FERRO FIVE SERIES - GB Industrial FIVE ® SERIES ... addition, check the tag on the charger for proper…

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  • FERRO FIVE SERIESMOTIVE POWER CHARGERSInstallation and operating instructions for singlephase and three-phase chargers

    FERRO FIVE FR, EFR, LIBERTY, and REVOLUTION SERIES chargers withRANGER II, COMPUCHARGEor SCOUT controls

    5-720

  • DANGERSHOCK HAZARD

    DO NOT TOUCHUNINSULATED BATTERY

    TERMINALS OR CONNECTORS

    WARNINGARC HAZARD

    CONNECT OR DISCONNECT BATTERY PLUG ONLY

    WHEN CHARGE CYCLE IS COMPLETE

    DANGERHIGH VOLTAGE

    DISCONNECT CHARGER FROM AC VOLTAGE SUPPLY

    AND BATTERY BEFORE SERVICING OR DISMANTLING

    WARNING!

    Battery chargers present an electrical hazard tothose who work with or service them. Although specific CAUTIONS and WARNINGS are includedthroughout the text of this manual, it is essential that extreme care be taken at all times to ensure a safe working environment.

    WARNINGA battery on charge gives off a mixture of oxygenand hydrogen gas, which is explosive. Ventilate thecharger room to prevent gas accumulation. C&Dchargers are convection cooled. To provide ampleventilation to carry off excess heat, keep chargersat least four inches from a wall and from otherchargers and obstructions.

    CAUTIONElectrical connections can work loose during shipping. Check all connections for tightnessbefore connecting the charger to the AC supply voltage.

    WARNING

    Check all warning labels!

    The charger should be connected to a fused safety disconnect switch or to a circuit breaker. Besure the protective device and the incoming ACcables to the charger meet the local electricalcodes and they match the current and voltagerequirements of the charger or chargers. Thecharger nameplate shows AC volts, phase and current requirements at nominal line and rated output and recommended external fusing. In addition, check the tag on the charger for properinput voltage.

    CAUTIONLIFT ALL FOUR

    CORNERS

    CAUTIONDO NOT ATTEMPT TO

    RECONNECT VOLTAGE WITHOUT READING

    INSTRUCTIONS

    CAUTION1. ALL THREE PHASES ON VOLTAGE CHANGEOVER

    TERMINALS MUST BE RECONNECTED WHEN CHANGING VOLTAGE.

    2. AC FUSES MUST BE CHANGED WHEN CHANGING VOLTAGE. SEE LABEL IN CHARGER.

    THIS CHARGERCONNECTED FOR120V - 208V - 240V480V - 575VOTHER

    JN-95

    HIGHVOLTAGE

    3-4-56-7-8

    10-12-1520-25-3035-40-45

    50-60

    208VOLTS

    3-4-56-7-8

    10-12-1520-25-3035-40-45

    50-60

    LOWVOLTAGE

    3-4-56-7-8

    10-12-1520-25-3035-40-45

    50-60

    CAUTIONPHASE FUSE RATING

    CAUTION

    Make sure the charger positive terminal is connected to the charger connector terminalmarked (+) and the negative terminal to the one marked (-).

    GROUND CONNECTION

  • TABLE OF CONTENTS

    Contents Page

    Receiving andinstallation Section 1 Receiving and installation 1

    1.1 Receiving 11.2 Identification 1-21.3 Storage 21.4 Location 2-31.5 Mechanical installation 31.6 Electrical connection 31.7 Input voltage changeover 3-41.8 AC input voltage cables 41.9 Grounding 41.10 DC cables and cable connectors 41.11 Maintenance 5

    RANGER II control Section 2 RANGER II control 52.1 Description 52.2 Basic settings 62.2.1 Real-time or fixed increment starting 62.2.2 Automatic equalizing 6-72.2.3 Automatic watering 72.2.4 Setting cool time 72.2.5 Monitoring water flow 72.2.6 Main power override 72.2.7 Water control override 7-82.2.8 Setting the number of cells 82.2.9 Selecting the shunt size 82.2.10 Setting the rated output current 82.2.11 Setting the charge mode 82.2.12 Setting the date 82.2.13 Setting the correct time 92.2.14 Setting the day of the week 92.2.15 Activating daylight savings time 92.2.16 Activating and setting the address 92.2.17 Setting the baud rate 92.3 Operations 92.3.1 Manual starting 9-102.3.2 Stopping the charge manually 102.3.3 Manual equalizing 102.3.4 Operation after loss of AC power (warm start) 102.3.5 Charge data retrieval 102.4 Special features with SMARTBATTERYII 112.4.1 Installing a SMARTBATTERY II communications board 112.4.2 Retrieving data from SMARTBATTERY II modules 11-122.5 Communications port 12

    COMPUCHARGE control Section 3 COMPUCHARGE control 133.1 Description 133.2 Operation 13-143.3 Basic settings 143.3.1 Setting the precharge delay 143.3.2 Activating cold storage 143.3.3 Setting the number of cells 153.3.4 Automatic equalizing 153.3.5 Manual equalizing 153.3.6 Automatic watering 15

    SCOUT control Section 4 SCOUT control 164.1 Description 164.2 Basic settings 164.2.1 Setting the number of cells 16

  • Contents Page

    SCOUT control Section 4.3 Operation 17(continued) 4.3.1 Basic operation 17

    4.3.2 Changing the five-second, factory-set delay 174.3.3 Changing the maximum charging time 184.3.4 Manual equalizing 184.3.5 Automatic equalizing 184.3.6 Cold applications 18

    Operation Section 5 Operation 195.1 Operating characteristics 195.2 Recommended charging procedures 20

    Options Section 6 Options 216.1 Remote control 216.2 Series connected charging cables 216.3 Parallel connected charging cables 216.4 Automatic watering systems 216.5 Computerized management system 226.5.1 RANGER MANAGEMENT SYSTEM 1000 226.5.2 RANGER MANAGEMENT SYSTEM 2000 226.6 Other options 22

    Troubleshooting Section 7 Troubleshooting 227.1 Procedure 227.2 Component testing 24-257.3 Replacing components 257.4 FERRO FIVE REVOLUTION: Troubleshooting a charger

    with no output 297.5 FERRO FIVE REVOLUTION: Troubleshooting a charger

    with output too high 307.6 FERRO LIBERTY: Troubleshooting a charger when output

    does not increase 317.7 Troubleshooting a charger that will not start 327.8 Troubleshooting a charger that produces

    no DC output 337.9 Troubleshooting a charger that will not stop 347.10 Troubleshooting a single-phase charger with

    low DC output 357.11 Troubleshooting a three-phase charger with

    low DC output 36

    Parts lists Section 8 Parts list 378.1 FERRO FIVE FR SERIES

    120/208/240 and 480 VAC inputs 378.2 FERRO FIVE FR SERIES

    575 VAC input 388.3 FERRO FIVE EFR SERIES

    120/208/240 and 480 VAC inputs 39

    Wiring diagrams Section 9 Wiring diagrams 409.1 Wiring diagram guide for FR, LIBERTY, 40

    and REVOLUTION charger models9.2 Wiring diagram guide for EFR charger models 419.3 FR wiring diagrams 42-489.4 LIBERTY wiring diagrams 49-559.5 REVOLUTION wiring diagrams 56-59

  • LIST OF ILLUSTRATIONS

    Contents Page

    Figure 1.1 Nameplate 11.2 FERRO FIVE FR, EFR, LIBERTY and REVOLUTION SERIES chargers 21.3 Cabinet dimensions 31.4 AC voltage rating label 41.5 AC fuse rating chart 4

    Figure 2.1 RANGER II control 5

    Figure 3.1 COMPUCHARGE control 133.2 Precharge delay 143.3 Cold storage 143.4 Number of cells 153.5 Automatic equalize 15

    Figure 4.1 SCOUT control 164.2 Printed circuit board panel with configuration jumpers circled 164.3 Close up of jumpers for changing cells 164.4 Delay time jumpers 174.5 Automatic equalize switch 18

    Figure 5.1 FERRO FIVE efficiency and power factor curve 195.2 Typical ferroresonant charger curve 19

    Figure 6.1 RANGER remote control option 216.2 RANGER WATERING SYSTEM module mounted on charger 216.3 Wall mounting brackets 22

    Figure 7.1 Component location, FERRO FIVE chargers, single-phase 267.2 Component location, FERRO FIVE chargers, three-phase 27-28

    TABLES

    Contents Page

    Table 1.1 AC input power codes 11.2 Allowable AC input ranges 4

    Table 7.1 Test instruments and tools for troubleshooting 247.2 Diode connection torque valves 25

  • 1

    1 RECEIVING AND INSTALLATIONInspect your C&D charger for anyshipping and handling damage assoon as it arrives. Describe anydamage on the receiving slip andimmediately notify the shipper.Verify the model and serialnumbers printed on the packing listagainst the nameplate (Figure 1.1).If they disagree, contact your C&Drepresentative before proceedingwith installation. Use caution whenmoving chargers. Do not drop orotherwise abuse them.

    A five-element model numberidentifies each C&D charger. Each element describes a different chargerperformance characteristic.The modelnumber of a FERRO FIVE chargerdescribes its basic operating charac-teristics. A typical model number is:

    Model: The first element in thenumbering system identifies themodel. In this example, an FRcharger.

    Cells charged: This entry indicatesthe number of lead-acid cells thesystem can charge. In this example,a six-cell lead-acid battery.

    AC input: Letter codes listed inTable 1.1 describe the voltage, phaseand frequency of the AC input current.In the example, the letters CE define a charger that requires a 240 or 480VAC, single-phase, 60 Hz input. The number 5 placed between any

    letters, C5E for example, denotes 50 Hz operation. Models with a CE or HK designation also include a tapfor 208 VAC.

    DC Ah: For EFR SERIES chargers,this is the largest size battery,discharged to 80 percent, that canbe charged in eight hours. For FRseries chargers, this is the largestsize battery, discharged to 100percent, that can be charged in eighthours. In this case, a 255 Ah battery.

    Charge control: The last element in the numbering system identifies the control:

    E indicates the optional RANGER II control.

    F indicates RANGER II withLIBERTY option.

    G indicates RANGER II with REVOLUTION option.

    M indicates the optional COMPUCHARGE control.

    S indicates the optional SCOUT control.

    T is the standard electro-mechanical timer.

    JM indicates a disconnect switch.

    R indicates remote control.

    Suffix letters may be combined. A charger designated MJM containsboth a COMPUCHARGE control and a disconnect switch.

    1.1 Receiving

    1.2 Identification

    CAUTIONLIFT ALL FOUR

    CORNERS

    MODEL

    SERIAL SPEC. T.C.50

    VOLTS AMPS CELLSDC OUTPUT

    8 HOUR RATED CAPACITY AH

    12 HOUR RATED CAPACITY TO AH

    AC INPUT

    VOLTS PHASE

    AMPS HZ

    RECM. LINE FUSES

    JM-280

    FR18HK750

    MP1 012320 204172

    36 135 18

    750 LH

    751 1100

    208/240/480 3

    19/17/8.5 60

    30/25/12

    Industrial Batteries and Chargers1400 UNION MEETING ROAD BLUE BELL PA 19422

    MMF

    mfg

    MF

    G D

    AT

    EJ

    AN

    . 1

    99

    9

    FR 6 CE 255 MChargecontrol

    DC ampere-hours

    AC inputCells charged

    Model

    FIGURE 1.1-Nameplate

    TABLE 1.1

    Code Input Power Phase Cycles(VAC) (Hz)

    S 380 1 50C5E 208/240/480 1 50M 575 1 60Z 380 3 50

    H5K 208/240/480 3 50L 575 3 60

    Code Input Power Phase Cycles(VAC) (Hz)

    A 120 1 60B 208 1 60C 240 1 60E 480 1 60G 208 3 60H 240 3 60K 480 3 60

    AC INPUT POWER CODES

  • 2

    1.2 Identification (continued)

    EFR CHARGERFR CHARGERS

    FIGURE 1.2-FERRO FIVE FR, EFR, LIBERTY and REVOLUTION SERIES chargers

    1.3 Storage Keep the charger in its original shippingcontainer until you are ready to proceedwith installation. The unit can be safely

    stored in any clean, dry area where temperatures remain between 40F and 120F (5C and 49C).

    1.4 Location Battery charging produces heat and apotentially explosive mixture of odorlessoxygen and hydrogen gases. Safeoperation requires a clean, dry, well-ventilated area, where the temperatureremains between 60F and100F (16Cand 32C).

    C&D chargers are convection-cooled.Chargers require a MINIMUM of fourinches of clearance between the floor,walls, chargers, and other obstructionsfor adequate air circulation.

    EXPLOSIVE, COMBUSTIBLE ORFLAMMABLE MATERIALS SHOULDNOT BE PERMITTED IN THE CHARGING ROOM. NEVER MOUNTA CHARGER ON OR ABOVE COMBUSTIBLE MATERIALS.

    To prevent the accumulation of explosive concentrations of hydrogenand oxygen, the charging area shouldhave sufficient ventilation to prevent formation of one percent, by volume, of hydrogen. It is important to notehydrogen is generated at different

    rates during various times in the chargecycle. Most of the gas forms during thelast two to three hours of the charge,when the average cell potentialexceeds 2.37 volts. Every pint of waterdissociated during recharge releases 23 cubic feet of hydrogen gas to theatmosphere. To calculate hydrogenformation, determine the number ofpints of water needed to correctly re-level cells after charging, then multiply the number by 23. Thus, alead-acid motive power battery thatrequires 1.5 pints of water to relevel, will produce 34.5 cubic (1.5 x 23) feet of hydrogen.

    An approximation technique may beused to estimate hydrogen productionfrom C&D batteries charged by chargersequipped with COMPUCHARGE,SCOUT and automatic Start/Stop controls. It is estimated a total of 0.24cubic feet of hydrogen gas will evolvefrom each cell per 100 ampere-hours of capacity.

    REVOLUTION CHARGERLIBERTY CHARGER

  • 3

    1.4 Location (continued)

    Chargers can be bolted to noncom-bustible floors or steel benches. Formaximum space saving, up to threeunits can be stacked. Consult

    Figure 1.3 for charger cabinet dimensions. Wall mounting requires the optional brackets described inSection 6.6.

    Cells x Capacity x = Cubic feet of hydrogen/charge cycle

    18 x 720 x = 31.1 Cubic feet of hydrogen/charge cycle

    1.5 Mechanical installation

    1.6 Electrical connection Each charger requires a fused safety disconnect switch or a circuit breaker.Use a line protection device rated for therecommended line fuse value shown onthe charger nameplate (Figure 1.1).

    Electrical installations must be performed by a qualified electrician and satisfy all local, national and federalelectrical codes. It is vital to the reliableoperation of the charger that it be provided a good earth ground.

    1.7 Input voltage changeover The voltage circled on the AC voltagerating label (Figure 1.4) must matchthe available line voltage. If the voltagesare different, it will be necessary tochange AC line fuses, AC phase fusesand the connection terminal on both theferroresonant power and control transformers. Consult the voltagechangeover instruction label inside the cabinet door. BE SURE THECHARGER IS DISCONNECTED FROM

    ITS AC POWER SUPPLY BEFORE ATTEMPTING THIS MODIFICATION.

    NOTE: AC voltage changeover must be made at the terminals of both theferroresonant power transformer andthe control transformer.

    Input voltage changeover CANNOT BE PERFORMED on chargers manufactured for 575 VAC only operation.

    FIGURE 1.3-Cabinet dimensions

    B

    J

    EC

    DA

    F

    G

    DA

    H

    J

    EC

    BAC Cable

    Entrance Hole1.094 (27.79 mm)

    DC CableEntrance Hole

    1.75 (44.45 mm)

    Clearance Holes0.56" (14.22 mm) diameter

    AC CableEntrance Hole

    1.094 (27.79 mm)F

    Clearance Holes0.56" (14.22 mm) diameter

    CABINETS 3517 AND 3518

    DIMENSIONAL DRAWINGS

    CABINET 3519

    0.24

    100

    0.24

    100

    CAUTIONElectrical connections can work loose during shipping. Check all connectionsfor tightness before connecting the charger to the AC supply voltage.

    For example, an 18-cell batteryrated at 720 ampere-hours:

    CABINET A B C D E F G H J

    NO. inches mm inches mm inches mm inches mm inches mm inches mm inches mm inches mm inches mm

    3517 32.22 818 24.00 610 21.81 554 30 762 19 483 11.00 279 2.81 71.4 4.38 111 1.50 38.13519 18.22 463 24.00 610 21.81 554 16 406 19 483 4.00 102 2.81 71.4 4.38 111 1.50 38.13518 43.22 1098 32.00 813 28.81 752 41 1041 26 660 16.50 419 2.81 71.4 4.38 111 1.50 38.1

  • 4

    1.7 Input voltage changeover(continued)

    1.8 AC input voltage cables

    CAUTIONDO NOT ATTEMPT TO

    RECONNECT VOLTAGE WITHOUT READING

    INSTRUCTIONS

    CAUTIONBe sure the charger positive terminal is connected to the charger connector terminal marked (+) and the negative terminal to the one marked (-).

    THIS CHARGERCONNECTED FOR120V - 208V - 240V480V - 575VOTHER

    JN-95

    HIGHVOLTAGE

    3-4-56-7-8

    10- 12 -1520-25-3035-40-45

    50-60

    208VOLTS

    3-4-56-7-8

    10-12-1520- 25 -3035-40-45

    50-60

    LOWVOLTAGE

    3-4-56-7-8

    10...

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