ELEMENT SERIES INDUSTRIAL BATTERY CHARGERS INSTALLATION & OPERATING INSTRUCTIONS
TABLE OF CONTENTS SAFETY PRECAUTIONS .......................................................................................................................... 1 CHARGER SPECIFICATIONS ................................................................................................................. 3 INSTALLATION PROCEDURE ................................................................................................................ 4 CHARGER ELECTRICAL INSTALLATION ........................................
SAFETY PRECAUTIONS BEFORE ATTEMPTING TO OPERATE THE CHARGER, PLEASE READ THIS GUIDE CAREFULLY. SAVE THESE INSTRUCTIONS – This guide contains important instructions for Element High Frequency series product line that shall be followed during installation and maintenance of the charger. Only qualified personnel should install, operate, or service this equipment.
¾ Risk of electrical component failure due to improper installation. To prevent damage from overheating, proper airflow must be ensured. Do not restrict fan inlets or exhaust outlets. Do not mount the charger in a confined space or where the exhaust air will recirculate. ¾ There are no user serviceable parts within the charger enclosure. If service is required, contact the local GNB Industrial Power service representative. ¾ The charger is NOT for outdoor use. Do not expose the charger to rain or snow.
CHARGER SPECIFICATIONS The Element system specifications are listed below. LMT-06kW-48-xxxS Nominal VA Ratings Input Specs. Voltage 48V / 150A AC Circuit Size Power Factor Output Specs. Voltage 48V Nom. / 62.5V Max. 150A Max. 6 kW Max. < 1% 92% at Full Load ¾ ¾ Output LMT-10kW-80xxxT 80V / 120A 480VAC, 3-phase +10% Delta Connection with Earth Ground 13.8A rms / 13.8A rms / 8.3A rms / phase phase phase 20A 20A 15A 0.
INSTALLATION PROCEDURE I. Charger Inspection 1. Upon receipt of the Element charger, verify that the shipping information (packing list) matches the charger rating (label on the side of the charger). 2. Upon receipt of the Element charger, ensure that there is no physical damage to the chassis, the LCD/keypad, the E-Stop/Disconnect switches, or the AC/DC cables. If you notice any damage, inform the shipping carrier and/or GNB Industrial Power.
CAUTION: When installing, do not lift the unit from the middle of the lower cover as this may damage the filter. To reduce potential for filter damage, lift the charger using the lifting handles mounted on either side of the charger chassis (see Figure 2). Lifting Handles Figure 2: Charger lifting instructions III. Installing / Removing Air Filter The charger is equipped with an air filter located in the lower cover of the unit. The air filter needs to be checked on a regular basis and cleaned if needed.
Air filter Filter Guides Figure 3: Installing / Replacing Air Filter Sales x Service x Recycling 888.563.6300 in the USA 800.268.
Charger Electrical Installation 1. Verify proper AC line voltage and current ratings per the charger specifications as listed on the label on the side of the unit (see table below for proper AC line ratings). AC Line Ratings for Element Chargers Charger Model AC Voltage AC Current Disconnect Circuit (@125%) LMT-06kW-48V 480VAC 3 (±10%) & GND 8.3 A nominal 15 A 480VAC 3 (±10%) & GND 13.8 A nominal 20 A LMT-10kW-48V-250A LMT-10kW-80V-120A 2.
AC Knockouts Figure 4: Removing top cover 480VAC 3 GND Figure 5: AC wire connections Sales x Service x Recycling 888.563.6300 in the USA 800.268.
Figure 6 : Making AC wire connections Figure 7: Connecting GND wire Sales x Service x Recycling 888.563.6300 in the USA 800.268.
Charger Controls and User Interface The charger main disconnect is located on the upper right side of charger. The user interface panel is located on the front of the charger (see Fig. 8). 2 -LCD / Keypad 1- Main Disconnect Power Switch Fig. 8: Charger Controls The following is a brief description of the charger controls: 1. Main Disconnect Switch: This is a padlock type disconnect switch that should be in the OFF position and padlocked before any panels or drawers are removed.
¾ The LCD/Keypad assembly shown in Figure 10 encompasses: o A 4x20 character LCD for operation and fault message display o A 1x6 push button keypad with separate START and STOP push button o Two status LEDs for run (OK) and Fault indication o A serial RS-232 connector and an IR window LCD Status LEDs RS-232 IR Fig. 10: LCD/Keypad and User Interfaces ¾ The status LEDs indicate the charger status, namely OK (Green LED lit) for normal operation, Fault (Red LED lit) when a fault trips (Fig. 11).
OPERATING PROCEDURE I. Turning on the Unit 1. Connect charger to truck’s battery using DC connectors. 2. Energize the AC Mains. 3. Energize the side panel AC input main disconnect switch (RED). Verify that the LCD display is lit and displays the “Connect Battery” screen shown below.
II. Starting a Charge Cycle 1. Connect the truck’s battery to the charger. Once the battery is detected, the LCD message will change to “Push Start to Begin Cycle”. 4 8 V 0 7 / 1 9 / 0 P U S H B E G 7 1 S I T N A R T C Y C 2 L : 0 T O 2 0 0 A 0 : 0 0 E If the above message is not displayed, the battery may not have been detected. Make sure that the battery cables are connected properly and verify that the auxiliary contacts are proper and making good contact.
C H B Y A R G E U S E C Y C L E S T O P P E D R Pressing the STOP button for the second time will stop the charger completely and the unit will default to the Charger Idle screen. If necessary, it is now safe to disconnect the charger from the battery. Pressing the START button from the CHARGE CYCLE STOPPED screen will resume the charge cycle and the screen will again display the Charger Operation screen. 5.
CHARGER MENUS Users can access various menus of the charger to view charge history, charger lifetime operational history, charger settings, charger model and serial number as well as activate a recovery cycle for a sulfated battery. The charger menus can be accessed when the charger is idle, i.e. when the “Connect Battery” or the “Push Start to Begin Cycle” screens are displayed.
3. Pressing the left/right (/) keys will display the second screen of the charger history. C H # 9 9 A C T I V T R C C S T T E A A : 0 7 / T E D C V X X X 1 9 / 0 7 P R O F E Q X X F I X X X 0 4 : 2 I L E S : X X X X X 0 X The second screen lists additional relevant information about the charge cycle including: ACTIVATED PROFILES: STATE: Lists the profiles that were activated during that cycle.
III. Charger Lifetime History While in the Main Menu, press the up/down (q/r) keys until the Lifetime Summary screen appears. M E A X I N L I I T F M E N U : E T I M E S U M M A R Y E N T E R Pressing the “ENTER” key will access the selected menu. The charger lifetime operational summary screen will then appear.
M E A I N R E C S U I T X M E N U O V E R Y L F A T E : C D Y C L E B A T T F O E R Y E N T R E R Pressing the”ENTER” key will access the selected menu. The user will then be prompted to enter the battery voltage, charge current, and required cycle time. N E X I O M I N A L V O L 4 B A T T A G E 8 V T E T R Y E N T E R Pressing the up/down (q/r) keys will change the battery voltage setting (24V/36V/48V).
Select the correct value then press the “ENTER” key. The recovery charge start screen will then appear. E T O X I T P U S H B E G I S N T A R T R E C O V E R Y E N T E R Pressing the “ENTER” key will start the recovery cycle. Once the cycle is completed, the Cycle Complete message will appear. Note that the recovery cycle is a separate cycle and activating it does not change the charger settings. Sales x Service x Recycling 888.563.6300 in the USA 800.268.
TROUBLESHOOTING Under normal operation, the Status OK LED (green) is lit. In case of a fault, the Status FAULT LED (red) is lit. If that occurs, perform the following: 1. Note the fault message that appears on the screen. Make sure to note the second line of the fault message as it indicates the type of fault. It is important to note the fault message precisely as that will help identify the cause of the fault so that a fix can be quickly found. 2.
II. Charger Faults 1. AC Fault A C E X F I A U L T : T Note that the drawer number that reported the fault is listed on the second line. Also note that the charging drawer that caused the fault is shown. Possible Causes: ¾ AC line voltage is below/above operational limits (±10%) ¾ Internal input stage failure Troubleshooting: 1. Press the STOP key to revert to the IDLE screen. 2. Open the charger drawer and identify the drawer with a RED LED lit (unit that initiated the fault). 3.
O V E R E X I T V O L T A G E F A U L T : Possible Causes: ¾ Worn DC cables (open or short) ¾ Improper DC cable connections Troubleshooting: 1. Press the STOP key to revert to the IDLE screen. 2. Verify that the output cables are in good working condition and are properly connected to the battery. 3. Restart the charge cycle by pressing the START key. 4. If the fault persists, turn off the charger and contact the local GNB Industrial Power service representative. 3.
4. Restart the charge cycle by pressing the START key. 5. If the charger starts with no faults, the fault was likely caused by the build up of heat in the charger. 6. If the fault persists, verify that all fans are operational. If one or more fans are not operational, switch off the disconnect switch and contact GNB Industrial Power. 4.
Possible Causes: ¾ Battery temperature exceeded preset limit ¾ Faulty (worn) thermistor Troubleshooting: 1. Press the STOP key to revert to the IDLE screen. 2. Measure the battery tray temperature. If an elevated battery temperature is detected, do not re-start the charge cycle. 3. If no elevated battery temperature is detected, verify battery cable connections including the auxiliary thermistor connections. 4. Restart the charge cycle by pressing the START key. 5.
Internal to Charger Wire Loop in one Battery Aux. contact Charger Aux J1 1 2 1 Battery Aux 2 J3 Charger Aux J2 RT1 1 2 t +Temp Sense 1 2 1 2 Battery Aux -Temp Sense J4 Thermistor in one Battery Aux. contact 8.
Appendix Charging System Block Diagrams Sales x Service x Recycling 888.563.6300 in the USA 800.268.
FAN 2 FAN 1 GND AC3 AC2 GND L L IR RS-232 EMI Filter F AC Fuses 25A/600V E +12V 1 2 VBAT- VBAT+ +12V 1 2 30 pin connector Key Pad LCD 30 1 DC Bus AC3 AC2 AC1 Boost Control Processor Interface Boost Control Output Fuse 300A Gate Drive Control Input Power Assembly Gate Drive Control Output Feedback Analog Control PCB -Vout +Vout Battery Charger System Block Diagram Fault OK +12V Microprocessor PCB 1 2 +12V Charger Idle More 1 2 Fan Power 1 2 Fan Power Discon
SALES – SERVICE – RECYCLING TOLL FREE 1-888-563-6300 in the USA 1-800-268-2698 in Canada GNB Industrial Power USA – Tel: 877.462.4636 Canada – Tel: 800.268.2698 www.gnb.
