Precision Trading 60 R3.0 User's Manual
Contents
1. seta 18 44 R2 Topping Discharge Current Selector ccsccscssssssssssscsscsscsscssssessssssscessssnescessessossessnesssssessoees 18 45 SWI1 Main Time selector switch 100 eee eese seen essen sine eta an 18 4 6 SW2 Total Time selector switch 1 1 eee neen einen sensn stesso seta sse sesso 18 4 1 Keypaduxzna 18 4 8 5 4 CELL SELECTOR 19 49 SW5 DIGITAL VOLTMETER INPUT SELECTOR 19 4 10 SW6 VOLTAGE MODE SELECTOR eerie esee teen states tatnen sata teta entusiasta totu sane tatu 19 4 11 SW7 TIMER SPEED SELECTOR 19 4 12 DSTA RESET m 21 413 CYC D Hed 21 4 14 DS2A DUALS X 21 4 15 1528 MAIN 21 4 16 DS3A WEIN OBU 21 4 17 DS3B 0 21 4 18 DS4A AUTO rem 21 119 DSB DEC HE 21 Page 1 of 62 Operator Manual Supercharger 60 R3 0 4 20 wn 21 4 21 08582. 115v 20 Figure 3 Line Voltage Wiring 115V Page 33 of 62 Operator Manual Supercharger 60 R3 0 d amp BREAKER FAM 1 FAM 2 10154 CARD 115v METERS p ies rae TRANSFORMER 1 TRANSFORMER 2 TO SFA 10 SERY WHT E gaem 35v WHT a eae E a E E c LINE CORO 2X 304 MAGRA DB 20 PLUG amp 30R SHOWN Figure 4 Line Voltage Wiring 208 230V 408 11 FAM 115 FAN 2 CARD 115 METERS 4 FUSE 14 45 Poar TRANSFORMER 1 To SEI TRANSFORMER 2 TO wHl 38V T9 WHT ET Pere fe fe fefe pepe esp pus apti t ted os Fro Y LINE CORD 20 POWER WFAM 230v 24047 PLUG amp 30 SHOW 230 n DEA TO Figure 5 Line Voltage Wiring 230 245V Page 34 of 62 Operator Manual Supercharger 60 R3 0 8 VERIFICATION OF PERFORMANCE The Charger Analyzer has been designed manufactured and tested to give thousands of hours of trouble free operation but if you find that your unit is not performing properly or as expected please refer first to the operating instructions for re assurance that proper procedures are being followed If it is determined then that your Charger Analyzer is malfunction
3. 59 11 2 JN HC 59 1453 DE Bde VO rs dev TU 59 BATTERY TESTING NOTES ran ze oro ga dna aki CON Rs eco xv aH Re oda a ob aa aU 60 BjieWl ie 61 REVISION INDEX cocta ccs iua e Eo Ta ES Ta EE Tua Fdo Pe ERR E RR 62 Page 3 of 62 Operator Manual Supercharger 60 R3 0 TABLE OF FIGURES Figure L Block Di gram 5 tere epe ere ope e vete ime A ee pa ae B pers 7 Figure 2 Eront Parel n ara ree e dei en mn abet e 20 Eigure 3 Line Voltage Wiring udin beo te aene AAE 33 Figure 4 Line Voltage Wiring 208 230V 34 Figure 5 Line Voltage Winng 230 245V ii iiie autre o arp bene pae dte 34 Figure 6 Meters Board Adjustments esee eene enne nennen eene 44 Figure 7 Control Switch Board Adjustments 45 Figure 8 Current Control Board Adjustments 47 Figure 9 Monitor Board Adjustments esses trennen enne 48 Figure 10 Voltage Control Board Adjustment 50 11 Circuit Board Sequence pte plo eee ehe EEE 52 Figure 12 Measuring for a shor
4. P 21 4 22 2 tee ee peek se a eee te eU eR NT eene eL ee REOR assoi eo tsa siian 21 423 DS6B OPEN DIL 21 4 24 DS7A OVR TEMP oes ego ssnsti ES ED ERA Eee eroe eee eae eroe Eo rape 21 4 25 DS7B OVR HEAT redo 22 426 DSSA 22 4 27 58 teet bak ee ees oaoa oL ee Uns ve eos a Eee ep e eo aee Pede doe de 22 428 059 Qm 22 ADD 10510 oic 22 4 30 DS11 22 431 AUDIBLE ATA NHAU ERR 22 5 MODES OF OPRERATIONL acciaio cose ioc raso c roo decay eoo oe 23 51 CONSTANT CURRENT CHARGE 23 52 CONSTANT VOLTAGE 24 53 PEAK CHARGE Rt 25 54 DISCHARGE 26 6 OPERATING 5 4 27 61 lt 5 27 62 CONSTANT CURRENT CHARGE 28 63 CONSTANT VOLTAGE 28 6 4 PEAK VOLTAGE CHARGE 29 6 5 DISCHARGE E 30 6 6 Float Peak Voltage 12 1 11131 ense
5. 9 2 3 5 1 R29 10 VOLT ADJUSTMENT e Static test no battery or Calibrator e Adjust for a reading of 10 000V 0 003V at E7 e NOTE Newer versions of this circuit board have a fixed 10V reference no adjustment Verify that it reads 10V 0 005V 9 2 3 5 2 R28 LOW CURRENT CALIBRATE Connect a battery and start the Charger Analyzer in Single Rate Adjust for a reading of 0 9 to 1 0 AMP at the current digital panel meter with the topping charge current potentiometer set for 1 AMP 010 9 2 3 5 3 R25 HIGH CURRENT CALIBRATE Connect a battery and start the Charger Analyzer in Dual Rate e Adjust for a reading of 25 0 AMPS at the current digital panel meter with the main current potentiometer set for 25 0 AMPS 250 Page 46 of 62 Operator Manual Supercharger 60 R3 0 NOTE 1 Other currents can also be used for High Current calibration 20A minimum NOTE 2 Adjustments of R28 and R25 interactive Therefore It will be necessary to repeat the adjustments once or twice to achieve exact results The Voltage reading at shunt amplifier output must correspond to the current as follows voltage at 0 1V A 2 e Examples 40 A equals 4 00V 0 08V 20 A equals 2 00V 0 04V 10 A equals 1 00V 0 02V 5 A equals 0 50V 0 01V 10V CURRENT CONTROL LOW HIGH 10V SUP IIA 9879903011 E6 REFERENCE AMPLIFIER COMMON DRIVE zx EO COMMON Figure 8 Curr
6. setas tease tastes 31 67 OPERATING NOTES AND PRECAUTIONS 32 7 2 25 33 Tel HH S 33 72 JLINE VOLTAQGE ien eerte trie rhe EP 33 8 VERIFICATION OF 35 81 REQUIRED TEST EQUIPMENT AND ACCESSORIES ee ee ense te eene tn estne tenens ete so sen uea 35 82 VISUAL VERIFICATION 255 ee Tee aeter ii eee 35 8 3 TIMER VERIFICATION wscisisessessssesvessssesvessssesvesnisesvessssesvesnisctnconsseadesndscxesosseaxesndsednconsseaxesndasdnesssseaxeste 36 84 BATTERY OVERTEMP CUT OFF 0 37 8 5 VOLTAGE FAULT TEST 37 8 6 REVERSE POLARITY 38 87 OVERVOLTAGE 2 e saspe se sosta se Paste se sesto 38 Page 2 of 62 Operator Ma
7. 3 2 2 1 60 AMPS Total power dissipation must not exceed 1 2KW 1200 watts the product of battery voltage and battery current 3 2 2 2 NOTE Discharge current is automatically limited to 30 AMPS for battery voltages in excess of 32 VOLTS A current fault will be generated if attempting to discharge at more than 30 AMPS MINIMUM INCREMENT 3 2 3 1 0 1 AMP ACCURACY and STABILITY of settings 3 2 4 1 1 of reading 0 1 AMP MODES 3 2 5 1 Analysis automatic cut off 3 2 5 2 Deep cycle full discharge Page 14 of 62 Operator Manual Supercharger 60 R3 0 3 3 3 2 0 TERMINAL VOLTAGE 3 2 7 3 2 8 3 2 9 3 2 10 FUSING 3 2 6 Programmable in accordance with the number of cells selected at the equivalent of 1 VOLT cell 3 2 6 2 TOLERANCE 1 0 1 VOLT 3 2 6 3 NOTE 1 Due to cable connector losses the voltage registered by the Charger Analyzer will be lower than the actual battery voltage up to 0 2V depending on current 3 2 6 4 NOTE 2 Terminal voltage is ignored in the full discharge mode OVERHEAT PROTECTION 3 2 7 1 Two thermistors measure the temperature of the bank of discharge transistors 3 2 7 2 Operation is terminated if the transistors surface temperature exceeds 90 C OVER UNDER CURRENT PROTECTION 3 2 8 1 3 2 8 2 3 2 8 3 A Monitor circuit continuously compares the actual discharge current with the programmed value Operation is terminated if they diffe
8. Page 31 of 62 Operator Manual Supercharger 60 R3 0 6 7 OPERATING NOTES AND PRECAUTIONS 6 7 1 6 7 2 6 7 3 6 7 4 6 7 5 6 7 6 6 7 7 6 7 8 6 7 9 6 7 10 6 7 11 6 7 12 Make sure that the instrument is in the reset position before turning power on off or before connecting or disconnecting batteries When a cycle is terminated either automatically or by resetting wait about two to three seconds before re starting in any mode the control switch circuit has a time delay that ignores switch selections during a 2 to 3 second interval It is possible to alternate between the two discharge modes or from the dual rate to the single charge rate mode while the unit is in operation but the charger must be reset before switching to an opposite mode e g from charge to discharge or vice versa NOTE The control switch circuit ignores mode change requests without previous resetting of the charger If the discharge current limiter opens it is still possible to operate in the charge mode by setting the switch in the Monitor board to Test but if the charge current limiter opens the unit is rendered completely inoperative It is imperative that the current limiter and fuses be replaced with the same type and value 6 7 5 1 Failure to do so will result in serious damage to the control and power circuitry of the instrument 6 7 5 2 Failure to observe this requirement will void the warrant
9. 5 MODES OF OPERATION 51 CONSTANT CURRENT CHARGE 5 1 1 DUAL RATE 5 1 1 1 5 1 1 2 5 1 1 3 The battery is charged at the main rate for a preset time at the end of which the current is switched automatically to the topping rate for the remainder of the total time selected Charging is automatically terminated at the end of the total time selected cycle end or as a fault if e Battery overtemperature is detected Overtemp fault e Battery voltage is in excess of 1 75V cell as determined by the number of cells programmed or if battery voltage is in excess of 85V voltage fault Actual charging current differs from the programmed value by more than 1 AMP current fault Charge operation may be terminated at any time by depressing the RESET green button 5 1 2 SINGLE RATE 5 1 2 1 5 1 2 2 5 1 2 3 The battery is charged at the topping rate for a preset time Charging is automatically terminated at the end of the total time selected cycle end or as a fault if e Battery overtemperature is detected Overtemp fault Battery voltage is in excess of 1 75V cell as determined by the number of cells programmed or if battery voltage is in excess of 85V voltage fault Actual charging current differs from the programmed value by more than 1 AMP current fault Charge operation may be terminated at any time by depressing the green reset button Page 23 of 62 Operator Manual Superch
10. BUTTON FOR AUTOMATIC MAM ND TOPPIND CURPEXTS SELECT SINGLE WIE BUTTON FON MIL GLE END XT ME END OF TES 5 W00 1 mt E PO EXE MAN 3 HUE BUTTON TEST IF THE BATTERY MEETS CAPACITY CLE AMD THE EXD THE BELTED DECANE FAUNE VLL EE VOIE P THE BATTERY REINES FL B hawer n Lb ph MAL DERNE LL TEMINAT NELE THE Eb OF THE SELECTED OPERATION ALSO TERMIMATED IF ANY ABNORSHLITY DETECTED Figure 2 Front Panel Page 20 of 62 Operator Manual Supercharger 60 R3 0 4 12 051 RESET 4 12 1 Indicates that the unit is in standby 4 13 DSIB CYC END 4 13 1 Flashing with pulsating beeper cycle end Indicates that the unit has completed its cycle 4 14 DS2A DUAL 4 14 1 Indicates that the DUAL rate mode MAIN and TOPPING is selected 4 15 DS2B MAIN 4 15 1 Indicates that the unit is in MAIN charge 4 16 DS3A SINGLE 4 16 1 Indicates that the SINGLE rate mode Topping is selected 4 17 DS3B TOP 4 17 1 Indicates that the unit is in TOPPING charge 4 18 DS4A AUTO 4 18 1 Indicates that the AUTO analysis mode is selected 4 19 DS4B DISCH 4 19 1 Indicates that the unit is in AUTO discharge 4 20 055 FULL 4 20 1 Indicate
11. VOLTAGE 10 to 11 36VAC 2V nominal line dependent NOTE 10 to 14 or 11 to 14 will read 7 the total voltage 15V nominal 12 12V B 11 4V 0 6V NOTE This is a battery backed up source During a power failure the voltage will drop to the backup battery voltage minus 0 6V approximately 7 8V for a 7 cell battery or 9 0V for an 8 cell battery 13 COMMON not chassis ground or battery negative 14 COMMON not chassis ground or battery negative 15 15 15 0 0 75 16 15V 15 0V 0 75 17 9V Battery 8 4V to 9 6 nominal for 7 or 8 cell batteries respectively 18 18V 17V 1 2V nominal line dependent 21 Timing pulse twice the line frequency and about 11V and 1ms duration will read 1 2V 0 1V 0 2V with a DC meter 22 12V A 11 4 0 6V Page 49 of 62 Operator Manual Supercharger 60 R3 0 lt e gt E lt O gt O o Figure 10 Voltage Control Board Adjustments 9 2 5 2 VOLTAGE CONTROL See Figure 10 9 2 5 2 1 R11 FLOAT VOLTAGE Connect a CAL 100 Calibrator or a power supply capable of producing at least 10V very little current required to the CAL and CAL COMMON test points The positive lead to COMMON and the negative lead to CAL Set the calibrator power supply to 2 70V to simulate a battery that has 27 0V NOTE The Calibrator voltage is 1 10 of the simulated battery voltage Connect a
12. Operator Manual Supercharger 60 R3 0 2 3 Peak Voltage Charge 2 3 1 Nominal Battery Voltage 2 3 1 1 2 3 1 2 2 3 1 3 2 3 1 4 2 3 1 5 2 3 1 6 2 3 1 7 Enter the nominal battery voltage using the cell selector see chart on page xxx Select transfer from Main to Topping on Peak or stop on Peak Program the Main and Topping Charge currents as required Program the Main and Total Time selectors to allow the battery to reach the required charge level consult battery manufacturers specifications Verify that the Timer Speed is consistent with the required elapsed time Start the Charger Analyzer in the Dual Rate mode The charger will transfer from Main to Topping charge when the battery reaches the peak voltage or Start in the Dual or Single Rate mode and the Charger Analyzer will stop on peak at any part of the cycle The charge will terminate automatically CYCLE END when the TOTAL TIME selected is reached The charge will terminate as a FAULT if the MONITOR CIRCUIT detects that Battery temperature exceeds 45 C 113 F BATTERY OVERTEMP FAULT e The actual charge current deviates from the programmed value by more than one AMP CURRENT FAULT Page 10 of 62 Operator Manual Supercharger 60 R3 0 2 4 Discharge NOTE 1 Do not place batteries on the Temp Plate during discharge Due to the normal heating of the battery a false Overtemp may be generated later during the charge proces
13. for the Temp Plate 7 1 2 Allow also at least 6 15 2 cm of separation from the wall and adjacent equipment in order to maintain proper air flow VITAL 7 1 3 NOTE I In non air conditioned rooms or if other heat dissipating equipment are nearby it is recommended that circulating or extracting fans be used to aid in the heated air removal 7 1 4 NOTE 2 Operation in dusty or otherwise dirty air environments will severely reduce the cooling capacity of the fans and lead to premature failure 7 2 LINE VOLTAGE 721 Connect the unit to a wall receptacle NEMA 6 30R 230V re wire the transformers input for 240V or 208V operation with a 30 AMP capacity This line must be a dedicated line originating at the breakers box and must be protected with a motor load rated circuit breaker Sharing of the line with other equipment may result in erratic operation of the Charger Analyzer and the other devices connected to the same line 7 2 2 NOTE Operation of this unit with a soft line or with a line voltage 10 above or below the nominal 208 230 240V AC will result in erratic operation and may also lead to equipment damage if large voltage surges occur 7 2 3 Power Mains Wiring Diagram 404 BREAKER 115 FAN 1 I19v FAN 2 115 CARD 119v METERS FUSE 1 44 SB TRANSFORMER 1 TRANSFORMER 2 TO SCRI TO SCR2 HT TZ TO Ti 3Bv WHT 2 la
14. 3 SHUNT 3 5 3 1 Accuracy 0 25 3 5 3 2 Output 1mV A 100mV 100A FUSES and BREAKERS Other than charge and discharge current limiters 3 6 1 Mains Dual Magnetic Circuit Breaker 3 6 2 Electronics and digital panel meters 1 4A SLO BLO Page 17 of 62 Operator Manual Supercharger 60 R3 0 4 CONTROLS AND DISPLAYS 4 1 4 2 4 3 4 4 4 5 4 6 4 7 M1 Ammeter 4 1 1 Oto 199 9ADC DIGITAL PANEL METER 4 2 Positive sign indicates charge current 4 1 3 Minus sign indicates discharge current M1 Voltmeter 4 2 1 Oto 1 999VDC 0 19 99VDC and 0 to 199 9VDC DIGITAL PANEL METER 4 2 2 Indicates battery voltage in the internal 20 200V position and voltage present at the RED and BLK jacks in the 2 20 200V external positions Positive sign indicates proper battery connection Minus sign indicates reversed polarity connection R1 Main Charge Current Selector 4 3 1 turn potentiometer with digital readout to program current 4 3 1 1 MAIN charge current 0 50 0 AMPS R2 Topping Discharge Current Selector 4 4 1 Ten turn potentiometer with digital readout to program 4 4 1 1 TOPPING charge current 0 to 50 0 AMPS 4 4 1 2 DISCHARGE current 0 to 60 0 AMPS SW1 Main Time selector switch 4 5 1 Oto 9 hours or minutes to determine the duration of the main charge SW2 Total Time selector switch 4 6 1 60 hours or minutes to determine total charge or discharg
15. 8 cells 8 4V or 9 6V rechargeable TIME LIMITS 3 3 5 1 Oto 9 in Main 3 3 5 2 Oto 79 Total 3 3 5 3 NOTE The time limit in Total is dependent on the type of Timer Newer instruments characterized by a Timer Speed Switch mounted on the Front Panel have a limit of 79 hours or minutes while older units have a limit of 60 3 4 LINE INPUT VOLTAGE 3 4 1 3 4 2 3 4 3 3 4 4 3 4 5 115V 208V 230 245V Note For proper operation of this instrument power line voltages must be within 10 of the nominal The instrument is normally wired for 230V operation A terminal block at the transformer inputs allows field re wiring for 245V 208V or 115V operation See figs 3 4 and 5 For operation at line voltages in excess of 220V at 50Hz it is required that the 245V tap be used NOTE Operation at 115V is not recommended at battery charging currents above 15A due to the increased line current Page 16 of 62 Operator Manual Supercharger 60 R3 0 3 5 3 6 DIGITAL PANEL METERS 3 5 VOLTMETER 3 5 1 1 Accuracy system 0 25 of reading 0 1V in the 200V scale 0 01V in the 20V scale 0 005V in the 2V scale 3 5 1 2 Inputimpedance 1 M OHM 3 5 1 3 Scale 2V 20V and 200V 1 999V 19 9V and 199 9V for external measurements and 20V and 200V for internal battery measurements 3 5 2 AMMETER 3 5 2 1 Accuracy system 0 5 of reading 0 1A 3 5 2 2 Scale 200A 199 9A 3 5
16. 9 1 13 CURRENT TRACKING IS OFF BY A SMALL AMOUNT WHICH INCREASES AS THE PROGRAMMED VALUE IS INCREASED High current calibrate out of adjustment CONTROL board 10 1 14 9 1 15 THE UNIT STARTS BUT EXHIBITS A CURRENT FAULT AFTER SOME TIME from a few seconds to a few minutes a Current tracking is off exceeding 1 AMP Verify Control board calibration See 8 2 5 and 8 2 2 b Current tracking is proper Verify that the shunt amplifier in the Control board reads properly See 8 2 5 and 8 2 2 10 1 15 FAULT LIGHT S ON AND NO AUDIBLE ALARM UNIT RUNS NORMALLY e Switch in the Monitor board is set in the test position e If the switch is in the correct position run turn power off and back on to clear the condition and resume operation without resetting 10 1 16 DIGITAL METERS DO NOT TURN ON Open fuse to digital panel meters 10 1 17 OPEN LIMITER SMALL CRACK Inconsequential opening Replace and resume operation 10 1 18 DPEN LIMITER BLOWN ELEMENT vaporized e Discharge transistors short e Perform test per 9 2 10 1 19 CURRENT FAULT IN CV e Attempting to charge a battery with a voltage higher than the programmed float voltage e Attempting to discharge a battery with a voltage lower than the float voltage 10 1 20 VOLTAGE FAULT IN CV OR PEAK Attempting to discharge a battery with a voltage grater than the float voltage 10 1 21 IMMEDIATE TRANSFER TO TOPPING IN PEAK Attempting to charge a battery with a voltage highe
17. battery to the Charger Analyzer Set the Voltage Control Mode Switch to CV Constant Voltage Program for 10A of Topping current Enter 24 in the cell selector nominal battery voltage Start the Charger Analyzer in Single rate The current will rise to the programmed 10A Increase the power supply voltage towards 2 8V and observe the current The charging current will begin to decrease at about 2 75V and should reach zero as the voltage is advanced to 2 8V NOTE Ignore the actual battery voltage The Float voltage control circuit is responding to the simulated battery voltage as provided by the power supply Page 50 of 62 Operator Manual Supercharger 60 R3 0 Adjust R11 as required to reduce the charging current to zero at a simulated battery voltage of 28 0V Note This test can also be performed directly on a battery no calibrator required preferably one that is soft rapid voltage change Adjust R11 as necessary to maintain the battery at the required voltage see Verification of Performance section 7 page 27 9 2 5 2 2 R14 PEAK VOLTAGE Connect a CAL 100 Calibrator or a power supply capable of producing at least 35V with very little current in place of the battery Set the calibrator power supply to 28 5 V Set the Voltage Control Mode to Peak Transfer Set both current selectors to zero Enter 24 in the cell selector nominal battery voltage Start the Charger Analyzer in Dual rate The c
18. selector to 20 Start the unit in the full discharge mode red Unit will run Increase the discharge current selector to any value above 1 AMP 010 Unit will continue to run Switch to Auto discharge Unit will go to Capacity Failure Disconnect from the voltage source Reset CURRENT TRACKING 8 10 1 8 10 2 8 10 3 8 10 4 8 10 5 8 10 6 8 10 7 8 10 8 Settings 8 10 1 1 Set the Time selectors to 1 01 and the Cell selector consistent with the battery 8 10 1 2 Set the main charge current selector to 25 AMPS 250 8 10 1 3 Setthe topping charge current selector to 1 AMP 010 Connect the Battery Cable to the battery Start the unit in the two rate mode Current will rise to 25 0A 0 35A Switch to the single rate mode Current will drop to 1 0A 0 2A Reset Repeat this test for other high and low settings Repeat also for the discharge mode NOTE In discharge the readings may be lower by 0 1A to 0 2A See 8 2 4 for adjustments VOLTAGE CONTROL 8 11 1 See 8 2 7 for adjustments Page 39 of 62 Operator Manual Supercharger 60 R3 0 8 12 FLOAT VOLTAGE 8 13 8 12 1 8 12 2 8 12 3 8 12 4 8 12 5 8 12 6 8 12 7 8 12 8 Settings 8 12 1 1 Setthe Voltage Control Selector to Float 8 12 1 2 Set the Current Selectors to zero Connect the Battery Cable to the battery and note the battery voltage Using the chart in figure 3 page 19 find in the FLOAT column the clo
19. than 1 AMP current fault e Overheating of the transistor heat sinks is detected overheat fault e NOTE Discharge operation can be terminated at any time by depressing the green reset button 5 4 2 DEEP CYCLE FULL DISCHARGE 5 4 2 1 battery is discharged at the selected rate for a preset time 5 4 2 2 Discharge is automatically terminated cycle end at the end of the time selected or as a fault if e The actual discharge current differs from the programmed value by more than 1 AMP current fault NOTE Undercurrent fault monitoring is disabled at battery voltages below 2V Overheating of the transistor heat sinks is detected overheat fault Page 26 of 62 Operator Manual Supercharger 60 R3 0 6 OPERATING INSTRUCTIONS 6 1 GENERAL 6 1 1 Verify RESET 6 1 1 1 Verify that the reset button is depressed before turning power on Connect the Battery 6 1 2 1 6 1 2 2 6 1 2 3 6 1 2 4 Connect the battery cable to the batteries and the Temp Plate If only one battery is used connect the free plug to the shorted receptacle provided in the Temp Plate Observe polarity when using the single cell adaptor If battery polarity is reversed a voltage fault condition will be indicated and further operation of the instrument will be inhibited Verify Voltmeter 6 1 3 1 6 1 3 2 The digital voltmeter will read battery voltage if the selector switch is in the internal position S
20. with very little current in place of the battery Set the calibrator power supply to 28 5V Start the Charger Analyzer in Dual rate The current will rise to the programmed value Increase the power supply calibrator towards 29 4V The Charger Analyzer will switch from Main to Topping at a battery voltage of 29 4V 0 5V Return the Voltage Control Mode to CC Page 40 of 62 Operator Manual Supercharger 60 R3 0 8 14 METERS 8 14 1 Verify the battery voltage and charge discharge current readings by comparing against a CAL 100 Calibrator or a reference voltmeter and a reference ammeter or reference shunt 8 14 2 See 8 1 for adjustments Page 41 of 62 Operator Manual Supercharger 60 R3 0 9 CALIBRATION e NOTE 1 The Charger Analyzer must be verified and calibrated if required at least once every 12 months or earlier if deviation from performance is observed see first note on section 7 NOTE 2 Perform adjustments only when changing parts and components that require re calibration e NOTE 3 Perform a Verification of Performance prior to attempting a calibration see Section 7 page 25 If the Charger Analyzer does not perform in accordance to what is called for in Verification of Performance then and only then proceed with an actual calibration adjustments 91 CIRCUIT BOARD ADJUSTMENTS AND CALIBRATION WARNING The ground of the electronics circuitry floats on the battery voltage Make no
21. 2 1 Time 6 4 3 1 6 4 3 2 RUN 6 4 4 1 6 4 4 2 6 4 4 3 Program the Main and Topping Charge currents as required Program the Main and Total Time selectors to allow the battery to reach the required charge level consult battery manufacturers specifications Verify that the Timer Speed is consistent with the required elapsed time Start the Charger Analyzer in the Dual Rate mode If transfer on peak is selected the charger will transfer from Main to Topping charge when the battery reaches the peak voltage If stop on peak is selected the Charger stop upon reaching the peak voltage The charge will terminate automatically CYCLE END when the TOTAL TIME selected is reached The charge will terminate as a FAULT if the MONITOR CIRCUIT detects that e Battery temperature exceeds 45 C 113 F BATTERY OVERTEMP FAULT e The actual charge current deviates from the programmed value by more than 1A CURRENT FAULT Page 29 of 62 Operator Manual Supercharger 60 R3 0 6 5 DISCHARGE NOTE Do not discharge batteries on the Temp Plate Normal battery heating of the Temp Plate during discharge will generate a false battery Overtemp fault when attempting to recharge it 6 5 1 Current and Time 6 5 1 1 6 5 1 2 6 5 2 RUN 6 5 2 1 6 5 2 2 6 5 2 3 6 5 2 4 6 5 2 5 Program the discharge rate and time duration Verify that the Timer Speed is consistent with the required elapsed time Dep
22. 3 3 elapsed time display must read zero colon must be off Page 35 of 62 Operator Manual Supercharger 60 R3 0 8 3 TIMER VERIFICATION 8 3 1 8 3 2 Settings 8 3 1 1 Setthe Main and Topping Charge Current Selectors to zero 8 3 1 2 Set both Time Selectors to zero 8 3 1 3 Set the Timer Speed Switch to the test center position NOTE Current and voltage readings must remain at zero during the following tests If voltage starts to rise which may lead to voltage a fault verify that the current selectors are completely at zero Start the unit by depressing the two rate charge selector 8 3 3 1 The unit will go immediately into Cycle End 8 3 3 2 Reset Set the total time to 01 and start 8 3 41 Unit will start in main charge and immediately transfer to topping going into cycle end after one second 8 3 4 2 Reset Set the main time to 1 total time to 02 and start 8 3 5 1 The unit will start in the main mode transfer to topping after one second and go into cycle end after two seconds 8 3 5 2 Reset Repeat the above tests each time advancing the main and total time selectors as follows 2 04 4 08 8 09 9 10 9 20 9 40 and 9 79 or 9 60 depending on the type of Timer Page 36 of 62 Operator Manual Supercharger 60 R3 0 84 BATTERY OVERTEMP CUT OFF 8 5 8 4 1 Settings 8 4 1 1 Setcurrent selectors to zero 8 4 1 2 Set the timer speed switch in the normal position to the r
23. ENT CONTROL circuit The SYSTEM MONITOR provides several safeguarding functions It compares the measured current against the programmed value and if they differ by more than one ampere operation is halted and a current malfunction is indicated It measures the battery voltage and compares it with the programmed number of cells From there it determines during charge if the total voltage exceeds the equivalent of 1 75 V per cell indicating an Overvoltage condition or during discharge if the total voltage is below the equivalent of 1 volt per cell indicating the end of the discharge cycle It checks for polarity reversal at voltages as low as 25V as well as an absolute Overvoltage at 85 volts both generating a voltage malfunction indication that prevents any further operation of the unit It measures the temperature of the discharge heat dissipators and signals an overheat malfunction if the internal temperature exceeds 90 as it could be caused by a fan failure or an installation with restricted air flow It also monitors the temperature of the batteries being charged via the TEMP PLATE and terminates the charge indicating battery Overtemp in the event of battery overheating that may lead to thermal runaway The POWER REGULATOR provides all regulated voltages and power amplification as required by the various circuits The VOLTAGE CONTROL CIRCUIT provides the functions that regulate the charging current in the Constant Voltage f
24. EVISION INDEX Table 2 Index of Revisions 1 0 21 January 2001 Release 2 0 15 January 2003 New Clock Timer Board and additional Peak function 2 1 23 July 2003 Overvoltage is now set at 1 75V cell was 1 70 Numerous other text updates clarifications 3 0 4 October 2007 Reformatted Many text changes for clarification Page 62 of 62
25. H BOA Eoi Figure 7 Control Switch Board Adjustments 9 2 3 CONTROL SWITCH see fig 8 NOTE For voltage measurements use pin 14 on the Current Control Board as reference common 9 2 3 1 R10 AMPLIFIER ZERO Static test no battery or Calibrator Adjust a reading of 0 000V 0 003V at E3 on the CONTROL circuit board NOTE 2 Newer versions of this circuit board no longer have a zero adjustment NOTE 3 Modified versions of this circuit board may not have a zero adjustment not required 9 2 3 2 R11 DISCHARGE CELL CALIBRATE No battery is required for this test Page 45 of 62 Operator Manual Supercharger 60 R3 0 e Setthe Cell Selector at 20 connect a voltage source set to approximately 21V and start the Charger Analyzer in AUTO Discharge Adjust for a Discharge CUT OFF Capacity Failure at 20 0 volts NOTE This step requires that the Overvoltage cut off on the MONITOR circuit board be previously calibrated 9 2 3 3 CLOCK TIMER No adjustments on this board e Older versions of the Charger Analyzer use two circuit boards associated with timer functions The Timer Board 9879903010 and the Clock Display Board 9879903009 Newer Superserseders use a single Clock Timer Board 9879903109 In either case there are no adjustments to perform 9 2 3 4 Blank 9 2 3 5 CURRENT CONTROL see fig 11 NOTE Use the hook at pin 14 as ground reference for voltage measurements test point EO
26. IMUM INCREMENT 0 1 AMP 3 1 4 ACCURACY and STABILITY of settings 1 of reading 0 1 AMP 3 1 4 1 FLOAT e The reference voltage is set at the equivalent of 2 33V cell Lead Acid The Cell Selector provides the basic reference as nominal battery voltage e g a 24V battery is entered as 24 on the Cell Selector Current reduction from within 0 5V of the float voltage with an accuracy of 0 5 3 1 4 2 PEAK The reference voltage is set at the equivalent of 2 45V cell Lead Acid e The Cell Selector provides the basic reference as nominal battery voltage e g a 24V battery is entered as 24 on the Cell Selector Voltage transfer or stop within 1 of the Peak Voltage Note Due to cable connector losses the peak voltage registered by the Charger Analyzer will be higher than the actual battery voltage up to 0 2V depending on current Page 12 of 62 Operator Manual Supercharger 60 R3 0 3 1 5 3 1 7 3 1 10 3 1 11 3 1 12 MODES 3 1 5 1 Main and topping for Constant Current 3 1 5 2 Constant Voltage 3 1 5 3 Peak Voltage TIMER 3 1 6 1 1to 9 hours for MAIN charge time and 1 to 60 hours for TOTAL time 3 1 6 2 Time can also be programmed in minutes by selecting the FAST mode in the TIMER SPEED selector switch Front Panel 3 1 6 3 NOTE I Topping charge time equals the total charge time minus the main charge time TOTAL MAIN TOP 3 1 6 4 NOTE 2 Newer i
27. Operator Manual Supercharger 60 R3 0 TABLE OF CONTENTS 1 INTRODUCTION AND SYSTEM DESCRIPTION 0 4 5 2 CONDENSED OPERATING 8 21 Constant Current Charge normal sesto sena 8 Mejia M 9 2 3 Peak Voltage Chafe senaera iener teo UL n dictas beides Va eo D DE ego 10 LT EEUU ia 11 3 SPECIFIC gue mehr D 12 E n 12 3 2 DISCHARGE o 14 3 3 D D i D Ced 15 34 LINE INPUT VOLTAGE iteresas osivo soiva ESSENS 16 35 DIGITAL PANEL METERS issecsssivsonsenssensensvnonsendisenseasunensensusensessesensensiveasessusensensovensenseseasendaseaseasensone 17 3 6 FUSES and BREAKERS Other than charge and discharge current limiters 17 4 CONTROLS AND DISPLAYS 18 41 18 4 2 T 18 43 R1 Main Charge Current 1 21
28. T RESULTS IN A CURRENT FAULT WHEN DISCHARGING TWO BATTERIES Attempting to discharge more than 20A on a battery with more than 28V or defective Monitor board THE UNIT CHARGES LOW CURRENT BELOW 10 AMPS PROPERLY BUT HUMS NOTICEABLY AT HIGHER CURRENTS One of the SCR s is inoperative or one of the rectifiers is open UNIT CHARGES ON TOPPING AND DISCHARGES CORRECTLY BUT WILL NOT CHARGE IN MAIN Defective Main Current Selector or defective Control board UNIT STARTS IN THE DISCHARGE MODE BUT GOES INTO CAPACITY FAILURE IMMEDIATELY Battery not properly connected Open link Open cable THE DISCHARGE CURRENT LIMITER OPENS THE MOMENT A BATTERY IS CONNECTED TO THE CHARGER Shorted discharge transistors s BURNED RESISTOR S IN THE DISCHARGE HEATSINK S Transistor s shorted and discharge current limiter did not open wrong limiter value or type 10 1 10 RESET INDICATOR AND TIMER DISPLAY DO NOT TURN ON Open fuse to electronics card rack or problems with the Power circuit board or the transformer feeding it 10 1 11 DIGITAL VOLTMETER REGISTERS A VOLTAGE APPROXIMATELY 36 VOLTS WITH THE UNIT IN RESET AND THE BATTERY IS NOT CONNECTED One or both SCR S shorted Page 53 of 62 Operator Manual Supercharger 60 R3 0 Do not connect a battery under this condition 10 1 12 9 1 12 CURRENT TRACKING IS OFF BY A SMALL CONSTANT AMOUNT Amplifier zero or low current calibrate out of adjustment CONTROL board 10 1 13
29. arger 60 R3 0 5 2 CONSTANT VOLTAGE CHARGE 5 2 1 5 2 2 5 23 5 2 4 The battery is charged at the topping rate for a preset time When the battery voltage is within 0 5V of the selected float voltage the charging current begins to diminish and settles to the level of current required to maintain the battery at the selected float voltage Charging is automatically terminated at the end of the total time selected cycle end or as a fault if e Battery overtemperature is detected Overtemp fault Battery voltage is in excess of 85V voltage fault e Actual charging current differs from the programmed value by more than 1 AMP current fault Note applicable only before the charger switches from constant current to constant voltage Charge operation may be terminated at any time by depressing the green reset button Page 24 of 62 Operator Manual Supercharger 60 R3 0 5 3 PEAK CHARGE 5 3 1 Transfer from Main to Topping on Peak voltage 5 3 1 1 battery is charged at the main rate for a preset time 5 3 1 2 When the battery voltage reaches the programmed peak voltage the charging current transfers from main to topping 5 3 1 3 Charging is automatically terminated at the end of the total time selected cycle end or as a fault if e Battery overtemperature is detected Overtemp fault e Battery voltage is in excess of 85V voltage fault Actual charging current differs from the p
30. connections between the electronics ground and the battery or chassis ground Serious damage to the wiring and control circuits will occur if any part of the circuitry becomes in contact with the chassis while a battery is connected 9 2 NOTE Most adjustments are performed with no current no battery required and require the use of a voltage source to simulate battery voltages such as the CAL 100 Calibrator or a Power Supply A battery is required for the adjustments of current output DIGITAL METERS see Figure 6 NOTE Digital meters are adjusted by means of multi turn trimming potentiometers trimpots located on the rear solder side of the METERS board 9 2 1 AMMETER 9 2 1 1 9 2 1 2 9 2 1 3 9 2 1 4 NOTE 1 Newer versions of this circuit board longer have zero adjustment NOTE 2 Modified versions of this circuit board may not have a zero adjustment not required ZERO e Adjust the zero with R3 for a reading of 00 0 the exact point is when the signs alternate SCALE e This meter has a full scale of 199 9 millivolts to read a 100 AMP shunt with an output of one millivolt per AMP e Verify and calibrate using an external ammeter with digital readout Adjust R10 at a minimum of 25 0A for a reading within 0 1A of the reference ammeter Page 42 of 62 Operator Manual Supercharger 60 R3 0 NOTE 3 Insert an external shunt ammeter in series with any of the battery leads U
31. e duration SW3 Keypad Five station membrane push button control switch to select and control the mode of operation as follows 4 7 1 GREEN Stop reset cycle end 4 7 2 WHITE Two rate charge mode main and topping 4 7 3 YELLOW Single rate charge mode 4 7 4 BLUE Auto cut off discharge analysis 4 7 5 Full discharge deep cycle Page 18 of 62 Operator Manual Supercharger 60 R3 0 4 8 SW4 CELL SELECTOR 4 8 1 Two digit selector to program the battery terminal voltage as a function of the number of cells 4 8 2 Rate 1 75 volts per cell for charge and 1 0 volts per cell for discharge 4 8 3 Used also in the Float and Peak Voltage modes to enter nominal battery voltage 4 9 SWS DIGITAL VOLTMETER INPUT SELECTOR 4 9 1 External 2 20 200V scale 4 9 2 Internal 20 200V scale 4 10 SW6 VOLTAGE MODE SELECTOR 4 10 1 Four position switch to select Normal Float and Peak Voltage modes 4 11 SW7 TIMER SPEED SELECTOR 4 11 1 Three position switch to select 4 11 1 1 Normal HH MM 4 11 1 2 FAST MM SS 4 11 1 3 TEST 55 5 60 19 62 Operator Manual Supercharger 60 R3 0 Supercharger 60 NICKEL CADMIUM BATTERY CHARGER ANALYZER DISCHARGE CURRENT OPERATING INSTRUCTIONS 1 PUSH GPEEM PITON TURNING POWER ON OR OFF CHAKE NODE 21 ETE OF CELE 21 amp I Gummi Ac BATTERY HAMAPCTURERS SPECIATION E E a
32. e power on or before connecting or disconnecting the battery NOTE 2 The current selector potentiometers display three digits indicating XX X AMPS e g in order to select 4A dial 040 04 0A and for 20A dial 200 20 0A 2 1 Constant Current Charge normal mode 2 1 1 Number of Cells 2 1 1 1 2 1 1 2 Enter the number of cells NOTE when charging more than one battery enter the total number of cells 2 1 2 Main Charge Time 2 1 2 1 2 1 2 2 2 1 2 3 2 1 2 4 2 1 2 5 2 1 2 6 2 1 2 7 Enter the MAIN CHARGE TIME TOTAL TIME if in the TWO RATE mode or enter the TOTAL CHARGE TIME only if in the SINGLE RATE mode Verify that the Timer Speed is consistent with the required elapsed time hours or minutes Enter the MAIN and TOPPING CHARGE CURRENTS if in the TWO RATE mode or enter the TOPPING CURRENT only if in the SINGLE RATE mode Place batteries on the TEMP PLATE When working with only one battery connect the free plug into the shorted receptacle provided in the TEMP PLATE Verify also that the small cable is connected to the TEMP PLATE the red BATTERY OVERTEMP INDICATOR will be on if not connected Depress the CONTROL BUTTON corresponding to the desired mode white for TWO RATE and yellow for SINGLE RATE The charge will terminate automatically CYCLE END when the TOTAL TIME selected is reached The charge will terminate as a FAULT if the MONITOR CIRCUIT detects that e Ba
33. elect the scale consistent with the battery voltage Program the number of cells 6 1 4 1 6 1 4 2 6 1 4 3 6 1 4 4 Enter the number of cells of the battery When working with more than one battery enter the TOTAL number of cells Note 1 In the full discharge mode the number of cells is ignored Note 2 In the Float and Peak voltage modes the cell selector becomes a nominal battery voltage selector See xxx Page 27 of 62 Operator Manual Supercharger 60 R3 0 6 2 CONSTANT CURRENT CHARGE 6 3 6 2 1 6 2 2 6 2 3 Main Charge 6 2 1 1 Program Main charging rate and time duration 6 2 1 2 Verify that the Timer Speed is consistent with the required elapsed time Topping Charge 6 2 2 1 Program Topping charging rate and total time of charge Total time Main Topping Times 6 2 2 2 Start in Dual Rate 6 2 2 3 Depress the Two Rate white control button 6 2 2 4 DUAL and MAIN indicators will turn on and current will rise to the set rate in about three to five seconds 6 2 2 5 Verify colon e The colon in the digital time display will flash a the rate of one cycle per second Single Rate Charge 6 2 3 1 Forasingle rate program the current using the Topping selector 6 2 3 2 Set the required total time and depress the single rate yellow control button 6 2 3 3 SING and TOP indicators will turn on and battery current will rise to the set rate in about three to five second
34. ent Control Board Adjustments Page 47 of 62 Operator Manual Supercharger 60 R3 0 9 2 4 FAULT DISAB E SWITCH 2 9879903012 MONITOR SUP IIA RUN TEST SW1 BATTERY VOLTAGE CELLS H d hb m 1 100000000000010 00 min Figure 9 Monitor Board Adjustments MONITOR see fig 12 NOTE Use pin 14 on the card connector or the Test Point on the Control Board as ground reference for voltage measurements 9 2 4 1 Ul2 pin 1 BATTERY VOLTAGE e This point corresponds to one tenth of the battery voltage present at the input terminals 9 2 4 2 012 pin 7 CELL SELECTOR This point corresponds to one tenth volt per cell e g 2 00V 20 cells Page 48 of 62 Operator Manual Supercharger 60 R3 0 9 2 5 9 2 4 3 R62 OVERVOLTAGE POWER no battery Set the Current Selectors to zero and set the Cell Selector to 20 1 75V cell Connect an external voltage source Power Supply or CAL 100 to simulate the battery voltage set at approximately 34V Start the Charger Analyzer in either of the Charge modes and adjust this trimpot for an Overvoltage charge cut off at 35 0V 0 1V There are no adjustments in the Power circuit board but the following voltages must be measured at the card edge connection fingers bottom using a standard digital voltmeter referenced to pin 14 9 2 5 1 PIN
35. formance not achieved by any of the older conventional battery charging methods The Supercharger will deliver current into a short circuit or a battery or combination of batteries totaling 50 cells within 1 of the programmed value independent of line voltage variations within 10 of the nominal line voltage The control circuitry of the Charger Analyzer consists of a CONTROL SWITCH a CLOCK a TIMER a CURRENT CONTROL a SYSTEM MONITOR a POWER REGULATOR and a VOLTAGE CONTROL CIRCUIT See Figure 1 The CONTROL SWITCH receives the function commands from the function selector switch on the front panel and outputs control signals to the rest of the circuit boards as well as to the charge SCR S and discharge transistors Page 5 of 62 Operator Manual Supercharger 60 R3 0 The TIMER provides all the required timing functions related to the charge and discharge durations Digital time and speed selectors provide the external inputs while the four digit readout of the CLOCK provides the elapsed time display The CURRENT CONTROL interprets the programmed current values and controls the angle of firing of two SCR s to maintain a constant current in accordance to the feedback received from a precision shunt Display of current is provided by an independent Digital Ammeter that uses the same shunt used by the CURRENT CONTROL circuit Inputs from the TIMER the SYSTEM MONITOR and the CONTROL SWITCH determine the operating mode of the CURR
36. ight 8 4 1 3 Settime selectors to 1 01 and cell selector to 20 8 4 1 4 Connect the battery cable to the unit but make no battery or Temp Plate connections The red Overtemp light will be on 8 4 2 Temp Plate simulations resistors 8 4 2 1 Connect 16 5 K OHM 1 resistor between pins D and B 8 4 2 2 Connect one each 30 1 K OHM 196 resistors between pins D and C D and E and D and H 8 4 2 3 The red light will turn off 8 4 3 Start in either of the charge modes 8 4 3 1 Theunit will start and immediately go into Overtemp fault red light flashing and alarm on 8 4 3 2 Reset 8 4 4 Repeat the previous test by rotating the 16 5 K OHM resistor in all four positions 8 4 5 Repeat the first test using four 17 5 K OHM 196 resistors 8 4 5 1 The unit must not show Overtemp fault VOLTAGE FAULT TEST 8 5 1 Disconnect battery cable from any external devices 8 5 2 Settings 8 5 2 1 Set the Current Selectors both to 010 8 5 2 2 the Time Selectors to 1 01 8 5 2 3 Set the Cell Selector to 20 8 5 3 Start in either of the charge modes 8 5 3 1 The unit will start and the output voltage will slowly rise 8 5 3 2 The unit will stop indicating a voltage fault 8 5 3 3 Reset Page 37 of 62 Operator Manual Supercharger 60 R3 0 8 6 REVERSE POLARITY TEST 8 7 8 8 8 6 1 8 6 2 8 6 3 Connect the battery cable to a voltage source CAL 100 or low current power supply and reverse the polarit
37. ing or appears to be malfunctioning please refer to the verification of performance calibration and troubleshooting sections which will show you how to use the various built in test features to determine or approximate the nature of the problem NOTE 1 The Charger Analyzer is a precision instrument Use only certified instrumentation capable of accuracies of at least 0 2596 on voltage and 0 596 on current The CAL 100 Battery Charger Analyzer Calibrator provides all necessary functions to monitor verify and calibrate the Charger Analyzer NOTE 2 In the following tests make no connection to a battery unless specifically indicated Always start from reset and always reset at the conclusion of a test 8 1 REQUIRED TEST EQUIPMENT AND ACCESSORIES 8 1 1 CAL 100 Calibrator and one 20 to 50A Hr 20 cell battery 8 1 2 IFa CAL 100 Calibrator is not available the following items are required in addition to the battery mentioned in a 8 1 2 1 Power Supply capable of 60V output with very little current capability less than 20mA 8 1 2 2 Ammeter or Shunt capable of at least 50A 8 1 2 3 Digital Voltmeter 3 1 2 digits or better 8 1 2 4 Four each of 16 5K 17 5K and 30 1K 196 resistors 1 4W 8 2 VISUAL VERIFICATION 8 2 1 Setthe Voltage Mode Selector to CC first position 8 2 2 Turn power on 8 2 3 Verify the following 8 2 3 1 Reset cycle end green light must be on 8 2 3 2 digital panel meters must read zero 8 2
38. loat mode and in the Peak Voltage mode transfers from Main to Topping charge on a voltage peak or ends charging on a voltage peak new feature The DIGITAL VOLTMETER provides internal battery voltage readings with resolutions of 0 1V and 0 01 V while a selectable external position allows single cell measurements to a resolution of 0 001V Additional protection is provided by a high speed current limiter for the discharge transistor bank a slow speed current limiter for the charge circuit and a magnetic circuit breaker capable of tripping under fast high current overload conditions Page 6 of 62 Operator Manual Supercharger 60 R3 0 OLTAGE ONTROL 4mm SHUNT ECTIFIERS AND SCR S OLTMETER ME LTMETER SELECTOR CIRCUIT BOARDS LINE INPUT SEREG ELECTORS Figure 1 Block Diagram Page 7 of 62 TORS CURRENT CONI NATUS ICATORS Operator Manual Supercharger 60 R3 0 2 CONDENSED OPERATING INSTRUCTIONS CAUTION Disconnect power and batteries before performing any internal maintenance Failure to observe this caution may result in serious damage to the unit and injury to the operator NOTE 1 Depress the RESET button before turning th
39. nstruments may have a new version of the Timer Identified by an external Timer Speed Switch that has a maximum of 79 hours or minutes in Total Time OVERTEMP PROTECTION 3 1 7 1 Four thermistors on the TEMP PLATE measure the battery temperature 3 1 7 2 charge is terminated when the surface temperature of the TEMP PLATE reaches 39 C 102 OVER UNDER CURRENT PROTECTION 3 1 8 1 Monitor circuit continuously compares the actual charge current with the programmed value 3 1 8 2 Operation is terminated if they differ by more than 1 OVERVOLTAGE PROTECTION 3 1 9 1 Programmable in accordance with the number of cells selected at the equivalent of 1 75 volts cell TOLERANCE 1 0 1V 3 1 9 2 Absolute maximum internal limit set at 85 VOLTS 3 1 9 3 NOTE Does not apply in the Float and Peak voltage modes Voltage is controlled in those modes REVERSE POLARITY PROTECTION 3 1 10 1 Operation of the unit is inhibited for reverse voltages greater than 0 5 VOLTS FUSING 3 1 11 1 Aircraft type current limiter ANL 60 slow AC LINE CURRENT Page 13 of 62 Operator Manual Supercharger 60 R3 0 3 1 12 1 3 AMPS idling plus 7 the value of the charging current e g when charging 40 AMPS the line current is 23 AMPS Note nominal values line voltage and frequency dependent 32 DISCHARGE 3 2 1 3 2 2 3 2 3 3 2 4 3 2 5 CONTROL Transistors air cooled MAXIMUM CURRENT
40. nual Supercharger 60 R3 0 10 11 12 13 14 8 8 DISCHARGE VOLTAGE 1 ses tesa see enss s senses tasas e enses teen ase 38 89 FULL 2222 046 dos taa ep ee 39 810 CURRENT TRACKING 5 ecietece po ea eva Te V PE oiae 39 511 VOLTAGE CON ER OL rrr P TE 39 812 FLOAT VOLTAGE sites eet pssbunesosovsesesbeben usb oadogesbseeesusessocsusensesse oe 40 8 13 PEAK VOLTA C DEP 40 t CM LOS MOL Hom 41 CALIBRATION Eee 42 91 CIRCUIT BOARD ADJUSTMENTS AND 2 4 4 8 00 ass tesa 42 92 DIGITAL METERS see Figure 6 eere eere eren eren eren 42 TROUBLESHOOTING AND 5 53 10 1 TROUBLESHOOTING esae es duse ved ei 53 10 2 FINDING A SHORTED DISCHARGE TRANSISTOR 4 55 REPLACEABLE MODULES AND PARTS 59 11 1 CIRCUIT BOARDS e eoo aei oeo esae pa e
41. o step 7 Remove any shorted transistors and repeat steps 4 and 5 until a no short reading is obtained Replace defective devices only with transistor type MJ15023 If all transistors appear to be shorted ALL emitter resistors reading a voltage then one or more have failed with a collector to base short causing the remainder of the transistors to turn on It will then be necessary to check each transistor individually e This be greatly facilitated by searching for a zero reading This will indicate the shorted device When replacing transistors make sure that the base and emitter pins engage properly in the socket contacts Add heat sink compound and torque the screws properly to insure a good thermal transfer e NOTE If replacing any of the control transistors Q1 and Q2 note that they are mounted with a mica insulator Page 55 of 62 Operator Manual Supercharger 60 R3 0 HEATSINI BULB C BE Figure 12 Measuring for a shorted transistor Page 56 of 62 Operator Manual Supercharger 60 R3 0 BATTE Figure 13 Location of Current Limiters Page 57 of 62 LIMITE LOW Operator Manual Supercharger 60 R3 0 Figure 14 Power Block Diagram Page 58 of 62 Operat
42. or Manual Supercharger 60 R3 0 11 REPLACEABLE MODULES AND PARTS 11 1 11 2 11 3 CIRCUIT BOARDS 9879101001 METERS LED 9879903004 VOLTAGE CONTROL 9879960001 CONTROL SWITCH 9879903009 CLOCK older units 9879903010 TIMER older units 9879903109 CLOCK TIMER newer units 9879903011 CURRENT CONTROL 9879960012 MONITOR 9879903013 POWER PARTS 30110003M0 INSULATOR MICA TO 3 391207R110 BATTERY RECHARGEABLE 7 cells 100mA Hr 4311 R25SBO FUSE W Slow Blow 4317ANL060 CURRENT LIMITER ANL 60 4317ANNO080 CURRENT LIMITER ANN 80 4741201 00 RESISTOR POWER 1 ohm 2W 5 47130 10 0 RESISTOR POWER 10 ohm 5 474120F1010 RESISTOR POWER 100 ohm 1 2W 590 47413CR33F RESISTOR POWER 0 33 ohm 3W 5 flameproof 4755101031 POTENTIOMETER with DIAL 10 turn 47562H1030 CELL SELECTOR 4822115001 POWER TRANSISTOR MJ15001 4822715002 POWER TRANSISTOR MJ15002 4822115023 POWER TRANSISTOR MJ15023 9811960461 SCR 9811960463 CHARGE DIODE 9811960462 DISCHARGE DIODE OTHER Contact the factory at TEL 305 592 2272 TEL 305 599 6893 FAX 305 594 4933 www jfmeng com Page 59 of 62 Operator Manual Supercharger 60 R3 0 12 BATTERY TESTING NOTES Note hazardous condition Handle batteries with extreme care as they are capable of very high discharge rates if short circuited Check the Battery Manual IMM or Aircraft Manufacturer Ins
43. r by more than 1 AMP NOTE Undercurrent monitoring is disabled in the full discharge mode for battery voltages below 2 5V REVERSE POLARITY PROTECTION 3 2 9 1 Operation of the unit is inhibited for reverse voltages greater than 0 5V 3 2 10 1 Aircraft type current limiter ANN 80 fast 3 2 10 2 NOTE The type of limiter and current rating are critical for proper protection of the discharge circuits Failure to replace the discharge current limiter with the proper type value may result in catastrophic damage of the load banks TIMER 3 3 TIME BASE 3 3 1 1 Microprocessor Controlled 3 3 2 MODES 3 3 2 1 NORMAL Timer advances at the rate of one count per minute HH MM 3 3 2 2 FAST Timer advances at the rate of one count per second MM SS 3 3 2 3 TEST Timer advances at the rate of 60 counts per second SS SS 60 Page 15 of 62 Operator Manual Supercharger 60 R3 0 3 3 2 4 NOTE The colon flashes at the rate of one cycle per second regardless of the selected mode ACCURACY AND STABILITY 3 3 3 1 0 01 POWER FAILURE PROTECTION 3 3 4 1 internal rechargeable battery maintains for several hours the clock and other vital circuits for a dependable resumption of operation after a power failure 3 3 4 2 colon will be lit in case of a power failure 3 3 4 3 NOTE not operate the Charger Analyzer without this battery or with a battery in bad condition Replace only with the same type 7 or
44. r than the programmed peak voltage 10 1 22 IMMEDIATE STOPPPING IN Attempting to charge a battery with a voltage higher than the programmed peak voltage Page 54 of 62 Operator Manual Supercharger 60 R3 0 10 2 FINDING A SHORTED DISCHARGE TRANSISTOR Since all discharge transistors are wired in parallel a single shorted transistor will short the entire bank The procedure that follows will allow the finding of the shorted transistor without requiring removal and testing of each device individually 10 2 1 EQUIPMENT REQUIRED e Digital Voltmeter e Battery 24V Lamp 24V lamp must draw at least 0 5 10 2 2 PROCEDURE 10 2 2 1 10 2 2 2 10 2 2 3 10 2 2 4 10 2 2 5 10 2 2 6 10 2 2 7 10 2 2 8 TURN UNIT OFF DISCONNECT IT FROM THE WALL OUTLET Connect the lamp in place of the discharge current limiter see fig 8 Connect the charger to the battery If the lamp illuminates it indicates that there is a short in the discharge circuit generated by one or more shorted transistors Measure the voltage across the individual 22 OHM emitter resistors RED RED GOLD GOLD see fig 8 e Anon zero reading approximately 0 1V for a lamp drawing 5A indicates current flow due to a transistor with a collector to emitter short NOTE A non zero reading on all emitter resistors 0 02V approx for a lamp drawing 0 5A indicates a different failure mode collector to base short refer t
45. ress auto discharge BLUE control button for analysis to one volt per cell Depress full discharge RED control button for battery deep cycling DISCHARGE will terminate automatically CYCLE END when the TOTAL time selected is reached or CAPACITY FAILURE if the BATTERY voltage reaches the equivalent of ONE VOLT per CELL prior to the selected time NOTE Battery voltage is ignored during full discharge Discharge will terminate as a FAULT if the MONITOR CIRCUIT detects e An overheating of the discharge transistors OVERHEAT FAULT e That the discharge current differs from the programmed value by more than one AMP CURRENT FAULT e That the programmed current exceeds 30A for a battery voltage in excess of 32V Page 30 of 62 Operator Manual Supercharger 60 R3 0 6 6 Float Peak Voltage Chart CHART RELATING THE COMPUTED FLOAT AND PEAK VOLTAGES TO THE SELECTED NOMINAL BATTERY VOLTAGE 6 6 1 Cell Selector becomes a Nominal Battery Voltage selector in other than the Constant Current settings of the Voltage Mode Selector 6 6 2 NOTE Nominal battery voltage is referenced on the basis of 1 2V cell for Nickel Cadmium batteries and 2V cell for Lead Acid batteries e g a 20 cell Nickel Cadmium battery and a 12 cell Lead Acid battery are both considered to be 24V batteries Consult manufacturers specifications for optimum float and peak voltage charge levels Table 1 Constant Voltage and Peak Voltage Chart
46. rogrammed value by more than 1 AMP current fault e NOTE Charge operation may be terminated at any time by depressing the green reset button 5 3 2 Stop on Peak Voltage 5 3 2 1 battery is charged at the main rate for a preset time 5 3 2 2 When the battery voltage reaches the programmed peak voltage the charging current stops 5 3 2 3 Charging is automatically terminated at the end of the total time selected cycle end or as a fault if e Battery overtemperature is detected Overtemp fault e Battery voltage is in excess of 85V voltage fault e Actual charging current differs from the programmed value by more than 1 AMP current fault e NOTE Charge operation may be terminated at any time by depressing the green reset button Page 25 of 62 Operator Manual Supercharger 60 R3 0 5 4 DISCHARGE NOTE For battery voltages greater than 32V the discharge current is automatically limited to 30A A current fault condition will result if more than 30A is programmed 5 4 1 ANALYSIS AUTO CUT OFF 5 4 1 1 battery is discharged at the selected rate for a preset time 5 4 1 2 Discharge is automatically terminated cycle end at the end of the time selected or if the battery voltage reaches the equivalent of 1 VOLT cell capacity failure as determined by the number of cells programmed or it is terminated as a fault if e The actual discharge current differs from the programmed value by more
47. s CONSTANT VOLTAGE CHARGE 6 3 1 6 3 2 6 3 3 Nominal Battery Voltage 6 3 1 1 Enter the nominal battery voltage using the cell selector see chart on page 19 Maximum Charge Current 6 3 2 1 Program the maximum charge current using the Topping Current selector Time 6 3 3 1 Program sufficient time in the Total Time selector to allow the battery to reach the required charge level consult battery manufacturers specifications 6 3 3 2 Verify that the Timer Speed is consistent with the required elapsed time Page 28 of 62 Operator Manual Supercharger 60 R3 0 6 3 4 RUN 6 3 4 1 6 3 4 2 6 3 4 3 Start the Charger Analyzer in the Single Rate mode The charger will start to reduce the charging current when the battery voltage is within 0 5V of the float level The charge will terminate automatically CYCLE END when the TOTAL TIME selected is reached The charge will terminate as a FAULT if the MONITOR CIRCUIT detects that e Battery temperature exceeds 45 C 113 F BATTERY OVERTEMP FAULT e The actual charge current deviates from the programmed value by more than 1A CURRENT FAULT 6 4 PEAK VOLTAGE CHARGE 6 4 1 6 4 2 6 4 3 6 4 4 Nominal Battery Voltage 6 4 1 1 6 4 1 2 Enter the nominal battery voltage using the Cell selector see chart on page 19 Select transfer from Main to Topping on Peak Voltage or stop on Peak Voltage Charge Currents 6 4
48. s NOTE 2 Do not attempt to discharge with the voltage mode selector in the Float or Peak voltage modes Voltage and current faults will occur depending on the battery voltage and the cell selector setting 2 4 1 Number of Cells 2 4 1 1 2 4 1 2 Enter the number of cells Ignore this step if FULL DISCHARGE is to be selected 2 4 2 Total Time 2 4 2 1 2 4 2 2 2 4 2 3 2 4 2 4 2 4 2 5 2 4 2 6 2 4 2 7 Enter the TOTAL TIME Verify that the Timer Speed is consistent with the required elapsed time Enter the DISCHARGE CURRENT Depress the Blue button for DISCHARGE with automatic cut off ANALYSIS or the RED button for FULL DISCHARGE DEEP CYCLE DISCHARGE will terminate automatically CYCLE END when the TOTAL time selected is reached or CAPACITY FAILURE if the BATTERY voltage reaches the equivalent of ONE VOLT per CELL prior to the selected time NOTE Battery voltage is ignored during Full Discharge Discharge will terminate as a FAULT if the MONITOR CIRCUIT detects e Anoverheating of the discharge transistors FAULT e That the discharge current differs from the programmed value by more than one AMP CURRENT FAULT That programmed current exceeds 30A for a battery voltage in excess of 32V Page 11 of 62 Operator Manual Supercharger 60 R3 0 3 SPECIFICATIONS 31 CHARGE 3 1 1 CONTROL SCR air cooled 3 1 2 MAXIMUM CURRENT 50 AMPS 3 1 3 MIN
49. s that the FULL deep cycle mode is selected 4 21 DSSB DISCH 4 21 1 Indicates that the unit is in FULL discharge 4 22 DS6A CAP FAIL 4 22 1 Indicates that the battery has failed to meet capacity 4 23 DS6B OPEN LIM 4 23 1 Indicates that either the charge or discharge limiters are open 4 24 DS7A OVR TEMP Indicates Overtemp fault 4 24 1 Continuous no beeper Indicates that the TEMP PLATE is not connected or open 4 24 2 Flashing Indicates battery temperature in excess of 45 Page 21 of 62 Operator Manual Supercharger 60 R3 0 4 25 DS7B OVR HEAT 4 25 1 Indicates that the discharge bank is overheated 4 26 DS8A VOLT FLT Indicates voltage fault 4 26 1 Continuous battery connected with polarity reversed 4 26 2 Flashing during charge battery voltage in excess of 1 75 volts per cell or in excess of 85 volts or open circuit 4 27 DS8B CURR FLT 4 27 1 Indicates that the actual current differs from the programmed value by more than 1A 4 28 DS9 4 28 1 Indicates that the charger is in the basic Constant Current mode 4 29 DS10 CV 4 29 1 Indicates that the charger is in the Constant Current Float mode 4 30 DS11 PEAK 4 30 1 Indicates that the charger is in the Constant Current Peak mode 4 34 AUDIBLE ALARM 4 31 1 Continuous turns on with any of the faults 4 31 2 Pulsating turns on with cycle end Page 22 of 62 Operator Manual Supercharger 60 R3 0
50. se the Single Cell adaptor to facilitate the connection or simply use the CAL 100 which is a calibrator designed specifically to test and certify Charger Analyzer Battery Charger Analyzers NOTE 4 The charge output current wave is in the form of short pulses at twice the line frequency The use of clamp on meters and moving magnet meters will yield erroneous readings Verify in discharge pure DC if better meters are not available 9 2 2 VOLTMETER 9 2 2 1 ZERO No zero adjustments 9 2 2 2 SCALE e This meter has a full scale of 1 999 volts but an attenuator on the board converts it to a full scale of 1 999 19 99 or 199 9 volts as selected by the DPM selector switch Verify and calibrate using a voltage source Power Supply or CAL 100 as a battery voltage simulator between 10 and 20 volts in the EXTERNAL 20V position e Adjust R17 for a reading within 0 01V of the reference voltmeter e NOTE individual scales cannot be adjusted Page 43 of 62 Operator Manual Supercharger 60 JLTMETER Figure 6 Meters Board Adjustments Page 44 of 62 Operator Manual Supercharger 60 R3 0 TROL SWITCH BOA top vie FRONT PANEL AMPLIFIER ISCHARGE CUT OFP ADJUST CALIBRATE ZERC CO TROL SWITC
51. sence of any particular instructions from the manufacturer charging at c 10 for 12 to 16 hours will insure a complete charge The Nickel Cadmium batteries can also be charged in the float mode with a voltage of 1 4 V cell a 20 cell battery would be set to 28 0V NOTE Prolonged use of the float constant voltage method on Nickel Cadmium batteries will result in cell imbalance which could eventually lead to premature cell failure due to un even charge acceptance and un even discharge capacity Page 60 of 62 Operator Manual Supercharger 60 R3 0 13 DISCLAIMER e The Supercharger is a precision system intended to be operated by personnel qualified in the servicing of aircraft batteries e The end user must establish suitability in the intended application Engineering s responsibility is limited to the repair replacement of malfunctioning part of the system not responsible for any losses incurred from the usage of the system tis the user s responsibility to verify the performance of the instruments and to operate and maintain it in accordance with the above given instructions e tis the user s responsibility to operate the Instrument within standard safety procedures applicable to the operation of a Battery Test Facility e tis the user s responsibility to install power receptacles and wiring in accordance with local wiring codes Page 61 of 62 Operator Manual Supercharger 60 R3 0 14 R
52. sest higher voltage by at least 1V to the observed voltage on the battery Set the cell selector to the value indicated in the Cell Selector column Start the Charger Analyzer in Single Rate an advance the Topping current to 1A Observe that the current will start to be reduced as the battery voltage approaches the corresponding float voltage Example for 24V measured on the battery set the cell selector to 22 This will result in a float voltage of 25 6 As long at the voltage at the battery is less than 25 1 the charge current will be as programmed As the voltage rises towards the expected 25 6 the current will start to decrease and will settle on a value of current to maintain the battery at 25 6 Depending on the condition of the battery a charge current higher than the initial 1A may be required for the battery to rise to the expected float voltage Conversely if the voltage rises too fast it will be necessary to select the next higher reading 23 for 26 8V and or a lower charge current Verify that the Charger Analyzer maintains the battery at the expected voltage 0 2AV PEAK VOLTAGE 8 13 1 8 13 2 8 13 3 8 13 4 8 13 5 8 13 6 Settings 8 13 1 1 Set the Voltage Control Mode to Peak 8 13 1 2 Set both current selectors to zero 8 13 1 3 Program for a nominal battery voltage of 24V on the cell selector setting 24 Connect the CAL 100 Calibrator or a power supply capable of producing at least 35V
53. t that allows the Charger Analyzer originally designed for Constant Current operation on Nickel Cadmium batteries to also be able to handle Lead Acid and other type of rechargeable batteries where the end voltage is a more reliable indicator of the state of charge as opposed to Nickel Cadmium batteries Dependability is another great plus of the Supercharger 10076 SOLID STATE circuitry requires no scheduled maintenance No relay contacts to inspect and clean No high current carrying contacts to arc and burn A simple performance verification procedure is all it takes to determine if the instrument requires re calibration or repair This instrument is also protected against certain internal performance deviations and programming errors plus it is also designed to sense certain battery abnormalities to protect the instrument and battery from possible damage In the event that any malfunction takes place VISUAL and AUDIBLE indicators will turn on alerting the operator and preventing any further operation of the unit The Supercharger Battery Charger Analyzer System is comprised of the Charger Analyzer the Temp plate the Battery Cable and several accessories The Charger Analyzer is basically a precision programmable constant current source for charge and a programmable constant current sink for discharge combined with voltage and temperature sensing circuits for total battery monitoring The specially designed circuitry provides a per
54. ted 15 1 eene enne ener 56 Figure 13 Location of Current Limiters 57 Figure 14 Power Block Diagram rennen enne nennen eene te inneren trennt trennen enne trennen enne 58 TABLE OF TABLES Table 1 Constant Voltage and Peak Voltage rennen nennen 31 Table 2 Index of Revision Soare iiie erroe ere ente tera debtor Marge ple ep ee Ree ede 62 Page 4 of 62 Operator Manual Supercharger 60 R3 0 1 INTRODUCTION AND SYSTEM DESCRIPTION Congratulations You now own the finest battery Charger Analyzer available today The Supercharger is a precision instrument designed to charge and analyze NICKEL CADMIUM LEAD ACID and other rechargeable batteries exactly as recommended by the battery manufacturers The simple to set controls plus the condensed operating procedure found on the front panel makes the Supercharger a very easy to operate CHARGER ANALYZER which combined with easy to read CURRENT VOLTAGE TIME and STATUS indicators makes it also a very simple unit to monitor The Supercharger is also designed for speed for it can charge two batteries actually any number of batteries where the total number of cells 15 50 or less at maximum currents and it can also discharge two batteries at reduced currents or one battery 25 cells or less at maximum current The Supercharger also provides a Voltage Control enhancemen
55. tructions for information on charging discharging and testing The Charge amp Float and the Charge amp Peak Stop modes are particularly useful with lead acid batteries where the battery voltage is a better indicator of the state of charge as compared with Nickel Cadmium batteries where terminal voltage gives little information on the state of charge Lead Acid batteries are normally float charged constant voltage typically at 2 3V cell A 6 cell pack 12V will then be float charged with the voltage selector at 13 8V In this mode the charge current is set to the highest level that the cells will safely take typically up to 1C depending on the battery type and specific manufacturer s instructions This will be the charge current until the float voltage is reached at which time the current will diminish to the level needed to maintain the float voltage Lead Acid batteries can also be charged in a manner in which it is possible to know much better the end of charge When a Lead Acid cell is charged with constant current at C 15 to C 10 the end voltage will rise rapidly at about 90 to 95 of charge which occurs at about 2 4 to 2 45V cell A 5A hr 6 cell pack can be charged at 335mA to 500mA with the voltage selector at 14 7V The CHARGER ANALYZER will stop the charge operation when the rapid rise of end of charge voltage is detected For Nickel Cadmium batteries the most effective charge method is constant current vs time In the ab
56. ttery temperature exceeds 45 C 113 F BATTERY OVERTEMP FAULT Battery voltage exceeds the equivalent of 1 75V cell VOLTAGE FAULT e The actual charge current deviates from the programmed value by more than 1 AMP CURRENT FAULT Page 8 of 62 Operator Manual Supercharger 60 R3 0 2 2 Constant Voltage 2 2 1 Battery Voltage 2 2 1 1 2 2 1 2 2 2 1 3 2 2 1 4 2 2 1 5 2 2 1 6 Enter the nominal battery voltage using the cell selector see chart on page 19 Program the charge maximum current in the Topping Current selector Program sufficient time in the Total Time selector to allow the battery to reach the required charge under constant voltage charge consult battery manufacturers specifications Verify that the Timer Speed is consistent with the required elapsed time Start the Charger Analyzer in the Single Rate mode The charger will begin to reduce the charging current when the battery voltage is within 0 5V of the float level The charge will terminate automatically CYCLE END when the TOTAL TIME selected is reached The charge will terminate as a FAULT if the MONITOR CIRCUIT detects that e Battery temperature exceeds 45 C 113 F BATTERY OVERTEMP FAULT e The actual charge current deviates from the programmed value by more than one AMP CURRENT FAULT Note this will occur only before the Charger Analyzer switches from constant current to constant voltage Page 9 of 62
57. urrent will rise to the programmed value Increase the power supply calibrator towards 29 4V The Charger Analyzer will switch from Main to Topping at a battery voltage of 29 4V Adjust R14 as required to switch at 29 4 0 1V Return the Voltage Control Mode to CC Note on newer models there is one extra Peak position to STOP at the peak voltage Set the Voltage Control Mode Switch to Peak Stop Verify that the Superseder will stop at the peak voltage as opposed to transfer from Main to Topping Page 51 of 62 Operator Manual Supercharger 60 POWER MONITOR CLOCK TIMER PANEL Figure 11 Circuit Board Sequence Page 52 of 62 Operator Manual Supercharger 60 R3 0 10 TROUBLESHOOTING AND REPAIRS 10 1 TROUBLESHOOTING The following are hints and directions to help you locate the most probable causes of deviation of performance as established in the procedures of section 8 10 1 1 10 1 2 10 1 3 10 1 4 10 1 5 10 1 6 10 1 7 10 1 8 10 1 9 UNIT CHARGES ON MAIN BUT DOES NOT CHARGE ON TOPPING AND DOES NOT DISCHARGE Defective Topping Discharge current selector or defective Control board UNIT CHARGES PROPERLY ONE BATTERY BUT CANNOT CHARGE TWO BATTERIES AT HIGH RATES Low line voltage UNIT GOES INTO VOLTAGE FAULT IMMEDIATELY OR SHORTLY AFTER STARTING UP charge mode Open link or one or more cells developing a high voltage UNIT DISCHARGES CORRECTLY ONE BATTERY BU
58. y Do not block air circulation A substantial amount of heat must be dissipated particularly in the discharge mode up to 1KW e External heat removal circulating fan is required when operating in confined spaces or hot environments Do not disconnect the battery cable while the unit is in operation e Large current surges can occur with corresponding arcing that can damage the charger the connectors and the battery Disconnect batteries and power from the instrument remove the line cord from the wall outlet before changing circuit boards and current limiters or to perform maintenance or repairs e Failure to do so can result in serious lethal personal injury and or serious damage to the instrument Do not exceed a setting of 79 in the total time selector e If exceeded times will be inconsistent with the dialed settings Do not run the unit with the monitor switch in the test position except for tests Loss of protection will occur Do not perform battery work on bare metal table tops Do not attempt to discharge with the Voltage Mode Selector in the CV or PEAK positions Voltage and currents faults will result depending on the battery voltage and cell selector settings Page 32 of 62 Operator Manual Supercharger 60 R3 0 7 INSTALLATION 7 1 BENCH SPACE 7 1 1 Charger Analyzer system occupies 19 x 17 48 3 cm x 43 2 of table top space for the charger and 10 x 25 25 X 63 5 cm
59. y Start at zero and advance towards 0 5V The unit will show a fault through the alarm and the voltage fault light at about 0 25V 0 20V to 0 35V Alternatively connect the battery cable with the single cell adaptor to one cell with the polarity reversed or to a standard 1 5V battery size is unimportant OVERVOLTAGE CUT OFF 8 7 1 8 7 2 8 7 3 8 7 4 Set the Current selectors to zero and Time selectors to 1 01 Set the Cell selector to 20 Connect the battery cable to an adjustable voltage source CAL 100 or low current power supply set to approximately 34V and start the unit in either charge mode Slowly increase the voltage Unit will stop and indicate a voltage fault at 35 V 0 5V Reset See 8 2 5 for adjustments DISCHARGE VOLTAGE CUT OFF 8 8 1 8 8 3 8 8 4 Settings 8 8 1 1 Setthe Current selectors to zero and the Time selectors to 1 01 8 8 1 2 Setthe Cell selector to 20 Connect the battery cable to a voltage source CAL 100 or low current power supply set to approximately 21V and start the unit in the auto discharge mode blue Slowly decrease the voltage Unit will go into fail at 20V 0 3V Reset See 8 2 1 for adjustments Page 38 of 62 Operator Manual Supercharger 60 R3 0 89 FULL DISCHARGE 8 10 8 11 8 9 1 8 9 2 8 9 3 Settings 8 9 1 1 Setthe Current selectors to zero 8 9 1 2 Setthe Time selectors to 1 01 8 9 1 3 Setthe Cell
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