Operations Manual

DIGITAL CHARGER DCR SERIES

DCR-110-0100-380-3-50-12-102-C

Document 95-100153 Revision A

Customer Name: AXION – SIEMENS

Purchase Order: 4500418276

PROPRIETARY NOTICE
The information herein is derived in part from proprietary data of AMETEK Solidstate Controls and its
presentation in this Technical Manual is solely for the convenience and assistance of our customers in
installing, operating and maintaining the equipment. It is not to be used for the purposes of
manufacturing the product or products described herein, transferring to third parties, showing or
transferring to competitors, reproducing or incorporating our designs in another product, or divulging
of same to others for whatever purpose. Publication of this Manual does not convey any rights to
reproduce or to use the information for any purpose other than that stated above. All rights
reserved.

The material contained in this Manual is for informational purposes and is subject to change without
notice.

AMETEK Solidstate Controls shall not be responsible for damages, incidental or consequential, from
reliance on the material presented in this Manual.

COPYRIGHT © AMETEK Solidstate Controls, 2018

875 Dearborn Drive

Columbus, OH 43085

For Sales:
8-5 Daily, Monday - Friday

Phone: (614) 846-7500

Toll-Free: (800) 635-7300
FAX: (614) 885-3990

For Service:
24 Hour/7 Days a Week Emergency Service

Within US: (800) 222-9079

Outside US: (614) 365-2662
Fax: (614) 785-7062

Printed in the United States of America.

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 Important Safety Instructions
SAVE THESE INSTRUCTIONS

This manual contains important instructions for AMETEK Solidstate Controls (SOLIDSTATE) Digital
Charger (DCR) Series that should be followed during installation and maintenance of the charger.

The equipment described in this manual is intended for the conditioning of the power in the system for
which it was specified. It should be installed, operated or serviced only by persons who have been
trained in the proper interpretation of its readings and the appropriate safety procedures to be
followed.

Although the equipment described in this manual is designed and manufactured in compliance with all
applicable safety standards, certain hazards are inherent in the use of electrical power equipment.

Warnings and Cautions are presented throughout this document to alert the user to potentially
hazardous situations. A Warning is a precautionary message preceding an operation that has the
potential to cause personal injury or death. A Caution is a precautionary message preceding an
operation that has the potential to cause permanent damage to the equipment and/or loss of data.
Failure to comply with Warning and Caution messages is at the user’s own risk and is sufficient cause to
terminate the warranty agreement between AMETEK Solidstate Controls and the customer.

Adequate warnings are included in this manual and on the product itself to cover hazards that may be
encountered in the normal use and servicing of this equipment. It shall be the owners or user’s
responsibility to see to it that the procedures described here are followed. Failure on the part of the
owner or user in any way to follow the prescribed procedures shall absolve AMETEK Solidstate Controls
and its agents from any resulting liability.

Periodic system maintenance and operational tests should be performed to assure that the product is
functioning properly. It is the owner’s or user’s responsibility to maintain records of all system
maintenance and testing performed on the product. Failure to perform regular system maintenance can
lead to reduced system life and or premature system failures.

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Configuration
Input Parameters Output Parameters
AC Input Phase 3Ø DC Bus Voltage 120 V
AC Input Voltage 380 V Output Current 45 A
AC Input Frequency 50 Hz Power Factor 0.75
AC Input Tolerance ±10 V Temperature Range -10 to 40 °C
Current Limit 100 A
Input / Output Data Output Ripple with Battery 2.0%
AC Input Current 55.8 A Output Ripple without Battery N/A
AC-DC Efficiency 91%
Float Voltage 135 V
Equalize Voltage 140 V System Configuration
1,187 W Charger Design 12 Pulse
Losses Full Load
4,049 BTU Parallel Redundant No

Meters & System Measurements

Charger Output Voltage Circuit Breakers
Charger Output Current Name kAIC Rating Current Rating
Input Power and Frequency AC Input 18 kAIC 35 A
Percent Inverter Loading DC Output 10 kAIC 150 A
CB

Options
High DC Disconnect High DC Voltage Low DC Voltage
Charger Output Diode With
AC Input Available AC Input Failure
Filter Caps
Top Cable Terminal Channels Lamp Test Battery CB Open
Battery Near Exhaustion Drip Shield Low AC Input Voltage
Charger Failure Input A Input B
Space Heater With
UL Kit (cUL, UL) Input C
Thermostat
AC Input CB Open Low DC Disconnect Input D
High AC Input Voltage Audible Alarm Battery Time Remaining
Equalize Relay Communications Package AC Input Monitoring Package
Charger Bridge Over
Battery Package Charge Fail
Temperature
Battery Current & Voltage
Battery Discharging Battery Test
Metering
Battery Current Limiting

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Table of Contents
1. INTRODUCTION ................................................................................................................................. 1
1.1. General Description .................................................................................................................1
1.1. Safety ......................................................................................................................................1
1.1.1. General Safety ............................................................................................................................. 1
1.2. Electrical Precautions ...............................................................................................................2
1.3. Other Recommendations .........................................................................................................2
1.4. Battery Safety ..........................................................................................................................2
1.4.1. Electrical shock hazard ................................................................................................................ 2
1.4.2. Short circuit hazard ..................................................................................................................... 3
1.4.3. Explosive gas hazard ................................................................................................................... 3
1.4.4. Electrolyte spill hazard ................................................................................................................ 3

2. SPECIFICATIONS ................................................................................................................................ 5
2.1. Electrical..................................................................................................................................5
2.2. AC Input Voltages ....................................................................................................................5
2.3. Output Specifications ...............................................................................................................5
2.4. DC Output Voltages .................................................................................................................6
2.5. Environmental .........................................................................................................................6
2.6. Physical ...................................................................................................................................7

3. PRODUCT DESCRIPTION ................................................................................................................ 9

3.1. Theory of Operation ................................................................................................................9
3.2. Base System Diagram ...............................................................................................................9
3.3. Fully Optioned System Diagram ...............................................................................................9
3.4. Components Description ........................................................................................................ 10
3.4.1. Charger Control Board .............................................................................................................. 10
3.4.2. Charger Display Board ............................................................................................................... 10
3.4.3. Configuration Memory Card ..................................................................................................... 10
3.4.4. USB interface............................................................................................................................. 10
3.4.5. Communication Package ........................................................................................................... 11
3.4.6. Alarm Relay Board(s) ................................................................................................................. 15

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 3.5. System Features .................................................................................................................... 16
3.5.1. Input Power Walking (Soft Start) .............................................................................................. 16
3.5.2. Reverse Polarity Protection....................................................................................................... 16
3.5.3. Over Temperature Shutdown ................................................................................................... 16
3.5.4. High DC Shutdown .................................................................................................................... 16
3.5.5. Low DC Disconnect .................................................................................................................... 16
3.5.6. High DC Disconnect ................................................................................................................... 16
3.5.7. Charger Output Diode ............................................................................................................... 16
3.5.8. Percent Loading......................................................................................................................... 16
3.5.9. Battery Monitoring Package ..................................................................................................... 16

4. OPERATION ....................................................................................................................................... 21
4.1. User Interface Panel............................................................................................................... 21
4.2. System Controls ..................................................................................................................... 21
4.2.1. Float/Equalize Controls ............................................................................................................. 21
4.2.2. Float/Equalize Timer ................................................................................................................. 21
4.2.3. Alarm Silence............................................................................................................................. 21
4.2.4. Lamp Test .................................................................................................................................. 21
4.3. Indicators .............................................................................................................................. 21
4.3.1. Float........................................................................................................................................... 21
4.3.2. Equalize ..................................................................................................................................... 22
4.3.3. Fault........................................................................................................................................... 22
4.3.4. High DC Voltage ........................................................................................................................ 22
4.3.5. Low DC Voltage ......................................................................................................................... 22
4.3.6. Charge Fail ................................................................................................................................. 22
4.4. LCD Panel .............................................................................................................................. 22
4.4.1. LCD Navigation Controls............................................................................................................ 22
4.4.2. Prev/Up ..................................................................................................................................... 22
4.4.3. Enter .......................................................................................................................................... 22
4.4.4. Esc ............................................................................................................................................. 23
4.4.5. Down/Next ................................................................................................................................ 23
4.5. LCD Screens ........................................................................................................................... 23
4.5.1. Main Screen .............................................................................................................................. 23
4.5.2. LCD Screen Map ........................................................................................................................ 24
4.5.3. Alarm Parameters ..................................................................................................................... 25
4.6. Operating Procedures ............................................................................................................ 29
4.6.1. Start-Up/Shut-Down ................................................................................................................. 29

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 4.6.2. Adjustments .............................................................................................................................. 29

5. MAINTENANCE ................................................................................................................................. 31
5.1. Preventive Maintenance ........................................................................................................ 31
5.2. Recommended Maintenance Procedure ................................................................................. 31
5.3. Torque Specifications ............................................................................................................. 32
5.3.1. General Torque Specification Chart for AMETEK Solidstate Controls Use ............................... 32
5.4. Diagnostics ............................................................................................................................ 33
5.4.1. No Output Voltage and/or Current ........................................................................................... 33
5.4.2. Low Output Voltage .................................................................................................................. 33
5.4.3. High Output Voltage ................................................................................................................. 33
5.4.4. High Output Current ................................................................................................................. 33
5.4.5. Low Output Current .................................................................................................................. 33
5.4.6. Unit Inoperative – Fuses Open or Input Breaker Tripped ......................................................... 34
5.4.7. Output Voltage Not Adjustable ................................................................................................. 34
5.4.8. High Ripple Voltage On Output ................................................................................................. 34

6. PRODUCT SUPPORT SERVICES ................................................................................................... 35

6.1. Services Available (Optional) .................................................................................................. 35
6.1.1. On-Site Start-Up ........................................................................................................................ 35
6.1.2. Preventive Maintenance Agreement ........................................................................................ 35
6.1.3. Maintenance Training Program ................................................................................................ 35
6.2. Warranty Coverage ................................................................................................................ 35
6.2.1. First Year Standard Warranty.................................................................................................... 35
6.2.2. Extended Warranty (Optional) .................................................................................................. 35
6.3. Return Material Authorization (RMA) ..................................................................................... 36
6.4. Recommended Spare Parts .................................................................................................... 36
6.4.1. Start-Up Spares ......................................................................................................................... 37
6.4.2. Operational Spare Parts ............................................................................................................ 37
6.4.3. Optional Custom Spares ............................................................................................................ 37
6.4.4. Service Organization Contact Numbers .................................................................................... 37

7. INSTALLATION ................................................................................................................................. 39
7.1. Unpacking and Inspection ...................................................................................................... 39
7.2. Storage .................................................................................................................................. 39
7.3. Mechanical ............................................................................................................................ 39

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 7.4. Electrical................................................................................................................................ 40
7.4.1. Equipment Required ................................................................................................................. 40
7.4.2. Input/Output Power Connections............................................................................................. 40
7.4.3. Conductor Terminations ........................................................................................................... 42
7.4.4. Alarm Interface Connections .................................................................................................... 42
7.5. Initial system startup configuration ........................................................................................ 43

8. APPENDIX A – MODBUS REGISTERS ......................................................................................... 45

8.1. Modbus ................................................................................................................................. 45
8.2. Read Holding Registers .......................................................................................................... 46
8.3. Read Coil Status ..................................................................................................................... 47

9. INDEX .................................................................................................................................................. 49

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 1. Introduction
1.1. General Description
The DCR Series Battery Chargers maintain constant DC voltage to power inverters, battery banks,
and other DC loads with the following basic components:

• AC Input circuit breakers

• Input Isolation Transformer
• Rectifier Bridge
• Float/Equalize Control
• Output Current Protection (Fuse Standard; Circuit Breaker Optional)

1.1. Safety
NOTE
Read all instructions before installing or
operating the equipment.

1.1.1. General Safety

The procedures described in these instructions are intended for use by persons knowledgeable in
the operation of Battery Chargers. Persons unfamiliar with this type of equipment should seek
guidance from those who have experience with it.

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1.2. Electrical Precautions
Always assume circuits are electrically “hot” when working on the equipment. Never handle a
component or assembly without confirming no voltage is present.

High voltages and currents exist inside this equipment and present an explosion and severe burn
hazard!

• Never handle a component or assembly without personally confirming that no voltage is applied
or present
• Use only insulated tools
• Keep door closed at all times during normal operations
• Wear safety glasses and appropriate PPE
• Use only insulated tools
• Remove all metal jewelry including earrings, necklaces and watches
• Keep doors closed at all times when starting equipment or during normal operations
• Use battery operated test equipment and/or isolated ungrounded test equipment. On
ungrounded test equipment, an electrical shock hazard will exist and one should avoid touching
the test equipment and UPS cabinet at the same time
• Lethal AC and DC voltages are present inside the UPS cabinet even when all circuit breakers are
open
• Use a “buddy” system when working on energized equipment

1.3. Other Recommendations

• Wear steel-toed shoes when handling heavy tools and parts
• Electronic circuit boards are susceptible to Electro-Static Discharge (EDS) damage. Take
appropriate EDS precautions (i.e.: grounded wrist bands)

1.4. Battery Safety

Battery systems will vary from one battery manufacture to the next. Always consult
the battery manufacturers recommended maintenance procedures before engaging
in any work on a battery system.

1.4.1. Electrical shock hazard

DC voltage tends to be more damaging and has a higher fatality rate than AC due to
the fact that AC voltage will cause involuntary convulsions that may free the victim
from the circuit while DC voltage causes extreme muscular contraction and may hold
the victim in the circuit indefinitely. Batteries cannot be de-energized and must be
maintained while energized. Don’t touch battery terminals without measuring DC voltage to ground.
Batteries may become referenced to ground, through external loads or high impedance acid
traces/corrosion causing a path for current. Only one person at a time should perform maintenance
on a battery. If two workers go to torque battery connections with uninsulated tools, they both may
receive a shock (current from one battery through one person, through the floor, through the
second person, to the other battery). A similar shock hazard may exist when a battery has an acid
trace or corrosion that creates a high impedance path to ground.

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1.4.2. Short circuit hazard
All metal objects must be prevented from contacting the negative and positive
terminal of the battery or any cell of the battery at the same time. One battery cell
can typically supply as much as 15,000 amperes short circuit current, causing possible
personal injuries, fire, and major damage to the battery terminal. Heat and chemicals
released during battery explosions and fires can cause serious injury and death.

1.4.3. Explosive gas hazard

Batteries produce hydrogen gas that should be ventilated through flame - arresting
vent caps and into a fume hood or ventilation system. The highest concentration of
hydrogen gas is in the space between the top of the electrolyte and top of the
battery case. Porous flame-arresting vent caps are provided to prevent any external
spark from entering the battery and causing an explosion.

1.4.4. Electrolyte spill hazard

Lead acid battery electrolyte is a mixture of sulfuric acid and water that varies from a
20 to 30 % concentration of acid (70 to 80 % water). Any spill of the electrolyte can
be neutralized using a mixture of one pound (453 grams) baking soda per one gallon
(3.78 liters) of water. The soda solution is added to the spill until it stops bubbling.

Other types of batteries contain similar electrolyte chemical hazards. Consult the manufacturers
recommended procedure for neutralizing battery chemical leakage.

NOTE: Do Not Allow Neutralizing Agent to enter Battery. Specific battery

maintenance recommendations are provided by each battery manufacture. Consult
the battery manufacture’s manuals for additional information.

The DCR Battery Charger is designed and built for safe operation when used to supply its rated load,
provided it is installed as specified by a qualified, licensed and competent electrician.

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 2. Specifications
2.1. Electrical
• Input Range: ±10%
• Frequency Range: ±5%
• Power Factor: 6 and 12 pulse: 0.75 typical (1 phase), 0.85 typical (3 phase) – At full load with
nominal input voltage and 100% resistive load
• Harmonic distortion: 6 pulse <35%, 12 pulse <10%; at full load, float voltage

2.2. AC Input Voltages

The DCR family of chargers incorporates the following standard input voltages as shown below:

60 Hz – Three Phase
208 V, 480 V

2.3. Output Specifications

• Output Current limitation: 70% up to 102% of the rated output current
• Grounding: Floating ground with optional positive and negative grounding schemes
• Static regulation: < 1% for simultaneous variations of ±10% input voltage, ±5% input frequency
and 0-100% load for both the Float and Equalize mode
• Dynamic regulation: ±8% from 10% to 90% and 90% – 10% load variation (t<300msec) with or
without batteries
• Efficiency: > 90% (at full load)
• AC ripple
o Unfiltered; < 2% ripple with the battery connected
o Filtered; 0.1% ripple filter with a battery connected
o Battery Eliminator filter; 0.1% ripple filter without battery connected (custom option)

NOTE: Ripple voltage measured at terminals of a connected battery with an 8Hr Amp/Hour rating of
≥ 4 times the full load current rating of the charger.

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2.4. DC Output Voltages
The DCR family of chargers incorporates the output voltages with an output voltage adjustment
range as follows:

Table 1: DC Output Voltage Adjustment Range

24 V 100% 125%
Float 100-125% of nominal (22v) 22 27.5
Equalize 110-135% of nominal (22v) 24.2 29.7
*Commission 120-145% of nominal (22v) 26.4 31.9
120 V 100% 125%
Float 100-125% of nominal (110v) 110 137.5
Equalize 110-135% of nominal (110v) 121 148.5
*Commission 120-145% of nominal (110v) 132 159.5
240 V 100% 125%
Float 100-125% of nominal (220v) 220 275
Equalize 110-135% of nominal (220V) 242 297
*Commission 120-145% of nominal (220V) 264 319
* NOTE: Commission (Custom Option) - A command in the supervisor menu that
will apply a high voltage for 24 hours or until a float or equalize
command is initialized. The voltage level is customer configurable.

2.5. Environmental
• Continuous operational temperature range: -10 °C to +40 °C
• Storage temperature range: -20 °C to +70 °C
• Operating humidity: 0 up to 95% non-condensing
• Operating Altitude: 0 to 2,000 meters (6,600 feet)
• Audible Noise: 65 dB (A) @ 1 meter
• Cooling: Convection cooled cabinet

NOTE: Operational temperature range may be de-rated 1% of current per °C to a maximum

temperature range of 55 °C.

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2.6. Physical
• Size ‘A’ Cabinets:
o Dimensions (mm): 1219 H x 609 W x 627 D
o Dimensions (in.): 48” H x 24” W x 24.7” D
• Size ‘B’ Cabinets:
o Dimensions (mm): 2006 H x 812.8 W x 914 D
o Dimensions (in.): 79” H x 32” W x 36” D

Table 2: Cabinet Sizes

DCR Charger Size Cabinet Size
100% 115% 120 V 240 V 24 V
Current Current
Limit Limit 6-Pulse 12-Pulse 6-Pulse 12-Pulse 6-Pulse 12-Pulse
32 A - A A A A A A
40 A 32 A A A A A A A
50 A 40 A A A A A A A
63 A 50 A A A A A A A
80 A 63 A A A A A A A
100 A 80 A A A A A A A
125 A 100 A A A A B A A
160 A 125 A A A B B A A
200 A 160 A B B B B B B
250 A 200 A B B B B B B
320 A 250 A B B B B B B
400 A 320 A B B B B B B
500 A 400 A B B B B B B
630 A 500 A B B N/A N/A B B

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 3. Product Description
3.1. Theory of Operation
Incoming AC power is converted to regulated DC output by an SCR charge bridge. The charger is a
constant potential, phase-controlled 2 or 6-pulse solid-state type with constant voltage and current
control circuitry. An isolation input transformer with an electrostatic shield is supplied for immunity
against input disturbances and galvanic isolation to the DC loads. The operation of the system is
insensitive to AC input phase rotation. In the event of input power loss, upon restoration of the AC
input power, the rectifier will automatically resume supply of the load.

3.2. Base System Diagram

The base system (with no options) will be configured as shown below:

V
A

AC Input DC Output/Battery

Figure 1: Base System Diagram

3.3. Fully Optioned System Diagram

The system with all available options is shown below:

AC Input DC Output External

Batt CB
S Battery
T
Output

ST

Figure 2: Base System Diagram

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3.4. Components Description
3.4.1. Charger Control Board
The Charger Control Board generates output pulses used to gate on the power SCRs in proper
sequence and, at the proper time, to regulate the output voltage. The precise time at which a pulse
is generated to fire an SCR is a function of the output voltage, the input voltage to the Charger and
the current into the load.

The Control Board compares the output of the rectifier to an internal reference and then generates
an error signal, which, in turn, adjusts the firing point of the SCRs. If the output of the rectifier
begins to drop, a signal is generated which increases the conduction interval of the SCRs and thus
returns the output voltage to its normal value. In addition, the Control Board has provisions for
immediately reducing the gate pulses should the output of the rectifier go abnormally high. This
feature protects the load against high DC voltages, which may occur if a drastic increase of AC
voltage should take place.

3.4.2. Charger Display Board

The Charger Display Board interfaces with the Control Board and provides the user a mechanism to
monitor and control the operation of the charger. The Display board communicates to the Control
board via a serial connection that also provides power for the Display board.

3.4.3. Configuration Memory Card

The information containing the specific setup for each unit is contained within a removable
configuration memory card. This removable card is located on J3 of the Display Board. The system
will not operate if this card is not present. All user settings and configurations are contained on this
card for ease of field replacements and duplication of configurations to multiple systems. This card
should never be removed or replaced while power is applied to the system.

3.4.4. USB interface

The Display board provides a USB connection that can be used to interface the Display board to a
standard computer using the Ametek Solidstate Controls SCILink software. This is provided to allow
an alternate means to configure the system other than using the LCD screens. A USB 2.0 Type A
(Male) to USB Type B male is required to interface to the display board as shown below.

Figure 3: USB Cable

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3.4.5. Communication Package
3.4.5.1. Serial Communication

3.4.5.1.1. Connection
Connect RS-485 to the Modbus interface using a two wire, half-duplex serial connection.
Communications can be configured with asynchronous speeds from 2400 baud to 19200 baud.

3.4.5.1.2. Configuration
The configuration can be changed using SCILink.

3.4.5.1.2.1. Default Configuration

Media: RS-485 Half-Duplex
Baud Rate: 19200
Station Number: 1
Data Bits (Size): 8
Stop Bits: 1
Parity: Even
Type of Connection: 2 Wire

3.4.5.1.3. Modbus RTU

Modbus RTU registers can be read over the RS-485 customer connection. A minimum delay of 2
seconds is required between polls. The Modbus registers, which are read only, can be found in
Appendix A – Modbus Registers.

3.4.5.2. Ethernet Communication

3.4.5.2.1. Connection
Connect 10/100Base-T Ethernet to the RJ-45 Ethernet port of the charger.

3.4.5.2.2. Configuration
The addressing mode of the Ethernet interface can be either DHCP or static. The network settings
can be viewed and changed via the display panel.

3.4.5.2.2.1. Default Configuration

Standard: IEEE 802.3
Physical Layer: 10/100Base-T
Data Rate: 10/100 Mbps (auto-sensing)
Mode: Full-Duplex or Half-Duplex (auto-sensing)
Addressing Mode: DHCP

3.4.5.2.3. Modbus TCP

Modbus TCP registers can be read using the Ethernet connection. The Modbus registers, which are
read only, can be found in Appendix A – Modbus Registers.

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3.4.5.2.4. Web Page
The web page allows the system to be monitored remotely. The web page can be viewed by
navigation to the IP address of the charger using a web enabled device. The web page displays
enabled meters and alarms of the system.

3.4.5.2.4.1. Main Screen

The main screen of the web page displays the parameters of the system, active alarms, and some
system measurements.

Figure 4: Main Screen

3.4.5.2.4.2. Buttons
All of the buttons appearing along the right side of the main screen, with the exception of the
Pause/Play button, will open the window corresponding to which button is clicked. The Alarms
button will flash red when there are active alarms, as will the Pause/Play button when pulling is
paused.

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 Meters

Alarms

Data Log
Data Store

I/O Terminal

Pause/Play

Settings

Figure 5: Buttons

3.4.5.2.4.3. Meters
System readings are separated into multiple groups that can be selected along the top of the
window. Many meters have a normal operating range. Meters with values outside this range will
have red tick marks and a flashing red light. Meters that display readings that are not enabled will
appear grayed out.

Figure 6: Meters

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3.4.5.2.4.4. Alarms
All alarms enabled on the system will appear in the alarms window. Inactive alarms will appear
green, while active alarms will appear red. All active alarms may not appear in the Active Alarm Log
on the main screen.

Figure 7: Alarms

3.4.5.2.4.5. Data Log, Battery History Log, Battery Test Log, and Data Store
The data log, battery history log, battery test log, and data store windows can be viewed by
selecting the appropriate tab at the top of the window.

3.4.5.2.4.5.1. Data Log

All data log events can be viewed and have reports generated through the web page. To see a
detailed snapshot of each event, click the View link in the right-most column of the data log table.

Reports can be downloaded in three different formats:

• Standard data log
o Contains the event name, date, and time only.
• Extended data log
o Contains the same information as the standard data log as well as system readings at the
time the event occurred.
• CSV (Comma-Separated Values) data log
o Contains the same information as the extended data log. The data is formatted to be easily
imported into a spreadsheet.

Figure 8: Data Log

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3.4.5.2.4.5.2. Data Store
The Data Store is where all system parameters and readings are stored.

3.4.5.2.4.6. I/O Terminal

The I/O Terminal displays the communication between the web browser and the server. It will only
keep the last 200 events.

Figure 9: I/O Terminal

3.4.5.2.4.7. Pause/Play
Clicking the Pause/Play button will either stop or start the browser polling data from the server. If
polling is paused, the button will be flashing red. When polling is active the values will be updated at
the following intervals:

Table 3: Web Page Polling Intervals

Data Interval Example
System Parameters 20 seconds Current class, DC bus voltage, …
System Readings 2 seconds Input voltage, output voltage, …
Data Log 2 minutes

3.4.5.2.4.8. Settings
The Settings window displays the network setting of the system as well as the software versions.

3.4.6. Alarm Relay Board(s)

The system will facilitate up to two additional alarm boards each containing 8 alarm contacts to
allow remote monitoring of up to an additional 15 alarms. Relay 3 on PCB 305 is reserved to
indicate if the relay board loses communication with the Charger Display board.

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3.5. System Features
3.5.1. Input Power Walking (Soft Start)
The system incorporates input power walking capability to gradually accept the load upon being
energized to prevent power surges.

3.5.2. Reverse Polarity Protection

The system incorporates a reverse polarity diode and an output fuse in the positive leg for reverse
polarity protection. In case the battery is connected in reverse, the diode will conduct and blow the
output fuse.

3.5.3. Over Temperature Shutdown

The system will shut down after a delay of 10 seconds if the rectifier heat sink temperature exceeds
its programmed limitation (hardcoded). In the event of an over temperature shut-down, the
charger will auto-restart after 5 minutes.

3.5.4. High DC Shutdown

The charger output will shut down if the DC voltage reaches the shutdown level which is software
defined (hardcoded). The charger will have to be power-cycled to restart after a high voltage
shutdown. Use of the charger in Equalize or Commission mode will temporarily disables this
function.

3.5.5. Low DC Disconnect

The system provides a trip signal to trip an external battery circuit breaker if the battery voltage
drops below a value established by the user.

3.5.6. High DC Disconnect

This feature will trip the input AC circuit breaker if the battery voltage exceeds a value established
by the user.

3.5.7. Charger Output Diode

This feature provides a blocking diode on the output of the charger. The charger then has the ability
to operate in parallel with another charger using droop compensation with both units equally
sharing the load.

NOTE: In this configuration, the temperature compensation will be disabled.

3.5.8. Percent Loading

This feature will display the percentage of output current being used as compared to the total
available output current.

3.5.9. Battery Monitoring Package

The following features are provided if the “Battery Package” was purchased with the charger that
provides the necessary hardware to accommodate monitoring and control of the battery current,
voltage and circuit breaker while also providing feedback information. Consult Battery
manufactures literature for recommend charging current level.

16 95-100153 Digital Charger® DCR Series Operations Manual Revision A

3.5.9.1. Battery Test
This feature enables the user to “fold-back” the charger voltage to a below nominal voltage level
thus placing the battery on load. Failsafe operation is ensured by the charge controller which
monitors battery voltage and test time. If the battery reaches the “fold-back” voltage the charger
will resume normal operation. Equally, should the test time reach completion then the test will
terminate also.

The user can set time (1-60 min) and fold-back voltage (1.00 to 1.95 V per cell) for this test. 1 min
and 1.92 V are the default settings.

The battery test function is automatically disabled when configured as a parallel charger system.

Navigation through the LCD screens (via the STATUS, CONTROLS screens) is used to start the battery
test.

NOTE: If an alarm occurs that would not be part of a normal discharge operation, the charger will
abort the test.

3.5.9.2. Battery Test Operation

The function consists of a controlled fail-safe discharge where the charger continues to operate but
puts the battery into discharge by reducing its output voltage. The sequence of operations is:

User initiates the test (not automatic). There are a few conditions to be met to start the test:

• The system must have a load

• Charger must be in a normal condition (No Alarm)
• Charger and/or battery breakers (if fitted) must be closed

The charger will decrease its output voltage so that the battery supplies current to the load. It will
stop the test when either:

• The battery voltage reaches charger fold-back level

• The test time has completely elapsed
• An abnormal system alarm (not associated with a discharging battery) occurs
• User Abort: This can be done by pressing either the Float or Equalize button on front
overlay.

3.5.9.2.1. User Defined Variables

• Test Time. A range of time that is desired to discharge the batteries. A range of 1-60 minutes is
allowed.
• Fold-back Voltage. This is the voltage at which the charger reduces its voltage to. This setting
can be between 1.00 to 1.95 volts/cell depending on the battery type.

3.5.9.2.2. Conditions to Abort the Test

• Battery voltage reaches the fold-back voltage
• The test time has elapsed

95-100153 Digital Charger® DCR Series Operations Manual Revision A 17

 • Battery breaker (if fitted) opens
• User Abort: This can be done by pressing either the Float or Equalize button on front overlay.
• Abnormal charger operation as defined by the charger controller.

3.5.9.3. Battery Capacity Available

This feature enables the user to input data concerning the batteries in use to enable the system
software to estimate the battery time remaining. The batteries must stay connected to the system
and monitored continuously or the test/data will become invalid while this option is being utilized.

3.5.9.3.1. User Data Required

• Battery Type: NiCad, Acid (default)
• 30 Minute Discharge Current: 0-10000 Amps (no default)
• Amp-Hour: 0-9999 A/Hours (no default)
• Age Adjustment: 10-120 % of initial capacity (default 100)
• Number of Cells: 0-999

3.5.9.4. Battery Current Limit

With this feature the charger current control regulates the amount of user defined recharge current
flows to the battery by means of current limit. Load current still has priority however where the
residual current available for battery exceeds the user defined limit then current flow is restricted by
decreasing the output voltage. Overall charger current limit still remains in force.

3.5.9.5. Battery Charge/Discharge

This feature allows the system monitor the current (Charge or discharge) to/from the battery and
will display it on the LCD screen.

3.5.9.6. End of Discharge

The charger provides an optional normally-open, potential-free contact to shunt trip an external
breaker. The set point and delay is user adjustable.

18 95-100153 Digital Charger® DCR Series Operations Manual Revision A

3.5.9.7. Battery Temperature Compensation
When this option is enabled, an external temperature probe must be connected and the user must
input the battery type, number of cells and volts per cell. The charger will calculate the final battery
voltage and display it on the LCD screen. Setting the number of cells at ‘000’ will disable
temperature compensation.

This option adjusts the DC battery float voltage based on room ambient temperature over a range of
0 °C (32 °F) to 40°C (104 °F). The Charger output voltage will continuously adjust to the proper value
based upon the measured battery room temperature. Temperature Compensation is disabled when
the charger is in ‘Equalize’ or ‘Commission’ charge regimes.

The compensation shall be accomplished using a “variable modified” method, based on mV/°C/Cell,
in accordance with battery manufacturer’s instructions. This variable corresponds to a mathematical
linear slope, similar to that illustrated below.

If the remote temperature goes below 0°C, or above 40°C, the compensation will stop at the
minimum or maximum value until the battery temperature returns within normal parameters, at
which point Temperature Compensation tracking shall re-commence.

Temperature Compensation has a preset “target voltage” value. This is derived from the nominal
float voltage parameter which is set as a normal function of the charger. This target voltage is the
pivot point at 25 °C (77 °F) that the charger voltage gradient is referenced to. The gradient of the
slope is the only parameter that can be programmed within the Temperature Compensation
function and is defined by X.X mV/°C/Cell. Consult Battery manufactures literature for recommend
compensation slope.

2.4

2.35
Cherger Voltage per Cell

2.3

2.25 2mV/°C/Cell
4mV/°C/Cell
2.2

2.15

2.1
0 5 10 15 20 25 30 35 40
Temperature (°C)

Figure 10: Charger Voltage Setpoint vs. Battery Temperature

95-100153 Digital Charger® DCR Series Operations Manual Revision A 19

 4. Operation
4.1. User Interface Panel
The User Interface Panel located on the front door simplifies the operation of the DCR Series Battery
Charger. The critical equipment controls, indicators, and alarms are located on this panel.

Figure 11: User Interface Panel

4.2. System Controls

4.2.1. Float/Equalize Controls
A pushbutton for Float and a pushbutton for Equalize are located on the User Interface Panel.
Depressing the Float button will reset the output voltage back to the Float level as well as reset the
Equalize timer to zero.

4.2.2. Float/Equalize Timer

The 0-100 hour Float / Equalize Timer is adjusted via the User Interface Panel to provide timed
equalize voltage.

4.2.3. Alarm Silence

A pushbutton to acknowledge system alarms and silence the local alarm buzzer is located on the
User Interface Panel.

4.2.4. Lamp Test

A pushbutton to manually test the operation of the lamps located on the user interface panel.

4.3. Indicators
4.3.1. Float
This green LED illuminates when the system is in Float mode.

95-100153 Digital Charger® DCR Series Operations Manual Revision A 21

4.3.2. Equalize
This amber LED illuminates when the system is in Equalize mode.

4.3.3. Fault
This red LED illuminates when an alarm occurs. By default, all alarms are mapped to this alarm.

4.3.4. High DC Voltage

This indicator illuminates when the DC bus voltage rises above the user defined level for the user
defined delay time.

4.3.5. Low DC Voltage

This indicator illuminates when the DC bus voltage drops below the user defined level for the user
defined delay time. A Fault (common alarm) as well as a low DC Voltage alarm relay is energized
when this alarm is active.

4.3.6. Charge Fail

This indicator illuminates when the charger has failed due to a loss of AC power input.

4.4. LCD Panel

The LCD Panel located on the front door simplifies the operation of the DCR Series Battery Charger.
All user configuration information can be obtained through the LCD Panel.

PREV / UP
FLT 1 20 V E V E N TS
100 .0 A S T A T US ESC
14:05:2 2 S E T U P ENTER

04/18/1 4 A L A R MS
NEXT/DOWN

Figure 12: Display Panel

4.4.1. LCD Navigation Controls

The LCD Panel located on the front door simplifies the operation of the DCR Series Battery Charger.
All user configurable items, alarms and system information can be obtained thru the LCD Panel.

4.4.2. Prev/Up
This pushbutton allows the user to select previous screens as well as navigate up in select screens.

4.4.3. Enter
This pushbutton allows the user to accept data that is entered or select options being presented on
the LCD screen.

22 95-100153 Digital Charger® DCR Series Operations Manual Revision A

4.4.4. Esc
This pushbutton allows the user to abort data entry on a specific LCD screen or to abort various LCD
screen selections.

4.4.5. Down/Next
This pushbutton allows the user to select the next screens as well as navigate down in select
screens.

4.5. LCD Screens

4.5.1. Main Screen
This screen is the typical main screen that is displayed while the unit is operational. Descriptions of
the text fields are shown below:

FLT = Float Mode Charger Output Current

EQ = Equalize Mode
Charger Output Voltage Screen Selections

Current Date Current Time or Screen Selection Indicator

Time Remaining for Equalize or
Time Remaining for Commission Mode
Figure 13: Main Screen

Navigation through the screens shown on the LCD Screen Map is accomplished by moving the
navigation highlighter to the front of the desired screen selection and pressing Enter.

95-100153 Digital Charger® DCR Series Operations Manual Revision A 23

4.5.2. LCD Screen Map
Main Screen Events Screen Status Screen Setup Screens Alarm Screen
FLT 120 V EVENTS System Reset STATUS ENTER PASSWORD ALARMS:
100.0 A STATUS MEASUREMENTS PASSWORD **** High DC Voltage
14:05:22 SETUP OCCURRED AT: CONTROLS Charger Loss of Com
04/18/14 ALARMS 04/17/14 15:46 ABOUT PCB19 Relay Comm DN

Controls Measurements About Setup Options

Password Entry Output V/I Mimic Screen

Alarms Values Behavior
Input V/I Versions
Battery Test
Battery V/I Low AC Input Float Battery Test
Auto EQ Enable
CEMF Voltage Charger Overload Equalize Temperature Comp.
Alarm Relay Test
Battery Temperature Battery Discharging Commission Batt Capacity – Type
Battery Time Remaining Battery Near Exhaustion Time Set Batt Capacity – Amp/Hr
Temp/Humidity Low DC Voltage Set Passwords Batt Capacity – Discharge
Percent Loading Low DC Disconnect Output Current Limit Batt Capacity – Age Adj.

Ground Voltage High DC Voltage Modbus Settings Alarm Relay Test Time

High DC Disconnect
System Overtemp
Cabinet Over Humidity Custom Input A
High AC Input Custom Input B
+ DC Ground Fault Custom Input C

- DC Ground Fault Custom Input D

NOTE: Itialicized screens are optional. AC Input Failure Ethernet Loss of Comm.

Figure 14: LCD Screen Map

24 95-100153 Digital Charger® DCR Series Operations Manual Revision A

4.5.3. Alarm Parameters
Table 4: Alarm Parameters
Option Event Log – Alarm Event Log – Normal
Alarm Name Alarm Qualifier and Conditions
Number Condition Name Status Name
௩ೌ್ ା ௩್೎ ା ௩೎ೌ
Active when AC Input > 70% of AC Input
AC Input Available ଷ
voltage.
AC Input Failure AC Input Failure AC Input Available Charger AC input voltage failure.
Chgr Bridge Indicates when the thermostat input to the Charger
Charger Bridge Overtemp Chgr Bridge Normal
Overtemp Control Board is active.
When AC voltage Good = true, DC Voltage is greater
than 96% of nominal DCV, Over Temperature = False,
High DC Voltage = False and P.S. Fail = False. If
“paralleled chargers” is true then use Battery voltage
instead of DC voltage. With parallel chargers the
voltage at the DC voltage input may always be
Charger Failure Charger Failure Charger Normal
available due to the parallel charger. By adding a
sense before the diode will allow the alarm to
operate. If the charger is shut down, it will show as
not being OK regardless of the DC voltage. Battery
voltage should not turn ON the alarm. Charger is
available or okay.
Active when the DCV value < set point and Battery
Low DC Voltage Low DC Voltage DC Voltage Normal
Near Exhaustion not true.
High DC Voltage High DC Voltage DC Voltage Normal Active when the DCV value > set point.
Equalize Equ Mode Initialized Flt Mode Initialized Indicates when the charger is in equalize mode.
Charger Loss of
Charger Loss of Comm. Charger Comm OK Active when communications timer > 5 seconds.
Comm
Common Any alarm enabled and active or latched.
System Reset System Reset System start-up.

95-100153 Digital Charger® DCR Series Operations Manual Revision A 25

 Option Event Log – Alarm Event Log – Normal
Alarm Name Alarm Qualifier and Conditions
Number Condition Name Status Name
Active when the Charger Control Board processor is
Charger Bd. Reset Charger Bd. Reset
reset.
Active when the system temperature ≥ set point.
System Temp
System Over Temperature System Over Temp System temperature is measured on the User
Normal
Interface Board.
Cabinet Humidity Cabinet Humidity
Cabinet Humidity Active when the system humidity ≥ set point.
High Low
Charger failure due to a loss of AC input. Charger not
Charge Fail Charge Fail Charge Normal
okay.
Software defined value that shuts the Charger output
High DC Shutdown High DC Shutdown down if the DC voltage level ≥ set point for > delay
time.
Active when the AC power supply failure input to the
Charger AC PS
Charger AC PS Fault Charger AC PS Fault Charger Control Board input is active and AC Input
Normal
Breaker is closed.
Active when the DC power supply failure input to the
Charger DC PS
Charger DC PS Fault Charger DC PS Fault Charger Control Board input is active and DC Output
Normal
Breaker is closed.
Active when the AC circuit breaker closed input to the
101 AC Input CB Open AC Input CB Open AC Input CB Closed Charger Control DSP is high, which is communicated to
the User Interface Board.
(Input Vab value or Input Vbc value or Input Vca value
68 Low AC Input Low AC Input AC Input Normal
< set point) and AC Input Voltage Failure = 0.
Active when any of the Fan fail inputs are active on
the Control PCB. Each fan Failure input is considered
120 Charger Fan Fail Charger Fan Failure Charger Fan OK
normal when the input frequency is greater than
40Hz. A high input is also a failure.
67 Charger Fuse Blown Charger Fuse Blown Indicates when the Charger fuse is blown.

26 95-100153 Digital Charger® DCR Series Operations Manual Revision A

Option Event Log – Alarm Event Log – Normal
Alarm Name Alarm Qualifier and Conditions
Number Condition Name Status Name
Indicates when the charger reaches current limit
119 Charger Overload Charger Overload Charger Normal
value.
Active when the DCV value < set point and external
197 Battery Discharging Battery Discharging Battery Charging
Battery Breaker (if present) is closed.
Batt Near Active when the DCV value < set point and external
60 Battery Near Exhaustion
Exhaustion Battery Breaker (if present) is closed.
The Charger will shut down when the DC voltage goes
107 Low DC Disconnect Low DC Disconnect below the Low DC Disconnect (EOD) level for the Low
DC Disconnect delay.
Trips the input AC circuit breaker if the battery voltage
2 High DC Disconnect High DC Disconnect
≥ 144v for 60 cells or 288v for 120 cells.
Negative to Ground Negative to Ground Ground Cleared Active when the voltage between positive DC and
3 ground or Negative to ground exceeds the user
Positive to Ground Positive to Ground Ground Cleared defined set point.
57 Battery CB Open Battery CB Open Battery CB Closed The Battery Circuit Breaker is open.
Custom Input A and delay timer A have met alarm
73 Input A Input A Input A Normal
criteria.
Custom Input B and delay timer B have met alarm
74 Input B Input B Input B Normal
criteria.
Custom Input C and delay timer C have met alarm
77 Input C Input C Input C Normal
criteria.
Custom Input D and delay timer D have met alarm
109 Input D Input D Input D Normal
criteria.
Charger control board Loss of Communication or Relay
Loss of Comm.
Board (PCB19 or PCB20) Loss of Communication.
AC Input is greater than set point and AC Voltage Fail
124 High AC Input High AC Input AC Input Normal
is false.
208 Battery Test Indicates when the Battery Test is in progress.

95-100153 Digital Charger® DCR Series Operations Manual Revision A 27

 Option Event Log – Alarm Event Log – Normal
Alarm Name Alarm Qualifier and Conditions
Number Condition Name Status Name
155 Equalize Inhibit Equalize Inhibit Equalize Enable Equalize mode is inhibited.
Must enable Battery Time Remaining by Charger and
157 Battery Time Remaining
send battery configuration.
Used to indicate to the Charger DSP that a diode is
29 Charger Diode
installed.
Charger Output CB Charger Output DB Active when the output circuit breaker closed input to
191 Charger Output CB Open
Open Closed the Charger Control DSP is high).
Active when there has not been any communication
Ethernet Loss of
Ethernet Loss of Comm. Ethernet Comm. OK between the display board and the Ethernet module
Comm.
in the last 90 seconds.

28 95-100153 Digital Charger® DCR Series Operations Manual Revision A

4.6. Operating Procedures
4.6.1. Start-Up/Shut-Down
Upon closing the AC input circuit breaker, the Charger is in the "Float" mode as shown by the green
indicator on the Users Interface Panel. Depressing the momentary Equalize pushbutton changes the
output to the Equalize voltage level and initiates a timed cycle indicated on the Equalize Timer.

Depressing the momentary Float pushbutton at any point in the Equalize cycle resets the equalize
timer and causes an immediate return to the float voltage output level.

4.6.2. Adjustments
The adjustments for the charger can be made via Ametek's SCI Link software which additionally will
allow the user to download reports from the equipment. Contact an Ametek representative to
obtain a copy of the SCI Link software and operating manuals.

Otherwise, please refer to section LCD Screen Map, on page 24.

4.6.2.1. Float/Equalize Voltage

The Charger Float and Equalize Voltage must be set up for the type of battery being charged.
Typical min/max values are given below; consult the specific battery manufacturer specifications for
the exact setting.

The Float and Equalize Voltage values can be independently adjusted by utilizing an external
computer interfaced with the display PCB using Ametek SCILink. Additionally, all values can be
adjusted via the user interface.

4.6.2.2. Security Access

The system is programmed up to allow the creation of multiple customer passwords with two
different security levels. The two security levels are “Operator” and “Supervisor”.

4.6.2.2.1. Operator Password – Level 1

Operator passwords are intended to be used for individuals to monitor the system and download
event logs. No configuration of the system is allowed under an “Operator” login password. All
Operator passwords are created by the supervisor.

4.6.2.2.2. Supervisor Password – Level 2 (Default 1962)

Supervisor passwords are intended to be used for individuals authorized to change parameters of
the system as well as monitor and download event logs.

95-100153 Digital Charger® DCR Series Operations Manual Revision A 29

 5. Maintenance
5.1. Preventive Maintenance
WARNING
Only qualified electrical personnel should perform
maintenance on this equipment.

The DCR Series Charger is designed and manufactured to assure maximum reliability, flexibility,
serviceability, and performance.

To assure longer component life and trouble free operation, minor preventive maintenance
procedures should be performed annually. More frequent inspection intervals are recommended
for severe operating conditions.

5.2. Recommended Maintenance Procedure

1. Verify output voltage is within specifications. If not refer to Diagnostics, on page 33.
2. Turn off all power to unit.
3. Assure all heat sink cooling fans (if applicable) are operational, clean, and free of dust and
debris.
4. During each service inspection, any accumulated dust, dirt, or foreign particles should be
carefully removed. Special care should be taken in cleaning thyristors, heat sinks, and the
control assembly.
5. Inspect all wiring for loose connections, burnt, frayed or broken wires. Check for burned
semiconductor components and circuit boards.
6. Re-torque all high current connections and secure any loose connections. Refer to Torque
Specifications chart in this section.

95-100153 Digital Charger® DCR Series Operations Manual Revision A 31

5.3. Torque Specifications
NOTE
The following recommendation is to be used
exclusively in the repair or replacement of parts in
or on AMETEK Solidstate Controls manufactured
equipment.

5.3.1. General Torque Specification Chart for AMETEK Solidstate Controls Use
Table 5: Torque Specifications
Bolt Mild Steel SAE 5 Brass Stainless Steel
in-lb ft-lb Nm in-lb ft-lb in-lb ft-lb Nm in-lb ft-lb Nm
#4 6 0.7 4.3 0.5 7 0.8
#6 11 1.2 8 0.9 10 1.1
#8 20 2.3 16 1.8 21 2.4
#10 32 3.6 19 2.2 24 2.7
1/4" 5-6 6.8-8.1 9-10 12.2-13.6 4 5.4 5 6.8
5/16" 10-12 13.6-16.3 14-18 19.0-24.4 6-8 8.1-10.9 9-11 12.2-14.9
3/8" 16-20 21.7-27.1 25-31 34-42 10-13 13.6-17.6 15-18 20.3-24.4
1/2" 37-48 50-65 37-74 50-100 25-31 34-42 37-44 50-60
5/8" 70-94 95-127 110-145 149-197 45-60 61-81 70-85 95-115

Metric Bolts Stud Type SCR or Diode Olympic Terminal Studs

Size in-lb Nm Size in-lb ft-lb Nm Size in-lb
Nm
M4 8-13 0.9-1.5 1/4" 24-30 2.7-3.4
1/4” 60-72 6.8-8.1
M5 16-22 1.8-2.5 3/8" 8-10 10.9-13.6
5/16” 120-132 13.6-14.9
M6 35-53 4.0-6.0 1/2" 11-14 14.9-19.0
3/8” 120-132 13.6-14.9
M8 70-90 7.9-10.2 3/4" 23-27 31-37

Fan Blade Set Screws Torque Specifications: 50-75 in-lb 5.7-8.5 Nm

M10 ‘E’ Box Clamp Torque Specifications: 13-16 ft-lb 17.6-21.7 Nm

1/4” Feed-Thru Torque Specifications: 35-40 in-lb 4.0-4.5 Nm

3/8” Nylon Bolt Torque Specifications: 37 in-lb 4.2 Nm

NOTE: Specifications listed are non-lubricated mating surfaces except for semiconductors.
NOTE: Information from P.A. Sturevant Co. & Snap-On Tool Co. & AMETEK Solidstate Controls part
vendors.

32 95-100153 Digital Charger® DCR Series Operations Manual Revision A

 NOTE: Torque values not specified by a range are ±5%
NOTE: Conversions: 12 in-lb = 1 ft-lb = 1.356 Nm

5.4. Diagnostics
As an aid in troubleshooting the unit, the following list of problems and possible causes is suggested
as a guide. Before attempting to troubleshoot any problem, record all system parameters and
indicator status. If a problem falls outside of this list, or is not cured by taking appropriate action
mentioned below, the factory should be consulted for additional help.

5.4.1. No Output Voltage and/or Current

1. No Input Voltage: Correct and reapply proper input voltage
2. Open Fuse or Breaker: Replace fuse with same type or reset breaker
3. Open Rectifier Fuse: Check for shorted SCR, replace with same type
4. Defective Control Board: Replace with new board. Move the configuration memory into the
new board prior to applying power.

5.4.2. Low Output Voltage

1. One Input Phase Dead: Locate reason for failed phase and repair
2. One Input Fuse Blown: Replace open fuse with same type
3. One Rectifier Fuse Blown: Replace open fuse with correct type, check for shorted SCR or diode
in rectifier.
4. Voltage Adjust Control Improperly Set: Readjust Float and Equalize values
5. Defective Control Board: Replace with new board. Move the configuration memory into the
new board prior to applying power.

5.4.3. High Output Voltage

1. Voltage Adjust Control Improperly Set: Readjust float or equalize control to correct voltage (See
“Operation” on page 21)
2. AC Input Voltage Too High (Out of Spec.)
3. Defective Control Board: Replace with new board. Move the configuration memory into the
new board prior to applying power.

5.4.4. High Output Current

1. Charger is Overloaded: Reduce load on Charger to within rating
2. Current Limit Adjusted Too High: Adjust current limit according to Control Board instructions
3. Defective Control Board: Replace with new board. Move the configuration memory into the
new board prior to applying power.

5.4.5. Low Output Current

1. Current Limit Adjusted Incorrectly: Adjust current limit
2. Defective Control Board: Replace with new board. Move the configuration memory into the
new board prior to applying power.

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5.4.6. Unit Inoperative – Fuses Open or Input Breaker Tripped
1. Input Voltage Too High or Low: Check input voltage against value shown on rating plate. Obtain
voltage of proper value.
2. Start-up or Shutdown Procedure Not Followed: Check procedure (See “Operation” on page 21)
3. Diode or SCR Shorted: Replace with new diode or SCR
4. Defective Control Board: Replace with new board
5. Shorted Wiring: Locate and replace defective wiring
6. Input Transformer Shorted: Replace with new transformer
7. Station Battery Defective or not in Circuit: Check battery and DC circuit

5.4.7. Output Voltage Not Adjustable

1. Float-Equalize Switch Bad: Replace
2. Bad Control Board: Replace with new board. Move the configuration memory into the new
board prior to applying power.

5.4.8. High Ripple Voltage On Output

1. Battery Disconnected or Open: Find the problem in the battery circuit and correct
2. Open Rectifier Fuse: Replace fuse with correct type and size
3. Bad Control Board: Replace
4. Open Output Filter Capacitor (if equipped): Replace defective capacitors
5. Shorted DC Output Choke: Replace with new one
6. Missing Input Voltage On One Phase Of Three Phase Input: Restore missing input phase

34 95-100153 Digital Charger® DCR Series Operations Manual Revision A

 6. Product Support Services
6.1. Services Available (Optional)
6.1.1. On-Site Start-Up
If you require assistance with start-up after the installation, AMETEK Solidstate Controls will provide
a Field Service Engineer to do initial start-up, and to check and adjust your system for maximum
reliability. The Engineer will also provide an overview of the system operation and maintenance to
appropriate staff members.

6.1.2. Preventive Maintenance Agreement

Provides for system inspection, cleaning, verification of connections and electrical components, and
operational testing on a single visit, semi-annual, or annual basis.

6.1.3. Maintenance Training Program

AMETEK Solidstate Controls has developed a program to train our customers in the maintenance
and repair of UPS products. This program is directed toward electronic technicians who will be
responsible for maintenance of the equipment after it has been installed.

6.2. Warranty Coverage

6.2.1. First Year Standard Warranty
The AMETEK Solidstate Controls' Standard Warranty covers labor and material for the first year after
shipment; however, this warranty excludes travel and living expenses. Refer to a copy of the
Warranty on the last page of this publication.

6.2.2. Extended Warranty (Optional)

For those customers who desire to purchase service over and above the Standard Warranty,
AMETEK Solidstate Controls will provide a quote for a service plan to meet your requirements.
Typical plans include the following:

• Service during warranty

o This plan covers travel and living expenses for warranty during the first year
• Extended warranty
o Provides for replacement parts as an extension to the standard one-year Warranty
• Limited Full Service Plan
o Extends the standard one-year Warranty and includes travel and living expenses for
warranty repair. This plan can be offered with or without preventive maintenance.

For additional information concerning product support services available, contact your local AMETEK
Solidstate Controls Representative or call the factory at (614) 846-7500 or Service Hotline at (800)
222-9079.

95-100153 Digital Charger® DCR Series Operations Manual Revision A 35

6.3. Return Material Authorization (RMA)
If the product requires service for any reason, the Customer should contact the Field Service
Department. If the product must be returned to the Manufacturer for repair or replacement, the
Customer must obtain a Returned Materials Authorization (RMA) number. The product must be
packed in the original shipping container or other equally suitable container. The product must be
shipped prepaid with the RMA number on the packing slip. Unauthorized returns of units will be
subject to an inspection and handling charge plus any repair and all transportation charges.

6.4. Recommended Spare Parts

The power system you purchased was probably selected for one or two key reasons: to provide line
voltage regulation and a reliable power source for your critical load. Knowing that unexpected
downtime of your DCR system, computers, instrumentation, or other critical loads could be
hazardous and/or expensive; AMETEK Solidstate Controls’ Engineering has developed our systems
with a strong emphasis on reliability. AMETEK Solidstate Controls custom manufacturers each
inverter, battery charger, voltage regulator and uninterruptible power supply in accordance with the
unique requirements of individual clients in the industrial, petrochemical, and utility markets. Many
components, such as semiconductors, fuses, printed circuit boards, and others, may be individually
selected to meet these unique requirements.

Although our emphasis is on reliability, we realize that failures can occur. As a result, AMETEK
Solidstate Controls has developed a Recommended Spare Parts Program, listing key components
selected specifically for your system and we strongly recommend that these items be available on
the job site. Should any malfunction occur, a quick phone call to our Client Support service desk will
aid you in rapid diagnosis and repair of the system - provided the spare parts are available at your
location.

The system was designed to allow easy replacement of components by trained personnel. In fact,
the immediate availability of parts on site will enable system repair so efficiently, that their cost may
be offset by the downtime saved! Your system may have customized features requiring specialized
parts, some possibly unique to your own system and unfortunately, beyond AMETEK Solidstate
Controls’ capability to maintain as an inventoried item. Consequently, we urge you to consider
having these spare parts available on site to avoid long delays in procurement.

Our Recommended Spare Parts kits are customized to individual product and/or site needs. The
unique features of our products limit our ability to offer standard recommended spare parts lists.
We include in this manual an outline of the components that are included in each of the following
kits. This outline is a generic listing of the types of semiconductors, fuses, printed circuit boards, etc.
that are included within the kit. An itemized list with part numbers is available upon request.

In addition to the kits listed, AMETEK Solidstate Controls will, upon request, customize the
recommended parts package to encompass multiple products at one location and/or include
components that are not currently listed in our kit offerings. These components may include
meters, circuit breakers, and buy out items which are unique to your system, or any other items.

36 95-100153 Digital Charger® DCR Series Operations Manual Revision A

6.4.1. Start-Up Spares
While it is unlikely that any parts would be required during the equipment start-up, occasionally the
need will arise. The components included in these kits are ones that would prevent the
“energization” of the equipment if found defective.

• Printed Circuit Board Kit (Startup)

o Includes one each of the major control printed circuit boards
• Hardware Kit (Startup)
o Contains one of each commutation capacitor, one of each type of power semiconductors,
and two of each type power fuse
• Combination Kit (Startup)
o All of the items included in A and B start-up kits

6.4.2. Operational Spare Parts

The equipment you purchased is very reliable and the need for spare parts is minimal; however, it is
not possible to predict which parts may fail during the life of the product. This package includes a
selection of the parts most commonly used when making repairs to our products.

• Printed Circuit Board Kit (Operational)

o Contains one of each of the printed circuit boards contained in your equipment.
• Hardware Kit (Operational)
o Contains one of each type of fan, pilot light (LED), and snubber /commutation capacitor, two
of each type of pilot light (neon), and power semiconductors, and five of each type of fuse.
• Combination Kit (Operational)
o All of the items included in A. and B. operational kits.

6.4.3. Optional Custom Spares

A. Circuit Breakers
B. Meters
C. Magnetics
D. Spare parts for items supplied with this contract, but manufactured by others.

6.4.4. Service Organization Contact Numbers

6.4.4.1. Corporate Headquarters
Telephone within US: 1 (800) 222-9079
Telephone Outside US: 1 (614) 365-2662
Fax: 1 (614) 885-3990

6.4.4.2. Houston Service Center

Telephone: 1 (281) 240-2135
Fax: 1 (281) 240-2716

6.4.4.3. Western Service Center

Telephone: 1 (760) 331-2220
Fax: 1 (760) 331-2219

95-100153 Digital Charger® DCR Series Operations Manual Revision A 37

6.4.4.4. Brazil Headquarters
Telephone: +55-19-2107-4100

6.4.4.5. Mexico Headquarters

Telephone: +52-55-5250-1232
Fax: +52-55-5250-7981

6.4.4.6. Asia Pacific Headquarters

Telephone: +65-6484-2388
Fax: +65-6481-6588

6.4.4.7. India Headquarters

Telephone: +91- 96-1964-6339
Fax: +91-80-6782-3232

6.4.4.8. Middle East Headquarters

Telephone: +971 50 5584054
Fax: +971 50 5720648

38 95-100153 Digital Charger® DCR Series Operations Manual Revision A

 7. Installation
7.1. Unpacking and Inspection
Upon receipt of the unit, inspect the equipment for damage. If it has been damaged during
shipment, keep the packing materials, and contact the carrier to file a claim for shipping damage.

Carefully remove the packing materials from the Charger. After all of the external packing materials
have been removed, inspect inside the Charger for any other temporary shipping materials which
may have been used. Materials such as tape, which may be used to hold relays in their sockets,
should be removed and discarded.

7.2. Storage
If the equipment is not to be placed in immediate service, it should be kept in a clean and dry area
and protected from water, condensation, dirt and extremes of temperature.

7.3. Mechanical
The equipment should be located in a controlled environment (an environment relatively free of
conductive contaminates and a temperature and humidity controlled indoor area). Adequate
ventilation should be provided by allowing at least three feet of space in front of the equipment, at
least one foot above the equipment.

The Charger has been supplied with a three inch, lifting base with mounting holes to attach the
Charger to its mounting surface. In most installations it is not necessary to bolt the equipment to
the floor. Due to the weight, the equipment is typically placed on a reinforced floor near load
bearing columns. If there is any doubt about floor loading capacity, an architect or structural
engineer should be consulted.

Cable entrance is available through the top or bottom of the equipment. The power connection
terminals are located behind the AC Input circuit breaker, and the alarm connections are located on
the right-hand side. Reference your outline drawing for detailed connection locations.

95-100153 Digital Charger® DCR Series Operations Manual Revision A 39

7.4. Electrical
WARNING
ELECTRICAL SHOCK HAZARD
The wiring and connections in and around this unit may
contain HIGH VOLTAGES. These HIGH VOLTAGES can
injure or kill personnel, and damage equipment. All
electrical connections must be made by a qualified
electrician and meet local code standards.

7.4.1. Equipment Required

The electrical connection of the DCR Series Chargers requires only a few tools:
• Wrenches
• Screwdrivers

7.4.2. Input/Output Power Connections

Wire lugs to power connections shall be a compression, die crimped, two-hole, 600V copper tin
plated, UL listed lug. See Conductor Termination Tables for recommended cable connections. Crimp
tooling shall be appropriate for the lugs being used.

Input and Output wires must be sized to carry the maximum ampere requirements shown on the
equipment outline drawing. See “Table 6: AC Input Circuit Breaker Sizes” on page 41 for
recommended wire sizes.

The wire size is based upon the National Electric Code Article 310-16 copper conductor assuming
90°C (194°F) wire, maximum wire length of 250 feet and 40°C (104°F) ambient temperature. It is a
recommended minimum size only; be certain to follow all applicable codes for your installation.

Connect a ground to the bus bar marked "grounding electrode" located behind the lower door or
panel located at the lower right-hand side.

Connect the DC output to its load and/or batteries. It is extremely important to observe the proper
polarity of the DC connections to prevent damage to the battery. The DC output cable should be
sized to carry the maximum ampere requirement when operating in the current limit mode
(recharging batteries).

Connect the Charger to the appropriate source of AC power. Connect any alarm cables or
communication cables. When routing the cable, make sure that the wire is not laying over any
sharp edges which may cut into the wiring.

40 95-100153 Digital Charger® DCR Series Operations Manual Revision A

 Table 6: AC Input Circuit Breaker Sizes

Input Circuit Breaker Rating Input Circuit Breaker Rating

System Output Current Rating
(Amps) for 60 Cell System (Amps) for 120 Cell System
100% Current 115% Current
208 VAC 480 VAC 208 VAC 480 VAC
Limit Limit
32 A - 25 A 15 A 50 A 25 A
40 A 32 A 35 A 15 A 70 A 30 A
50 A 40 A 40 A 20 A 80 A 35 A
63 A 50 A 50 A 25 A 100 A 45 A
80 A 63 A 70 A 30 A 125 A 60 A
100 A 80 A 80 A 35 A 175 A 70 A
125 A 100 A 100 A 45 A 200 A 90 A
160 A 125 A 125 A 60 A 250 A 110 A
200 A 160 A 175 A 70 A 350 A 150 A
250 A 200 A 200 A 90 A N/A 175 A
320 A 250 A 250 A 110 A N/A 225 A
400 A 320 A 300 A 150 A N/A 300 A
500 A 400 A 400 A 175 A N/A 350 A
630 A 500 A 500 A 200 A N/A N/A

Table 7: DC Output Circuit Breaker Sizes

Nominal Charger Output Current Maximum Charger Output Current
Circuit Breaker
100% Current 115% Current 100% Current 115% Current
Rating (Optional)
Limit Limit Limit Limit
32 A - 33 A - 45 A
40 A 32 A 41 A 37 A 60 A
50 A 40 A 51 A 46 A 70 A
63 A 50 A 64 A 58 A 80 A
110 A (120 VDC)
80 A 63 A 82 A 73 A
125 A (240 VDC)
100 A 80 A 102 A 92 A 150 A
125 A 100 A 128 A 115 A 175 A
160 A 125 A 163 A 144 A 225 A
200 A 160 A 204 A 184 A 300 A
250 A 200 A 255 A 230 A 350 A
320 A 250 A 326 A 288 A 500 A
400 A 320 A 408 A 368 A 600 A
600 A (120 VDC)
500 A 400 A 510 A 460 A
700 A (240 VDC)
630 A 500 A 643 A 575 A 800 A

95-100153 Digital Charger® DCR Series Operations Manual Revision A 41

 Contractors are encouraged to size power cables according to the circuit breaker ratings (when
applicable) otherwise the cables should be sized to the maximum possible current.

The incoming power cables must be terminated with lugs as specified in the “Conductor
Terminations” table. Lugs must be secured to the bus bar terminals using 'grade 5' or better steel
hardware consisting of bolts, flat washers, lock washers and nuts. The hardware should be torqued
as specified in the “Torque Specifications” table. The steel hardware should be plated with zinc or
other acceptable anti-corrosion material.

7.4.3. Conductor Terminations

Table 8: Conductor Terminations

Burndy Connector Bolt Hole Installation

Wire Size
Part Number Size Spacing Tool
#10 AWG YAV102TC14E2 M8ND
#8 AWG YA8CL2TC14E2
#6 AWG YA6CL2TC14E2
#4 AWG YA4CL2TC14E2 1/4" 3/4"
#2 AWG YA2CL2TC14E2
#1 AWG YA1CL2TC14E2 MY29-3
YA25L2TC14E2
1/0
YA25L2TC38
2/0 YA26L2TC38 3/8" 1"
3/0 YA27L2TC38
YA28L2TC38
4/0
YA282LN
250MCM YA292LN
300MCM YA302LN
350MCM YA312LN 1/2" 1-3/4" Y35
400MCM YA322LN
500MCM YA342LN
600MCM YA362LN

For “Power Cable Connections” refer to the equipment Outline Drawings to determine the hole to
select the proper Burndytm pressure terminal connectors from the following table. DO NOT EXCEED
the maximum wire size capability of the connectors. The recommended Burndytm Installation tools
are listed along with the connector diameter and spacing of the bus bar connectors supplied with
your unit.

7.4.4. Alarm Interface Connections

The Alarm Interface Connections provide connections for remote monitoring of system alarms.
SPDT contacts are provided for all standard and optional alarms. The connections are located
behind the upper door on the right-hand side. These alarm connections are clearly indicated by

42 95-100153 Digital Charger® DCR Series Operations Manual Revision A

 function and should be connected using wiring appropriate for the annunciation system being used.
The alarm contacts are rated for a maximum of 130VDC, 3A. DC contacts must be supplied from a
single voltage source. For alarm wire connections it is recommended that T&B STA-KONtm
connectors be used. Recommended Thomas & Bettstm installation tools are #WT2000, WT145C,
WT1455, WT145A, or WT2130A (RC).

Table 9: Thomas and Betts

Wire Size T&B Ring Terminals T&B Locking Fork Terminals
18 AWG RA18-XX RA18-XXFL
16-14 AWG RB14-XX RB14-XXFL
12-10 AWG RC10-XX1 RC10-XXFL
NOTE: XX = bolt hole size

7.5. Initial system startup configuration

The following items must be configured when the system is initially powered on. The procedures to
set these parameters can be found in the Operations section of this manual.

1. Turn on the AC input circuit breaker.

2. Using the local keypad or Ametek's SCILink software and a USB cable, set the following
parameters:
• Float voltage
• Equalize voltage and time
• System date/time
• System passwords
• Alarm parameters
• Enable Auto-equalize if desired
• System “behavior” characteristics (as required)

95-100153 Digital Charger® DCR Series Operations Manual Revision A 43

 8. Appendix A – Modbus Registers
8.1. Modbus
The flow of information between the Charger and the Client Control and Data Acquisition system
will be unidirectional (reads only from the charger unit). The information that the user will have
access can be summarized as:

• Metering (current, frequency, Power etc)

• Alarms (low dc, overload etc)
• Status (inverter to load, in sync etc)

Modbus supports the addresses of measured quantities and alarms as shown below. These are
Modbus addresses and the client needs to use them to interface to their SCADA system.

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8.2. Read Holding Registers
Table 10: Read Holding Registers
4x Resister 4x Resister
Description Description
Address Address
N/A 4x0001 AC Input Current A-Phase # 4x2004
N/A 4x0002 AC Input Current B-Phase # 4x2005
N/A 4x0003 AC Input Current C-Phase # 4x2006
N/A 4x0004
N/A 4x0005 Serial Number (Byte 1) 4x3001
N/A 4x0006 Serial Number (Byte 2) 4x3002
N/A 4x0007 Serial Number (Byte 3) 4x3003
N/A 4x0008 Serial Number (Byte 4) 4x3004
N/A 4x0009 Serial Number (Byte 5) 4x3005
N/A 4x0010 Serial Number (Byte 6) 4x3006
N/A 4x0011 Serial Number (Byte 7) 4x3007
N/A 4x0012 Serial Number (Byte 8) 4x3008
N/A 4x0013 Serial Number (Byte 9) 4x3009
N/A 4x0014 Serial Number (Byte 10) 4x3010
Serial Number (Byte 11) 4x3011
N/A 4x1001 Serial Number (Byte 12) 4x3012
Cabinet Temperature 4x1002 Serial Number (Byte 13) 4x3013
N/A 4x1003 Serial Number (Byte 14) 4x3014
N/A 4x1004 Serial Number (Byte 15) 4x3015
DC Battery Current * 4x1005 Serial Number (Byte 16) 4x3016
DC Battery Voltage * 4x1006 Serial Number (Byte 17) 4x3017
Charger DC Current 4x1007 Serial Number (Byte 18) 4x3018
Charger DC Voltage 4x1008 Frequency 4x3019
Percent Output Loading 4x1009 Charger Output Current Class 4x3020
N/A 4x1010 N/A 4x3021
Communication Status Good 4x1011 N/A 4x3022
Charger DC Output Voltage 4x3023
AC Input Voltage A-B 4x2001 AC Input Voltage Class 4x3024
AC Input Voltage B-C 4x2002 System Type 4x3025
AC Input Voltage C-A 4x2003

NOTE: * Only available with Option 210 (Battery Current and Voltage Metering).

NOTE: # Only available with Option 111 (Power Metering).

46 95-100153 Digital Charger® DCR Series Operations Manual Revision A

8.3. Read Coil Status
Table 11: Read Coil Syatus
0x Register 0x Register
Description Description
Address Address
Charger Fan Fail 1 Spare 49
Charger Bridge Overtemp 2 Low DC Voltage * 50
Battery Discharging 3 AC Input Failure * 51
Equalize 4 Spare 52
Spare 5 Spare 53
Spare 6 Spare 54
Spare 7 Spare 55
Spare 8 Spare 56
Spare 9 Spare 57
Spare 10 Spare 58
Spare 11 Spare 59
Spare 12 Spare 60
Spare 13 Battery CB Open 61
Spare 14 Batt Near Exhaustion * 62
Spare 15 Spare 63
Spare 16 Charger Fuse Blown * 64
Spare 17 Low AC Input * 65
Spare 18 Charger Failure * 66
Charger Loss of Comm. 19 Input A * 67
Charger PS Fault 20 Input B * 68
Spare 21 Input C * 69
Spare 22 Spare 70
Spare 23 AC Input CB Open * 71
Spare 24 Spare 72
Charger AC P.S.Fail 25 Spare 73
Charger DC P.S.Fail 26 Input D * 74
PCB 19 Relay Comm DN 27 Spare 75
PCB 20 Relay Comm DN * 28 Charger Overload * 76
Spare 29 High AC Input * 77
Spare 30 Spare 78
Spare 31 Charger System Over Temperature 79
Spare 32 Charger Cabinet Humidity 80
Common 33 Charge Fail 81
Low DC Disconnect 34 Charger High DC Shutdown 82
Spare 35 Spare 83
Spare 36 Spare 84
Spare 37 Spare 85
Spare 38 Spare 86
Spare 39 Spare 87
Spare 40 Spare 88
High DC Disconnect * 41

95-100153 Digital Charger® DCR Series Operations Manual Revision A 47

 0x Register 0x Register
Description Description
Address Address
Negative to Ground * 42
Positive to Ground * 43
High DC Voltage * 44
Spare 45
Spare 46
Spare 47
Spare 48

NOTE: * Alarms may not be available. Reference your system drawings.

48 95-100153 Digital Charger® DCR Series Operations Manual Revision A

 9. Index
AC ripple ........................................................................................................................................................ 5

Configuration Memory ............................................................................................................................... 10

Cooling .......................................................................................................................................................... 6

Diagnostics .................................................................................................................................................. 33

Equalize Voltage .......................................................................................................................................... 29

Float Voltage ............................................................................................................................................... 29

Frequency ..................................................................................................................................................... 5

Grounding ..................................................................................................................................................... 5

Input Voltages ............................................................................................................................................... 5

Installation .................................................................................................................................................. 39

LCD Panel .................................................................................................................................................... 22

Operation ...................................................................................................................................................... 9

Preventive Maintenance ............................................................................................................................. 35

Recommended Spare Parts......................................................................................................................... 36

Specifications ................................................................................................................................................ 5

System Features .......................................................................................................................................... 16

Temperature Compensation ................................................................................................................. 16, 19

Torque Specification ................................................................................................................................... 32

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