Motor

Appliance
Corporation
555 Spirit of St.Louis Blvd.
St.Louis, MO 63005
(636) 532-3406 M13577
FAX (636) 532-4609 REV. C

INDUSTRIAL BATTERY CHARGER

OWNER'S
MANUAL

PHAZER
INDUSTRIAL BATTERY CHARGER
 TABLE OF CONTENTS

PAGE

GENERAL INFORMATION 1

Safety 1

Receipt & Installation 1

Operation 2

Service 3

DESCRIPTION OF EQUIPMENT 4

OPERATING INSTRUCTIONS 5

SERVICE 5

General Service 5

Troubleshooting 6

Diode/Capacitor checkout 7

Replacement Parts 8
 GENERAL INFORMATION
If it is impractical to open the main power switch
SAFETY USE EXTREME CAUTION WORKING ON ENERGIZED
CIRCUITS. Even though power circuits may be off,
Safety First! Please take time to study this manual certain control circuits may still be energized. To
before installing, operating or troubleshooting. take voltage readings on energized components, turn
Special attention should be given to WARNING and off the charger and attach alligator clips before
CAUTION labels on the charger and in this manual. turning the charger back on. This procedure will
Battery chargers are safe when properly operated avoid sticking both hands with meter probes into a
under intended use and by trained operators. live charger, which is extremely dangerous.
Untrained operators and service personnel risk the DO NOT WORK ALONE. Have someone capable of
possibility of serious injury to themselves and others. rendering first aid. Do not wear loose clothing or
Improper application of battery chargers can also jewelry. Do not use bare hands to remove live parts,
result in extensive and costly damage to batteries and such as fuses. Think before you act.
equipment. Only trained operators and service
personnel that are familiar with this manual should RECEIPT AND INSTALLATION
install, operate, or trouble shoot the battery chargers.
WARNING: EXPLOSION Equipment Identification
Connect or disconnect the battery plug only when the Chargers are identified with a model number which
AC line is disconnected or the charger is in the "OFF" appears on the charger nameplate.
position. Failure to follow this instruction may result
in arcing and burning of the DC connector contacts. Charger Model Designation eg. 6***600TB
Arcing contacts may ignite a mixture of oxygen and 6 - battery cells
hydrogen, which is produced during battery charging. 600 - 8 HR. recharge rate
DO NOT smoke, weld, grind, or use torches around S - 1 PHASE
batteries. T - 3 PHASE
DANGER: ELECTRIC SHOCK A - 120/208/240
Do not touch uninsulated portion of output connector B - 208/240/480
or uninsulated battery terminal. Do not operate
charger unless connected to battery. Receiving
Before maintenance or troubleshooting, make sure all Check the charger nameplate against packing lists
circuits are de-energized in the following manner: and purchase orders to verify receipt of proper
1. Make sure charger is in "OFF" position equipment. Any discrepancies should be brought to
2. Disconnect charger plug from battery. our attention. All shipments leaving our facility have
3. Make sure no AC power can be supplied to been carefully inspected. If a shipment arrives with
the charger from breaker or disconnect switch. the crating or packing damaged, have the carrier
note the condition on the receipt. Check as soon as
4. Short circuit capacitors with insulated possible for concealed damage. NOTIFY AND FILE A
screwdriver. CLAIM WITH THE CARRIER AT ONCE OF ANY DAMAGE.
Avoid operating or trouble shooting in damp or wet DO NOT RETURN THE UNIT TO THE SHIPPER. Failure
locations. Use insulating gloves and shoes in such to follow this procedure may result in refusal by the
environments. carrier to honor any claims.
Replace defective cord or wires immediately.
Location
GENERAL SAFETY PRECAUTIONS Operating life and performance will be influenced by
charger location. Select a dry and well-ventilated
When servicing battery chargers, the main power location. Allow 6 inches from walls and other
supply switches or other switches from which power chargers for proper ventilation. Chargers should not
could enter the circuit should be locked in an open be exposed to rain, high temperatures, dust,
position and tagged e.g. corrosive fumes, combustible materials, or explosive
"Open Circuit for Repairs - DO NOT Tamper". gases. Dusty environments may require more

3
frequent maintenance to obtain maximum life and
optimum performance. Check that charger is connected for proper input
voltage - arrow on voltage adjust board matches
Moving and Transport incoming AC line voltage on main panel.
Care should be taken when lifting units with forklifts Refer to charger nameplate for input amps at
or pallet jacks. Forks should extend completely under incoming line voltage. See table on pg.3 for
charger so as to prevent accidents. recommended disconnect switch, branch fuse size,
power and ground cable size. Route appropriate
Grounding conductor through AC knock-out provided on side of
Follow applicable local codes or National Electric Code charger case. Crimp wire to inside ring terminal
revisions that may supersede the following barrel located at base of fuses.
instructions.
The battery charger must be grounded to prevent DC Cables and Plugs
lethal injury. Route ground conductor through knock- When changing DC cables use the following table for
out side of charger. Connect AC ground wire (green) up to 20 feet.
to ground terminal next to fuses. The case is then Max DC Amp Wire Size A.W.G.
grounded once this connection is made. 65 #6
If the AC supply cable does not include a ground 75 #4
conductor see table on pg. 3 for proper sizing of 120 #2
separate ground conductor or consult the National 180 1/0
Electrical Code. 240 2/0
270 3/0
AC Line Voltage Changeover For lengths over 20 feet use one size larger cable.
Before making any reconnection, check the charger Cable length over 35 feet is not recommended.
nameplate to make sure the disconnect switch and Make sure DC plug is connected for proper polarity.
supply wiring is of sufficient size to carry the desired Positive on plug to positive charging lead. Negative
input voltage and amps. on plug to negative charging lead. Improper
Check the fuse label on inside of door to make certain connections may result in dangerous arcing and
the input fuses are proper for input line voltage. blown DC fuses.
INCORRECT FUSING WILL VOID CHARGER WARRANTY. When changing or repairing connectors make certain
plug contacts are crimped and/or soldered properly.
1. Remove nuts on voltage select panel. A poor solder joint will overheat and drop output.
2. Align arrow on removable board to match Make sure the plug contacts are firmly seated in the
AC line voltage on main panel. plug housing.
3.Tighten mounting nuts previously
removed. Charger Fusing
The fuse label (inside door) is marked to show
The above procedure automatically makes all original factory set voltage and AC fuse size. The
connections on the power transformers and control label is also marked to show proper fuse size for
transformer. No further adjustments, taps, or jumper other voltages.
wires are necessary.
INCORRECT FUSING WILL VOID CHARGER
AC Line Connection WARRANTY.
Follow applicable local codes or National Electrical OPERATION
Code revisions that may supersede the following See Pg.5 for specific operating instructions and
instructions: additional information.
Make sure main power supply switches or other
switches from which power could enter the circuit are Pre-Operation
locked in an open position. Make sure the charger has been installed according
to the directions in this manual. Failure to do so
could result in personal injury and damage to the

4
equipment. Connections
Make sure all connections are clean and tight. Look
Double check nameplate to verify charger is correct for discolored connections and broken or loose wires.
DC voltage for batteries being recharged. Ampere- All DC connections are especially critical. Loose DC
hour capacity on nameplate should correspond to the connections create high resistance hot spots that
battery ampere-hour capacity for normal 8-hour reduce charger output and impair efficiency.
recharge cycle. Inspect the DC cables to make sure the cable
insulation is not damaged. Check charger connector
General Operating Instructions for damage and check to make sure plug contacts
WARNING EXPLOSION are properly seated. See page 6 for trouble shooting
Connect or disconnect the battery plug only when information.
the AC supply is disconnected or the charger is in the
"OFF" position. Failure to follow this instruction may REPLACEMENT PARTS
result in arcing and burning of DC connector For replacement parts call service with Spec No.
contacts. Arcing contacts can ignite a mixture of Date Code & Serial No.
oxygen and hydrogen, which is produced during
battery charging.

AC SUPPLY WIRING
Operating Characteristics
The battery charger, when connected to a MAX Line Disconnect Branch Copper Size No.
Amps Switch Fuse Size Cable Ground
discharged battery and energized, delivers maximum
Amps (Amps) Power
rated output current. As battery voltage rises,
output charge current decreases in proportion to 2.5 30 5 14 14

increasing battery voltage. When the battery 4.5 30 7 14 14

becomes nearly full, the charger reduces output 7.5 30 10 14 14
current to a pre-established finish rate. This ensures
12.0 30 15 14 14
proper mixing of electrolyte.
16.0 30 20 12 12

SERVICE 18.0 30 25 10 12
22.0 30 25 10 10
Maintenance
24.5 60 35 10 10
Observe all safety instructions presented in the front
32.5 60 40 8 8
of this manual before attempting any maintenance
or service. 40.0 60 50 6 8
The charger is designed to provide years of trouble 45.0 60 60 6 8
free service. Routine maintenance checks will
57.5 100 80 4 8
prevent potential problems and ensure maximum
78.0 100 100 2 8
performance.
102.5 200 125 1/0 6
Cleaning 135.0 200 150 3/0 4
Keep the charger free from accumulated dirt and
dust buildup. Wipe or blow dirt and dust deposits The above table is based on 60 deg. C (140 deg. F) rated
from the charger interior at least twice a year or as conductors and 40 deg. C (104 deg. F) ambient
the situation demands. Clean components will keep temperatures. Refer to National Electrical Code Tables
the charger running cooler and more efficiently. 310-16 corrected to 40 deg. C (140 deg. F).

5
 DESCRIPTION OF EQUIPMENT

The battery charger is designed to recharge lead acid batteries. The rugged case is constructed to protect
internal components, and provide adequate cooling plus component accessibility. Figure 1 shows overall
Dimensions of case.

6
 OPERATING INSTRUCTIONS
LED Microprocessor Control

FEATURES

This control transforms ordinary chargers into "smart" chargers. A microcomputer monitors the battery,
determines when it is fully charged, and terminates the charge cycle.

Charge Complete Indicator - Remains lighted after the charge has been terminated by the control
circuit to indicate that the battery has received a full charge.

80% Charge Indicator - Lights when the battery reaches 80% of full capacity.

Incomplete Indicator - Lights to indicate that charging is required.

Charger On - Provides an indication that the charger is supplying power to charge the battery.

Abnormal Cycle - A back-up 16 hr. timer on the control turns off the charger and lights this lamp if a
normal shutoff does not occur. This would happen if the batteries are too large for the charger.

AC interrupt - When AC power is interrupted the circuit switches to standby mode. When power is
restored the charger will continue where it left off.

DC interrupt - Always STOP the charger before disconnecting the DC plug. If the plug is inadvertently
disconnected the charger will shut off. Charger will then be ready for another charge cycle.

CONTROLS
Stop Button - Stops charge cycle. If charger is on, always use this button before disconnecting charging
plug from battery.
Equalize Button - Extends charge cycle by 100 minutes.

OPERATING INSTRUCTIONS

Operation is completely automatic. Just connect battery to the charger and the automatic circuit takes control of
the charge operation. By analyzing the rate of change in battery voltage, the charge control determines when the
batteries are full and terminates the charge cycle. Batteries are completely charged each time - no over charging
or under charging. The automatic control is designed to extend battery life and reduce operation costs.
In a typical charge sequence, when the charger is connected to the battery, the control circuit goes through an
automatic self-diagnostic check. Indicator lights flash indicating the check is in progress. Following a short delay
the charger initiates charge and the yellow Charger On indicator illuminates. Charger On light remains on until
batteries are charged, then the green Complete Light will come on and remain on until batteries are disconnected.

GENERAL SERVICE INFORMATION

WARNING: Observe all safety instructions presented in the front of this manual before attempting any service.
DANGER: Electric Shock Hazard - Disconnect AC Power and battery plug before any service is performed.
Discharge capacitors with insulated screwdriver.
NOTE: If testing requires energized circuits, observe all safety precautions in the front of this manual.
Disconnect all AC power, apply alligator clips so that you do not have to touch any probes or part of
the equipment before turning the power back on to take a reading. Follow the sequence of this
trouble shooting manual step by step, as each successful procedure will aid in isolating the causes of
problems and point you to necessary steps of corrective actions.

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 TROUBLE SHOOTING
1. Will not turn on. No self-test. Charge plug not connected to Connect DC plug.
battery.

AC fuse or wall breaker open Check fuse size, wire size to wall
breaker, and wall breaker size

DC fuse open Check 1st for shorted diode and

reverse polarity, if OK replace
fuse.

TURN WALL CIRCUIT OFF - DISCONNECT BATTERY PLUG

Control Circuit fuse blown. Replace. Check that circuit,

battery, and charger are correct
voltage.

Loose DC connection to control Clean and tighten. Repair as

circuit. found.
Check control circuit lead
connections at both ends.

Loose AC connection in control Check connections.

circuit wires.

2. Will not turn on. Self test OK. Loose DC connection between Clean and tighten. Repair as
battery and control circuit. found.

No AC to charger. Check control circuit lead

connections at both ends.

3. Abnormal charge cycle lamp Battery not fully charged. Battery and charger not
lit. matched. " Battery too big."
Check battery for shorted or
open cell.
Check all DC connections
between circuit board and
battery.

4. Early turn off (battery not Loose DC connection. Check all connections from
charged). Less than 1 hour battery to Control Circuit.
run time.
If battery voltage higher than
charger voltage, charger will
shut off a few seconds after turn
on.

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 DIODE/CAPACITOR CHECKOUT PROCEDURE

QUICK TIP - a shorted diode can be diagnosed by checking for continuity at positive and negative of plug
contacts. If test shows open, DC fuse is probably blown - check for continuity. To bypass open DC fuse check
continuity for shorted diode at positive and negative lugs behind DC fuse. Reverse the ohmmeter probes. A
shorted diode will show continuity on both tests.

To isolate defective diode, unbolt connection at end of flexible lead to isolate from circuit. Set ohmmeter to
RX100 range.

TEST #1 Place one ohmmeter lead on aluminum heatsink and the other probe at end of loose flexible lead.

TEST #2 Reverse the position of the ohmmeter probes.

GOOD DIODE - The ohmmeter needle should deflect on either test #1 or #2 - not both.

SHORT DIODE - The ohmmeter needle will deflect on both tests #1 and #2. Replace diode.

OPEN DIODE - The needle will not deflect in either tests #1 or #2. Replace diode.

CAPACITOR CHECKOUT PROCEDURE

CAUTION: Short out capacitors with insulated screwdriver before performing test.
Disconnect leads. Set ohmmeter to RX100 scale. Connect meter leads to capacitor terminals.

GOOD CAPACITOR - Needle will deflect toward right and then be followed by a deflection in the opposite
direction. Reverse ohmmeter probes to validate test accuracy.

SHORTED CAPACITOR - Needle deflects toward right and remains. Replace.

OPEN CAPACITOR - No needle deflection. Replace.

BATTERY VOLTAGE TABLE (INDUSTRY STANDARD)

CELLS DC VOLTS DEAD @1.9 DISCH START FINISH

W/LOAD RATE RATE
@ 1.75 @ 2.133 @ 2.5

6 12 11.4 10.5 12.8 15.0

12 24 22.8 21.0 25.6 30.0

18 36 34.2 31.5 38.4 45.0

24 48 45.6 42.0 51.2 60.0

36 72 68.4 63.0 76.8 90.0

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 AC Fuse Part Number Conversion

AMP VOLT BUSS P/N SHAWMUT P/N

RATING RATING
6 250 NON6 OR FRN-R6 OT6 OR TR6
10 250 NON10 FRN-R10 OT10 TR10
15 250 NON15 FRN-R15 OT15 TR15
20 250 NON20 FRN-R20 OT20 TR20
25 250 NON25 FRN-R25 OT25 TR25
30 250 NON30 FRN-R30 OT30 TR30
6 600 NOS6 FRS-R6 OTS6 TRS6
10 600 NOS10 FRS-R10 OTS10 TRS10
15 600 NOS15 FRS-R15 OTS15 TRS15
20 600 NOS20 FRS-R20 OTS20 TRS20
25 600 NOS25 FRS-R25 OTS25 TRS25
30 600 NOS30 FRS-R30 OTS30 TRS30
35 600 NOS35 FRS-R35 OTS35 TRS35
40 600 NOS40 FRS-R40 OTS40 TRS40
45 600 NOS45 FRS-R45 OTS45 TRS45
50 600 NOS50 FRS-R50 OTS50 TRS50
60 600 NOS60 FRS-R60 OTS60 TRS60

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