INSTALLATION & OPERATING INSTRUCTIONS

CHP 100 SERIES INDUSTRIAL BATTERY CHARGERS

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PACIFIC CHLORIDE

Champion is a registered trademark of Federal-Mogul Corporation

GNB Industrial Power Motive Power

829 Parkview Boulevard Lombard, IL 60148-3249 U.S.A. Tel: 877.GNB.INFO Fax: 630.691.7869 GB-3653 RPT 11/01

GNB Industrial Power Motive Power

8301 Keele Street Maple, Ontario Canada L6A 1T2 Tel: 905.669.9326 Fax: 905.669.7688
Printed on recycled paper

Exide Technologies Chloride Motive Power

P.O. Box 1, Salford Road Over Hulton, Bolton BL5 1DD United Kingdom Tel: 44.1204.661.230 Fax: 44.1204.652.100

www.gnb.com

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TABLE OF CONTENTS TITLE

1.0 IMPORTANT OPERATING AND SAFETY INSTRUCTIONS 2.0 INTRODUCTION 3.0 RECEIVING CHARGER 4.0 LOCATION AND INSTALLATION OF CHARGER 4.1 Stacking 5.0 AC ELECTRICAL SUPPLY 5.1 AC Fuse Mounting 5.2 Input Voltage Change 5.3 AC Voltage Connections 5.4 Ground connection 6.0 DC OUTPUT 7.0 APPLICATION 7.1 Fault and Display Codes 7.2 Options TABLE 2 - SINGLE PHASE RATINGS TABLE 3 - THREE PHASE RATINGS 8.0 CABINET OUTLINE/DIMENSIONS 9.0 CHP100 CHARGER OPERATION 9.1 CHP100 Charger Functional Description 10.0 CHARGE TIME 11.0 MAINTENANCE APPENDIX A: ELECTRICAL SCHEMATICS

PAGE
2 3 3 3 3 3 3 3 7 7 7 8 8 8 9 10 13 14 15 16 16 18

Instr. 4770-65-95005-20 Rev. 12/06/01

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CHP100 SERIES INDUSTRIAL BATTERY CHARGERS

1.0 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 uninsulated 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; ALWAYS press the STOP pushbutton before unplugging the battery to prevent arcing or burning. d) If the battery is unplugged during charging, the charger will indicate CHG INTERRUPTED XXAH, UNPLUGGED BATTERY. To restart charging, wait for five seconds when the display will read UNIT READY and plug in the next battery. e) Only qualified personnel should operate or service this equipment. 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. Operating environment should not contain any contaminations that may cause corrosion or contamination of a charger in degree that can degrade the performance of a charger or the safety requirements i) Do not operate this unit if it has received a sharp blow, been dropped or otherwise damaged. Take it to a qualified GNB service center. Do not disassemble the charger. Have the charger examined by a GNB service representative or local qualified service facility. Incorrect re-assembly of the charger may result in an explosion, electric shock or fire.

j)

k) The charger profile is set at the factory for a charger DC cable length of 9ft and a battery DC cable length of 25in. If DC cable lengths are adjusted please contact you local GNB service representative.

Instr. 4770-65-95005-20

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2.0

INTRODUCTION

The GNB CHP100 battery chargers are convection cooled, solid state, micro-processor controlled SCR regulated chargers designed to make battery charging simple. They are factory set to charge sealed lead-acid batteries but it may be configured by a GNB service representative 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. Large easy to read vacuum fluorescent display, three button keypad and LEDs report on charger and battery status.

WARNING: TO REDUCE THE RISK OF FIRE, INSTALL BATTERY CHARGER ON A FLOOR OF NON-COMBUSTIBLE MATERIAL SUCH AS STONE, BRICK, CONCRETE OR METAL. IF THIS IS NOT AVAILABLE, A FLOOR PLATE OF AT LEAST 1.43mm GALVANIZED OR 1.6mm UNCOATED STEEL EXTENDED AT LEAST 150mm BEYOND THE EQUIPMENT ON ALL SIDES MUST BE INSTALLED. 5.0 AC ELECTRICAL SUPPLY

3.0

RECEIVING CHARGER

The charger must be connected to either a single phase, or three phase 50 or 60 Hertz ( 2%) AC power source. The following options are available:

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 portect your rights. Before installing check that the charger namelpate data corresponds to the packing slip and to the model specified on the original sales order. The CHP100 chargers are delivered on skids for easy handling using a fork lift truck.

TABLE 1 INPUT VOLTAGE CHOICES

Single phase a) 120/208/240VAC, 60Hz b) 208/240/480VAC, 60Hz c) 600VAC, 60Hz d) 240VAC, 50Hz Three phase e) 208/240/480VAC, 60Hz f) 480VAC, 60Hz g) 600VAC, 60Hz h) 380VAC, 50Hz g) 415VAC, 50Hz

Only in a multi-input charger can the AC input wire configuration be changed. Follow Figure 1 (page 4) for single phase input or Figure 2 and Figure 3 (pages 5-6) for three phase input transformers. This change should be done by a qualified electrical contractor.

4.0

LOCATION AND INSTALLATION OF CHARGER

5.1

AC FUSE MOUNTING

Proper installation is important in order to achieve good charger performance, long troublefree operation and to prevent damage to the charger and batteries. The charger should be located in a clean, dry and well ventilated area, where the ambient temperature is between +45F/7.2C and 90F/32.2C. To permit free air flow for convection cooling allow four inches minimum between the charger and any wall, six inches from other equipment, and never store anything beneath or on top of the charger.

The charger comes with a fuseblock rated big enough to accommodate the highest possible current and voltage for that particular model. When needed, find the proper AC fuse rating from Table 2 and Table 3 (see pages 912) for the input fuses (F1, F2 in case of a single phase input or F1, F2, F3 in case of a three phase input). Fuses with an ampere rating of 30A or less are smaller and need fuse reducers when placed in a 60A fuseblock.

5.2

INPUT VOLTAGE CHANGE

4.1

STACKING

When stacking chargers on top of each other, ensure that cabinets are bolted together using properly sized black #1/4-20 UNC hardware provided in all four corners on top cover. The floor mounting must be done with #3/8-16 UNC bolts (steel rack) or #3/8 lag screws and anchors (concrete floor). All charger models with a Z, CHP100-XX-XXXT1Z OR CHP100-XX-XXXS1Z, can be stacked to a maximum of three high.

WARNING: THE ABOVE PROCEDURES MUST BE FOLLOWED EXACTLY TO AVOID INJURY OR RISK OF ELECTRIC SHOCK. Instr. 4770-65-95005-20 Page 3

When changing the taps on the input side between 1) 120, 208, 240 VAC or 2) 208, 240, 480 VAC (single phase input), be sure to change the wires and/or jumpers according to Figure 1 (page 4). Once finished, refer to Table 2 (page 9) for the correct size of input fuses. Similarly when changing input voltage between 1) 208, 240, 480 VAC or 2) 380, 415VAC (three phase input) follow the schematics on Figure 2 or Figure 3 (pages 5-6) whichever is applicable. Following that, check Table 3 (page 10) for the correct size of the input fuse. Figure 3 applies to 12 cell 475, 600, 750, 865 Ah; 18 cell 475, 600, 750, 865, 1050 Ah; and 24 cell 475, 600, 750, 865Ah chargers only.

NOTE: Upon completion and proper verification of the

input voltage configuration change, markings on the door label and the unit nameplate must be revised 120 VAC CONFIGURATION (120/208/240V INPUT)

(crossing out factory set markings); re-mark the label with a permanent marker to reflect new input voltage configuration and fuse size. 208 VAC CONFIGURATION (208/240/480V INPUT)

BLK

BRN

BLK

BRN

L2

L1

L2

L1

208 VAC CONFIGURATION (120/208/240V INPUT)

240 VAC CONFIGURATION (208/240/480V INPUT)

BLK

BLK

BRN

BRN

L2

L1

L2

L1

240 VAC CONFIGURATION (120/208/240V INPUT)

480 VAC CONFIGURATION (208/240/480V INPUT)

BLK

BLK

BRN

BRN

L2

L1

L2

L1

Instr. 4770-65-95005-20

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FIGURE 2: THREE PHASE INPUT WARNING: IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE DAMAGE TO THE CHARGER AND BATTERY
208VAC CONFIGURATION (208/240/480V INPUT) 380VAC CONFIGURATION

L2

L1

L3

L2

L1 L3

L2

L1

L3

L2

L1 L3

240VAC CONFIGURATION (208/240/480V INPUT)

415VAC CONFIGURATION

L2

L1

L3

L2

L1

L3

L2

L1

L3

L2

L1

L3

480VAC CONFIGURATION (208/240/480V INPUT)

L2

L1

L3

L2

L1

L3

Instr. 4770-65-95005-20

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FIGURE 3: THREE PHASE WARNING: IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVER DAMAGE TO THE CHARGER AND BATTERY.

208VAC CONFIGURATION (208/240/480V INPUT) (CHARGERS WITH SPEC V16-893XX-XXONLY)

L1

L2

L3

L1

L2

L3

240VAC CONFIGURATION (208/240/480V INPUT) (CHARGERS WITH SPEC V16-893XX-XXONLY)

L1

L2

L3

L1

L2

L3

480VAC CONFIGURATION (208/240/480V INPUT) (CHARGERS WITH SPEC V16-893XX-XXONLY)

L1

L2

L3

L1 L3

L2

Instr. 4770-65-95005-20

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5.3

AC VOLTAGE CONNECTIONS

6.0

DC OUTPUT

To connect the input AC voltage, route the AC conduit through the knockout hole provided. Continue the AC wiring to fuseholder terminals L1 (N) and L2 (L) (single phase input) or L1, L2, and L3 (three phase input), ensuring that the AC source phases match the phase rotation on the AC input. For proper connection torque the screws to approximately 25 inch-pounds.

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 (-), and the RED DC cable must be connected to the battery positive (+). 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.

5.4

GROUND CONNECTION

It is a requirement to ground the chassis while the charger is connected to AC power. The charger comes with a ground wire attached to the stud, clearly marked on the chassis. To ensure good continnuity keep the contact area clean. The stud is designed for a 3/16 hardware. See gounding method shown below (Figure 4.).

NOTE: Use only identical replacement fuses obtainable

from your GNB service representative

WARNING: DO NOT OPERATE THE UNIT WITHOUT PROPER GROUNDING. IMPROPER GROUNDING CAN RESULT IN THE RISK OF AN ELECTRIC SHOCK AND ELIMINATES CHARGER WARRANTY. CAUTION: USE MINIMUM 75C WIRING. FOR SUPPLY CONNECTIONS, GROUND CHARGER PROPERLY USING GROUNDING STUD [SDOACI1](GND) PROVIDED. USE COPPER-CLAD ALUMINUM, ALUMINUM OR COPPER CONDUCTORS ONLY.
After electrical connection is completed, the charger is ready for operation.

FIGURE 4: GROUNDING METHOD

Instr. 4770-65-95005-20

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7.0

APPLICATION

7.2.4

CHP100 REMOTE CONTROL

The charger will automatically charge a battery per the Ah rating set at the factory. The charger can be re-set for anywhere between 45% to 200% of the nameplate Ah rating. Ensure that battery and charger are matched. Keep in mind if the charger is set for more than 100% of Ah of the charger the charging time will increase proportionately to up to 16 hours. For battery sizes not listed, contact your local GNB service representative.

The CHP100 has an available remote control kit that allows the operator to control the charger from a remote control panel (included) away from the charger. Request Instruction number V16-92625-00 for complete details.

7.2 7.2.1

OPTIONS JIC SWITCH ASSEMBLY

All CHP100 battery chargers can come with a factory installed fused JIC switch assembly option for extra protection of the operator. In the "OFF" position, the door can be opened but AC power on the input side is present with the ramainder of the charger void of AC power. In the "ON" position, AC power is supplied to the charger but the door cannot be opened. See applicable drawing 4770-65-73041-05, 4770-65-73041-15 or 4770-6573041-17 for electrical schematic (Appendix B, pages 18-27). NOTE: Only HRCI-R type fuses (ECSR or equivalent) with the notched ferrule at one end can be used. A JIC option can only be factory installed and it will be in a B, C or D size cabinet.

7.2.2

BATTERY WATERING OPERATION

The CHP100 battery charger has an available watering control, in the form of a relay contact at terminals TB10-1 to TB10-2 (supplied for customer connection). The relay closes thirty minutes after the charger reaches gassing voltage. It remains closed for approximately ten minutes. NOTE:These options require a different control card per drawing 4120-65-68650-05 (see Appendix B, pages 1827).

RELAY CONTACT RATINGS:

- AC: 125V 0.6A 1.0PF maximum - DC: 30V 2A resistive maximum

7.2.3

MOMENTARY REMOTE STOP OPERATION

The CHP100 battery charger has an available remote stop control option that allows the operator to turn off the charger from a remote site. An external momentary pushbutton rated at or above 2.7 times the number of cells (Vdc) and at least 0.5Adc is required. The pushbutton is connected to terminal TB-1, -2. Once the stop button is depressed the charger will stop the charge cycle. To re-start charging battery has to be unplugged and then re-connected. See drawing 4120-65-68650-20 (Appendix B pages 18-27) for electrical schematics. Instr. 4770-65-95005-20 Page 8

TABLE 2 SINGLE PHASE TECHNICAL DATA

STANDARD MODEL CHP100-XX-XXXX-S1Z CHP100-06-260S1Z CHP100-06-475S1Z (50 Hz) DC AMPS 40 74 74 93 93 134 AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS 74 (50 Hz) FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE 120 12 15 19 25 X 26 35 X C.F. C.F. 26 35 C.F. C.F. C.F. 18.5 25 X X X X X C.F. C.F. C.F. C.F. C.F. AC AMPS @ AC VOLTS 208 7 10 11 15 X 15 20 X 20 25 23 30 15 20 19 25 27 35 30 40 10.5 15 X 19.5 25 X 25.5 35 X 34 45 34 45 38 50 16 20 30 40 240 6 8 9.5 12 9.5 12 14 20 13.5 20 18 25 20 25 14 20 16 20 23.5 30 26 35 9 12 9 12 17 25 17 25 22 30 22 25 29 40 29 40 34 45 14 20 26 35 480 3 4 5 7 X 7 10 X 9 12 10 15 6.5 10 8 10 12 15 13 20 5 7 X 8.5 12 X 11 15 X 14.5 20 14.5 20 17 25 7 10 14 20 B 240 109 B 195 88.5 B 305 138 B 270 122 B 270 122 B 235 107 B 225 102 B 212 96.4 B 200 90.7 A 130 59.1 A 120 54.4 B 300 136 B 260 118 B 210 95 B 160 72.5 B 295 134 B 255 116 B 205 93.2 B 190 86.2 A 130 59.1 CABINET TYPE A A WEIGHT LBS 76 120 KGS 34.5 54.4

CHP100-06-600S1Z (50 Hz) CHP100-06-865S1Z

CHP100-06-965S1Z

150

CHP100-09-475S1Z

74

CHP100-09-600S1Z

93

CHP100-09-865S1Z

134

CHP100-09-965S1Z

150

CHP100-12-260S1Z

40

(50 Hz)

40

CHP100-12-475S1Z

74

CHP100-12-600S1Z

93

(50 Hz)

93

CHP100-12-750S1Z

116

CHP100-12-865S1Z

134

CHP100-12-965S1Z

150

CHP100-18-260S1Z

40

CHP100-18-475S1Z

74

Instr. 4770-65-95005-20

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TABLE 2 SINGLE PHASE TECHNICAL DATA

STANDARD MODEL CHP100-XX-XXXX-S1Z CHP100-18-600S1Z CHP100-18-750S1Z 116 CHP100-18-865S1Z 134 (50 Hz) 134 CHP100-24-260S1Z 40 CHP100-24-475S1Z 74 (50 Hz) CHP100-24-600S1Z 93 (50 Hz) 93 74 DC AMPS 93
AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE

AC AMPS @ AC VOLTS 120 C.F. C.F. C.F. X X X X X X X 208 36.5 50 48 60 48 60 X 22 30 39 50 X 48 60 X X 240 31.5 40 44 60 44 60 44 60 19 25 33.5 45 33.5 45 41 60 41 60 480 16 20 22 30 22 30 X 10 15 17 25 X 21 30 X X C C C C B C C C CABINET TYPE B

WEIGHT LBS 260 260 325 340 300 315 340 380 400 KGS 118 118 147 155 135 143 155 172 182

NOTE: C.F.: CONTACT FACTORY; X: NOT AVAILABLE; -: DATA NOT AVAILABLE

Instr. 4770-65-95005-20

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TABLE 3 THREE PHASE TECHNICAL DATA

AC AMPS @ AC VOLTS STANDARD MODEL CHP100-06-475T1Z CHP100-06-600T1Z CHP100-06-750T1Z CHP100-06-865T1Z CHP100-06-965T1Z CHP100-06-1050T1Z CHP100-06-1200T1Z 186 CHP100-06-1450T1Z CHP100-09-600T1Z CHP100-12-475T1Z CHP100-12-600T1Z CHP100-12-750T1Z CHP100-12-865T1Z CHP100-12-965T1Z CHP100-12-1050T1Z CHP100-12-1200T1Z CHP100-12-1450T1Z CHP100-18-260T1Z CHP100-18-475T1Z CHP100-18-600T1Z CHP100-18-750T1Z CHP100-18-865T1Z CHP100-18-965T1Z 225 93 74 93 116 134 150 163 186 225 40 74 DC 208
AMPS FUSE AMPS

CABINET 50Hz CABINET TYPE B B B B B B C WEIGHT LBS 170 190 220 220 235 245 260 KGS 77.1 86.2 99.8 99.8 107 111 118 380 C.F. C.F. C.F. C.F. C.F. C.F. C.F. C.F. C.F. 5.5 8 7 10 9.2 12 10 15 C.F. 12 15 C.F. C.F. C.F. C.F. C.F. 16 20 16 20 18 25 415 C.F. 3.5 5 C.F. C.F. C.F. C.F. C.F. C.F. C.F. 5.0 7 7 10 9 12 9 12 C.F. C.F. C.F. C.F. C.F. 8 12 10.7 15 15 20 15 20 17 25 C B B B B / C* C C C C C B B B / C* B / C* C C 290 220 215 220 250 255 260 270 298 310 215 255 300 310 325 340 132 99.8 97.6 100 113.5 116 118 122 135 141 98 116 136 141 148 155

60Hz 240 4.5 6 6 8 8 12 9 12 10 12 11 15 11 15 14 20 10 15 8 12 10 15 14 20 14 20 18 25 19 25 22 30 26 35 8 10 11 15 14 20 18 25 21 30 22 30 480 2.2 3 3.5 5 4 6 5 7 5 6 5.5 8 5 7 7 10 5 7 4 6 5 7 7 10 7 10 9 12 9.5 12 11 15 14 20 4 6 5.5 8 7 10 9 12 10.5 15 11 15 5 7 7 10 9 12 10 15 11 15 12 15 12.7 20 15 20 12 15 9 12 11.5 15 15 20 16 20 21 30 22 30 26 35 30 40 9 12 14 20 16 20 20 30 24 35 26 35

CHP100-XX-XXXX-T1Z AMPS 74 93 116 134 150 163

FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS

93 116 134 150

FUSE AMPS FUSE AMPS FUSE AMPS FUSE

Instr. 4770-65-95005-20

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TABLE 3 THREE PHASE TECHNICAL DATA

AC AMPS @ AC VOLTS STANDARD MODEL CHP100-18-1050T1Z CHP100-18-1200T1Z CHP100-18-1450T1Z CHP100-18-1700T1Z CHP100-24-475T1Z CHP100-24-600T1Z CHP100-24-750T1Z 116 CHP100-24-865T1Z CHP100-24-965T1Z CHP100-24-1050T1Z CHP100-24-1200T1Z CHP100-24-1450T1Z CHP100-24-1700T1Z CHP100-36-475T1Z CHP100-36-600T1Z CHP100-36-750T1Z CHP100-36-865-T1Z 134 150 163 186 225 264 74 93 116 134 DC 208
AMPS FUSE AMPS

CABINET 50Hz CABINET TYPE C C C D B / C* C C WEIGHT LBS 380 410 450 550 290 320 345 KGS 163 186 204 250 132 145 157 380 19 25 26 35 26 35 C.F. C.F. 15 20 18 25 18 25 C.F. 24 35 28 40 27 35 31 40 C.F. 21 35 C.F. C.F. C.F. C.F. C.F. C.F. C.F. C.F. 415 17.5 25 C.F. 27 35 C.F. 10 15 12 15 17.2 25 17.6 25 20 30 22 30 C.F. 22 30 25 35 C.F. 20.5 30 27 35 27 35 29.4 40 42 60 19.5 25 C.F. C.F. C.F. C C C C C D C C C C 380 400 425 440 490 525 330 420 460 480 173 182 193 200 222 239 150 190 209 218

60Hz 240 24 35 32 45 41 60 44 60 15 20 18 25 24 35 27 40 36 50 38 50 46 60 C.F. C.F. 29 40 35 50 40 60 46.5 60 C.F. C.F. 34 45 C.F. 42 60 C.F. 480 12 15 16 20 21 30 22 35 7.5 10 9.5 12 12 15 14 20 18 25 18.5 25 23 30 27 35 31 40 14.5 20 18 25 20 30 23 30 27 40 37 50 17 25 33 45 21 30 C.F. 28 40 37 50 47.5 60 48 60 17 25 21 30 28 40 31 45 40 60 44 60 C.F. C.F. C.F. 34 45 41 60 46 60 C.F. C.F. C.F. 39 50 C.F. 48 60 C.F. -

CHP100-XX-XXXX-T1Z AMPS 163 186 225 264 74 93

FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE

CHP100-36-965-T1Z CHP100-36-1450-T1Z CHP100-40-475-T1Z CHP100-40-1200-T1Z CHP100-48-600-T1Z CHP100-48-865-T1Z

150 225

AMPS FUSE AMPS FUSE AMPS FUSE AMPS FUSE

C D C D D D

500 550 450 500 550 600

227 250 204 227 250 272

74 186 93 134

AMPS FUSE AMPS FUSE

NOTE: C.F.: CONTACT FACTORY; X: NOT AVAILABLE -: DATA NOT AVAILABLE

Instr. 4770-65-95005-20

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8.0 CABINET OUTLINE/DIMENSIONS FOR Z MODEL CHARGERS ONLY

CABINET A B C D D (Mining) E (Mining)

DIM. A 15.10 22.70 32.10 24.30 24.30 24.30

DIM. B 20.65 26.50 26.50 42.00 42.00 59.00

DIM. C 12.75 22.25 22.25 23.65 23.65 31.50

NOTE: Mining chargers are equipped with a drip cap and four lifting eyebolts for sling lifting. Add an additional 5.000 to the height. (DIM.C)

Instr. 4770-65-95005-20

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9.0 CHP100 CHARGER OPERATION

LED (NONE) DISPLAY UNIT READY DESCRIPTION PLUG IN THE BATTERY TO COMMENCE CHARGING.

(NONE)

(TIME) START TIME: XX:XX START EQUAL FAULT DELAY START EQUAL FAULT

DELAY MODE, PRESS START BUTTON TO OVERRIDE.

(BATTERY VOLTAGE/CURRENT/AH RETURNED) XX.XV XX.XA XXXAH CHARGING STOP EQUAL FAULT HIGH RATE CHARGING (First stage) (Orange) HIGH RATE STOP EQUAL FAULT (BATTERY VOLTAGE/CURRENT/AH RETURNED) XX.XV XX.XA XXXAH 80% CHARGED STOP EQUAL FAULT FINISH RATE CHARGING (Second stage) (Yellow) FINISH RATE (CV) STOP EQUAL FAULT (BATTERY VOLTAGE/CURRENT/AH RETURNED) XX.XV XX.XA XXXAH 80% CHARGED STOP EQUAL FAULT FINISH RATE CHARGING (Third stage) (Yellow) FINISH RATE (CC) STOP EQUAL FAULT (NONE) CHARGE INTERRUPTED XAH UNPLUG BATTERY XXXAMP-HR RETURNED UNPLUG BATTERY XXXAMP-HR RETURNED UNPLUG BATTERY POWER FAILURE NEXT WHEN? EXIT TO INTERRUPT CHARGING, PRESS STOP BUTTON BEFORE UNPLUGGING THE BATTERY. CHARGING IS COMPLETE. UNPLUG THE BATTERY

CHARGE COMPLETE (Green) (NONE)

NO ALARMS ARE PRESENT. FAULT CONDITION EXISTS. DO NOT UNPLUG THE BATTERY. PRESS WHEN? BUTTON TO FIND THE DATE AND TIME OF FIRST FAULT. PRESS NEXT BUTTON TO FIND ANY OTHER FAULTS. SEE SECTION 10.1.19 FOR DETAILS.

FAULT (Red)

(BATTERY VOLTAGE/CURRENT/AH RETURNED) EQUALIZE XX.XV XX.XA XXXAH PRESS EQUAL BUTTON TO EQUALIZE THE (Orange) STOP EQUAL FAULT BATTERY. PRESS AGAIN TO CANCEL. AND 80% CHARGED EQUALIZE (Yellow) STOP EQUAL FAULT

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10.1

CHP100 CHARGER FUNCTIONAL DESCRIPTION

10.1.11

XX.XV

XX.XA

XXXXAH

This section gives a brief description of each LED, softkey, and display message on the CHP100 charger control panel.

10.1.2

CHARGING (LED)

The first number indicates the battery voltage, the second number indicates the charging current, and the third number indicates the Amp-hours of charge that have been returned to the battery. This information alternates with the following messages: HIGH RATE while in High Rate mode, FINISH RATE while in Finish Rate mode, or EQUALIZE while in Equalize mode.

This LED indicates that the charger is ON and in High Rate charge mode.

10.1.12 START (softkey function)

Press this softkey to override a previously set delay and start the High Rate charge cycle.

10.1.3

80% CHARGED (LED)

This LED indicates that the battery is 80% charged and the charger is in Finish Rate charge mode.

10.1.13 HIGH RATE (Orange LED)

This message indicates that the charger is in the High Rate mode.

10.1.4

CHARGE COMPLETE (LED)

This LED indicates that the charge cycle has completed. The battery can now be safely unplugged.

10.1.14 FINISH RATE (Yellow LED)

This message indicates that the charger is in the Finish Rate mode.

10.1.5

EQUALIZE (LED)

This LED indicates that the charger is in the equalize mode. Refer to SECTION 10.1.18 for more details.

10.1.15 STOP (softkey function)

This softkey will interrupt the charge cycle when depressed. The battery can now safely be unplugged.

10.1.6

FAULT (LED)

This LED indicates that a fault occured prior to or during the charge cycle. Refer to SECTION 10.1.19 for detailed descriptions of each fault.

10.1.16 XXXAMP-HR RETURNED (Green LED)

This message indicates that the charge cycle is complete and the battery can safely be unplugged.

10.1.7

DISPLAY

The display shows the battery voltage, charging current, and amp-hours returned during high rate, finish rate, and equalize modes. Different fault messages are also displayed here. Furthermore it identifies the function of each softkey while in different modes. (Normal or Program)

10.1.17 CHARGE INTERRUPT UNPLUG BATTERY

This message indicates that the "STOP" softkey has been pressed or a fault has occured during charge. Refer to SECTION 10.1.19 for detailed descriptions of each fault.

10.1.8

UNIT READY

10.1.18

EQUALIZE (softkey function)

This indicates that the AC supply is correct and that the unit is ready to start charging as soon as the battery is plugged in.

10.1.9

START TIME:

XX:XX

This message indicates the time the battery charger will start charging. It alternates with the "DELAY" message for 10 seconds, then the cycle starts.(A 10 second delay is automatically initiated as soon as the battery is plugged in).

NOTE: New CHP100 program #3611-66-12267-98 v.1.20 and greater have the choice of either manual equalize (MAN), auto-equalize by number of charge cycles completed (NUM), or auto-equalize on a particuliar day of the week (DAY). Only in the manual mode will pressing the softkey make the charger go into the equalize mode. The "EQUALIZE" LED will light. Press the softkey a second time to cancel the equalize mode; the LED should extinguish. The auto modes disable the EQUAL softkey as equalizing will occur automatically.

10.1.19 FAULT (softkey function) 10.1.10 DELAY

This message indicates that the charger is in the delay mode and charging will not start until the delay time has elapsed. Refer to SECTION 10.1.27 for further details. Instr. 4770-65-95005-20 Page 15 DO NOT UNPLUG BATTERY or the alarms will clear as the control resets. Press this softkey to view the alarms that have occured since battery plug-in. Press WHEN? to find out the date and time of the alarm(s).

10.1.20 NO ACTIVE ALARM

This message indicates that no alarms have occured.

Once you have completed the clock and/or delay settings, press the 'QUIT' softkey.

10.1.27.1

CLOCK

10.1.21 AC VOLTAGE HI/LO OR PHASE LOSS/ROTATION

This fault message indicates that prior to or during charge, the AC supply is low, one or more phases are missing, and/or the phase sequence is incorrect (three phase input units only).

Press the 'CLOCK' softkey then press the appropriate softkeys to set the time, the date, and the day of the week (new on program v.1.20 and greater).

10.1.27.2

DELAY

10.1.22 POWER FAILURE

This fault message indicates that the AC supply was interrupted.

NOTE: Only the 'TIME' (actual start time of charger start-up with the battery plugged in) OR the 'HOURS' (actual delay period in hours and/or minutes from the time of battery plug in) DELAY mode should be used. Ensure that the unused mode is set to zeros before unit start-up. Press the DELAY softkey then press: 1. HOURS and the appropriate softkeys to change the delay time in hours/minutes or 2. TIME and the appropriate softkeys to activate the actual time of day to start the charging process. NOTE: New CHP100 program #3611-66-12267-98 v.1.20 and greater have the POWERSAVE STARTX/STOPX feature to allow the user to set up to 3 start/stop times to save AC energy. However, the total of the running times must be equal to or greater than the normal total charging time. Contact factory representative for settting up this delay mode

10.1.23 OUTPUT FUSE BLOWN

This fault message indicates that the charger output fuse is blown.

10.1.24 LOW BATTERY VOLTAGE

This fault message indicates that prior to or during charge, the battery voltage is lower than the preset value (1.5 V/C).

10.1.25 HIGH BATTERY VOLTAGE

This fault message indicates that prior to charge, the battery voltage is greater than the preset value (2.25V/C). If the battery voltage dropped to within acceptable range, the charger will not start.

11.0

MAINTENANCE

10.1.26 DEFECTIVE BATTERY

This fault message indicates that the battery has not reached the gassing voltage after the preset high rate time has elapsed.

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 AC input and DC output of the charger are fused and should these fuses fail, the cause of the failure must be determined and corrected before the fuse(s) is (are) replaced. Never replace the fuse(s) with one of a higher capacity than the one originally fitted with (see Tables 2 and 3 pages 9-12).

10.1.27 CLOCK AND DELAY SETTINGS

This feature allows the user to set the date and time. It also allows to setup a delay. NOTE: The following procedures must be done with the AC power on and the battery unplugged. To access either feature: a. Press the left softkey three times. b. Press the middle softkey two times. c. Press the right softkey once. This will make the display show: XXX/XX/XX XX:XX:XX CLOCK DELAY QUIT

Instr. 4770-65-95005-20

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APPENDIX A: ELECTRICAL SCHEMATIC DRAWINGS Pages 19 - 27

Instr. 4770-65-95005-20

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