Manual de Investigação JJJ
Manual de Investigação JJJ
Manual de Investigação JJJ
REV: 5
DATE: Sept 9, 2021
Series ABC11B-120-XX
1.1 DESCRIPTION
1.2 SPECIFICATIONS
2.0 INSTALLATION
5.1 MAINTENANCE
5.2 TROUBLESHOOTING PROCEDURES
1.0 GENERAL DESCRIPTION
1.1 Description
The American Battery Charging rectifiers described in this manual are designed
to supply a constant voltage output for any load within their ratings. Beyond
approximately 110% of the rated load the output voltage will drop rapidly,
thereby protecting the rectifier and the system to which it is connected, this
makes the ABC rectifier ideal for use as a battery charger since it supplies a
constant current to a discharged battery.
ABC11B chargers are two rate float battery chargers for charging standby and
on-line batteries.
1.2 Specifications
1.2.1 Input
AC Input Voltage: Models are provided with taps for specific ranges of AC input
The bold type indicates the voltage setting for a particular model when shipped.
The Table below lists the particular models, AC input voltages and the
recommended external AC line protection. Caution: To reduce the risk of fire,
use only on circuits with branch circuit protection in accordance with the National
Electric Code, NFPA 70.
1.2.2 Output
Voltage Stability: +/- 1/2" from no-load to full load with an AC input voltage
variation of +/- 10% and an AC input frequency variation of +/- 5% with battery
connected.
1.2.3 Controls
1.2.6 Protection
1.2.7 Wiring
1.2.8 Enclosures
CBC Battery Chargers are suitable for indoor use only, and supplied in cabinets
for floor mounting.
2.1 Location
Locate the battery charger in the desired location (refer to dimensional drawing
in last section of manual). Avoid locations near heat generating equipment, or
subject to extremes of dirt or moisture.
Install the wall-mounted unit with suitable bolts, according to unit weight, wall
material and structure. Use eight 1/4" diameter bolts. With bolts in place, install
the unit over the bolts with keyslot mounting holes. Open the cabinet door for
access to the bolts for tightening.
Cable entry to the cabinet is normally from the bottom. Conduit may be
connected through the top, back or sides as required if bottom entry is impractical
or undesirable. Refer to the dimensional drawing in the last section of the manual
and Figure 2.3.
Figure 2.3: Cable entry for AC input at P1 and charger output at TB521
2.4 Ventilation
The design of the cabinet provides satisfactory for convection cooling. Allow a
minimum of 3 inches (75mm) clearance on each side, and 6 inches (150mm) on
top for ventilation.
Connect the charger and load to the battery using separate cables. The charger
output terminals are at TB521. The DC load terminals are at TB522. Use two
sets of cables to connect these to the battery. The charger to battery cables will
carry the charger output current. The DC load cables will carry the maximum DC
loads.
NOTE: If correct polarity is not observed at TB521, the charger will not operate.
Locate the input/output terminal strip (P1). Check the AC line for input voltage,
frequency and phase to match the specifications as listed on the battery
charger's nameplate, located on the cabinet front. The AC line must be sized to
allow for the maximum current capacity as indicated by the rating of the input
fuse or breaker. Connect the AC line to the terminals indicated. Connect ground
to proper terminal: GND.
2.7 Energizing
Energize the AC line then energize the charger AC BREAKER. The "AC ON"
lamp should light, and the charger should be operating.
3.0 Output Adjustments
ABC11B-series battery chargers have been adjusted at the factory. See Figure
3.0 for voltage and current limit adjustment potentiometers. For charging
batteries, "Float" and "High Rate" voltages have been set according to the
following table. Alternate voltage settings are indicated for other battery types.
The charging voltage may be adjusted if needed according to the following
instructions. The selection of "Float" or "High Rate" is controlled by the "High
Rate" switch (S1), or the automatic charge control circuit.
CAUTION: The "Float/High Rate" switch (S1) controls the "High Rate" charge.
Never leave the switch in the "High Rate" position for long periods of time
(consult the battery manual). Excessive "High Rate" charging will cause cells to
gas (through electrolysis) and dissociate the water in the electrolyte into
hydrogen and oxygen. Never let the electrolyte level drop below the minimum
level line.
It is recommended that all settings be checked before putting the charger into
service. The following procedure should also be followed if the voltages require
resetting in the future or when a new control card, E1, is installed.
Attach a precision voltmeter of the correct range in parallel with the rectifier's
voltmeter. (Accuracy should be better than +/- 0.5%)
Switch the charger's switch (S1) to "Float". The "High Rate" lamp should be out.
If the charger's high-rate LED is lit, the automatic timer has initiated a high-rate
charge cycle. Allow the charger to "High Rate" charge until the "High Rate" lamp
goes out. This may take from 4 to 30 hours. When the lamp goes out, proceed
to Paragraph 3.1.3.
The current should be considerably lower than the output current listed on the
rectifier nameplate. The "High Rate" lamp should be out. Check that the voltage
is at the desire level. Consult the battery manufacturers recommendations. If
the voltage is incorrect, adjust as per Paragraph 3.1.4.
CAUTION: Set "Float" voltage per paragraph 3.1 before adjusting "High Rate"
voltage.
Switch the charger to the "High Rate" mode with switch (S1). The "High Rate"
LED should be lit. Allow the "High Rate" voltage and current to stabilize. The
DC output current must be less than the maximum value as shown on the
nameplate. If it is not, wait until the level drops. Check that the voltage is at the
desired level. Consult the battery manufacturers recommendations. If the
voltage is incorrect, adjust per Paragraph 3.2.2
If the voltage is incorrect, adjust the potentiometer (HR), located on the printed
circuit card (E1), using a small screwdriver. The potentiometer is labeled "High
Rate". Turn the adjusting screw clockwise to increase voltage, and counter-
clockwise to reduce voltage. Adjust in small increments, allowing voltage to
stabilize after each adjustment. When properly set, return the switch (S1) to
"Float".
The "Current Limit" potentiometer (CL), is located on the printed circuit card (E1).
It is factory set normally at 110% of rated output.
CAUTION: The "Current Limit" potentiometer (P3), is set at the factory and
sealed. Do not change this adjustment. An improper setting may damage the
rectifier.
The bridge is the heart of the power circuit. This assembly is a standard full-
wave silicon bridge, incorporating three diodes and two SCR's (silicon controlled
rectifiers) which are capable of being made conductive for any part of each half
cycle. This is accomplished by the application of positive pulses to the gate
terminals of the SCR's at the desired time. Before the pulses are applied, the
SCR is open, and no current flows in the circuit. However, as soon as the SCR
is fired, it operates as a standard silicon rectifier until the forward current is
reduced to almost zero. Charger output control can therefore be accomplished
by changing the point in time the SCR's are fired.
The firing angle determines the output of the bridge. When large, the SCR
conducts for only a short time and the bridge output power is low. When is
small, the SCR conducts for nearly the complete half cycle, and the bridge
output power is high.
Following the bridge is a snubber circuit, (E2), consisting of varistors, and RC-
suppressors. These act to suppress AC and DC line surges and thereby protect
the bridge rectifiers and other equipment connected.
A printed circuit card (E1) is used for charger control. This solid state card,
which utilizes integrated circuits, provides the charger with voltage regulation
and automatic current limiting by controlling the SCR conduction angle.
Since the SCR's are now conducting for a longer period of time, the average
output voltage is increased by an amount, which will reduce the error to zero.
Thus, the rectifier maintains the output voltage at an essentially constant value,
despite changes in input voltage or load condition.
The current limiting circuit of (E1) will override the voltage regulation circuit and
begin to reduce the output voltage to (zero if necessary) as the output current
begins to exceed the adjusted value (normally 110% of rated load).
Charger models 1060637-500, 600, 700 and –800 have an EMI/RFI filter (X1)
provided at the AC input. The filter reduces high-frequency noise emissions.
4.5 Accessory device – Multi-alarm with Auto-Charge
This battery charger is equipped with a Multi-alarm board (E3), part number
4111-95046-01. The E3 board is located on the inside of the charger door. The
circuit board is supplied with DC voltage from the battery. The board is
connected to the charger by plug P2. See Figure 4.5
This circuit is used to automatically switch the charger's output from float
charging to high rate charging. The automatic charging circuit senses a signal
from the main control card (E1) that indicates when the rectifier is operating in
current limit. If this condition remains longer than a set period of time, normally
about 3 minutes, the charger is switched to high rate charge.
When the charger leaves current limit and changes over to voltage control, the
charger will be kept in high rate for a specific charging time, normally 8 to 12
hours. After the set charging time has elapsed, the charger is switched back to
float charging. Should the charger return to current limit and remain longer than
the 36 second set period, the high rate timer is reset and started again when the
rectifier leaves current limit.
Hysterisis: Approximately 5%
Time delay: 10 msec maximum
Accuracy: +/- 1%
Adjustment: Rotate LVA clockwise to raise the alarm level
Hysterisis: Approximately 5%
Time delay: 10 msec maximum
Accuracy: +/- 1%
Adjustment: Rotate HVA clockwise to raise the alarm level
RECTIFIER FAILURE ALARM WITH LIGHT (LED)
This circuit utilizes advanced integrated circuitry to indicate if the fault current to
ground from the DC system positive or negative becomes too high. Upon
ground fault, when the impedance between the charger output and ground
becomes too low, a ground fault current will result. This current is converted to a
voltage in a current-voltage converter. The ground fault current to be indicated is
set via a 25-turn potentiometer (GFA), connected after the converter. The
voltage from the potentiometer (GFA) is fed to a comparator circuit with a preset
trigger level. Indication is given via a front panel mounted GND FAULT light
(LED).
The ground fault alarm circuit may be de-activated if desired, via switch SW1.
See Figure 4.5. Moving switch SW1 to the lower position will disable the ground
fault alarm function.
All alarms are connected to a summary (group) alarm relay, included on the E3
board. This circuit will initiate an alarm signal for any of the provided alarms:
LOW VOLTS, HIGH VOLTS, RECT FAILURE, or GND FAULT (if enabled).
Contacts for remote indication are provided at terminal block P3.
5.1 Maintenance
The ABC11B-series chargers do not employ any moving parts, other than the
adjusting potentiometers and a relay. Other than blowing dust off the rectifier, no
maintenance should be required during the life of the charger.
4. AC input voltage and frequency. Must match design input of the charger's as
shown on the nameplate.
If all external connections are correct, cell voltages are within tolerance, and AC
input voltage and frequency match the nameplate, then using Table 1, locate the
applicable symptom and perform the corrective action as indicated. In some
cases it will be necessary to use the diagnostics of Figures 1,2,3, and 4. To use
these diagnostics, perform the steps in each box and proceed to the step
indicated by your result. Refer to Figure 5.2 for key component locations.
NOTE: Care must be exercised at all times to avoid contact with live circuits.
Figure 5.2: Key component locations
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600
X INDICATES ITEM USED ON SOLAR 1060367 DASH NUMBER