CHLORIDE
Constant Potential
Battery Charger Handbook
Operating & Maintenance Manual
Project : Intel A9
Contract No. 20071214-E1”
“JOB NO.: SF2187”
Submitted by
CONTENTS
Section Page No.
Safety Precautions
1. Application... 1 2. General Principles ... 1 3. Brief Description of Charger... 1
3.1 Rectification - Regulation 3.2 Protection
3.3 Control and Signaling
4. Introduction ... 1 5. General Specifications ... 2 6. Installation... 3
6.1 Positioning 6.2 Connections
7. Operating Instruction / Commissioning Procedure... 4 7.1 Normal Operation (AC healthy)
7.2 AC Mains Fail
8. General Description of the CBC-4 Controller Board... 5 8.1 Operating Modes
8.2 Float - Boost 8.3 Control 8.4 Adjustment 8.5 Servicing
9. Brief Description on CBC-4 Controller - 901872 Series ... 5 9.1 Firing Circuit
9.2 Regulator Circuit 9.3 Boost Charge Circuit 9.4 Alarms
9.5 Voltage Programmed Module 9.6 LED Module
10. Control Card Adjustment ... 9 11. Voltage Detection Module Adjustment ... 10
11.1 Voltage Sensing Module (VS1)
12. Maintenance ... 11 12.1 General
12.2 Precautions 12.3 Fault Finding
13. Spare Parts... 12 14. Component Part Lists………... 13 Drawings
- CBC-4 Controller Block Diagram (901872D Series) - 9303007 - Schematic Diagram for CBC110/30Battery Charger - 280319
- Cabinet for CBC110/30 Battery Charger - 280320
SAFETY PRECAUTIONS
It is essential that all safety instructions are strictly observed.
Installation, maintenance and repair of the equipment and batteries should only be undertaken by qualified electrical personnel.
Use only insulated tools, particularly when connecting a battery. Personal metal belongings such as rings, watches & etc which may cause a short circuit should be removed.
Ensure the ac supply, battery supplies have been isolated before working on the equipment. NATURE OF HAZARD
Electrical energy can be supplied from the battery, the charging equipment or the AC supply. The battery terminals are LIVE at all times. A short circuit, even on a discharged battery, will result in a high current which can cause personal injury, fire or damage to the battery or battery cables.
Battery electrolyte in all batteries is dangerous and can cause severe burns if allowed to come into contact with the skin or eyes. It will also attack clothing, some paint finishes and metals. LEAD ACID batteries contain sulphuric acid solution. NICKEL CADIUM ALKALINE batteries contain potassium hydroxide solution. In SEALED cells, the electrolyte is absorbed in the plate/separator structure and cannot spill. Electrolyte contact is only possible if the cell container is broken. Vented or flooded cells contain electrolyte liquid which will spill if the cell is overturned, overfilled or the cell container is broken.
1. Application
The charger assembly, associated with a stationary storage battery, is intended for dc supply to various types of loads such as :-
* Switchgear Closing Tripping * Emergency Lighting
* Telecommunications
* Control and Monitoring Systems
* Microwave Links and Radio Installations * Fire and Security Systems
The use of a storage battery provides the system with an independent operating capability by supporting the load in the event of mains power failure.
2. General Principles
This standby power system is composed of 2 major sub-assemblies:
The Charger - supplied from the AC mains. It rectifies and controls the float and boost voltages for the battery.
The Battery - works as an energy tank to feed the load when the mains fails or charger breaks down. 3. Brief Description of Charger
3.1 Rectification - Regulation
* a main transformer to adapt the mains to the battery voltage.
* a half-controlled bridge, consisting of diodes and thyristors, rectifies and regulates the dc voltage.
* a smoothing circuit, consisting of electrolytic capacitor and choke (optional).
* a controller board consisting both a regulating section and an alarm section.A simplified block diagram of the controller board is as shown in Dwg. No. 9303007.
3.2 Protection
* ac input circuit breaker * dc output fuse
* freewheel diode which acts as reverse polarity protection 3.3 Control and Signalling
* ac input circuit breaker
* Led indications for monitoring.
* Meters for measuring voltage and current. 4. Introduction :
The Chloride CBC-4 series standby power system charger is built for both lead acid and nickel cadmium batteries. It offer a high degree of standarisation and reliability incorporating standard features which include:-
i) Full automatic operation, correctly designed for long battery life and simplified maintenance. ii) A ‘soft start’ feature which provides sufficient time for the current limit to operate on start up
even under short circuit conditions.
iii) Control cards are interchangeable ensuring continuous availability of spare parts.
The CBC-4 solid state constant potential charger is designed to float and boost charge nickel cadmium and lead acid (sealed and vented) batteries in nominal voltages of 12, 24, 30, 48 and 110 volts.
5. General Specifications :
Input : Voltage - See test report. Frequency - See test report.
Power Factor - Approximately 0.6 - 0.8.
Efficiency - Typically 70% - 80% at full load.
Output : Voltage - Nominal 12, 24, 30, 48 and 110 volts, which are determined by control card programme module.
Voltage Stability - Better than +0.5% of voltage setting for simultaneous excursion of +5% to -10% mains supply voltage.
Voltage Range - Float and boost voltages may be adjusted within any nominal voltage range by individual potentiometers on the control card.
Output Voltage Adjustment Range
Nominal Float Boost
Voltage Voltage Voltage
12V 11.8 - 18.7 14.2 - 18.7 24V 20.5 - 36.2 25.9 - 36.2 30V 24.1 - 43.4 30.8 - 43.4 48V 46.8 - 88.8 61.4 - 88.8 110V 75.2 - 145.4 99.7 - 145.4 Float-Boost
Selection - Automatic Boost indicated by red LED indicator. Current - See test report.
Current Stability - Output current held at preset level of +/-1% for simultaneous changes in mains input voltage of +5% too -10% and load variations from 0% to 100%.
Current Range - Adjustable from zero to 125% of full load current by potentiometer on control card.
Smoothing - Ripple voltage better than 5% rms to average at full load without battery.
Ambient Rating - Continuous full load operation up to 45 deg C ambient temperature.
Soft Start - A fast resetting soft start feature minimizes in inrush current surge both in turn-on and during intermittent mains interruptions. Standard Function Indicators - A.C. On Boost Low Electrolyte High Volts Low Volts Earth Fault Charge Fail Float Mains Fail
Summary Alarm relay contacts and rating -1 changeover set rated D.C. 100V, 1 amp. 30 watt resistive; AC 240V,1A.
6. Installation :
6.1 Positioning -
After the cabinet has been unpacked it should be inspected for damage in transit. Take note of cabinet paint condition, the voltmeter and ammeter faces, and internal connections, making sure that all leads and components are intact.
The unit should be installed in a clean, well ventilated room, meeting the climatic requirements of the specifications.
It must not be near a source of heat.
The ventilating louvers should not be obstructed and should have a side clearance of approximately 300mm from walls or other obstructions to allow normal air flow.
The cabinet can be attached to the floor, which must be flat, so as not to stress the framework (the cubicle must be levelled).
6.2 Connections -
6.2.1 External Protection :
The charger supply connections must be connected to the mains through an external protection device such as circuit breaker or isolator.
6.2.2 Preliminary Precautions:
Ensure all protection devices are in off position. 6.2.3 Connection:
Connect the mains to the charger AC input terminals. Ensure the earth connection is securely made.
Note : Input and Output voltages used in this system are HAZARDOUS. Do not use uninsulated tools
or touch uninsulated wires or terminals.
Battery is high current source, accidental short circuit can cause severe arcing, equipment damage, battery explosion and personal injury.
Ensure that the correct number of cells are interconnected and that the polarity is observed. A reverse polarity connection could damage the charger.
Battery - The battery positive lead should be connected to terminal B+ and the negative lead to terminal B-.
Load - When single pole load distribution circuit breakers are fitted the positive load connection should be made directly to the appropriate circuit breakers and the negative load connection to the negative terminal provided. When double pole distribution circuit breakers are fitted, the load connections should be made directly to the circuit breakers. If no distribution circuit breakers are fitted, the load connections should be made directly to the load terminal studs. It is important the leads from the charger to the load be of adequate cross section in order minimize the voltage drop in the line. All circuit breakers are fitted with auxilliary contacts to provide a common alarm in case of any circuit breaker trips.
Electrolyte
Sensing Probe - Remove the jumper wire located at the “Low E’lyte” terminal and connect the ‘Low E’lyte sensing’circuit cable to the brown wire (wire 41) terminal. The probe must be located in the most positive cell applicable to Nickel Cadmium batteries.
N O T E :
The C.B.C. charger is designed for use on an unearthed battery system and is fitted with an earth fault detector, which will operate on leakage currents from either positive or negative battery pole to earth of greater than 5m.a. Donot earth the battery.
If one side of the battery must be earthed the Earth Fault alarm circuit cannot be used and can be inhibited by disconnecting the connection between pin 33 of the control socket and the chassis earth connection.
7. Operating Instruction / Commissioning Procedure 7.1 Normal Operation (AC healthy)
1. Prior to connecting the battery as per section 6.2, the voltmeter indicated battery voltage.
2. Charge-fail and low volts alarm indicator will only illuminate when the battery voltage fall below its preset level .
3. Check for fault condition if exists.
4. Switch on the charger input circuit breaker and check that the A/C and boost indicators illuminate.
5. Within a few seconds, the charger ammeter will show an increasing current under the control of the soft start and rises to the full load current rating of the charger.
6. Close observation will show an increase in the battery voltage. The rate at which the voltage rises is dependent upon the state of charge of the battery. The battery charging current will start to fall as the battery voltage rises.
7. The charge fail and low volt alarm indicators are automatically reset when the battery voltage rises above its preset level.
8. The charger is charging the battery at maximum rate.
9. For fully charged battery, the voltage will rise towards the boost voltage setting within a short period. If this occurs, the charger will automatically revert to the float voltage mode after a predetermined time.
10. If the battery is in a discharged or partially discharged state, the voltage will gradually increase and the preset boost charge timer will continue the boost charge for the preset time after the voltage rises to 90% of the preset boost voltage settings.
11. At the end of the boost charge period the charger will revert to float voltage mode. 12. When the charger is operating in the float mode, the boost indicator is extinguished. 13. Provided that the charger performs in accordance with the above, the load may be
connected as detailed in section 6.2 and the remainder of the installation tested. 14. Load voltage are maintained within 110V +16%/-10% via the diode network.
7.2 AC Mains Fail
On Mains Fail, batteries will feed the load. Upon battery voltage being drops to their preset voltage level settings of VS1; the respective diodes will be bypassed to maintain the output voltage to 110V +16%/-10%.
8. General Description of the CBC-4 Controller Board 8.1 Operating modes
The Chloride C.B.C. series battery charger is designed to operate in two distinct modes :- (i) Constant potential mode
(ii) Constant current mode
Rapid changeover from mode (i) to mode (ii) is effected whenever the specified full load current is demanded. Mode (ii) can be maintained indefinitely even under short circuit conditions.
8.2 Float - Boost
Two output voltage levels, float and boost, are available and are selected by the solid state sensing circuit to ensure the battery is correctly charged. Boost charge is initiated upon restoration of mains supply or by low battery voltage.
8.3 Control
Regulation of the output is achieved by phase controlled switching of the thyristors fed by a step-down transformer connected to the mains. The switching signals are generated by the plug-in printed circuit board. Circuitry on the board senses the output voltage and current and varies the phase of the switching signal to maintain a constant output.
8.4 Adjustment
Three potentiometers on the control card enable the boost voltage, float voltage and full load current to be finely adjusted. Three additional potentiometers enable the alarm voltage settings for High Volts, Low Volts and Charge-fail to be adjusted. All these potentiometers are factory set and sealed and should not be adjusted without consultation with CHLORIDE BATTERIES S.E. Asia Pte Limited, otherwise the warranty of both the battery and charger may be rendered null and void.
8.5 Servicing
As the control printed circuit boards used in all CBC-4 series chargers are of identical circuitry, the number of spare parts and the expense of servicing are reduced to a minimum. CBC-4 series battery chargers are normally supplied adjusted and programmed during manufacture, details of which are provided on test report.
9. Brief Description on CBC-4 Controller - 901872 Series
The CBC-4 series of chargers afford constant voltage current limited charging of batteries.
The CBC-4 controller basically consists of control board, voltage module and 'LED' module. The control board and voltage programmed module are housed together.
Control Board
The control board contains both a regulating section and an alarm section. A simplified block diagram of the card is shown in Dwg. No. 9303007.
9.1 Firing Circuit
The purpose of this portion of the circuit is to provide phase controlled trigger pulses to the thyristors of the rectifer bridge, in response to the output from the regulator portion of the board.
The firing circuit comprises IC3 which produce a train of trigger pulses which are applied to the primary winding of the pulse transformer whose seocndary windings supply gate drive to the thyristors of the main rectifier via pins 4/6 & 9/11 of the controller board.
9.2 Regulator Circuit
The regulator circuit comprises a voltage regulating IC, and two current regulating IC's whose purpose is to override the voltage regulator in the event of excessive load being connected to the output of the charger. The excessive load will cause the charger output voltage to fall (back off).
The main CURRENT regulator is utilised as standard in all CBC-4 chargers whereas BATTERY CURRENT LIMIT (BCL) is used in only certain charging applications eg. small battery with large standing load.
In chargers not utilising BATTERY CURRENT LIMIT, the BCL setting potentiometer should be wound fully clockwise, prior to setting the CURRENT potentiometer.
The voltage and current amplifier outputs are compared; and the one having the highest output voltage will be in control of the firing circuit and hence the charger output.
Output voltage is set via the FLOAT and BOOST potentiometers which vary the feedback signal level. Switching from one charging mode to the other is achieved as outline in the BOOST CHARGE CIRCUIT.
Setting the CURRENT potentiometer positions the slider such that with rated output current flowing the current amplifier is on the verge of dictating control over the firing circuit ( and hence the output voltage.
9.3 Boost Charge Circuit
The two output voltage levels (i.e. float and boost) is controlled by the transistor. The transistor is turned on, the FLOAT potentiometer is bypassed and the BOOST potentiometer is in circuit. If the transistor is ‘off’ the FLOAT potentiometer is in circuit.
NB As these two potentiometers are in series, there is interaction between them. The BOOST potentiometer must be set first, followed by the FLOAT potentiometer, whose range of control has a maximum value equal to the actual BOOST potentiometer setting.
The standard CBC-4 mode of operation is for automatic initiation of a boost cycle with automatic return to float at the end of the cycle.
Boost charge is initiated by any of the following :- (i) Initial switching on the charger.
(ii) Restoration of mains to the charger after an outage.
(iii) Battery falling below approximately 90% of the float voltage setting - due, for example, to application of a load in excess of the charger output rating.
Boost cycle will terminate in accordance with the following:
i) With only ‘long time’ switched in (i.e. only DIP Switch 3 or 4 closed)
Boost will terminate a preset number of hours after the battery voltage reaches 90% of the Boost potentiometer setting.
ii) With ‘long time’ and ‘short time’ switched in (i.e. DIP Switch 3 or 4, plus Switch 5) Boost will terminate approximately 40 minutes after initiation, if battery voltage has reached 90% of the set BOOST level.
If battery voltage has not reached this 90% level at the end of 40 minutes, the boost mode will continue. When the 90% level is reached, the ‘long time’ cycle will be initiated. At the end of this time interval the system will return to float mode.
Boost Timer Options DIP SW HOURS 1 1 2 2 3 4 4 8 5 * 40 mins Test Points
TP1, TP2, TP3 - Test points to enable various operations to be checked. Shorting TP1 & TP2 forces charger from BOOST to FLOAT.
Shorting TP2 & TP3 forces charger from FLOAT to BOOST.
TP4, TP5 - Test points which when shorted speed up the clock pulse generator enabling the timed circuit to cycle in seconds.
Charge Mode Options
The description above apply where the charger is placed in auto mode. There are two other options; namely -
i) Boost Inhibited Charger
Where only single voltage charging is required - usually at the battery manufacturers recommended FLOAT voltage level, controller pins 18, 21 & 22 are bridged permanently on the edge connector.
This forces the charger to be permanently in float position. ii) Manual Boost Initiation
A NO spring return switch is connected between controller pins 18 & 20.
Momentary closure of this switch forces the charger to go into boost charge state.
A timed BOOST cycle will follow in accordance with timer switch settings and time taken for battery to reach the 90% setpoint - as detailed above.
At the end of this cycle, normal auto-boost charger operation is resumed.
9.4 Alarms
The alarm relay “AR” is driven by each of the following alarms: High Volts
Low Volts Charge Fail Earth Fault Low Electrolyte
Two sets of voltage free changeover contacts are brought out at pins 35 - 40, the relay being energised in the event of an alarm i.e. the contacts change state in the event of an alarm.
In latching alarm / manual reset units, reset is achieved via a normally opened pushbutton switch connected between pins 42 & 43. Closing this switch will reset the alarm when the charger is operating mode.
a) High Volts Alarm
The battery feedback voltage is compared with a portion of the reference voltage. When battery voltage exceeds the set point voltage, the output of the high volts IC will go high, lighting the HIGH VOLTS LED and energises the alarm relay.
The alarm is automatic resetting upon reduction of battery voltage to below the set point, but can be converted to latching/manual reset by bridging link J5.
b) Low Volts Alarm
The battery feedback voltage is compared with a portion of the reference voltage. When the battery voltage falls to the set point voltage, the output of the low volts IC will go high, lighing the LOW VOLTS LED and energises the alarm relay.
The alarm is automatic resetting upon battery voltage rising to above the set point, but can be converted to latching/manual reset by bridging link J6.
c) Charge Fail Alarm
The battery feedback voltage is compared with a portion of the reference voltage. When the battery voltage falls to the set point voltage, the output of the charge fail IC to go high, lighting the CHARGE FAIL LED & energises the alarm relay.
The alarm is automatic resetting upon battery voltage rising to above the set point, but can be converted to latching/manual reset by bridging link J7.
d) Earth Fault Alarm
No leakage from either battery pole the input to the comparator will remain low, the output will be low and the earth fault led is inhibited.
Earth leakage currents from either pole to ground will result in an imbalance and the output of the comparator will go high, illuminating the EARTH FAULT LED & energises the alarm relay.
The alarm is automatic resetting upon removal of a fault, but can be made latching/manual reset by bridging link J8.
The alarm is automatic resetting upon battery voltage rising to above the set point, but can be converted to latching/manual reset by bridging link J6.
e) Low Electrolyte Alarm
NB Electolyte level detection is not applicable to Sealed Lead Acid Batteries.
This alarm is for use in conjunction with a suitable conducting probe fitted into the electrolyte of the MOST POSITIVE CELL only, of the battery. The probe will provide a signal until such time as the electrolyte level drops and the probe fails to make contact; LOW ELECTROLYTE LED illuminating and the alarm relay energises.
The circuit is automatic resetting upon rectification of the problem. It does not have a latching facility as per the other alarms, as the nature of the feature is such that it requires manual correcting once a problem has occurred.
For charger not requiring this alarm, edge connector pin 41 is permanently connected to charger ‘positive’; forcing the circuit into a ‘healthy’ state.
In installations using this alarm, the length of cable between charger positive output terminal and the battery positive terminal should be such that when the maximum charging current is passing through it the cable voltage drop does not exceed 0.5V.
This voltage is in series with the probe voltage and, if excessive, will cause the alarm to turn on.
Note: Before connection of the probe wire to the pin 41 of the control board, switch on the incoming supplies and battery circuit breaker (if included), then remove the link wire between pin 41 and positive terminal and connect the probe wire to pine 41. 9.5 Voltage Programmed Module
The voltage module houses the resistor network for the correct operating voltage. 9.6 LED Module
It provide standard alarm indication from the CBC-4 controller board.
10. Control Card Adjustments
Before making any adjustments to the Control Card, please refer to the test certificate to obtain the precise voltage and current settings specified for the unit supplied.
Adjustment Procedure Boost Voltage
(1) Close mains circuit breaker. (2) Boost 'LED' should illuminate.
(3) Adjust the boost potentiometer clockwise until the voltmeter indicate the specified boost voltage level.
Float Voltage
(4) Momentarily, short TP1 and TP2 on CBC-4 Controller Card or turn the Boost/Float selector switch to float position.
(5) Float ‘LED’ should illuminate.
(6) Adjust the Float potentiometer clockwise until the voltmeter indicate the specified float voltage level.
Adjustment Procedure For Current Limit (1) Open mains circuit breaker.
(2) Disconnect both battery and external load.
(3) Turn the current potentiometers on the control card fully anti-clockwise.
(4) Connect a resistive load across the B+ and B- terminals sized to the full rated current. (5) Close mains circuit breaker. Both ammeter and voltmeter read zero.
(6) Wait at least 15 seconds for the soft start to clear.
(7) Slowly adjust the current potentiometer in a clockwise direction until the ammeter indicate the specified full-load current.
(8) Open mains circuit breaker. (9) Disconnect the resistive load.
Alarm Voltage Settings Low Voltage Alarm
(1) Turn the selector switch to float position or momentarily short TP1 and TP2 on CBC-4 Controller Card.
(2) Float ‘LED’ should illuminate.
(3) Adjust the 'Low V' potentiometer fully anti-clockwise.
(4) Adjust the float potentiometer on the charger control card to the low volts alarm level. (5) Slowly adjust the 'Low V' potentiometer clockwise until the 'LOW VOLT' LED just
start to illuminate. Charge-fail Alarm
(1) Adjust the 'CHG FAIL' potentiometer fully anti-clockwise.
(2) Adjust the float potentiometer on the charger control card to the charge fail alarm level.
(3) Slowly adjust the 'CHG FAIL' potentiometer clockwise until the 'CHG FAIL' LED just start to illuminate.
High Volt Alarm
(1) Turn the selector switch to boost position or momentarily short TP2 and TP3 on CBC-4 Controller Card.
(2) Boost 'LED' should illuminate.
(3) Adjust the 'HIGH V' potentiometer fully clockwise.
(4) Adjust the boost potentiometer on the charger control card to the high volts alarm level.
(5) Slowly adjust the 'HIGH V' potentiometer in anti-clockwise until the 'High Volt' LED just start to illuminate.
Earth Fault Alarm
Adjust the 'EF Sen' potentiometer to mid range. The earth fault alarm is activated when either the positive or negative rail is shorted directly to earth or greater than 5mA.
N O T E :
The following potentiometer are optional and are not applicable to this system.
a. HI V CUT
b. LO V CUT
c. BCL
d. THRESH
11. Voltage Detection Module Adjustment 11.1 Voltage Sensing Module (VS1)
(1) Momentarily short TP1 and TP2 to force the charger to float mode.
(2) Adjust VR1 potentiometers on the voltage detection modules fully anticlockwise. The LED on voltage detection modules are inhibited.
(3) Adjust the float potentiometer on the CBC-4 Controller to their respective voltage settings. (4) Slowly adjust the VR1 potentiometer on the voltage detection module until the LED on the
12. Maintenance: 12.1 General
As solid-state and integrated circuitry is used, maintenance is reduced to a minimum. To obviate delays in repairs should a fault occur, it is recommended that a spare control card be kept in stock. When ordering it is essential that the full specifications shown on Page 1 be provided so that all adjustments can be effected in our factory prior to despatch.
12.2 Precautions
The CBC-4 series charger will only function correctly if connected to a battery or a simulated battery made up of a large capacitance and a parallel load resistance.
A load resistor drawing about 1 amp at the nominal voltage of the unit would be suitable. 12.3 Fault Finding
The following table is a list of possible fault conditions observed when the charger is connected to a battery and with any other load disconnected.
SYMPTOM POSSIBLE FAULT ACTION
Full load output current.
No fault. The battery is discharged and charger is functioning
correctly.
No action required.
LOW BATTERY VOLTAGE
Less than full load output current.
Fault indicator on
(a) Power circuit faulty. Check :-
(a) Mains circuit breaker. (b) Transformer secondary.
voltage.(Approx. double nominal D.C. output voltage.)
(c) Control card supply voltage at pins 14 & 15 of connector plug (42 V.A.C).
(d) For broken connections.
particularly those to control card connector.
(b) Control card out of adjustment.
(e) Perform the adjustment procedures in section 10. (c) Control card faulty. (f) Replace control card.
Fit correct voltage programme module.
Perform adjustment procedure in section 10.
(d) Faulty thyristor bridge. (g) If current still zero replace thyristor bridge.
SYMPTOM POSSIBLE FAULT ACTION
HIGH
Output current over full scale.
Fault indicator on
Faulty thyristor bridge. Remove control card.
If no change in output current replace thyristor bridge. If current is zero, control card is out of adjustment or faulty. Loss of current feedback signal, check ammeter to control card.
BATTERY
Current at or below full load output level.
(a) Control card out of adjustment.
Perform the adjustment procedure in section 10.
VOLTAGE
Fault indicator on (b) Control card faulty. Replace card. Fit correct voltage
programme module. Perform adjustment procedure in section 10.
(c) Sensing leads open circuited.
If above checks do not eliminate fault, test continuity of sensing leads from pins 16, 17 and 44 of control card connector.
Fault indicator on Cell electrolyte level low. Top up cells with distilled water.
LOW ELECTRO- LYTE ALARM Charge-fail indicator on.
Electrolyte level probe not correctly positioned in appropriate cell. Connecting cable disconnected.
Reposition probe and check connections.
EARTH FAULT ALARM
Fault indicator on Earth leak connection to either
D.C. line, either inside charger or on external load or cabling.
Disconnect load to determine if earth fault is internal or external. Do not use a megger to test charger for earth faults. Check visually or use an ohmmeter.
Fault indicator on Loss of A.C. supply. Check A.C. supply to charger and input
circuit breaker.
CHARGE- Charger output fuse blown. Replace fuse cartridge.
Faulty thyristor bridge. Replace thyristor bridge.
FAIL Control card out of adjustment. Perform adjustment procedures in section
10.
ALARM Control card faulty. Replace card. Perform adjustment
procedure in section 10.
Broken connections. Check connections and correct.
Fault indication cannot be canceled or fault located.
Control card faulty. Replace control card.
13. Spart Parts:-
To order spare parts it is necessary to nominate the item and the serial no. of the charger on which the part is to be used and addressed to :
SERVICE DEPARTMENT
Chloride Batteries S.E.Asia Pte Limited 106 Neythal Road, Jurong
Singapore 628594 Tel : 6265-2444
14.
COMPONENT PART LIST
S/NO PART DESCRIPTION TYPE BRAND/SUPPLIER CIRCUIT REF.
1. Charger Cabinet H1590 x W600 x D520mm Chloride -
2. Surge Suppresor 14K 431 - SS-1
3. Bridge Rectifier SKKH 92/08 Zenli BR1
4. Freewheel Diode MD110A 120 HJS D1
5. Dropping Diode MDC 100/08 Zenli D2-D6
6. Diode Link - - -
7. Controller Board CBC-4 PCB Chloride -
8. Voltage Module 110VDC Chloride -
9. Voltage Detection Module 110VDC Chloride VS1
10. Resistor/Diode Matrix Board - Chloride RB1
11. Led Module Rev. 4A Chloride -
12. Heatsink For Bridge Rectifier P3 200mm Chloride -
13. Heatsink For Dropping Diode P3 200mm Chloride -
14. Mains Fail Relay MY2 220/240VAC RE-208AL Goodsky MF
15. Charger Output Fuse gG40A 14x51mm Df F1
16. DC Control Fuse gG2A 10x38mm Jasco F2
17. DC Control Fuse gG6A 10x38mm Jasco F3
18. Load Fuse gG50A 14x51mm Df F4
19. Fuse Holder PMF 14x51mm Df -
20. Fuse Holder RT18-32X 32A Jasco -
21. AC Input Circuit Breaker Multi 9 C60N D63 SP Merlin Gerin CB1
22. Battery Circuit Breaker Multi 9 C60N D63 DP Merlin Gerin CB2
23. Load Circuit Breaker Multi 9 C60N D6 DP Merlin Gerin CB3-CB7
24. Transformer Input: 220VAC Output: 110/30 L Chloride TFR
25. DC Voltmeter 2094 200VDC Yokogawa M1
26. DC Ammeter 2094 40ADC 60mV Yokogawa M2
27. DC Output Voltmeter 2094 200VDC Yokogawa M3
28. Edge Connector MP-0156-44-SP-1K - -
29. Shunt 40A 60mV - SH
30. AC Input Terminal Block UK10N Phoenix Contact -
31. DC Output Terminal Block IN60 Mack -
32. Alarm Terminal Block UK5N Phoenix Contact -
33. MF Terminal Block UK5N Phoenix Contact -
34. Low Electrolyte Terminal Block UK5N Phoenix Contact -
35. Load Terminal UK10N Phoenix Contact -
36. End Bracket Clipfix 35 Phoenix Contact -
37. Isolation Partition ATP UK Phoenix Contact -
38. End Plate D-UK 4/10 Phoenix Contact -
39. Capacitor 22,000uF 200V Nippon CAP
40. Boost/Auto/Float Sel. Switch ASW 0323 c/w HWC10x3 Idec BAF
41. Inductor 2mH 30A Chloride L
42. DC Contactor SW80B-1437-883 125V Albright C1
43. Transducer M100-DV21 Aux: Supply: 120V
I/P: 0-200VDC O/P: 4-20mA