DEC200 SERIES INDUSTRIAL BATTERY CHARGER I&O MANUAL
TABLE OF CONTENTS TITLE 1. Important Operating Instructions 2. Introduction 3. Receiving Instructions 4. Location and Installation of Charger 5. Stacking 6. AC Electrical Supply 6.1 Branch Circuit Protection 6.2 AC Voltage Connections 6.3 Ground Connection 7. DC Output 8. Fault and Display Codes 9. DEC200 Standard Charger Operation 10. Charger Functional Description 10.1 LED Descriptions 10.2 Pause Push Button 10.3 Smart Start Stage 10.4 Auto Balance 10.5 Equalize Stage 10.6 Equalize Pushbutton 10.
DEC200 SERIES INDUSTRIAL BATTERY CHARGERS 1. IMPORTANT OPERATING AND SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS 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. b) Do not touch un-insulated parts of the DC output connector or the battery terminals, as there is a possibility of electric shock. c) Connect or disconnect the battery plug only when the charger output is off.
2. INTRODUCTION 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.
b) Remove the bolts from the top cover of the base unit, but do not discard these, as they will be required to fix the two units together. 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.
. AC ELECTRICAL SUPPLY 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. The following transformer options are available: TABLE 1 – INPUT VOLTAGE CHOICES Single phase 208/240/480VAC, 60Hz Three phase 208/240/480VAC, 60Hz Only the AC input wire configuration for multi-input chargers can be changed.
FIGURE 1: SINGLE PHASE INPUT WARNING: IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE DAMAGE TO THE CHARGER AND BATTERY 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.
FIGURE 2: THREE-PHASE INPUT WARNING: IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE DAMAGE TO THE CHARGER AND BATTERY NOTE: PCB connections must NOT be altered from factory setting.
6.2. AC VOLTAGE CONNECTIONS 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. 6.3. GROUND CONNECTION It is a requirement to ground the chassis while the charger is connected to AC power. The charger comes with a threaded M6 hole, clearly marked on the chassis.
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10. CHARGER FUNCTIONAL DESCRIPTION 10.1. LED Descriptions LED Yellow Flashing Yellow Solid Green Solid Red Description High Rate Current 80% Charged Charge Complete Fault – See page 15 for codes 10.2. PAUSE PUSH BUTTON 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. 10.3 SMART START If the time to gassing voltage, (2.
10.6 EQUALIZE PUSHBUTTON Equalize charge can be enabled/disabled, when the FUNCTION button is depressed > 5 second at anytime whilst a battery is connected. Only one equalize charge per recharge cycle is permitted. CAUTION: DO NOT EQUALIZE MORE OFTEN THAN REQUIRED BY THE CONDITION OF THE BATTERY, AS SPECIFIED IN THE BATTERY MAINTENANCE INSTRUCTIONS. EXCESSIVE EQUALIZING MAY DAMAGE THE BATTERY. 10.7 LOW BATTERY OVERRIDE/RECOVORY 10.7.
11 MAINTENANCE The charger requires minimum maintenance. ENSURE THE CHASSIS IS SECURELY GROUNDED per the local/federal Electrical Code. Do not allow excessive dust to accumulate on the components inside. Blow out with clean compressed air when necessary. The chargers are designed with a breaker and fuse for the AC input and DC output respectively. Should this fuse fail or breaker trip, the cause must be determined before they are corrected or replaced.
APPENDIX A – FAULT CODES CODE STATUS DESCRIPTION F01 N Over discharged battery (<1.90vpc after 30 seconds of charge) F02 N Deep discharged battery (<1.90vpc after 30 seconds of charge > 1.90vpc) F03 N Sulphated battery F04 S Charger over heating F05 S Mains failed during charge F06 R No output current F07 C Incorrect battery < 1.70 F07 (+Y led on) C Incorrect battery > 2.
APPENDIX B – DEC200 TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE No Display No AC Power F01 Deeply Discharged Battery F02 Over discharge F03 Sulphated Battery F04 Charger Overheating F05 Mains Failure F06 No Output Current Incorrect Battery F07 Low Voltage High Voltage EXPLANATION / ACTION Check Input Power. Check Breaker. Mains fuse on Control Board Battery Voltage less than 1.9 volts per cell initially but rose above this level within the first minute. Check battery condition and Equalize.
APPENDIX C –TECHNICAL DATA Model Numbers Amp-Hour Rating DC Volt DC Amps Single Phase 10 Hour 12 Hour 14 Hour DEC200-24V-40AS1H 330 400 470 24 40 DEC200-24V-75AS1H 625 750 880 24 75 DEC200-24V-95AS1H 790 950 1120 24 DEC200-24V-115AS1H 955 1150 1350 DEC200-24V-135AS1H 1125 1350 DEC200-36V-75AS1H 625 DEC200-36V-95AS1H AC AMPS (RMS) @ AC VOLTS @ 2.4 VPC 208 Vac SHIPPING DATA WEIGHT 240 Vac 480 Vac Cabinet Size Lbs KG 11.4 9.8 4.9 M4 94.8 43 21.3 18.4 9.
APPENDIX D Component No: CLT6006 DRAWING TITLE: GNB [UL] 3phase wiring diagram KEY For 208V input connect to 208V connections on T1 L1 L1 For 240V input connect to 240V connections on T1 L2 L2 L3 L3 For 480V input connect to 480V connections on T1 bl bk br gy rd wh YL/G BLUE BLACK BROWN GREY RED WHITE YELLOW / GREEN OR L1 L1 240V 480V 208V 480V 208V 240V 480V 240V N 208V YL/G L2 L2 L3 L3 bl br gy br bl bl T1 PCB1 CON1 4 3 2 1 13 12 11 10 9 8 7 6 5 4 3 bk 14 wh
APPENDIX D Component No: CLT6005 DRAWING TITLE: GNB [UL] Single phase wiring diagram Fuse / Breakers KEY bl bk br gy rd wh YL/G N For 120V input connect to 120V connections on T1 For 208V input connect to 208V connections on T1 L BLUE BLACK BROWN GREY RED WHITE YELLOW / GREEN OR For 240V input connect to 240V connections on T1 N N For 480V input connect to 480V connections on T1 YL/G OR L L 240V 208V 120V 0V 240V 0V PCB1 br bl gy br bl bl OR CON1 4 3 2 1 480V 240V 208V 0V F
APPENDIX E – DIMENSIONS CABINET Size M4 Size M5 DIM. A 19.69” 23.62” DIM. B 26.65” 26.65” DIM. C 16.93” 20.87” Sales • Service • Recycling 1-888-563-6300 DIM. D 17.54” 21.48” DIM. E 12.99” 16.
SALES – SERVICE - RECYCLING 1-888-563-6300 TOLL FREE GNB Industrial Power A division of Exide Technologies U.S.A. Tel: 877.462.4636 GNB Industrial Power A division of Exide Technologies Canada Tel: 800.268.2698 V19CIL5200ULD 2004-05 www.gnb.
