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HindlePower SCR series Operating Instructions Manual

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Download this manual See also: Operating/service Instructions
Operating and Service Instructions
SCR/SCRF
SERIES
BATTERY CHARGER
SINGLE PHASE INPUT

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Summary of Contents for HindlePower SCR series

  • Page 1 Operating and Service Instructions SCR/SCRF SERIES BATTERY CHARGER SINGLE PHASE INPUT...

  • Page 2: Important Safety Instructions

    IMPORTANT SAFETY INSTRUCTIONS READ AND FOLLOW ALL SAFETY INSTRUCTIONS Before using the battery charger, read all instruction and cautionary markings on: A) battery charger, B) battery, C) equipment connected to charger and battery This manual contains important safety and operating instructions, and therefore should be filed for easy access.
  • Page 3 SCR/SCRF SERIES BATTERY CHARGER SPECIFICATIONS JF0026-00 MODEL No. INPUT VOLTAGE Volts AC SERIAL No. FLOAT VOLTAGE Volts DC SMART PART No. EQUALIZE VOLTAGE Volts DC (items A-F req’d) CORE (BB####) SMART PART DESCRIPTION DESCRIPTION Pos. CODE UNFILTERED OUTPUT (L1) JE0121 SURGE WITHSTAND FILTER (SWC) PER IEE-472 FILTERED OUTPUT (L1/L2/C1)

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Page No. IMPORTANT SAFETY INSTRUCTIONS ......................i SCR/SCRF BATTERY CHARGER SPECIFICATIONS................... ii TABLE OF CONTENTS ............................iii SECTION II 1. Safety Notice..............................1 2. Application..............................1 3. Installation..............................1 4. Placing Charger in Service..........................2 5. Adjustments of Float & Equalizing Charge ....................2 6.
  • Page 5 SECTION IV System Adjustments..............................10 1. Voltage Adjustments and Response ......................10 a. Float Adjustment .............................11 b. Equalize Adjustment..........................11 2. Current Limit Response and Adjustment .....................11 a. Checks and Adjustments..........................11 b. Checks to Make if Malfunctioning ......................12 SECTION V Customer Options ..............................12 1.

  • Page 7: Safety Notice

    SECTION II SINGLE PHASE SCR AND SCRF TYPE BATTERY CHARGER INSTALLATION AND OPERATION 1. SAFETY NOTICE THERE ARE DANGEROUS VOLTAGES WITHIN THE BATTERY CHARGER CABINET. CAUTION! READ “IMPORTANT SAFETY INSTRUCTIONS” ON PAGE I. a. Only qualified personnel should attempt to adjust or service this equipment. b.

  • Page 8: Placing Charger In Service

    c. Wire Sizes DC: The size of the charger leads should be selected to (a) carry the charger (ampere) current rating, and also (b) provide less than 0.5 volt total drop at rated current in the loop or leads between the charger and battery terminals. Choose the larger wire size that meets conditions (a) and (b). Do not undersize.

  • Page 9: Manual Equalize Timer

    5. ADJUSTMENTS OF FLOAT & EQUALIZING CHARGE (also see Section IV, 1) a. Each adjustment is made by means of a potentiometer with a slotted shaft for a screwdriver. The potentiometers are front-panel mounted and appropriately marked. A lock nut on each potentiometer is provided and should be tightened after the proper adjustment is completed.

  • Page 10: Description Of Operation

    9. DESCRIPTION OF OPERATION a. 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. 1. The Power Transformer T1. This section includes T1 and its associated input protection. Its purpose is basically to supply an AC voltage of the proper magnitude and capacity to the rectifier section.

  • Page 11: Testing Of Components

    1. TROUBLE SHOOTING PROCEDURE a. When a charger is not operating properly, the cause must be determined by checking various components until the fault is located. b. The major components are not checked in the order as listed in Section II, 9, since a charger may exhibit a number of difficulties, each with different symptoms.

  • Page 12: External Circuit Wiring

    TABLE B SECONDARY VOLTAGE OF TRANSFORMER T1 (USE AC VOLTMETER) Expected Voltages (AC) Leads or Locations Approximately 2 times float voltage, see page ii X1 to X5 120V AC Y1 to Y2 NOTE: The "X" of Table B voltages should be measured as they terminate on the full-wave bridge components.

  • Page 13: Surge Suppressors

    1. These diodes are a part of an SCR-diode module(s) in which the SCR's 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. The diode portions should be checked by disconnecting one terminal and measuring their forward and reverse resistance in either of two ways.

  • Page 14: Control Module

    4. An SCR can also be checked for operation with a Simpson Model 260 voltohmmeter. With the black lead in common and red lead in +, put polarity switch to + DC. Connect the red lead to the anode and the black lead to the cathode. The meter should now indicate high resistance above 50,000 ohms (when on the R x 10,000 scale).

  • Page 15: Current Sensing Resistor

    h. Current Sensing Resistor 1. In light current chargers, the current sensing signal is taken directly across the DC ammeter. In chargers with 50 Amp or higher output current, the sensing resistor is a meter shunt which also serves as the shunt for the panel ammeter.

  • Page 16: Internal Wiring

    1. Before attempting to check the output ripple, it should be determined that in all other respects the charger is operating normally. Having determined this, the ripple may be checked as follows. Connect a sensitive AC voltmeter (digital type preferred) to the battery terminals and measure the AC ripple voltage.

  • Page 17: Float Adjustment

    a. Float Adjustment 1. Since the charger must be operable for this adjustment, preceding checks in Section IV, 1 above must indicate a serviceable charger. Set SW1 to “FLOAT”. Use a portable voltmeter of one percent accuracy. Connect the battery supply leads to the battery and close DC (battery) circuit breaker, CB2. Set AC circuit breaker CB1 to ON.

  • Page 18: Checks To Make If Malfunctioning

    1. If the batteries are in a discharged condition, switching to the equalize mode will cause the charger to automatically go into a current limit condition. If, however, the batteries are fully charged they probably will not draw current in the current limit range. In order to cause this condition, it will be necessary to connect additional load to the battery charger or battery bank.

  • Page 19: Ground Detection Circuits

    1. GROUND DETECTION CIRCUITS Purpose: The purpose of a ground detector circuit is to indicate to the user when either the positive (+) or negative (—) output terminal of the battery charger (or its connected load) is grounded. This is important for many applications where a full floating system is required for operation or safety reasons.

  • Page 20: Ac Voltmeter/Ac Ammeter

    Description: The principle of operation utilizes the normally closed contacts of an AC relay. The relay is powered from the AC line at the primary of the power transformer T1. The relay, when energized, holds the normally closed contacts open disabling the alarm indication. When the AC line fails or the AC circuit breaker is opened for any reason, the alarm contacts will close activating the alarm indicator.

  • Page 21: Charger Failure Alarm Relay

    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.

  • Page 22: Equalize Timers

    7. EQUALIZE TIMERS Purpose: Equalize Timers are used to switch the charger into the equalize charging mode when required by the batteries. Float and equalize indicating lights can be included on all timers to indicate the charging mode. There are three basic timers which are described below. Description: a.

  • Page 23: Common Alarm Buzzer

    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 to the battery voltage.

  • Page 24: Dc Zero-Center Ammeter For Battery/Load Monitoring

    Once the system is balanced any changes in the load will be shared equally by the two chargers. If either charger is shut down or becomes inoperative, the other will assume the total load up to the point where its current limit circuit operates. It is possible to operate each charger independently by setting switch SW10 (LOAD SHARE) to the OFF position.

  • Page 25: End Of Discharge Alarm Relay

    14. END OF DISCHARGE ALARM RELAY (EJ0143) WITH OPTIONAL LIGHT Purpose and Description: The EDA option provides a low-limit threshold voltage set at the lowest safe voltage to which the batteries may be discharged. The remote relay terminal connections may b used to operate a system load disconnect circuit by tripping a shunt trip DC load circuit breaker or opening a DC load contactor.

  • Page 26: Over-Temperature Alarm Relay

    18. OVER-TEMPERATURE ALARM RELAY WITH BUZZER (EJ0439) Purpose: The Over-Temperature Alarm provides an alarm indication whenever the battery charger internal components become overheated for any reason. A built-in audible alarm is furnished, along with alarm contacts at TB3 terminals 47, 48, 49. This feature is standard on battery chargers rated over 300A output current.

  • Page 27: Parts List - Mainframe

    SECTION VI 1. PARTS LIST - MAIN FRAME SINGLE PHASE SCR AND SCRF TYPE BATTERY CHARGER To order parts specify: 1) Battery Charger Model Number 2) Battery Charger Serial Number 3) Circuit Symbol and Quantity Desired Circuit Symbol refer to Schematic page 28 Note 1 Description...
  • Page 28 Circuit Symbol refer to Schematic page 28 Note 1 Description Manual Float/Equalize Switch Power Transformer AC Input Terminal Board DC Output Terminal Board Remote Alarm Terminal Board (Supplied A/R with alarm relay options) Internal + / - Signal Connection Terminal Board (Supplied A/R with customer options) TB15 Remote Alarm Terminal Board...

  • Page 29: Parts List - Options

    2. PARTS LIST - OPTIONS OPTIONS FOR SCR AND SCRF TYPE BATTERY CHARGERS To order parts specify: 1) Battery Charger Model Number 2) Battery Charger Serial Number 3) Circuit Symbol and Quantity Desired 4) Option Name and Number Option Ref. Circuit Number Page...
  • Page 30 Option Ref. Circuit Number Page Symbol Note 1 Description EJ0089 Positive Ground Det. Indicating Light Negative Ground Det. Indicating Light Voltage Dropping Resistor Voltage Dropping Resistor SW12 Test Switch EJ0093 Float/Equalize Switch Float Indicating Light Equalize Indicating Light EJ0094 Gnd. Det./Output Switch Gnd.
  • Page 31 Option Ref. Circuit Number Page Symbol Note 1 Description EJ0131 AC Failure Relay Switching Relay Auto Equalize Timer 0-72 Hour Time Delay Relay Timing Resistor Voltage Dropping Resistor CR52 Zener Diode SW11 Float Reset Switch Float Indicating Light Equalize Indicating Light EJ0133 Load Sharing Control PCB Load Sharing Signal Terminal Board...
  • Page 32 Option Ref. Circuit Number Page Symbol Note 1 Description EJ0143 End of Discharge Alarm PCB w/relay Sockt for A8 Voltage Dropping Resistor Voltage Dropping Resistor DS12 End of Discharge Indicating Light EJ0145 Heater Strip AC Input Circuit Breaker Thermostat Heater Strip Input Terminal Board TB14 Interface Terminal Board Heater Strip(s)

  • Page 59: Electrical Ratings And Replacement Parts - Mainframe

    ELECTRICAL RATINGS AND REPLACEMENT PARTS Single Phase SCR/SCRF Battery Chargers - Mainframe BATTERY CHARGER MODEL SCR/SCRF 12V 6A 12V 12A 12V 20A 12V 25A 24V 6A 24V 12A 24V 25A 24V 50A 24V 75A 120V 240V AC INPUT CURRENT (MAXIMUM) 480V SYMBOL DESCRIPTION C1/C2...
  • Page 60 ELECTRICAL RATINGS AND REPLACEMENT PARTS Single Phase SCR/SCRF Battery Chargers - Mainframe BATTERY CHARGER MODEL SCR/SCRF 24V 100A 48V 6A 48V 12A 48V 16A 48V 25A 48V 35A 48V 50A 48V 75A 48V 100A 120V 240V AC INPUT CURRENT (MAXIMUM) 480V SYMBOL DESCRIPTION FILTER CAPACITOR...
  • Page 61 ELECTRICAL RATINGS AND REPLACEMENT PARTS Single Phase SCR/SCRF Battery Chargers - Mainframe BATTERY CHARGER MODEL SCR/SCRF 130V 6A 130V 12A 130V 16A 130V 20A 130V 25A 130V 35A 130V 50A 260V 6A 260V 16A 120V 240V AC INPUT CURRENT (MAXIMUM) 480V 10.5 SYMBOL DESCRIPTION...

  • Page 63: Replacement Parts - Options

    REPLACEMENT PARTS Single Phase and Three Phase SCR/SCRF Battery Chargers − Options BATTERY CHARGER OUTPUT Vdc NOMINAL Option Circuit Number Symbol Description EJ0083 HLVA Alarm Control PC Board GK0045-01 (Specify dc voltage) Low Voltage Indicating Light RA0001-00 RA0001-01 RA0001-01 RA0001-01 RA0001-06 High Voltage Indicating Light RA0001-06...
  • Page 64 REPLACEMENT PARTS Single Phase and Three Phase SCR/SCRF Battery Chargers − Options BATTERY CHARGER OUTPUT Vdc NOMINAL Option Circuit Number Symbol Description EJ0120 Battery Discharging Alarm PC Board GK0052-01 GK0052-02 GK0052-05 GK0052-06 GK0052-07 DS10 Battery Discharging Alarm Indicating Light RA0001-00 RA0001-02 RA0001-02 RA0001-04...
  • Page 65 REPLACEMENT PARTS Single Phase and Three Phase SCR/SCRF Battery Chargers − Options BATTERY CHARGER OUTPUT Vdc NOMINAL Option Circuit Number Symbol Description EJ0134 AC Current Transformer 75 Aac max AT0057-01 AT0057-01 AT0057-01 AT0057-01 AT0057-01 100 Aac max AT0057-02 AT0057-02 AT0057-02 AT0057-02 AT0057-02 10 Aac max...
  • Page 66 REPLACEMENT PARTS Single Phase and Three Phase SCR/SCRF Battery Chargers − Options BATTERY CHARGER OUTPUT Vdc NOMINAL Option Circuit Number Symbol Description EJ0141 Common Alarm Buzzer RA0004-00 RA0004-00 RA0004-00 RA0004-00 RA0004-00 Common Alarm Relay RF0010-01 RF0010-03 RF0010-03 RF0010-06 RF0010-06 Ballast Resistor for AU1 RJ0015-46 RJ0035-48 Ballast Resistor for K8...
  • Page 67 REPLACEMENT PARTS Single Phase and Three Phase SCR/SCRF Battery Chargers − Options BATTERY CHARGER OUTPUT Vdc NOMINAL Option Circuit Number Symbol Description EJ0803 AC Failure Time Delay Relay (5 sec) RF0016-00 EJ0826 Temperature Compensation Series Resistor (Pb- RJ0062-90 RJ0063-57 RJ0064-00 RJ0064-46 RJ0076-77 Acid)
  • Page 72 …a World Class Organization …AN INDUSTRY LEADER IN 200W to 230kW STANDARD AND SPECIALTY DC POWER SYSTEMS Address: 1075 Saint John Street Easton, PA 18042-6661 Phone: 610-330-9000 Fax: 610-330-8510 Online: www.hindlepowerinc.com JA5009-00 - Rev. 09-2002 Printed in USA - 09-2002 ©2002 HindlePower, Inc.

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