Model A45e Battery Charger

Transcript

MODEL A45E INSTRUCTION MANUAL MODEL A45E BATTERY CHARGER CPN35921 ECN/DATE 14575 – 2/01 14268 – 10/00 15349-10 – 8/02 106 BRADROCK DRIVE DES PLAINES, IL. 60018-1967 (847) 299-1188 FAX: (847) 299-3061 ISSUE DATE: 10378 – 9/96 INSTRUCTION DRAWING NUMBER: LA45E-1 P25- Page 1 of 12 MODEL A45E INSTRUCTION MANUAL IMPORTANT SAFETY INSTRUCTIONS FOR THE LA MARCHE POWER CONVERSION EQUIPMENT SAVE THESE INSTRUCTIONS This manual contains important safety and operating instructions for the La Marche Power Conversion Equipment. Before using this equipment, read all instructions and cautionary markings on (1) unit, (2) battery, and (3) product using the battery. CAUTION: To reduce risk of injury and/or damage to the batteries, use only the type of batteries specified on the charger. Do not expose equipment to rain or snow. Do not operate equipment if it has received a sharp blow, been dropped, or otherwise damaged in any way; take it to a qualified serviceman. Do not disassemble this unit; take it to a qualified serviceman when service or repair is required. Incorrect re-assembly may result in a risk of electric shock or fire. To reduce risk of electric shock, disconnect this unit from the a.c. supply, or batteries and loads before attempting any maintenance or cleaning. Turning off controls will not reduce this risk. WARNING – THERE IS A RISK OF EXPLOSIVE GASSES AND WORKING IN THE VICINITY OF A BATTERY IS DANGEROUS. SOME BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE USING THIS UNIT, YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY. To reduce risk of battery explosion, follow these instructions and those published by the battery manufacturer and manufacturer of any equipment you intend to use in the vicinity of the battery. Review cautionary marking on all products. PERSONAL PRECAUTIONS: 1. Someone should be within range of your voice or close enough to come to your aid when you work near a battery. 2. Have plenty of fresh water and soap nearby in case the battery electrolyte contacts skin, clothing, or eyes. 3. Wear complete eye protection and clothing protection. Avoid touching eyes while working near a battery. 4. If the battery electrolyte contacts skin or clothing, wash immediately with soap and water. If the electrolyte enters the eye, immediately flood the eye with running cold water for at least ten (10) minutes and get medical attention immediately. 5. Never smoke or allow a spark or flame in vicinity of a battery. 6. Be extra cautious to reduce risk of dropping a metal tool onto a battery. It might spark or short circuit the battery or other electric part that may cause an explosion. 7. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a battery. A battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing a severe burn. 8. NEVER charge a frozen battery. Page 2 of 12 MODEL A45E INSTRUCTION MANUAL PREPARING TO CHARGE 1. If necessary to remove the battery connections, always remove grounded terminal from the battery first. Make sure all loads are disconnected and unit is off, so as not to cause an arc. 2. Be sure the area around the battery is well ventilated while the battery is being charged. 3. When cleaning battery terminals, be careful to keep corrosion from coming in contact with eyes. 4. Study all the battery manufacturer’s specific precautions such as removing or not removing cell caps while charging, recommended rates of charge, and maintenance procedures. UNIT LOCATION • Never place this unit directly above the battery. Gases from the battery will corrode and damage equipment. A sealed maintenance free or valve regulated lead acid (VRLA) may be placed below this equipment. • Never allow the battery electrolyte to drip on this unit when reading the specific gravity or filling the battery. • Do not operate this unit in a closed-in area or restrict ventilation in any way. • Do not set a battery on top of this unit. D.C. CONNECTION PRECAUTIONS Connect and disconnect d.c. output cables only after setting all of this unit's switches to off position and removing a.c. input supply. GROUNDING INSTRUCTIONS This battery charger should be connected to a grounded, metal, permanent wiring system; or an equipment grounding conductor should be run with circuit conductors and connected to equipmentgrounding terminal or lead on battery charger. Connections to battery should comply with all local codes and ordinances. CAUTION: DO NOT PULL ON OUTPUT CABLES WHEN DISCONNECTING CHARGER FROM BATTERY. Page 3 of 12 MODEL A45E INSTRUCTION MANUAL RECEIVING INSTRUCTIONS AND GENERAL EQUIPMENT INFORMATION CAUTION: To ensure safe installation and operation, the information given in the instruction manual should be read and understood before installing or using the equipment. RECEIVING INSTRUCTIONS Unpacking and Inspection: Examine the shipping crate upon arrival. If there is obvious damage, describe on the receiving documents. Within a few days after delivery, the equipment should be uncrated and carefully inspected for hidden damages. When removing packaging material, be careful not to discard any equipment, parts, or manuals. If any damage is detected you should: 1. File a claim with the carrier within five (5) days. 2. Send a copy of the claim to La Marche Mfg. Co. 3. Call La Marche Mfg. For a RETURN MATERIAL AUTHORIZATION NUMBER. Failure to properly file a claim for shipping damages, or provide a copy of the claim to La Marche Mfg., may void warranty service for any physical damages reported for repair. HANDLING WARNING: Equipment can be very heavy, and top-heavy. Use adequate manpower or equipment for handling. Until the equipment is securely mounted, care must be used to prevent the equipment from being accidentally tipped over. NOMENCLATURE PLATES Each piece of La Marche Mfg. Equipment shipped is identified by part number on the nomenclature plate. ADJUSTMENTS All equipment is shipped from the factory fully checked and adjusted. Do not make any adjustments unless the equipment has been powered-up and the settings have been determined to be incorrect. SPARE PARTS To minimize downtime during installation or normal service, it is advisable to purchase spare fuses, circuit boards and other recommended components. Please refer to the list of recommended spare parts and their La Marche Mfg. Part numbers included with the instruction manual. It is recommended that spare fuses be ordered for all systems. To order spare parts, please contact La Marche Mfg. (847)-299-1188 during business hours and ask for the Parts Department. Page 4 of 12 MODEL A45E INSTRUCTION MANUAL MODEL A45E BATTERY CHARGER The Model A45E is a microprocessor controlled industrial battery charger for use on forklift and electric vehicle batteries. It is designed to recharge a battery of the proper amp-hour capacity in eight hours. The Model A45E features: ™ Microprocessor based control ™ Automatic start/stop circuitry ™ Automatic Sensing of Fully-Charged Battery ™ Automatic 12 hour override timer ™ 3 Hour timing after 80% (normal mode) ™ 6 Hour timing after 80% (equalize mode) ™ DI/DT rate of change sensing ™ High d.c. output shutdown ™ Low a.c. voltage shutdown ™ Digital Display - Indicates amps, volts, amp hours, elapsed time ™ “On Charge”, “80%/Complete”, “Equalize”, and “Failure” lamps ™ 208/240/480 Volt input. (Certain units 120 volts on request) Page 5 of 12 MODEL A45E INSTRUCTION MANUAL INSTALLATION INFORMATION Figure 1 lists the a.c. input and the d.c. output minimum wire size requirements. At distances exceeding 10 feet, the d.c. wire size should be chosen to keep the voltage difference between the units d.c. output terminals and the battery at less than ½ volt when the unit is fully loaded. ELECTRICAL CONNECTIONS & FIELD WIRING An a.c. input fuse block is provided for connecting the a.c. input. A ground wire must be connected to the units’ case ground. A.C. INPUT A fuse block is provided within the unit for a.c. input connections. Before connecting the a.c. input cable, check the line power with the internal a.c. voltage connections, if necessary change the a.c. jumper connections to match the a.c. input. Refer to schematic drawing included in manual or tap jumper card inside door panel. D.C. OUTPUT NOTE: MOST UNITS HAVE D.C. OUTPUT CABLES WHEN ORDERED. Make sure that the battery which is being connected to the battery charger matches the cell type and number of cells that is marked on the charger nameplate. ***OBSERVE PROPER POLARITY!*** The negative wire from the battery must be connected to a terminal marked “NEGATIVE” or “NEG” and the positive wire from the battery must be connected to the terminal marked “POSITIVE” or “POS” on the battery charger. OPERATION START UP (Electronic Timer) After the installation has been completed, the unit is ready for operation. Be sure that the battery charger is the correct type for the battery that is to be charged. CAREFULLY READ AND ADHERE TO ALL BATTERY AND BATTERY CHARGER INSTRUCTIONS AND SAFETY WARNINGS. A. With the a.c. input connected to the charger, turn the on/off switch to the “on” position. B. Connect the battery to the charger. After a 5 second delay, which assures proper battery connection, the input contactor will close. The battery charger will start to charge and the “ON CHARGE” light will turn on. This completes the “Autostart” sequence. The display will read, OUTPUT AMPS, push the select switch down once and the display will read D.C. VOLTAGE, a second push the display will read AMP/HOURS RETURNED and a third push the display will read ELAPSED TIME. Push the select switch UP and the unit will equalize the battery. C. When the “80% CHARGE” point is reached in the charge cycle, the “80%” light will turn on and a three (3) hour timer will start. (If in the equalize mode, the unit will operate for six (6) hours after 80% light turns on.) Page 6 of 12 MODEL A45E INSTRUCTION MANUAL NOTE: THE EQUALIZE SWITCH CAN ALSO BE USED TO START THE CHARGER EVEN IF A BATTERY IS DISCHARGED BELOW 1.6 Vpc. CAUTION MUST BE USED WHEN USING THIS FEATURE TO START THE CHARGER BECAUSE THE INITIAL BATTERY VOLTAGE SENSING IS BEING DISABLED AND THE WRONG BATTERY MAY BE CONNECTED. D. When the charge cycle is complete, normally 6 to 8 hours, the charge “COMPLETE” light will turn on. E. If for some reason the a.c. input voltage fails, the battery charger will turn off. During this interval the time registers in the auto timer is held at the present count. When the a.c. has returned to normal, the charge cycle resumes where it left off. CAUTION: Turn the on/off switch to the “off” position when disconnecting the battery during the charge cycle to prevent arcing at the d.c. connector. F. Fault Codes - Code Code Code Code Code Code Code 1 2 3 4 5 6 7 - Low or no a.c. input voltage N/A Wrong size battery 12 Hour overrides timer N/A Possible shorted cells Fully charged battery when connected to charger G. If the A45E has been programmed for a start delay, the digital display will alternate between time remaining and “IDLY”. After the delay is finished the unit will start and charge the battery. DIPSWITCH SETTINGS FOR START DELAY: (ARE LOCATED ON THE S2A-191-XXXX P.C.B.) HOUR 0 1 2 4 8 12 16 24 X = ON S1 X O X O X O X O S2 X X O O X X O O S3 X X X X O O O O O = OFF Page 7 of 12 MODEL A45E INSTRUCTION MANUAL FIGURE 1 Page 8 of 12 MODEL A45E INSTRUCTION MANUAL THEORY & ADJUSTMENTS CAREFULLY READ AND ADHERE TO ALL BATTERY AND BATTERY CHARGER INSTRUCTIONS AND SAFETY WARNINGS. To operate the charger, it is only necessary to turn on the on/off switch and connect a battery. After the on/off switch is placed in the “on” position and prior to the battery connection, all of the LED’s on the front panel will flash until a battery is connected. This is the lamp test mode. When the battery is finally connected, the “ON CHARGE” lamp will light and the digital display will indicate an increase in output current. The charger will automatically start to charge the battery at some rate up to its maximum capacity depending upon the state of charge of the battery. A saturable reactor regulator controls the charge rate so that the charger puts out near maximum output current down to a trickle charge on a taper curve as the battery comes up to full charge. The charger’s battery EMF sensing circuit continuously samples the battery voltage during the complete charge cycle and controls the saturation of the reactor which in turn controls the power output of the charger. The charger provides automatic power line compensation. This eliminates the need for adjusting taps to match the input line voltage. The automatic compensation also eliminates charging problems that arise from a varying line when charging continually day and night or for two or three shift operations. The unit is self protecting when subjected to abnormal overloading conditions. The current limiting feature limits the output current to not more than 130% of the output rating of the charger. The charger is factory tested and preset such that no field adjustments are necessary. If field adjustments must be made, the taper and shutdown point may be adjusted. This adjustment may be made by moving the red slider band on the voltage reference variable resistor RV1. Moving the slider band toward the series connected resistor RV2 raises the shut down point which allows the battery voltage to rise to a higher point before shutting down to a trickle charge. Moving the red slider band away from the series connected RV2, lowers the shutdown point. It should not be necessary to make any adjustments to this charger and should any adjustments be necessary, extreme care should be taken in making the adjustment. An accurate d.c. voltmeter should be used and the d.c. voltage at the charger and battery terminals should be measured. The battery voltage should not exceed 2.50 volts per cell on a fully charged battery. Settings above this point may cause excessive (gassing) use of water and battery heating. Because of the stability of design, the unit needs no periodic adjustment. This along with the rugged construction and conservation rated components, a insure long life and trouble free operation. Page 9 of 12 MODEL A45E INSTRUCTION MANUAL TROUBLESHOOTING Before troubleshooting unit, check for shipping damage, i.e. broken wires, loose connections, etc. Quick-Check A45E Trouble Analysis Problem: Open a.c. input fuse Problem: Open d.c. fuse Problem: Open control transformer Problem: Charger finish rate , too low fuse CTF1 or too high. 1. Check a.c. tap setting diagram and a.c. input voltage. 2. Check input and output voltage of control transformer. NOTE: Voltage across secondary of control transformer X1 - X2 = 120Vac; X3 - X4 = 11Vac; X5 - X6 = 11Vac; X3 - X6 = 22Vac. 3. Check shorted power diode. 1. Check polarity of output cables and connector. 2. Check shorted power diode. 4. Connectors at d.c. fuse and shunt. 1. Check defective contactor (shorted coil). 2. Check control taps set wrong. 3. Check for defective control transformer. Check setting on control panel (AC1). - If field adjustments must be made, the taper and shutdown point may be adjusted. This adjustment may be made by moving the red slider band on the voltage reference variable resistor RV1. Moving this slider band toward the series connected resistor RV2 raises the shut down or finish rate which allows the battery voltage to rise to a higher point before shutting down to a trickle charge. Moving the red slider band away from the series connected RV2, lowers the shut down point. Extreme care should be taken in making the adjustment. An accurate d.c. voltmeter should be used and the d.c. voltage at the charger and battery terminals should be measured. The battery voltage should not exceed 2.50 volts per cell on a fully charged battery. Settings above this point may cause excessive (gassing) use of water and battery heating. A.) Check for defective control panel (AC1). 1. Red slider band must be connected to wires on resistor; with volt-ohmmeter, check continuity of resistor. 2. To Check control panel, disconnect the blue and black wires going to Terminal #1 on control panel; Page 10 of 12 MODEL A45E INSTRUCTION MANUAL connect the two (2) wires together, but do not reconnect to panel. Connect battery and turn on unit. If charger goes into high rate, the control panel is defective. B.) Check control relay, To check cutout relay, turn unit on and measure the voltage from pin one on the control panel to the positive output terminal of the battery charger. If zero d.c. voltage is measured, the relay is defective. NOTE: IF A.C. CONTACTOR DOES NOT PULL IN WHEN BATTERY IS CONNECTED, JUMP TERMINALS 1 & 3 ON TERMINAL J2 ON S2A-191 P.C.B. Problem: Failure light on CODE 0001 Problem: Failure light on CODE 0003 Problem: Failure light on CODE 0004 1. Check a.c. input voltage. 2. Check a.c. input fuses. • 1. Check battery for correct number of cells. 2. Check for defective or shorted cells in battery. 3. Open circuit battery voltage must be above 1.6V.p.c.. 1. Check battery for defective or shorted cells. 2. S2A-122A “p.c.” board may be defective. • Problem: Failure light CODE 0006 CODE 0002 - Not used CODE 0005 - Not used 1. Check for defective or shorted cells in battery. 2. Check finish rate of charger. Note: To make contactor pull in, jump terminals 1 & 3 on S2A-191 printed circuit board. Problem: CODE 0007 This is NOT a failure or problem, but when illuminated indicates a fully charged battery was connected to the charger. OPTIONAL ACCESSORIES 10D = JIC Switch - A.C. fused disconnect switch. 14B = Emergency Stop Button - For emergency charger shutdown. Sequence Control - The sequence control allows charging of 2 or 3 batteries. After the first battery plugged in completes its charge, the sequence control will automatically start to charge the second battery. A circuit light indicates which battery is charging. For sequence operation the DIPswitch “S8” must be on. 191* = Two-Position Sequencing Circuit - For charging two batteries unattended. 192* = Three-Position Sequencing Circuit - For charging three batteries unattended. This option is only available for Type 1 models. Page 11 of 12 MODEL A45E INSTRUCTION MANUAL MANUFACTURER’S WARRANTY All La Marche Manufacturing Co. equipment has been thoroughly tested and found to be in proper operating condition upon shipment from the factory and is warranted to be free from any defect in workmanship and material that may develop within one year from date of purchase. In addition to the standard one (1) year warranty, La Marche warrants it’s magnetics and power diodes on a parts replacement basis only for nine (9) more years under normal use. Any part or parts of the equipment (except fuses, d.c. connectors and other wear-related items) that prove defective within a one (1) year period shall be replaced without charge providing such defect, in our opinion, is due to faulty material or workmanship and not caused by tampering, abuse, misapplication or improper installation. Magnetics and power diodes are warranted for ten (10) years after date of purchase. During the last nine (9) years of this ten (10) year warranty period, the warranty covers parts replacement only, no labor or other services are provided by La Marche, nor is La Marche obligated to reimburse the owner or any other person for work performed. Should a piece of equipment require major component replacement or repair during the first year of the warranty period, these can be handled in one of two ways: 1. The equipment can be returned to the La Marche factory to have the inspections, parts replacements and testing performed by factory personnel. Should it be necessary to return a piece of equipment or parts to the factory, the customer or sales representative must obtain authorization from the factory. If upon inspection at the factory, the defect was due to faulty material or workmanship, all repairs will be made at no cost to the customer during the first year. Transportation charges or duties shall be borne by purchaser. 2. If the purchaser elects not to return the equipment to the factory and wishes a factory service representative to make adjustments and/or repairs at the equipment location, La Marche's field service labor rates will apply. A purchase order to cover the labor and transportation cost is required prior to the deployment of the service representative. In accepting delivery of the equipment, the purchaser assumes full responsibility for proper installation, installation adjustments and service arrangements. Should minor adjustments be required, the local La Marche sales representative should be contacted to provide this service only. All sales are final. Only standard LaMarche units will be considered for return. A 25% restocking fee is charged when return is factory authorized. Special units are not returnable. In no event shall La Marche Manufacturing Co. have any liability for consequential damages, or loss, damage or expense directly or indirectly arising from the use of the products, or any inability to use them either separately or in combination with other equipment or materials, or from any other cause. In addition, any alterations of equipment made by anyone other than La Marche Manufacturing Co. renders this warranty null and void. La Marche Manufacturing Co. reserves the right to make revisions in current production of equipment, and assumes no obligation to incorporate these revisions in earlier models. The failure of La Marche Manufacturing Co. to object to provisions contained in customers' purchase orders or other communications shall not be deemed a waiver of the terms or conditions hereof, nor acceptance of such provisions. The above warranty is exclusive, supersedes and is in lieu of all other warranties, expressed or implied, including any implied warranty of merchantability or fitness. No person, agent or dealer is authorized to give any warranties on behalf of the Manufacturer, nor to assume for the Manufacturer any other liability in connection with any of its products unless made in writing and signed by an official of the manufacturer. Page 12 of 12