) ....................... 15 3. Single Phase AC Input Voltmeter (EJ0095) / Single Phase AC Input Ammeter (EJ0134)......15 4.

  • Page 6: Section Ii - Installation And Operation

    SECTION II INSTALLATION AND OPERATION 1. SAFETY NOTICE CAUTION! READ “IMPORTANT SAFETY INSTRUCTIONS” ON PAGE i. There are dangerous voltages within the battery charger cabinet! a. Only qualified personnel should attempt to adjust or service this equipment. b. Refer to instruction manual for service procedures and CAUTION notes. 2.

  • Page 7: Placing Charger In Service

    4. PLACING CHARGER IN SERVICE a. With the AC and DC breakers OFF and the system in float mode, install the charger making AC and DC connections, as described in Section II, 3, and in accord with local regulations as they apply. b.

  • Page 8: Maintenance

    7. MAINTENANCE a. This charger is designed to require a minimum of maintenance. There are no rotating parts except in the optional timer and all components have a nominally indefinite life with no expected aging effect. It should be kept clean, dry and checked periodically to make sure all connections are tight. If necessary, dry air may be used to blow dust out of the interior.

  • Page 9: Description Of Operation

    9. DESCRIPTION OF OPERATION There are four major sections of the SCR single-phase charger, which work together to produce stable, regulated, filtered output. The functions of these four sections may be described as follows. a. The Power Transformer (T1): This section includes T1 and its associated input protection.

  • Page 10: Section Iii - Troubleshooting

    SECTION III TROUBLESHOOTING 1. CAUTION NOTICE Before troubleshooting, always isolate and de-energize the charger by opening the AC circuit breaker (CB1) and the DC circuit breaker (CB2). This avoids the possibility of high short circuit current damaging the charger, tools, test equipment, or injuring personnel. NOTE: Circuit breaker terminals (CBx), printed circuit boards (Ax) and terminals/terminal blocks (TB1, TB2, TB3, TB5 &...

  • Page 11: Power Transformer (T1)

    b. Power Transformer (T1) 1. With the AC and DC circuit breakers open or "OFF", open the cabinet and carefully check the line voltage across the line terminals (TB1-L1 and TB1-L2). Refer to Section III, 2, a, 1 on page 6 if no AC voltage is indicated.

  • Page 12: Rectifier Diodes (Scr1 / Scr2)

    e. Rectifier Diodes (SCR1/SCR2) - (also see Section III, 2, f) 1. These diodes are a part of an SCR-diode module(s) in which the SCRs and diodes are contained in a module(s) mounted by an electrically insulated heat sink plate. Three connections (plus one SCR gate terminal) are available for checking.

  • Page 13: Control Module (A1)

    g. Control Module PC Board Assembly (A1) One preliminary note that should be kept in mind: The action of the overall feedback circuit controls the battery charger output voltage so that the feedback voltage from the slider of the "FLOAT ADJUST" potentiometer (R3) to the control module board matches the 6.4 Volt reference voltage on the module.

  • Page 14: Dc Ammeter (M1)

    k. DC Ammeter (M1) 1. The charger DC ammeter is connected in series between the charger output and battery. If open it will indicate zero, or if shorted, it will also indicate zero. First be certain the connections are tight. If still no indication, turn CB1 and CB2 breakers to OFF, disconnect the charger ammeter (and/or shunt) and substitute a precision ammeter of suitable range.

  • Page 15: Section Iv - System Adjustments

    SECTION IV SYSTEM ADJUSTMENTS 1. VOLTAGE ADJUSTMENTS AND RESPONSE When abnormal output voltage exists (or no output current is present), and the previous checks in Table A on page 27 “VOLTAGE ADJUST INEFFECTIVE” have been made without locating the fault, switch the AC breaker (CB1) to OFF.

  • Page 16: Equalize Adjustment

    b. Equalize Adjustment 1. Since the equalize adjustment will not affect the float voltage adjustment and requires a higher voltage it should always be made after the float voltage is determined. Use a portable voltmeter of one percent accuracy as in the float adjustment. Set switch (SW1) to “EQUALIZE”. Close the DC (battery) breaker (CB2).

  • Page 17: Current Limit Response And Adjustment

    2. CURRENT LIMIT RESPONSE AND ADJUSTMENT a. Checks and Adjustments: Make certain the charger leads are connected to the battery and that the panel voltmeter indicates the proper polarity. Switch the DC breaker (CB2) to "ON" and AC breaker (CB1) to "ON". The "AC ON" indicating light (DS1) should illuminate, indicating power has been applied.

  • Page 18: Ground Detection Circuits (Ej0088 / Ej0089 / Ej0094 / Ej0086)

    SECTION V SCR/SCRF SERIES BATTERY CHARGER CUSTOMER OPTIONS The following pages describe customer options available in SCR/SCRF Series battery chargers. The text describes the basic operational philosophy and theory of operation. Block diagrams (or schematics) for these options are shown in Section VIII, in numerical order of the "EJ####" specification number. 1.

  • Page 19: Ac Power Failure Alarm Relay (Ej0085)

    2. AC POWER FAILURE ALARM RELAY (EJ0085) - WITH OPTIONAL INDICATOR LIGHT Purpose: The purpose of this alarm is to notify the user that the AC input power to the battery charger has been interrupted. A front panel "AC FAILURE" lamp is optional for local indication. Relay contacts are provided for remote monitoring.

  • Page 20: Charger Failure Alarm Relay (Ej0127)

    If it is necessary to adjust the LVA threshold in the field, the user must load the battery bank and allow the battery voltage to drop while decreasing the float voltage adjustment to the desired cut-off potential. The LVA potentiometer is then adjusted so that the LVA relay is activated into the low voltage alarm condition. Note that there is a delay time, up to 30 seconds before the relay operates once the threshold voltage is reached.

  • Page 21: Equalize Timers (Ej0097 / Ej0096 / Ej0869 / Ej0131 / Ej0084)

    7. EQUALIZE TIMERS Purpose: Equalize Timers are used to switch the charger into equalize charging mode for a set period of time, when required by the batteries. "FLOAT" and "EQUALIZE" indicating lights mounted on the instrument panel can be included with all timers to indicate the charging mode. There are three basic timers described below.

  • Page 22: Common Alarm Buzzer (Ej0123)

    8. COMMON ALARM BUZZER (EJ0123) Purpose: The Common Alarm Buzzer is a charger mounted audible alarm, which is activated when any of several different alarm circuits goes into an alarm state. Description: This circuit simply utilizes a set of contacts on each separate alarm relay. All of the contacts are wired in parallel and connect the audible alarm (AU1) to the battery voltage.

  • Page 23: Zero-Center Dc Ammeter For Battery/Load Monitoring (Ej0138)

    12. ZERO-CENTER DC AMMETER FOR BATTERY/LOAD MONITORING (EJ0138) Purpose and Description: The zero-center dc ammeter (M7) lies within the negative return lead of the battery. A current-sensing shunt (SH2) is provided when the range is greater than 50 Amperes. M7 indicates the direction and amount of the battery current.

  • Page 24: Current Limit Alarm Relay (Ej0137)

    15. CURRENT LIMIT ALARM RELAY W/INDICATOR LIGHT (EJ0137) Purpose: The Current Limit Alarm provides an alarm signal whenever the battery charger output reaches the maximum limit set by the current limit circuit. An indicator lamp (DS24) mounted on the instrument panel also lights when the current limit alarm is activated.

  • Page 25: Combined Alarm-Status Monitor "Casm" Pc Board Assembly (Ej0837)

    19. COMBINED ALARM STATUS MONITOR "CASM" PC BOARD ASSEMBLY (EJ0837) Note: Refer to the Drawing (EJ0837-XX) on page 49 for additional information. Purpose: The Combined Alarm-Status Monitor (CASM) provides a comprehensive, cost-effective method to monitor the integrity of the battery charger and the dc bus. Description: The CASM combines the monitoring and alarm functions of the High-Low AC Voltage Alarm, High-Low DC Voltage Alarm, Ground Detection Relay Alarm, Charger Failure Alarm, and a Common Alarm Relay into one printed circuit board assembly (A24).
  • Page 26 SECTION VI COMPONENT DESCRIPTION SCR/SCRF SERIES BATTERY CHARGER - SINGLE PHASE MAIN FRAME Circuit Symbol Spare? Component Description (Note 2) (Note 1) Single Phase Input Main Control Module PC Board Holder for Control Module PC Board (A1) Socket for Control Module PC Board (A1) Filter Capacitor (SCRF models only) Filter Capacitor Bracket (SCRF models only) Battery Eliminator Filter Capacitor (SCRF-E models only)
  • Page 27 Circuit Symbol Spare? Component Description (Note 2) (Note 2) Bleeder / Feedback Resistor Voltage Divider Resistor Float Adjustment Potentiometer Voltage Divider Resistor Equalize Adjustment Potentiometer SCR1 Silicon-Controlled Rectifier / Diode Module SCR2 Silicon-Controlled Rectifier / Diode Module DC Ammeter Shunt (supplied with 50 Adc nominal dc output or greater) A, B DC Output Surge Suppressor...

  • Page 28: Ej0083

    COMPONENT DESCRIPTION SCR/SCRF SERIES BATTERY CHARGER OPTIONS - SINGLE/THREE PHASE NOTES: 1) "B" indicates recommended operating spare part 2) For component placement of circuit symbols, refer to SCR/SCRF Series Option Schematics in Section VIII starting on Page 34 3) For option replacement parts, refer to Section IX starting on Page 57 Option Ref.

  • Page 29: Ej0096

    Option Ref. Circuit Spare? Component Description Number Page Symbol (Note 1) EJ0096 0-72 Hour Manual Timer Float Indicator Light Equalize Indicator Light EJ0097 0-72 Hour Manual Timer EJ0120 Battery Discharging Alarm PC Board w/Relay Socket for A5 DC Current Shunt DS10 Battery Discharging Indicator Light 3-Position DC Output Terminal Block (+batt/load, -load, -batt)

  • Page 30: Ej0141 (W/Buzzer)

    Option Ref. Circuit Spare? Component Description Number Page Symbol (Note 1) EJ0141 Common Alarm Relay (w/Buzzer) Common Alarm Buzzer SW13 Buzzer ON/OFF Switch Voltage Dropping Resistor Voltage Dropping Resistor EJ0143 End of Discharge Alarm PC Board w/Relay Socket for A8 Voltage Dropping Resistor Voltage Dropping Resistor DS12...
  • Page 31 SECTION VII...
  • Page 33 SCR/SCRF Series Battery Charger...
  • Page 34 Section VII...
  • Page 35 FIGURE 2 - TYPICAL WAVEFORMS OF SINGLE-PHASE CONTROL TRIGGER BOARD (GK0058-XX) (See Section III, 3, g)
  • Page 38 Option Schematics...
  • Page 39 SCR/SCRF Series Battery Charger...
  • Page 40 Option Schematics...
  • Page 41 SCR/SCRF Series Battery Charger...
  • Page 42 Option Schematics...
  • Page 43 SCR/SCRF Series Battery Charger...
  • Page 44 Option Schematics...
  • Page 47 SCR/SCRF Series Battery Charger...
  • Page 48 Option Schematics...
  • Page 49 SCR/SCRF Series Battery Charger...
  • Page 50 Option Schematics...
  • Page 51 SCR/SCRF Series Battery Charger...
  • Page 57 ELECTRICAL RATINGS AND REPLACEMENT PARTS SCR/SCRF Series Battery Charger (Single Phase Mainframe) PLEASE CONTACT YOUR SALES REPRESENTATIVE FOR DATA ON MODELS NOT LISTED. SCR/SCRF BATTERY CHARGER MODEL 12V-6A 12V-12A 12V-20A 12V-25A 24V-6A 24V-12A 24V-25A 24V-50A 24V-75A Enclosure Type Style-1A Style-1A Style-1A Style-1B Style-1A...
  • Page 58 ELECTRICAL RATINGS AND REPLACEMENT PARTS SCR/SCRF Series Battery Charger (Single Phase Mainframe) PLEASE CONTACT YOUR SALES REPRESENTATIVE FOR DATA ON MODELS NOT LISTED. SCR/SCRF BATTERY CHARGER MODEL 24V-100A 48V-6A 48V-12A 48V-16A 48V-25A 48V-35A 48V-50A 48V-75A 48V-100A Enclosure Type Style-3 Style-1A Style-1A Style-1B Style-1B...
  • Page 59 ELECTRICAL RATINGS AND REPLACEMENT PARTS SCR/SCRF Series Battery Charger (Single Phase Mainframe) PLEASE CONTACT YOUR SALES REPRESENTATIVE FOR DATA ON MODELS NOT LISTED. SCR/SCRF BATTERY CHARGER MODEL 130V-6A 130V-12A 130V-16A 130V-20A 130V-25A 130V-35A 130V-50A 260V-6A 260V-16A Enclosure Type Style-1B Style-1B Style-1B Style-1B Style-1B...
  • Page 60 ELECTRICAL RATINGS AND REPLACEMENT PARTS SCR/SCRF Series Battery Charger (Single Phase Mainframe) PLEASE CONTACT YOUR SALES REPRESENTATIVE FOR DATA ON MODELS NOT LISTED. SCR/SCRF BATTERY CHARGER MODEL Enclosure Type 120Vac AC INPUT CURRENT 240Vac (MAXIMUM) 480Vac SYMBOL DESCRIPTION MANUFACTURER'S PART No. C1/C2 FILTER CAPACITOR SNUBBER...
  • Page 61 REPLACEMENT PARTS SCR/SCRF Series Battery Charger Options (1PH/3PH) BATTERY CHARGER NOMINAL OUTPUT 12 Vdc 24 Vdc 48 Vdc 130 Vdc 260 Vdc OPTION CIRCUIT DESCRIPTION MANUFACTURER'S PART NO. NUMBER SYMBOL EJ0083 HLVA Alarm Control PC Board GK0045-01 (specify dc voltage) Low Voltage Indicating Light RA0001-00 RA0001-01...
  • Page 62 REPLACEMENT PARTS SCR/SCRF Series Battery Charger Options (1PH/3PH) BATTERY CHARGER NOMINAL OUTPUT 12 Vdc 24 Vdc 48 Vdc 130 Vdc 260 Vdc OPTION CIRCUIT DESCRIPTION MANUFACTURER'S PART NO. NUMBER SYMBOL EJ0120 Battery Discharging Alarm PC Board GK0052-01 GK0052-02 GK0052-05 GK0052-06 GK0052-07 DS10 Battery Discharging Alarm Indicating Light...
  • Page 63 REPLACEMENT PARTS SCR/SCRF Series Battery Charger Options (1PH/3PH) BATTERY CHARGER NOMINAL OUTPUT 12 Vdc 24 Vdc 48 Vdc 130 Vdc 260 Vdc OPTION CIRCUIT DESCRIPTION MANUFACTURER'S PART NO. NUMBER SYMBOL EJ0134 AC Current Transformer 75 Aac max AT0057-01 AT0057-01 AT0057-01 AT0057-01 AT0057-01 100 Aac max...
  • Page 64 REPLACEMENT PARTS SCR/SCRF Series Battery Charger Options (1PH/3PH) BATTERY CHARGER NOMINAL OUTPUT 12 Vdc 24 Vdc 48 Vdc 130 Vdc 260 Vdc OPTION CIRCUIT DESCRIPTION MANUFACTURER'S PART NO. NUMBER SYMBOL EJ0141 Common Alarm Buzzer RA0004-00 RA0004-00 RA0004-00 RA0004-00 RA0004-00 Common Alarm Relay RF0010-01 RF0010-03 RF0010-03...
  • Page 65 REPLACEMENT PARTS SCR/SCRF Series Battery Charger Options (1PH/3PH) BATTERY CHARGER NOMINAL OUTPUT 12 Vdc 24 Vdc 48 Vdc 130 Vdc 260 Vdc OPTION CIRCUIT DESCRIPTION MANUFACTURER'S PART NO. NUMBER SYMBOL Combined Alarm-Status Monitor 1 Form-C EN0014-82 EN0014-82 EN0014-82 EN0014-82 EN0014-82 EJ0837 Control PC Board 2 Form-C...
  • Page 66 SECTION X MANUAL SPECIFICATIONS DOCUMENT NUMBER: The internal text and graphics contained within this manual are controlled by the battery charger manufacturer's internal part number (JA5035-00). Revision level and dates for this part are listed below. These controls supercede all other available dates. The first two and last two pages of this manual are reserved for company-specific front and back cover artwork.
  • Page 67 SCR/SCRF Series Battery Charger JD5022-00 Preventive Maintenance Procedure MAINTENANCE DATE PERFORMED BY Step (standard features) Instructions Results • All vents clean and open. ¨ OK Clean battery charger • Remove dust and debris from inside of unit. ¨ OK • TB1 and TB2 connections all tight. ¨...
  • Page 68 North America and Europe and a truly global reach (operations in more than 80 countries) in sales and service, GNB Industrial Power takes pride in its commitment to a bet- GNB Industrial Power is best positioned to satisfy your ter environment.

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