Tudor Manual Dec200
Tudor Manual Dec200
INDUSTRIAL BATTERY
CHARGER I&O MANUAL
a) Before using the battery charger, read all the instructions in addition to the
CAUTION, WARNING, and DANGER markings on the charger, battery, and all
the associated equipment.
c) Connect or disconnect the battery plug only when the charger output is off.
ALWAYS press the PAUSE pushbutton before unplugging the battery to
prevent arcing or burning.
d) If the battery is unplugged during charging, the charger will indicate “F18”. To
restart the charger, plug in the next battery. Do not connect the next battery
before you see indication “- - - -” or “F18”.
f) De-energize all AC and DC power connections before servicing this unit. If injury
does occur, apply the prescribed treatment for electrical shock and obtain
medical attention immediately.
g) The charger is NOT for outdoor use. Do not expose the charger to rain or snow.
h) This charger is factory set to charge lead-acid batteries only. The operating
environment should not contain any materials that may cause corrosion or
contamination that would degrade the performance of a charger.
i) Do not operate this unit if it has received a sharp blow, been dropped or
otherwise damaged. Take it to a qualified GNB Industrial Power Motive Power
service center.
k) The charger profile is set at the factory for a charger DC cable length of 9 ft and a
battery DC cable length of 25 in. If DC cable lengths are adjusted, please
contact your local GNB Industrial Power Motive Power service representative.
The GNB® DEC200 battery chargers are fan cooled, solid state, microprocessor
controlled, SCR regulated chargers designed to make battery charging simple. They
are designed to charge flooded lead-acid batteries. The charger has a
comprehensive self-checking diagnostic program to control all charger functions,
monitor the quality of charge and check its own safety conditions.
3. RECEIVING CHARGER
Examine the charger thoroughly before using, to make sure that no parts have been
loosened or damaged during shipment. Check the contents of the package against
the delivery slip before disposing of the shipping package. If any shipping damage or
partial loss is found, file a claim with the carrier without delay and take any necessary
steps to protect your rights. Before installing, check that the charger nameplate data
corresponds to the packing slip and to the model specified on the original sales
order. The DEC200 chargers are delivered on skids for easy handling using a forklift
truck.
5. STACKING
a) The base unit should be secured to the floor or a solid base using appropriate
bolts and with accordance to local building codes and regulations.
c) If a lifting sling is used, the sling should be placed under the unit where the base
plate is located to avoid damage to the units.
a) Secure the base unit to the floor or solid base. The bolts can be accessed and
secured from the underside of the unit at the front and rear or from inside the unit
where the large holes are located directly above mounting holes (see appendix G
for mounting hole locations). When accessing the mounting holes from the
inside, it is recommended you use a long handle hexagon key or screwdriver with
the hexagon key inserted. This will allow you to go through the base plate to the
bolts, which are located on the flange.
c) Use an appropriate lifting sling to lift the second unit on to the base unit, inch the
second unit over the base unit and align the holes before resting the second unit
on top.
d) Secure the two units together using the bolts removed from the top cover of the
base unit. Use the access between the two units or inside the second unit using
the tools as recommended above.
e) If stacking three high, use the above procedure for stacking the third unit.
The charger must be connected to either a single phase or three phase, 60 Hertz
(± 2%) AC power source. Three phase chargers cannot be powered with a single
phase source.
Only the AC input wire configuration for multi-input chargers can be changed. Follow
Figure 1 (page 6) for single-phase input or Figure 2 (page 7) for three-phase input
transformers. A qualified electrical contractor should perform this adjustment.
NOTE: Live connection ‘L’ Must be connected to the breaker. The mains input are
the only user configurable connections. PCB connections must NOT be
altered from factory setting.
PCB
Mains Input L (Brown)
(Black) L1 N (Blue)
(Black) L2
(Black) L3
PCB
Mains Input L (Brown)
(Black) L1 N (Blue)
(Black) L2
(Black) L3
PCB
Mains Input
L (Brown)
(Black) L1
N (Blue)
(Black) L2
(Black) L3
To connect the input AC voltage, route the AC conduit through the knockout hole
provided. Continue the AC wiring to the breaker terminals L1 (N) and L2 (L) (single
phase input) or L1, L2, and L3 (three phase input). For proper connection, torque the
screws to approximately 25 inch-pounds.
7. DC OUTPUT
The DC charging cable has a commonly used battery plug or receptacle. The polarity
of the charger plug must be the same as the battery connector. The BLACK DC
cable must be connected to the battery negative terminal (-) and the RED DC cable
must be connected to the battery positive terminal (+). The charger will not operate in
a reversed polarity condition. The DC output fuse is a "fast-acting" fuse used to
protect the power semiconductors of a charger.
NOTE: Use only identical replacement fuses available from your GNB Industrial
Power Motive Power service representative. The DC fuse must be replaced
with a fast acting fuse capable of protecting semiconductors. See Appendix C
and D for correct fuse sizes.
Refer to Appendix A and B (on pages 13 and 14) for a complete list of fault codes.
DISPLAY
CHARGE CONDITION FUNCTION BUTTON DISPLAY SELECTION LED
DEFAULT
CHARGING A A, Ph Y
TERMINATION rEdy G
Charge
SETTING EQUALISE EqAL for 5 seconds then default display
stage
A = Output current
F = Fault code, display will alternate with the two codes
Ph = Phase of charge i.e. 1, 2 and 3
StSt = Smart start
LoBt = low battery override
/ = Display will alternate with the two-displayed information
*= flashing LED.
NOTE: In LoBt, StSt, Equalize and Termination charge function display will only be displayed for 10 seconds, not
permanently.
LED Description
Yellow Flashing High Rate Current
Yellow Solid 80% Charged
Green Solid Charge Complete
Red Fault – See page 15 for codes
This PAUSE push button will halt the charge cycle. The battery can then be safely
unplugged for up to 10 minutes. If the battery is still connected after this time, the
charger will continue with the present charge cycle.
If the time to gassing voltage, (2.40 VPC), is less than 30 minutes, the normal charge
profile will terminate and the unit will charge at constant voltage (2.35VPC) until 22%
of the maximum current is reached. The charger will then proceed to the auto-
balance stage.
The charger maintains a constant current level of 22% of maximum output that is
activated by voltage, on at 2.20VPC and off at 2.40VPC with a time limit of 1 hour if
2.40VPC is not reached.
When current is flowing, amps will be displayed and the yellow LED will be
illuminated. When no current is flowing, the display will show ‘StSt’. The FUNCTION
button can select charge information. The green LED will remain illuminated.
The following table summarizes the action taken when Equalize is set manually
during different charge modes…
10.7.1 CONFIGURATION
There is the ability to manually override the low ‘Incorrect Battery’ threshold
of 1.70 VPC, down to a minimum of 1.00 VPC - the level at which the charger
will recognize a battery connection. This is achieved by holding the
FUNCTION push button for 5 seconds when the incorrect battery fault has
been detected.
10.7.2 OPERATION
If ‘Low Battery Override’ has been enabled and a battery (voltage > 1.00
VPC) is connected to the charger, the charger will pass current at 75% of the
maximum output current.
If less than 3.0VPC, current will flow for 5 minutes and the charge will be
suspended for 5 minutes. The cycle is repeated until the battery voltage is
greater than 1.70 VPC at the end of the 5-minute rest period.
If the battery voltage is greater than 1.70 VPC at the end of the 5-minute rest
period, the battery recovery mode will cease and charge will start from stage
1 with smart start disabled.
If 3.0 VPC is reached within the 5 minutes of charge, the charge will be
suspended equal to the ‘on’ time, maximum of 5 minutes. During this period
the display will show ‘Lobt’. During the 5-minute off period the display will
show the battery volts per cell alternating with ‘Lobt’.
Incorrect battery detection limits will be < 1.70 VPC and > 2.25 VPC (off
charge). If the battery voltage comes within this window the charger will
automatically commence charging.
If the AC power fails during a charge cycle, the charger will resume the cycle
at the point of termination as soon as AC power is restored.
F02 N Deep discharged battery (<1.90vpc after 30 seconds of charge > 1.90vpc)
Key: -
C = critical fault Ö charge stopped Ö fault code displayed permanently
S = suspend fault Ö charge suspended until criteria fulfilled Ö fault code displayed permanently
R = retry fault Ö charge retries after 20 seconds Ö fault code display alternating with standard
display
N = non-critical fault Ö charge continues Ö fault code display alternating with standard display
POSSIBLE
SYMPTOM EXPLANATION / ACTION
CAUSE
No Display No AC Power Check Input Power. Check Breaker. Mains fuse on Control Board
Deeply
Battery Voltage less than 1.9 volts per cell initially but rose above this
F01 Discharged
level within the first minute. Check battery condition and Equalize.
Battery
Battery less than 1.9 volts per cell after the first minute of charge. Check
F02 Over discharge
battery condition and Equalize
Make sure your battery gets a full charge every cycle. Check battery
F03 Sulphated Battery
condition and Equalize.
Check Fan for operation on initial power up. Ensure adequate
Charger
F04 ventilation. Contact your local GNB Industrial Power Motive Power
Overheating
representative.
F05 Mains Failure Electrical Supply failure during charge. (Power Cut)
No Output
F06 Check DC Fuse, SCRs. Connection to Battery.
Current
Incorrect Battery Make sure the battery voltage matches the charger voltage.
Check battery voltage with a voltage meter. Make sure battery voltage
F07 Low Voltage
matches charger. Battery may require servicing.
Check battery voltage with a voltage meter. Make sure battery voltage
High Voltage
matches charger.
Battery did not reach gassing volts within the time limit.
Check battery for low voltage. Confirm charger capacity is correctly
F09 Battery Failure
matched to battery. Check battery condition.
Contact your local GNB Industrial Power Motive Power representative.
Second Stage I2 limit not reached within time limit. Check battery condition.
F10
Time-Out Contact your local GNB Industrial Power Motive Power representative.
Incorrect Mains
F11 Check the mains supply.
Frequency
Board
F12 Contact your local GNB Industrial Power Motive Power representative.
Failure
Temperature
F13 Contact your local GNB Industrial Power Motive Power representative.
Sensor Failure
Auto Balance
F17 Check battery condition.
Stage Time Out
Battery Check battery for High Temperature. Allow battery to cool. Check battery
F16
Overheating condition. Confirm charger capacity is correctly matched to battery
Battery
F18 Press the PAUSE button before disconnecting the battery.
Disconnection
Overheated
F22 Check battery condition.
Battery
AC AMPS (RMS) @ AC
Amp-Hour Rating SHIPPING DATA
Model Numbers DC DC VOLTS @ 2.4 VPC
10 12 14 Volt Amps 208 240 480 Cabinet WEIGHT
Single Phase Hour Hour Hour Vac Vac Vac Size Lbs KG
DEC200-24V-40AS1H 330 400 470 24 40 11.4 9.8 4.9 M4 94.8 43
DEC200-24V-75AS1H 625 750 880 24 75 21.3 18.4 9.2 M4 134 61
DEC200-24V-95AS1H 790 950 1120 24 95 27 23.4 11.7 M4 145 66
DEC200-24V-115AS1H 955 1150 1350 24 115 32.6 28.3 14.1 M4 163 74
DEC200-24V-135AS1H 1125 1350 1590 24 135 38.3 33.2 16.6 M4 169 77
DEC200-36V-75AS1H 625 750 880 36 75 29.9 25.9 13 M4 158 72
DEC200-36V-95AS1H 790 950 1120 36 95 37.9 32.9 16.4 M4 163 74
DEC200-36V-115AS1H 955 1150 1350 36 115 45.9 39.8 19.9 M5 216 98
DEC200-36V-135AS1H 1125 1350 1590 36 135 53.9 46.7 23.3 M5 238 108
Three Phase
DEC200-24V-75AT1H 625 750 880 24 75 12 11 5.3 M4 134 61
DEC200-24V-95AT1H 790 950 1120 24 95 15 13 6.7 M4 145 66
DEC200-24V-115AT1H 955 1150 1350 24 115 19 16 8.1 M4 145 66
DEC200-24V-135AT1H 1125 1350 1590 24 135 22 19 9.5 M4 180 82
DEC200-36V-75AT1H 625 750 880 36 75 18 16 7.9 M4 180 82
DEC200-36V-95AT1H 790 950 1120 36 95 23 20 10 M4 180 82
DEC200-36V-115AT1H 955 1150 1350 36 115 28 24 12 M4 209 95
DEC200-36V-135AT1H 1125 1350 1590 36 135 33 28 14 M5 275 125
DEC200-36V-150AT1H 1250 1500 36 150 36.4 32 16 M5 297 135
DEC200-48V-95AT1H 790 950 1120 48 95 30.7 27 13 M5 264 120
DEC200-48V-115AT1H 955 1150 1350 48 115 37.2 32 16 M5 288 130
DEC200-48V-135AT1H 1125 1350 1590 48 135 43.6 38 19 M5 299 136
L1
L1 YL/G
L2
208V
240V
240V
208V
208V
480V
480V
480V
240V
N
L2
L3
L3
bl
br
br bl bl gy
T1
PCB1 CON1
4 3 2 1
FS1
bl gy
wh '1'
wh '0'
wh '2'
bl '0'
bl '1'
bl '2'
wh
bk
rd
rd
rd
bl
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
CON 5
wh '2'
bl '2'
wh '1'
bl '1'
wh '0'
bl '0'
wh
Shunt bl
FS2 rd
_ bk +
DRAWING No: 4 - CMP - 2600 - 01 - WD - E If any errors are apparent within this
diagram please inform CMP
Drawn by: Checked by: MOD No: REV: engineering.
CMP Batteries Ltd,
Trev Peacock 13 12 02 - C000007 B Materials: White Polypropylene 60u PP198 TC Charger Division,
Clear Overlaminate 60u PP20 Unit 2 Pisces,
Trev Peacock 10 12 03 - C000044 C Adheasive: AP51 Mosley Road,
Size: A5 (210mm x 147mm) Trafford Park,
Trev Peacock 19 12 03 - C000045 D Text: As shown Manchester.
Colour: Black on white M17 1PF.
Trev Peacock 17 03 04 - C000068 E
L
120V
240V
208V
0V
240V br bl bl gy
0V OR
br PCB1 CON1
bl 4 3 2 1
208V
240V
480V
FS1
0V
bl gy
wh
wh
bk
rd
rd
rd
bl
8 7 6 5 4 3 2 1
CON 5
T1
wh
wh
wh
Shunt bl
rd
FS2
_ bk +
DRAWING No: 4 - CMP - 2600 - 02 - WD - E If any errors are apparent within this
diagram please inform CMP
Drawn by: Checked by: MOD No: REV: engineering.
CMP Batteries Ltd,
Trev Peacock 17 04 03 - C000007 B Charger Division,
Materials: White Polypropylene 60u PP198 TC
Clear Overlaminate 60u PP20 Unit 2 Pisces,
Trev Peacock 10 12 03 - C000044 C Mosley Road,
Adheasive: AP51
Size: A5 (210mm x 147mm) Trafford Park,
Trev Peacock 19 12 03 - C000045 D Manchester.
Text: As shown
Colour: Black on white M17 1PF.
Trev Peacock 17 03 04 - C000068 E