C-D Ferro Five
C-D Ferro Five
C-D Ferro Five
CAUTION
CAUTION PHASE FUSE RATING
LIFT ALL FOUR
CORNERS HIGH 208 LOW
VOLTAGE VOLTS VOLTAGE
CAUTION
Electrical connections can work loose during CAUTION
shipping. Check all connections for tightness
before connecting the charger to the AC Make sure the charger positive terminal is
supply voltage. connected to the charger connector terminal
marked (+) and the negative terminal to the
one marked (-).
WARNING
Check all warning labels!
The charger should be connected to a fused
safety disconnect switch or to a circuit breaker. Be
sure the protective device and the incoming AC
cables to the charger meet the local electrical
codes and they match the current and voltage
requirements of the charger or chargers. The
GROUND
charger nameplate shows AC volts, phase and
current requirements at nominal line and rated
CONNECTION
output and recommended external fusing. In
addition, check the tag on the charger for proper
input voltage.
CAUTION CAUTION
DO NOT ATTEMPT TO 1. ALL THREE PHASES ON VOLTAGE CHANGEOVER
TERMINALS MUST BE RECONNECTED WHEN
RECONNECT VOLTAGE CHANGING VOLTAGE.
WITHOUT READING 2. AC FUSES MUST BE CHANGED WHEN CHANGING
VOLTAGE. SEE LABEL IN CHARGER.
INSTRUCTIONS
Receiving and
installation Section 1 Receiving and installation 1
1.1 Receiving 1
1.2 Identification 1-2
1.3 Storage 2
1.4 Location 2-3
1.5 Mechanical installation 3
1.6 Electrical connection 3
1.7 Input voltage changeover 3-4
1.8 AC input voltage cables 4
1.9 Grounding 4
1.10 DC cables and cable connectors 4
1.11 Maintenance 5
TABLES
Contents Page
1 RECEIVING AND
INSTALLATION
1.1 Receiving Inspect your C&D charger for any
JAN. 1999
M F G D AT E
shipping and handling damage as
soon as it arrives. Describe any Industrial Batteries and Chargers
MODEL FR18HK750
immediately notify the shipper.
LIFT ALL FOUR Verify the model and serial
SERIAL MP1 012320 SPEC. 204172 T.˚C.50
DC OUTPUT
CORNERS numbers printed on the packing list VOLTS 36 AMPS 135 CELLS 18
A 120 1 60 S 380 1 50
B 208 1 60 C5E 208/240/480 1 50
C 240 1 60 M 575 1 60
E 480 1 60 Z 380 3 50
G 208 3 60 H5K 208/240/480 3 50
H 240 3 60 L 575 3 60
K 480 3 60
TABLE 1.1
2
FIGURE 1.2-FERRO FIVE FR, EFR, LIBERTY and REVOLUTION SERIES chargers
1.3 Storage Keep the charger in its original shipping stored in any clean, dry area where
container until you are ready to proceed temperatures remain between 40˚F
with installation. The unit can be safely and 120˚F (5˚C and 49˚C).
1.4 Location Battery charging produces heat and a rates during various times in the charge
potentially explosive mixture of odorless cycle. Most of the gas forms during the
oxygen and hydrogen gases. Safe last two to three hours of the charge,
operation requires a clean, dry, well- when the average cell potential
ventilated area, where the temperature exceeds 2.37 volts. Every pint of water
remains between 60˚F and100˚F (16˚C dissociated during recharge releases
and 32˚C). 23 cubic feet of hydrogen gas to the
C&D chargers are convection-cooled. atmosphere. To calculate hydrogen
Chargers require a MINIMUM of four formation, determine the number of
inches of clearance between the floor, pints of water needed to correctly
walls, chargers, and other obstructions re-level cells after charging, then
for adequate air circulation. multiply the number by 23. Thus, a
lead-acid motive power battery that
EXPLOSIVE, COMBUSTIBLE OR requires 1.5 pints of water to relevel,
FLAMMABLE MATERIALS SHOULD will produce 34.5 cubic (1.5 x 23) feet
NOT BE PERMITTED IN THE of hydrogen.
CHARGING ROOM. NEVER MOUNT
A CHARGER ON OR ABOVE An approximation technique may be
COMBUSTIBLE MATERIALS. used to estimate hydrogen production
from C&D batteries charged by chargers
To prevent the accumulation of equipped with COMPUCHARGE,
explosive concentrations of hydrogen SCOUT and automatic Start/Stop
and oxygen, the charging area should controls. It is estimated a total of 0.24
have sufficient ventilation to prevent cubic feet of hydrogen gas will evolve
formation of one percent, by volume, from each cell per 100 ampere-hours
of hydrogen. It is important to note of capacity.
hydrogen is generated at different
3
0.24
Cells x Capacity x = Cubic feet of hydrogen/charge cycle
100
0.24
18 x 720 x = 31.1 Cubic feet of hydrogen/charge cycle
100
1.5 Mechanical installation Chargers can be bolted to noncom- Figure 1.3 for charger cabinet
bustible floors or steel benches. For dimensions. Wall mounting requires
maximum space saving, up to three the optional brackets described in
units can be stacked. Consult Section 6.6.
DIMENSIONAL DRAWINGS
B AC Cable B
AC Cable DC Cable Clearance Holes Entrance Hole Clearance Holes
Entrance Hole Entrance Hole 0.56" (14.22 mm) diameter 1.094 (27.79 mm) 0.56" (14.22 mm) diameter
G 1.094 (27.79 mm) 1.75 (44.45 mm) J F J
F H
D E D E
A C A C
A B C D E F G H J
CABINET
NO. inches mm inches mm inches mm inches mm inches mm inches mm inches mm inches mm inches mm
3517 32.22 818 24.00 610 21.81 554 30 762 19 483 11.00 279 2.81 71.4 4.38 111 1.50 38.1
3519 18.22 463 24.00 610 21.81 554 16 406 19 483 4.00 102 2.81 71.4 4.38 111 1.50 38.1
3518 43.22 1098 32.00 813 28.81 752 41 1041 26 660 16.50 419 2.81 71.4 4.38 111 1.50 38.1
1.6 Electrical connection Each charger requires a fused safety Electrical installations must be
disconnect switch or a circuit breaker. performed by a qualified electrician
Use a line protection device rated for the and satisfy all local, national and federal
recommended line fuse value shown on electrical codes. It is vital to the reliable
the charger nameplate (Figure 1.1). operation of the charger that it be
provided a good earth ground.
CAUTION
Electrical connections can work loose during shipping. Check all connections
for tightness before connecting the charger to the AC supply voltage.
1.7 Input voltage changeover The voltage circled on the AC voltage ITS AC POWER SUPPLY BEFORE
rating label (Figure 1.4) must match ATTEMPTING THIS MODIFICATION.
the available line voltage. If the voltages NOTE: AC voltage changeover must
are different, it will be necessary to be made at the terminals of both the
change AC line fuses, AC phase fuses ferroresonant power transformer and
and the connection terminal on both the the control transformer.
ferroresonant power and control
transformers. Consult the voltage Input voltage changeover CANNOT
changeover instruction label inside BE PERFORMED on chargers
the cabinet door. BE SURE THE manufactured for 575 VAC only
CHARGER IS DISCONNECTED FROM operation.
4
1.8 AC input voltage cables Customers or electrical contractors ALLOWABLE AC INPUT RANGES
must furnish the AC connection. Cables
should be sized for the recommended Nominal AC
charger voltage
line fuse values shown on the charger voltage ranges
nameplate. Allowable variations from
nominal AC line voltages appear in 120 106 - 127
Table 1.2. 208 184 - 220
240 212 - 254
480 424 - 508
575 508 - 600*
*Certain kinds of control and protective equipment
have a maximum voltage limit of 600V. The
manufacturer or power supplier, or both, should be
consulted to assure proper application.
TABLE 1.2
1.9 Grounding The AC system and the charger to dependable performance of the
enclosure connect to ground from the charger that it be provided a reliable
tagged stud, located in the lower left earth ground.
front of the enclosure. It is imperative
1.10 DC cables and cable C&D ships each charger with a SHOULD NOT EXCEED 35 FEET.
connectors standard, eight-foot long DC output When specifying replacement cable
cable that terminates with an connectors, it is important to
appropriate cable connector. As an remember C&D single-phase chargers
option, other lengths are available. produce higher peak currents than
If it is necessary to install longer similarly rated C&D three-phase
cables, they must be properly sized systems. The maximum DC current
to prevent overheating and ensure flowing from a single-phase charger
compliance with electrical codes. is typically 1.3 times the panel
DC CABLE LENGTHS FROM 15 TO ammeter reading.
25 FEET SHOULD BE ONE CABLE C&D recommends higher capacity
SIZE LARGER THAN THE STANDARD SB-350 connectors be specified as
CABLE. CABLE LENGTHS FROM 25 retrofit equipment for all single-phase
TO 35 FEET SHOULD BE TWO CABLE chargers rated at over 135 amperes.
SIZES LARGER. DC CABLE LENGTHS
CAUTION
Be sure the charger positive terminal is connected to the charger connector
terminal marked (+) and the negative terminal to the one marked (-).
CAUTION
Due to the high currents involved it is imperative that connectors be properly
maintained. See your C&D representative for more information.
5
1.11 Maintenance Battery chargers work most efficiently twice a year, check input and output
and deliver better service life with good circuit connections to make sure they
heat dissipation. Periodic cleaning with are tight. Otherwise, there are no
dry, low-pressure air will remove maintenance adjustments to the FERRO
accumulated dust to assure good heat FIVE SERIES chargers.
transfer to the surrounding air. At least
2 RANGER II
CONTROL
WARNING
Battery chargers present an electrical hazard to those who work with or
service them. Read and understand all warnings and cautions in this manual
2.1 Description as well as those affixed to the charger. Exercise extreme care to assure a
safe working environment.
2.2 Basic Settings Basic control settings such as number from selection to selection, and the
of cells, shunt size, delay before start- Arrow keys are used to enter informa-
ing, etc. are set from the front panel tion. Begin by using the Arrow key to
using a “hidden” menu with restricted select “parameters,” then press the
access. Before operating your charger, Scroll key to view the first parameter.
check to be sure these initial settings To return to the idle display, press
have not been changed. the Stop key. All parameters are
Should you need to change any of automatically saved and overwrite
these settings, you may access them existing parameters.
through the RANGER II control panel. NOTE: An internal, nonrechargeable
The battery must be disconnected in lithium battery permits the RANGER II
order to enter the parameters menu. control to retain programmed operating
To access this menu, press both parameters in memory even when the
Arrow keys at the same time when charger is disconnected from an AC
the seconds portion of the time line. This battery has an expected
display indicates :01 changing to :02. service life of more than 10 years,
and, when required, should be
The Scroll key is used to move replaced by C&D. In the event of
battery malfunction, contact your
local C&D representative.
2.2.1 Real-time or fixed after the preset start time has passed,
increment starting PP: Delay mode [ ➔ ➔ ] the battery will still be charged after a
short delay. This allows for unusual
situations, such as extended-shift where
IMPORTANT: When using real-time the battery would not be available until
starting or fixed increment delay after the preset time.
starting, be sure to allow for at least Real-time or fixed delay starts can be
eight hours of charging before the selected from the programmable
battery is used again. parameters menu.
Delayed starting lets you delay the Use the Arrow keys to select either
time when the charge begins in order “Start at real time” or “Fixed delay
to take advantage of lower, off-peak mode.” If you have selected “Start at
utility rates, or to spread out peak real time,” press the Scroll key, and use
demand loads. the Arrow keys to enter the start time in
HH:MM. If you have selected “Start
after delay,” press the Scroll key, and
➔ ➔
PP: Delay [ ]
use the Arrow keys to enter the delay
in HH:MM:SS.
NOTE: When using real-time start, if
you connect a battery within four hours
2.2.2 Automatic equalizing If you have selected number of cycles NOTE: When a RANGER II charger
(continued) or day of the week, press the Scroll key programmed to equalize by cycles is
and use the Arrow keys to enter the connected to a SMARTBATTERY II it will
appropriate information. Equalizing equalize by battery cycles. Otherwise,
cycles can be programmed for two it will equalize by charger cycles.
to 50 cycles.
2.2.3 Automatic watering Provisions for automatic watering the RANGER II will always water the battery.
have been made within the RANGER II Once watering has been activated, it is
control. NOTE: If a charge mode other important that it remain activated long
than conventional has been selected, enough to ensure all cells have been fully
these do not apply and the menus will watered. In order to limit possible over-
not appear. It can be set to always, never, flow due to damage or malfunction, the
and if a communications board has been RANGER II only maintains water flow for
added for SMARTBATTERY II, every 5 a limited duration. This time is factory set
cycles or every 10 cycles. To select auto- at one minute, but can be adjusted.
matic watering, scroll through the
programmable parameters until the To adjust automatic watering time, press
display shows: the Scroll key until the display reads:
➔ ➔
PP: Water mode [ ] PP: Set WTR tm [ ]
➔ ➔
Use the Arrow keys to select
watering options. Use the Arrow keys to set the length
of the watering cycle. The watering
NOTE: If the automatic watering cycle can last from 15 seconds to
parameter is set to every 5 cycles three minutes.
or every 10 cycles and a battery
without SMARTBATTERY II is connected,
2.2.5 Monitoring water flow To monitor the flow of water during a watering triac is turned on. If no flow is
watering cycle, use the Arrow keys to detected, the triac is turned off and a
select “enable.” fault appears “(- Flo)”. The flow is also
checked at the end of the watering
cycle, and if flow is still detected, the
➔ ➔
2.2.6 Main power override turn on. Press the Arrow key to activate
➔ ➔
2.2.7 Water control override If charge mode is set for other than Use the Arrow keys to turn the second
(continued) conventional, the CTL water display will stage ON or OFF for troubleshooting
be replaced by the following: purposes. Watering mode functions,
including flow check, are not available
PP: CTL STAGE 2 [
➔
]
➔
in non-conventional modes.
2.2.8 Setting the number of cells display appears. Use the Arrow keys to
➔ ➔
PP: Set CELLS [ ] set the number of cells to match the
charger nameplate rating. You may
enter from six to 36 cells in one cell
The number of cells for the charger and increments.
the RANGER II control are designed to
match. After entering the programming
menu, as explained above, scroll
through the selections until the above
2.2.9 Selecting the shunt size Should you need to change the shunt
➔ ➔
PP: Set SHUNT [ ] size, refer to the parts lists on pages 34,
35, 36. Use the Arrow keys to set the
shunt at 100 mV to 100, 200, 300, or
The RANGER II control is matched to its 500 amperes.
shunt size at the C&D factory. There Press the Scroll key to set the
should be no need to change the shunt shunt size.
size unless a replacement control board
is installed.
2.2.10 Setting the rated output Use the Arrow keys to enter rated
➔ ➔
2.2.11 Setting the charge mode If the charger is set for Flooded Low
➔ ➔
2.2.13 Setting the correct time set when it leaves the factory; however
➔ ➔
PP: Set TIME [ ] it may need to be adjusted if you live in
a different time zone than the factory.
The correct time must be set before
The RANGER II charger has a 24-hour placing the charger in operation. Set the
clock, which allows charger operation to current time HH:MM:SS by pressing the
begin at a preset time or at a fixed delay Arrow keys until the current time is
from time of connection. It also allows shown.
the charger to report the actual time, Press the Scroll key to set the
date and when the charge was begun correct time.
and completed. The 24-hour clock is
2.2.14 Setting the day of the week the RANGER II so all Friday charges
➔ ➔
PP: Set DAY [ ] include an equalizing charge. Refer to
Section 2.2.6. Using the Arrow keys,
set the current day of the week.
By keeping track of weekdays, Press the Scroll key to set the
RANGER II can perform equalizing day of the week.
charges on the day most convenient for
the user. For example, you can program
2.2.16 Activating and setting If RMS system is in use, set the address for
➔ ➔
the address PP: Set NET [ ] this charger ON. On the RANGER NET ™, if
no RMS system is in use set to net inactive.
2.2.17 Setting the baud rate If the network is activated, set the baud
➔ ➔
2.3 Operations
2.3.1 Manual starting 1. CONNECT THE CHARGER TO THE battery is 80 percent charged, an
AC SUPPLY LINE. The digital display “(80%)” will appear after the elapsed
will show the number of cells for which time display.
the charger has been set as well as the If manual or automatic equalize is
charge mode selected (see 2.2.11) and selected, an “(E)” will appear in the
the time of day. upper left hand corner. When voltage
2. CONNECT THE BATTERY. The and current have stabilized “(EXT)” will
charge cycle will begin within five appear after the elapsed time display.
seconds, if no other delay time has When equalization has begun, an
been selected. The RANGER II control “(EQU)” will appear on the display after
display will show the time remaining the elapsed time.
until the start of charge. If the battery is When the charge is complete, the
fully charged, the charger will move RANGER II will show the ampere-hours
from charging to post-charge, or if and kilowatt-hours returned to the
manual equalize is selected, to equalize. battery.
When the charge begins, the display will
show the elapsed time charging, volt-
age and current in amperes. When the
10
2.3.1 Manual starting In the event of a charging problem or NOTE: This error message will clear
(continued) error, an error message will be displayed. if the battery is disconnected.This infor-
Refer to Section 7, Troubleshooting, for mation and other charge parameters
more information on error messages. are also available during the charge
and can be accessed by pressing the
Scroll key twice.
CAUTION
Always be sure charger is turned off—either manually or automatically—before
disconnecting the battery from the charger. Otherwise, hazardous arcing will occur.
2.3.3 Manual equalizing In the course of the normal charge/ overridden, and so this feature can be
discharge cycle, a motive power used to equalize a fully charged battery.
battery develops inequalities of
voltage and specific gravity among
➔
MNU: Manual EQU [ ]
➔
its cells. Equalizing batteries at
regular intervals will restore cell
equality, assuring rated performance.
Manual equalizing is activated by To activate manual equalize, press
pressing the Scroll key at anytime an Arrow key. To deactivate manual
before or during a charge. The equalize, press an Arrow key again.
normal equalization program is After 60 seconds, the display will
return to the idle charger display.
2.3.4 Operation after loss of If the charger has been started will resume operation as soon as power
AC power (warm start) manually, it will return to its previous is restored and continue the charging
operating mode as soon as power is sequence until the charge cycle is
restored and continue charging the completed. An exception to this would
battery until the charge cycle is be if the power outage lasted into the
completed. If the charger is set for next day (beyond 24:00, midnight), in
real-time start and the power is which case the charger would not
discontinued and then restored before restart until the preset hour that day.
the selected start time, charger To reduce the possibility of tripping a
operation is unaffected. breaker in multiple charger installations,
If the charger is set for real-time start the RANGER II control distributes
and the power loss occurs 1) after start charger starts randomly. The minimum
or 2) before start and extends into the delay time is 15 seconds and the maxi-
preselected charge period, the charger mum delay time is 3 minutes and 30
seconds.
2.3.5 Charge data retrieval When a charge is completed, the additional removed data will be available:
RANGER II control can display the ampere-hours moved on discharge and
ampere-hours and kilowatt-hours on charge temperatures. Press the
required for the charge, followed by Scroll key until the display reads:
the word “complete.” Pressing the
Scroll key will enable the user to access
➔ ➔
2.4 Special features A RANGER II charger connected with After equalization or watering, the
with SMARTBATTERY II a SMARTBATTERY II module will operate RANGER II checks the SMARTBATTERY II
in the same manner as described in again for temperature. It may enter the
Sections 2.1 through 2.4, except for the cooling stage again, indicating it on
enhancements noted below. the display.
While the charger is charging a battery Because the SMARTBATTERY II keeps
with SMARTBATTERY II connected, the track of battery cycles, you can equalize
RANGER II control checks the and water the battery by battery cycles,
SMARTBATTERY II module to see that not charger cycles. If equalization is
the last charge was full and the battery selected, the display will show “c:E.”
is discharged. It then calculates and During equalization, the percent charge
displays the percent charged. If the is displayed. You may specify equalizing
SMARTBATTERY II indicates the battery parameters as indicated in Section
is already fully charged, the charge 2.2.2 on Page 6.
cycle is terminated within two minutes. When a SMARTBATTERY II module is
The display will indicate the percent connected to a RANGER II charger, the
charge. The charger may enter a watering options are always, never,
cooling cycle if the SMARTBATTERY II every five battery cycles or every 10
module indicates temperatures within a battery cycles.
certain range; if it does so it is indicated NOTE: A SMARTBATTERY II capable,
on the display as C:Cooling xx°F, with RANGER II control programmed for
the hours, minutes and seconds. When watering by battery cycles will always
the battery temperature is less than perform the watering cycle if connected
105°F, the RANGER II resumes the to a battery without SMARTBATTERY II.
charge cycle and will enter the equalize Changing watering parameters is also
mode, if necessary. described in Section 2.2.7 on Page 8.
2.4.1 Installing a SMARTBATTERY II The RANGER II control is designed charger must have a communications
communications board to interface with a SMARTBATTERY II, board installed.
enabling you to get data such as depth The communications board is installed
of discharge information, start and end by inserting it into the RANGER II board
of charge temperatures, minimum volts at expansion slot A. Firmly seat the
per cell, low volts per cell and more. communications board onto the
In order for a RANGER II control to RANGER II board. (Be sure to discon-
interface with SMARTBATTERY II, the nect both AC power and the battery
during this procedure.)
2.4.2 Retrieving data from When entering the programmable the SMARTBATTERY II attached to a
SMARTBATTERY II modules parameters, a choice is given between RANGER II control. If the RANGER II
the programmable parameters and cannot communicate with the
the SMARTBATTERY II menu. SMARTBATTERY II, COMerr is displayed
The SMARTBATTERY II terminal menu is on the interface. If COMerr is displayed,
used to retrieve information from contact your local C&D representative.
12
BT: Dischrg data [C] Shows minimum volts per cell, ampere-hours
2.37V 329AH 14.21 removed and time in discharge. When this
information is retrieved, the equivalent information
in the charge summary report is replaced with
this new data.
BT: Low VPC [C] The number of low volts per cell cycles and
25 cycles 2.5% the percent of the total.
BT: Lo DOD cycls [C] The number of low depth of discharge cycles for
< 250, 30-70% 700 30% (indicated by “<”) and 30 to 70% categories.
BT: Hi DOD cycls [C] The number of high depth of discharge cycles
70-90% 45, > 5 for 70-90% and > 90% (indicated by “>”).
BT: SOC T cycls [C] The number of cycles in each of three start of
< 250, 500, > 250 charge temperature categories: < 60˚F
(indicated by “<”), 60˚F-100˚F, and > 100˚F
(indicated by “>”).
BT: EOC T cycls [C] The number of cycles in each of the three end of
< 250, 500, > 250 charge temperature categories: < 60˚F
(indicated by “<”), 60˚F-100˚F, and > 100˚F
(indicated by “>”).
BT: Power cycls [C] The number of times the power to the
2 SMARTBATTERY II has been cycled.
2.5 Communications port RANGER II controls are designed to The network address should be set
be able to interface with a computerized to inactive unless there is an RMS.
management system. The unique This will hide the baud rate menu.
RANGER NET fiber optic communica- For information on setup and using an
tions bus establishes a link with the RMS, see the RMS operating manual.
RMS-2000, enabling a user to have For more information on the RMS-1000
complete charging information on a or RMS-2000, ask your local C&D
fleet of FERRO FIVE SERIES chargers representative for a brochure.
with RANGER II controls.
13
3 COMPUCHARGE
CONTROL
3.1 Description COMPUCHARGE continually monitors
the changes in voltage and current over
SCROLL KEY time to determine the proper length of
access additional charge. This efficient method prevents
information undercharging and overcharging,
keeping energy costs down and
maximizing battery life.
LED DISPLAY Other COMPUCHARGE features are:
1/2-inch, visible
in ambient light
• Zero current shut off—within five
seconds of detecting battery
disconnect
STOP
• Battery voltage sensing—the
charger will only start if connected to
MANUAL a battery with proper voltage
EQUALIZE ®
• Battery refresh—every three days
COMPUCHARGE
initiate manual CONTROL
equalize • Turn on time delay—five seconds to
seven hours, 45 minutes, in 15 minute
increments
• LED display—easy to read in
ambient light
• Automatic equalize—never, every
Do not touch Turn off charger before Disconnect charger
seven days, 1, 2, 3, 4, 5, 6 or 7 cycles
uninsulated battery connecting or from AC supply and battery
terminals or connections disconnecting battery before servicing or dismantling
3.2 Operation The operating panel of the is five seconds, which is set at the
COMPUCHARGE control is a sealed factory.) The current from the charge
membrane with a five character, 1⁄2 inch cycle is shown on the display during
LED display, a Stop key, an Equal key the charge.
and a Scroll key. COMPUCHARGE monitors the change
When the charger is idle, the in voltage and current to determine the
COMPUCHARGE display will show the exact time of charge. When the charge
number of cells for which the charger is greater than 80% complete, the last
is set. letter on the display will flash.
Charging begins when the battery is Pressing the Scroll key at any time
connected. COMPUCHARGE checks to during the charge cycle will reveal
be sure the charger is connected to a voltage of the battery (“99.9U”). Pressing
battery with the proper voltage. If the the Scroll key twice reveals ampere-
match is correct, the display will show hours returned (“999r”). The display will
a countdown until the charge starts. return to normal if left unattended or if
If a mismatch is detected, an error the Scroll key is pressed a third time.
code— “bU E”—will appear. (Refer Charging continues until cell electrolyte
to Section 7, Troubleshooting, for is completely mixed and the battery is
more information.) charged to the rated capacity. If the
If equalize is scheduled, either auto- battery remains connected to the
matically or by pressing the Equal charger for more than three days,
key, a dot will appear on the display COMPUCHARGE will automatically
after the last character on the right. If activate a refresh charge.
automatic equalize is selected, this dot Sometimes, cells nearing the end of
will flash; if manual equalize is selected, their operating life and mistreated
it will not flash. After the user-selected batteries are unable to accept a
start up delay, the charge cycle begins. complete charge without overheating.
(For safety reasons, the minimum delay
14
WARNING
If it is necessary to disconnect the battery during the charge, press the Stop
key before removing the battery cable. FAILURE TO TAKE THIS PRECAUTION
CAN CAUSE A SERIOUS ARC HAZARD AND A POTENTIALLY SERIOUS
PERSONAL INJURY.
Note: The COMPUCHARGE delay is designed to give users maximum flexibility in deciding the delay. Therefore, when
multiple jumpers are put on the pins, the times are additive. Thus, if jumpers are on both one hour and 15 minute pins,
the total time is one hour and 15 minutes. Extra jumpers are located on the upper right corner of the board, as shown.
3.3.6 Automatic watering The COMPUCHARGE control has COMPUCHARGE will first initiate the
provisions for automatic watering. watering cycle and then the
The watering cycle lasts for 3 equalize cycle.
minutes. If equalize is also selected,
16
4 SCOUT
CONTROL
The SCOUT is a microprocessor-based
4.1 Description
control that reduces the chance for
overcharging by continually monitoring
battery voltage. When it reaches gassing
SCOUT ®
voltage, the system activates a timer,
CHARGER CONTROL which will allow sufficient charge time to
complete the recharge.
Other SCOUT features include:
• Automatic start—helps prevent
operator errors
• Maximum charge time—helps
prevent overheating
• Safety features—checks for correct
battery before charge begins
• Automatic equalization
• dV/dt termination—prevents
Do not touch
uninsulated battery
Turn off charger before
connecting or
Disconnect charger
from AC supply and battery overcharging, undercharging
terminals or connections disconnecting battery before servicing or dismantling
and overheating
5 36 cells
4 24 cells
3 18 cells
2 12 cells
4.3 Operation The operating panel of a FERRO FIVE when the charge is in progress. When
4.3.1 Basic operation SERIES charger equipped with the the battery is 80 percent charged, the
SCOUT control contains an LED display yellow LED is lit, and the red LED will
and keypad for operator interface. An be extinguished. When the charge is
LED indicates the charger is ready to complete, the green LED will glow.
operate, another LED indicates the If equalize is selected, the charge is
battery is being charged and a third extended by three hours. The red
LED indicates when gassing voltage is LED will flash when the battery is
reached. An Equal key activates the connected and during the charge.
equalization charge mode and a Stop During equalization, the yellow LED
key allows the charger to be turned off will flash and will continue to do so
during a charge. throughout the equalize cycle. When
Chargers equipped with the SCOUT the charge is complete, the green
control do not have start switches. LED will flash.
Charging automatically begins five When an improperly sized battery is
seconds after the operator connects connected, the charger will not start.
the battery, unless another delay is Refer to Section 7, Troubleshooting.
specified by the user (refer to
Section 4.3.2). In the event of an accidental disconnect,
the system will shut down automatically,
When no battery is connected, the green protecting charger components.
LED will flash briefly every four seconds
to indicate the charger is ready to begin If AC power is interrupted, charging will
charge. Once a battery is connected, the begin after a randomly timed startup
red LED will flash and glow steadily delay, not exceeding three minutes,
WARNING
If it is necessary to disconnect the battery during the charge, press the Stop key
before disconnecting the battery. FAILURE TO TAKE THIS PRECAUTION CAN
CAUSE A SERIOUS ARC HAZARD AND A POTENTIALLY SERIOUS
PERSONAL INJURY.
4.3.3 Changing maximum The maximum charging time is set use with FERRO FIVE FR SERIES or
charging time from the factory at 12 hours. This FERRO FIVE EFR SERIES chargers.
feature should not need adjustment for
4.3.5 Automatic equalizing The SCOUT control can be set to auto- 3) Locate the bank of configuration
matically equalize: never, every seventh jumpers shown in Figure 4.2.
cycle or every tenth cycle. To activate
4) Move the switches to the desired
automatic equalization:
equalization cycle as shown in
1) Disconnect the AC power supply at Figure 4.5.
the circuit breaker or fused safety
5) Close the cabinet and reconnect
disconnect.
the AC power supply.
2) Open the cabinet and locate the
printed circuit board mounted directly
behind the control panel.
JP8 EQU 10c
7 EQU 7c
6 EQU never
4.3.6 Cold applications An additional 30 minute charge applications using special combinations
extension may be programmed for cold of the maximum charge time jumpers.
5 OPERATION
5.1 Operating characteristics As with all electrical apparatus, the off-peak service connection. Your
FERRO FIVE operating economics are local utility representative can help you
influenced by electric utility rates, the determine the type of off-peak program
user’s choice of single-phase or three- that best fits your application.
phase power, and the electrical efficiency Efficiency is the measure of the useful
and power factor of the charger. energy the charger makes available to
Electric utility rates are significantly the cell, as measured at the charger
lower during off-peak periods. However, output. It is determined by the equation:
to take advantage of these rates you
may need a separate electric meter for
As the graph in Figure 5.1 illustrates, The power factor is the ratio of the
FERRO FIVE SERIES chargers achieve true power and the apparent power a
89 percent efficiency. This means that charger actually requires to operate.
for every kilowatt of AC input, they will The equation for determining power
deliver 890 watts of DC output to the factor is:
battery and lose only 110 watts of ener-
gy as wasted heat.
EFFICIENCY
60 42600
PERCENT
DC WATTS
FIGURE 5.1-Typical efficiency and power factor FIGURE 5.2-Typical ferroresonant charger curve
performance for FERRO FIVE SERIES chargers
20
5.2 Recommended charging Chargers require little attention • freshening charges if batteries remain
procedures beyond periodic removal of dust out of service for three or more days.
buildup and inspection for loose
• periodic inspection of their DC
connections. Proper charging
connectors to assure that they
procedures are important to prevent
still make a good low resistance
damage to chargers, batteries
connection and have exposed metal
and operators.
which would present a hazard.
Proper charging procedures require
Operators should only connect batteries
lead-acid batteries receive:
to chargers with matching voltage and
• watering at the end of the charge, sufficient power output. The charger
as needed, to maintain proper power must be OFF before batteries
electrolyte level and concentration; are connected or disconnected.
• an equalizing charge approximately Motive power batteries are designed to
every fifth charge to correct voltage be discharged daily but should not be
imbalances among cells; (except discharged by more than 80 percent of
FERRO FIVE LIBERTY SERIES and their capacity during an eight-hour work
FERRO FIVE REVOLUTION SERIES shift. This allows sufficient time for them
which do not require equalizing to charge and cool before they are
charges.) returned to service and extends
cycle life.
• periodic cleaning to remove
corrosive spills;
21
6 OPTIONS
6.2 Series connected C&D series connected charging cables be connected before the charger
charging cables provide a safe, convenient way to will operate.
charge identically discharged batteries C&D offers series connected charging
of the same size connected in series. cables for all FERRO FIVE SERIES
The cables have either two plugs or systems. They can be user-installed.
two receptacles, both of which must
6.3 Parallel connected Parallel connected charging cables press the Stop key (or turn the electro-
charging cables make it possible to charge two batteries mechanical timer to OFF) before
in parallel. The option consists of an connecting the second battery. For
extra set of cables which terminate in chargers equipped with RANGER II,
either a plug or receptacle and a fuse to COMPUCHARGE or other automatic
protect against reverse connection of controls, both batteries must be
one battery. removed before restarting the charger.
In order to deliver an eight-hour charge Use the turn-on time delay feature of
to two batteries in parallel, the charger the control to allow enough time to
must be rated equal to or higher than safely connect both batteries before
the sum of the ampere-hour capacities the charger starts automatically.
of both batteries. Chargers equipped with the electro-
mechanical timer must be reset to the
Ideally, similarly discharged batteries eight-hour mark. To avoid overheating,
should be placed on the charger at the progress of the charge should be
the same time. If this is not possible, carefully monitored.
6.5.1 RANGER MANAGEMENT RMS 1000 computer system is avail- and provides centralized annunciation
SYSTEM 1000 able to operators to achieve optimal of charger alarm conditions.
rotation of batteries for maximum life,
6.5.2 RANGER MANAGEMENT The RMS-2000, a computerized standard reports facilitates usage and
SYSTEM 2000 management system, is available for maintenance reviews. The two-way
monitoring large RANGER Series and RANGER NET communications network
RANGER II Series installations. The gives centralized control over operating
easy-to-install system alerts the parameters, such as delayed start and
operator to abnormal battery operating automatic equalize. For more information
conditions, helping to prevent costly on the RMS-2000, request a brochure
battery damage caused by overdis- from your local C&D representative.
charge and hot batteries. A variety of
6.6 Other options Fungus proofing: The internal information tags on wiring and
components of FERRO FIVE SERIES cables. Lengths over six-feet are
chargers used in high-moisture environ- tagged on both ends. A single tag
ments can be factory treated with a is attached at the middle of
special fungus-resistant varnish. This shorter lengths.
option is only available on original Lifting eyes: Factory-installed lifting
equipment. eyes make it possible to move FERRO
Export service: C&D manufactures FIVE SERIES chargers using a sling.
chargers intended for export service in Wall mounting bracket: C&D offers
accordance with ANSI 42.25. Cabinets wall mounting brackets as a user-
are fitted with a vapor barrier. installed option. See Figure 6.3
Lead tagging: C&D can affix for dimensions.
7 TROUBLESHOOTING
7.1 Procedure The following charts are designed to IMPORTANT: This equipment must
help a qualified technician diagnose and be serviced by qualified personnel
remedy malfunctions in the RANGER II, familiar with both local and national
SCOUT and COMPUCHARGE controls. electrical codes.
In all cases, acknowledge the error WARNING: Line voltages are present
message by pressing the Stop key. within the battery charger cabinet.
NOTE: For RANGER II chargers, the When performing the following trouble-
abort condition clears when the battery shooting procedures, be sure to observe
is disconnected. all appropriate safety precautions.
Principally, the chart covers the control; ALWAYS BE SURE THE CHARGER
more extensive troubleshooting instruc- IS TURNED OFF BEFORE
tions for the charger are presented in DISCONNECTING A BATTERY.
Sections 7.4 through 7.8. Also refer to
the wiring diagrams in Section 9.
23
7.2 Component testing A visual inspection can often reveal C&D supports FERRO FIVE SERIES
many problems. In new chargers, look chargers with prompt field service and
for connections that may have loosened overnight delivery of most components.
during shipment. In previously operating If you do not know the name of your
systems, look for the whitish powder nearest C&D representative contact:
residue created by burning varnish, or a C&D TECHNOLOGIES
broken, melted or discolored wire. 1400 Union Meeting Road
When troubleshooting three-phase P.O. Box 3053
chargers, be sure to test all three sets Blue Bell, PA 19422-0858 USA
of components. (215) 619-2700
Always read and follow all warning Fax (215) 619-7899
labels and turn off the charger before
touching, removing or installing
components.
• 0 to 200 mV scale VOM that reads up to 600 VAC and 250 VDC with
minimum accuracy of 0.5 percent
• Clamp-on ammeter
• SB-175 or SB-350 shorting connector
• Wrench set
• Screwdriver set
• Jumper cables with alligator clips
Diode replacement requires a supply of thermal joint compound and a torque
wrench capable of achieving the values in Table 7.2.
TABLE 7.1
25
7.2 Component testing AMMETER: Confirm reading with a lead to isolate the diode from the
(continued) calibrated millivolt meter connected charger circuit.
across the charger shunt. • A good diode shows low resistance
CAPACITORS: when tested in one direction and high
resistance when the ohmmeter
CAUTION probes are reversed.
Before testing, be sure the capacitor • An open diode shows very high
is discharged. resistance in both directions.
• A shorted diode shows zero or low
Test capacitors with a calibrated resistance in both directions.
ohmmeter. Different sizes of capacitors
require different ohmmeter range FUSES: Remove the fuse from the fuse
settings. Begin with the highest setting. holder and test it with an ohmmeter set
Before testing, disconnect both leads to to any scale.
isolate the capacitor from the charger • A good fuse shows zero resistance.
circuit. Be sure to reverse the leads for • An open or “blown” fuse shows
each check. infinite resistance.
• A good capacitor deflects the RESISTORS: Test resistors with an
ohmmeter needle toward zero ohmmeter. Different values of resistors
then steadily rises toward infinite require different ohmmeter range
resistance. settings. Begin with the highest setting.
• An open capacitor immediately Before testing, disconnect both leads
shows infinite resistance. to isolate the resistor from the
• A shorted capacitor remains at zero charger circuit.
resistance. • A good resistor shows a specific
CONTROL TRANSFORMER: Output value.
should be between 22 and 26 VAC. • An open resistor shows an infinite
DIODES: Test diodes with the resistance.
ohmmeter set at either the 10X or 100X • A shorted resistor shows zero
scale. Before testing, disconnect one resistance.
7.3 Replacing components Ammeters, ammeter shunts, 1) Disconnect the charger from the AC
capacitors, control transformers, line and battery.
fuses, line contactors, line contactor 2) Remove the rectifier assembly.
coils, electromechanical timer, power
transformers and resistors can be 3) Clamp the heat sink portion of the
user-replaced. Simply mate the leads assembly in a vise.
of the replacement component with 4) Remove the faulty diode.
their appropriate connectors. 5) Coat the mating surfaces of the
Printed circuit boards in RANGER II, diode and the heat sink with a
COMPUCHARGE, SCOUT and suitable thermal joint compound.
automatic Start/Stop controls do not 6) Place the diode on the heat sink
contain user-repairable parts. The entire and hand tighten the diode
printed circuit board must be replaced. connection hardware.
A printed circuit board repair shop is
operated by C&D. Contact your local 7) Torque diode connections to values
C&D agent for this service. shown in Table 7.2.
C&D recommends replacing the entire 8) Remove excess thermal joint
rectifier assembly rather than individual compound.
diodes. Users attempting diode 9) Reinstall the assembly and
replacement MUST observe the reconnect leads.
following procedure:
TABLE 7.2
26
PRIMARY COIL
RESONANT RESISTOR
TRANSFORMER
SECONDARY COIL
RESONANT CAPACITORS
TOP
CONTROL CAPACITOR
TRANSFORMER
AC FUSES
RESONANT
LINE AMMETER SHUNT RESISTORS
CONTACTOR
DC FUSE
AC INPUT
TERMINALS RECTIFIER
ASSEMBLY
FERRORESONANT
CONTROL TRANSFORMER
BOARD
HARNESS
FRONT BACK
AC FUSES
DC FUSES
CONTROL TRANSFORMER
POWER TRANSFORMERS
RECTIFIER ASSEMBLY
CONNECTOR
FRONT
RESONANT CAPACITORS
RESONANT RESISTORS
FERRORESONANT TRANSFORMERS
BACK
TOP
PROBLEM
NO CHARGER OUTPUT
IN VR MODE
POSSIBLE CAUSE
OPEN VR DIODE(S)
OR WIRING
PROCEDURE
CHECK VR DIODES
AND WIRING
RESULT
OPEN DIODE(S)
SOLUTION
REPLACE DIODE(S)
RESULT
CHARGER OPERATES
30
7.5 FERRO FIVE REVOLUTION SERIES: Troubleshooting a charger with output too high
PROBLEM
1 2 3 4
SET RANGER BOARD CHECK FOR 24 VAC CHECK WIRING AND FOR 24
TO VR MODE AT TB4 VAC AT CONTACTOR COIL CHECK DIODE(S)
SOLUTION SOLUTION
RESULT
RESULT
7.6 FERRO FIVE LIBERTY SERIES: Troubleshooting a charger when output does not increase
PROBLEM
1 2 3 4 5
POSSIBLE CAUSE POSSIBLE CAUSE POSSIBLE CAUSE POSSIBLE CAUSE POSSIBLE CAUSE
SET RANGER BOARD CHECK FOR 24 VAC CHECK WIRING AND FOR 24 VAC
TO LM MODE AT TB4 AT CONTACTOR COIL(S) CHECK BOOST CAPACITOR(S) CHECK BOOST DIODES
AND RESISTOR(S)
RESULT
CONTACTOR ENERGIZES,
OUTPUT STILL LOW
GO TO CAUSE 4
32
RESULT RESULT
POSSIBLE CAUSE
DEFECTIVE LINE
CONTACTOR COIL (LCC)
SOLUTION
CHECK FOR LINE VOLTAGE
ACROSS YEL. & BLUE WIRE
TERMINALS ON LINE
CONTACTOR (LC)
CHARGER STARTS CHARGER STARTS DEFECTIVE LINE DEFECTIVE CONTROL CHARGER CONNECTED FOR
CHARGING CHARGING CONTACTOR COIL (LCC) TRANSFORMER (CXF) WRONG VOLTAGE
PROBLEM
CHARGER DELIVERS
NO DC OUTPUT
POSSIBLE CAUSE
BLOWN DC OUTPUT
FUSE (F2)*
SOLUTION PROCEDURE
CORRECT POLARITY OF DISCONNECT LEADS FROM
CHARGER/BATTERY POWER TRANSFORMER (PXF) TO
CABLE CONNECTORS RECTIFIER ASSEMBLY (SR) AND
CHECK DIODE WITH OHMMETER
RESULT SOLUTION
REPLACE RECTIFIER
CHARGER DELIVERS ASSEMBLY (SR); RECONNECT
RATED DC OUTPUT LEADS; START CHARGER
RESULT
CHARGER DELIVERS
RATED DC OUTPUT
34
PROBLEM
CHARGER WON’T SHUT
OFF AT END OF
CHARGE CYCLE
SOLUTION SOLUTION
RESULT RESULT
CHARGER SHUTS CHARGER SHUTS
OFF AT END OF OFF AT END OF
CHARGE CYCLE CHARGE CYCLE
35
PROBLEM
SINGLE-PHASE CHARGER
DELIVERS LOW OUTPUT
CURRENT/VOLTAGE
1 2 3 4
RESULT
CHARGER DELIVERS
RATED OUTPUT
CURRENT
RESULT RESULT
OHMMETER READS VERY OHMMETER READS VERY
HIGH RESISTANCE IN HIGH RESISTANCE IN ONE
BOTH DIRECTIONS DIRECTION, VERY LOW
IN THE OTHER
SOLUTION CONCLUSION
REPLACE RECTIFIER
ASSEMBLY (SR); RECONNECT DIODE IS GOOD;
LEADS; START CHARGER GO TO STEP 4
RESULT
CHARGER DELIVERS
RATED OUTPUT
CURRENT
36
PROBLEM
THREE-PHASE CHARGER
DELIVERS OUTPUT CURRENT
ONE-THIRD OR TWO-THIRDS
THAT OF ITS RATING†
POSSIBLE CAUSE
ONE OR TWO OF THE THREE
POWER TRANSFORMER (PXF)
CIRCUITS IS NOT
OPERATING
SOLUTION
ISOLATE INOPERATIVE
POWER TRANSFORMER (PXF)
CIRCUIT(S) AND
TROUBLESHOOT IT
PROCEDURE
CONNECT AMMETER PROBE
ACROSS DC FUSE (F2)* LEADS
FROM POWER TRANSFORMER
(PXF)* TO CHECK FOR
CHARGING CURRENT
RESULTS
CIRCUIT(S) WITH NO OUTPUT
CURRENT IS FAULTY AND
REQUIRES FURTHER
TROUBLESHOOTING
1 2 3 4
†Three-phase chargers have three power transformer circuits so they can deliver an output current (lower) even with one or two circuits
inoperative. TROUBLESHOOTING TIP: If output current is approximately two-thirds of rated output, one power transformer circuit is
inoperative. If output current is approximately one-third of rated current, two power transformer circuits are inoperative.
37
8 PARTS LIST
FR6AC255 100 381 2 30 510 12 7/6 100 630 125 300 225 253 698 509 2765 2468 2746 2382
FR6CE255 100 381 2 30 510 7/6 03 100 630 125 300 225 254 698 509 2765 2468 2746 2382
FR6AC375 200 327 2 30 510 20 10/10 200 620 125 300 225 253 698 509 2765 2468 2746 2382
FR6CE375 200 327 2 30 510 10/10 05 200 620 125 300 225 254 698 509 2765 2468 2746 2382
FR6AC450 200 327 2 30 510 25 15/12 200 620 125 300 225 253 698 509 2765 2468 2746 2382
FR6CE450 200 327 2 30 510 15/12 06 200 620 125 300 225 254 698 509 2765 2468 2746 2382
FR6CE510 200 327 2 30 510 15/12 06 200 620 125 300 225 254 698 509 2765 2468 2746 2382
FR6CE640 200 327 2 30 510 20/15 07 325 625 185 300 206 254 698 509 2765 2468 2746 2382
FR6CE750 300 328 2 30 510 20/20 10 325 625 185 300 206 254 698 509 2765 2468 2746 2382
FR6HK830 300 328 3 30 513 7/6 03 200 620 185 300 182 254 698 509 2765 2468 2746 2382
FR6HK1000 300 328 3 30 513 10/10 05 200 620 345 300 208 254 698 509 2765 2468 2746 2382
FR6HK1125 300 328 3 30 513 12/10 05 200 620 345 300 208 254 698 509 2765 2468 2746 2382
FR6HK1700 500 328 3 30 513 15/12 07 200 620 345 300 208 254 698 509 2765 2468 2746 2382
FR9CE255 100 381 2 30 510 8/8 04 100 630 125 300 225 254 698 509 2765 2468 2746 2382
FR9CE640 200 327 2 30 510 25/20 10 325 625 185 300 206 254 698 509 2765 2468 2746 2382
FR9HK830 300 328 3 30 513 10/10 05 200 620 185 300 182 254 698 509 2765 2468 2746 2382
FR9HK1160 300 328 3 30 513 15/12 07 200 620 345 300 208 254 698 509 2765 2468 2746 2382
FR12CE255 100 381 2 30 510 15/12 06 100 630 125 300 225 254 698 509 2765 2468 2746 2382
FR12CE375 200 327 2 30 510 20/20 10 200 620 125 300 225 254 698 509 2765 2468 2746 2382
FR12CE450 200 327 2 30 510 20/20 10 200 620 125 300 225 254 698 509 2765 2468 2746 2382
FR12CE550 200 327 2 30 510 25/25 12 200 620 125 300 225 254 698 509 2765 2468 2746 2382
FR12CE640 200 327 2 30 510 35/30 15 325 625 185 300 206 254 698 509 2765 2468 2746 2382
FR12CE750 300 328 2 40 511 40/35 20 325 625 185 300 206 254 698 509 2765 2468 2746 2382
FR12HK550 200 327 3 30 513 8/8 05 100 630 185 300 182 254 698 509 2765 2468 2746 2382
FR12HK640 200 327 3 30 513 10/10 05 200 620 185 300 182 254 698 509 2765 2468 2746 2382
FR12HK850 300 328 3 30 513 15/12 07 200 620 185 300 182 254 698 509 2765 2468 2746 2382
FR12HK1000 300 328 3 30 513 15/15 08 200 620 345 300 208 254 698 509 2765 2468 2746 2382
FR12HK1200 300 328 3 30 513 20/20 10 200 620 345 300 208 254 698 509 2765 2468 2746 2382
FR15HK830 300 328 3 30 513 15/15 08 200 620 185 300 182 254 698 509 2765 2468 2746 2382
FR15HK1200 300 328 3 30 513 25/20 10 200 620 345 300 208 254 698 509 2765 2468 2746 2382
FR16HK830 300 328 3 30 513 20/15 08 200 620 185 300 182 254 698 509 2765 2468 2746 2382
FR16HK1200 300 328 3 40 514 25/20 10 200 620 345 300 208 254 698 509 2765 2468 2746 2382
FR18CE255 100 381 2 30 510 20/20 10 100 630 125 300 225 254 698 509 2765 2468 2746 2382
FR18CE450 200 327 2 30 510 30/25 12 200 620 125 300 225 254 698 509 2765 2468 2746 2382
FR18CE510 200 327 2 30 510 35/30 15 200 620 125 300 225 254 698 509 2765 2468 2746 2382
FR18CE640 200 327 2 40 511 45/40 20 325 625 185 300 651 254 698 509 2765 2468 2746 2382
FR18CE750 200 327 3 60 616 60 30 325 625 185 300 206 254 698 509 2765 2468 2746 2382
FR18CE850 300 328 3 60 616 60 30 325 625 250 600 790 254 698 509 2765 2468 2746 2382
FR18HK640 200 327 3 30 513 15/15 06 200 620 185 300 182 254 698 509 2765 2468 2746 2382
FR18HK750 200 327 3 30 513 20/15 08 200 620 185 300 182 254 698 509 2765 2468 2746 2382
FR18HK850 300 328 3 30 513 20/15 10 200 620 185 300 182 254 698 509 2765 2468 2746 2382
FR18HK1000 300 328 3 30 513 25/20 10 200 620 345 300 208 254 698 509 2765 2468 2746 2382
FR18HK1200 300 328 3 40 514 30/25 15 200 620 345 300 208 254 698 509 2765 2468 2746 2382
FR18HK1360 300 328 3 40 514 30/30 15 200 620 345 300 208 254 698 509 2765 2468 2746 2382
FR18HK1600 500 382 3 50 515 35/30 15 200 620 345 300 208 254 698 509 2765 2468 2746 2382
FR18HK2175 500 382 3 40 514 25 325 625 590 300 657 254 698 509 2765 2468 2746 2382
FR20HK800 300 328 3 30 513 20/15 10 200 620 185 300 182 254 698 509 2765 2468 2746 2382
FR24CE225 100 381 2 30 510 20 10 200 620 125 300 225 254 698 509 2765 2468 2746 2382
FR24CE510 200 327 2 40 511 50/40 20 200 620 185 600 789 254 698 509 2765 2468 2746 2382
FR24BC750 200 327 3 90 615 80/70 325 625 185 600 789 254 698 509 2765 2468 2746 2382
FR24HK510 200 327 3 30 513 20/15 8 200 620 185 600 196 254 698 509 2765 2468 2746 2382
FR24HK640 200 327 3 30 513 20/15 10 200 620 185 600 196 254 698 509 2765 2468 2746 2382
FR24HK750 200 327 3 30 513 25/20 10 200 620 185 600 196 254 698 509 2765 2468 2746 2382
FR24HK900 300 328 3 40 514 30/30 15 200 620 345 600 209 254 698 509 2765 2468 2746 2382
FR24HK1100 300 328 3 40 514 35/30 15 200 620 345 600 209 254 698 509 2765 2468 2746 2382
FR24HK1360 300 328 3 40 514 35/30 15 200 620 345 600 209 254 698 509 2765 2468 2746 2382
FR36CE450 200 327 3 60 616 60/50 30 200 620 185 600 788 254 698 509 2765 2468 2746 2382
FR36HK450 200 327 3 30 513 20/20 10 200 620 185 600 196 254 698 509 2765 2468 2746 2382
FR36HK550 200 327 3 40 514 25/25 12 200 620 185 600 196 254 698 509 2765 2468 2746 2382
FR36HK750 200 327 3 40 514 30/30 15 200 620 185 600 196 254 698 509 2765 2468 2746 2382
FR36K935 300 328 3 30 513 20 200 620 345 600 209 254 698 509 2765 2468 2746 2382
FR36K1600 500 382 3 50 515 35 200 620 350 600 209 254 698 509 2765 2468 2746 2382
38
FR6M255 100 381 2 30 510 03 100 630 125 300 225 255 698 509 2765 2468 2746 2382
FR6M375 200 327 2 30 510 05 200 620 125 300 225 255 698 509 2765 2468 2746 2382
FR6M450 200 327 2 30 510 05 200 620 125 300 225 255 698 509 2765 2468 2746 2382
FR6M510 200 327 2 30 510 05 200 620 125 300 225 255 698 509 2765 2468 2746 2382
FR6M640 200 327 2 30 510 06 325 625 185 300 206 255 698 509 2765 2468 2746 2382
FR6M750 300 328 2 30 510 06 325 625 185 300 206 255 698 509 2765 2468 2746 2382
FR6L830 300 328 3 30 513 03 200 620 185 300 182 255 698 509 2765 2468 2746 2382
FR6L1000 300 328 3 30 513 03 200 620 345 300 208 255 698 509 2765 2468 2746 2382
FR6L1125 300 328 3 30 513 03 200 620 345 300 208 255 698 509 2765 2468 2746 2382
FR6L1700 500 328 3 30 513 05 200 620 345 300 208 255 698 509 2765 2468 2746 2382
FR9M640 200 327 2 30 510 10 325 625 185 300 206 255 698 509 2765 2468 2746 2382
FR9L830 300 328 3 30 513 03 200 620 185 300 182 255 698 509 2765 2468 2746 2382
FR9L1160 300 328 3 30 513 05 200 620 345 300 208 255 698 509 2765 2468 2746 2382
FR12M255 100 381 2 30 510 06 100 630 125 300 225 255 698 509 2765 2468 2746 2382
FR12M375 200 327 2 30 510 06 200 620 125 300 225 255 698 509 2765 2468 2746 2382
FR12M450 200 327 2 30 510 06 200 620 125 300 225 255 698 509 2765 2468 2746 2382
FR12M550 200 327 2 30 510 10 200 620 125 300 225 255 698 509 2765 2468 2746 2382
FR12M640 200 327 2 30 510 10 325 625 185 300 206 255 698 509 2765 2468 2746 2382
FR12L550 200 327 3 30 513 03 100 630 185 300 182 255 698 509 2765 2468 2746 2382
FR12L640 200 327 3 30 513 03 200 620 185 300 182 255 698 509 2765 2468 2746 2382
FR12L850 300 328 3 30 513 03 200 620 185 300 182 255 698 509 2765 2468 2746 2382
FR12L1000 300 328 3 30 513 05 200 620 345 300 208 255 698 509 2765 2468 2746 2382
FR12L1200 300 328 3 30 513 05 200 620 345 300 208 255 698 509 2765 2468 2746 2382
FR15L830 300 328 3 30 513 05 200 620 185 300 182 255 698 509 2765 2468 2746 2382
FR15L1200 300 328 3 30 513 10 200 620 345 300 208 255 698 509 2765 2468 2746 2382
FR16L830 300 328 3 30 513 05 200 620 185 300 182 255 698 509 2765 2468 2746 2382
FR16L1200 300 328 3 40 514 10 200 620 345 300 208 255 698 509 2765 2468 2746 2382
FR18M255 100 381 2 30 510 010 100 630 125 300 225 255 698 509 2765 2468 2746 2382
FR18M450 200 327 2 30 510 010 200 620 125 300 225 255 698 509 2765 2468 2746 2382
FR18M510 200 327 2 30 510 015 200 620 125 300 225 255 698 509 2765 2468 2746 2382
FR18M640 200 327 2 40 511 020 325 625 185 300 651 255 698 509 2765 2468 2746 2382
FR18EM750 200 327 3 60 616 30 025 325 625 185 300 785 255 698 509 2765 2468 2746 2382
FR18EM850 300 328 3 60 616 30 025 325 625 250 600 785 255 698 509 2765 2468 2746 2382
FR18L750 200 327 3 30 513 005 200 620 185 300 182 255 698 509 2765 2468 2746 2382
FR18L850 300 328 3 30 513 005 200 620 185 300 182 255 698 509 2765 2468 2746 2382
FR18L1000 300 328 3 30 513 006 200 620 345 300 208 255 698 509 2765 2468 2746 2382
FR18L1200 300 328 3 40 514 010 200 620 345 300 208 255 698 509 2765 2468 2746 2382
FR18L1360 300 328 3 40 514 010 200 620 345 300 208 255 698 509 2765 2468 2746 2382
FR18L1600 500 382 3 50 515 200 620 345 300 208 255 698 509 2765 2468 2746 2382
FR18L2175 500 382 3 40 514 325 625 590 300 657 255 698 509 2765 2468 2746 2382
FR20L800 300 328 3 30 513 06 200 620 185 300 182 255 698 509 2765 2468 2746 2382
FR24EM510 200 327 2 40 511 35 30 200 620 185 600 789 255 698 509 2765 2468 2746 2382
FR24EM750 200 327 3 90 615 35 30 325 625 185 600 790 255 698 509 2765 2468 2746 2382
FR24L510 200 327 3 30 513 05 200 620 185 600 196 255 698 509 2765 2468 2746 2382
FR24L750 200 327 3 40 513 06 200 620 185 600 196 255 698 509 2765 2468 2746 2382
FR24L900 300 328 3 40 514 10 200 620 345 600 209 255 698 509 2765 2468 2746 2382
FR24L1100 300 328 3 40 514 10 200 620 345 600 209 255 698 509 2765 2468 2746 2382
FR24L1360 300 328 3 40 514 10 200 620 345 600 209 255 698 509 2765 2468 2746 2382
FR36EM450 200 327 3 60 616 30 25 200 620 185 600 789 255 698 509 2765 2468 2746 2382
FR36L450 200 327 3 30 513 06 200 620 185 600 196 255 698 509 2765 2468 2746 2382
FR36L550 200 327 3 40 514 10 200 620 185 600 196 255 698 509 2765 2468 2746 2382
FR36L750 200 327 3 40 514 10 200 620 185 600 196 255 698 509 2765 2468 2746 2382
FR36L935 300 328 3 30 513 15 200 620 345 600 209 255 698 509 2765 2468 2746 2382
39
8.3 FERRO FIVE EFR SERIES 120/208/240 and 480 VAC inputs
EFR6AC470 200 327 2 30 510 20 10/10 200 620 125 300 225 253 698 509 2765 2468 2746 2382
EFR6CE470 200 327 2 30 510 10/10 05 200 620 125 300 225 254 698 509 2765 2468 2746 2382
EFR6AC560 200 327 2 30 510 25 15/12 200 620 125 300 225 253 698 509 2765 2468 2746 2382
EFR6CE560 200 327 2 30 510 15/12 06 200 620 125 300 225 254 698 509 2765 2468 2746 2382
EFR6CE640 200 327 2 30 510 15/12 06 200 620 125 300 225 254 698 509 2765 2468 2746 2382
EFR6CE800 200 327 2 30 510 20/15 07 325 625 185 300 206 254 698 509 2765 2468 2746 2382
EFR6CE940 300 328 2 30 510 20/20 10 325 625 185 300 206 254 698 509 2765 2468 2746 2382
EFR6HK1040 300 328 3 30 513 7/6 03 200 620 185 300 182 254 698 509 2765 2468 2746 2382
EFR6HK1250 300 328 3 30 513 10/10 05 200 620 345 300 208 254 698 509 2765 2468 2746 2382
EFR9CE640 200 327 2 30 510 25/20 10 325 625 185 300 206 254 698 509 2765 2468 2746 2382
EFR12CE320 100 381 2 30 510 15/12 06 100 630 125 300 225 254 698 509 2768 2465 2746 2382
EFR12CE470 200 327 2 30 510 20/20 10 200 620 125 300 225 254 698 509 2765 2468 2746 2382
EFR12CE560 200 327 2 30 510 20/20 10 200 620 125 300 225 254 698 509 2765 2468 2746 2382
EFR12CE690 200 327 2 30 510 25/25 12 200 620 125 300 225 254 698 509 2765 2468 2746 2382
EFR12CE800 200 327 2 30 510 35/30 15 325 625 185 300 206 254 698 509 2765 2468 2746 2382
EFR12CE940 300 328 2 40 511 40/35 20 325 625 185 300 206 254 698 509 2765 2468 2746 2382
EFR12HK690 200 327 3 30 513 8/8 05 100 630 185 300 182 254 698 509 2765 2468 2746 2382
EFR12HK800 200 327 3 30 513 10/10 05 200 620 185 300 182 254 698 509 2765 2468 2746 2382
EFR12HK1060 300 328 3 30 513 15/12 07 200 620 185 300 182 254 698 509 2765 2468 2746 2382
EFR12HK1250 300 328 3 30 513 15/15 08 200 620 345 300 208 254 698 509 2765 2468 2746 2382
EFR12HK1500 300 328 3 30 513 20/20 10 200 620 345 300 208 254 698 509 2765 2468 2746 2382
EFR18CE320 100 381 2 30 510 20/20 10 100 630 125 300 225 254 698 509 2765 2468 2746 2382
EFR18CE560 200 327 2 30 510 30/25 12 200 620 125 300 225 254 698 509 2765 2468 2746 2382
EFR18CE640 200 327 2 30 510 35/30 15 200 620 125 300 225 254 698 509 2765 2468 2746 2382
EFR18CE800 200 327 2 40 511 45/40 20 325 625 185 300 651 254 698 509 2765 2468 2746 2382
EFR18HK800 200 327 3 30 513 15/15 06 200 620 185 300 182 254 698 509 2765 2468 2746 2382
EFR18HK940 200 327 3 30 513 20/15 08 200 620 185 300 182 254 698 509 2765 2468 2746 2382
EFR18HK1060 300 328 3 30 513 20/15 10 200 620 185 300 182 254 698 509 2765 2468 2746 2382
EFR18HK1250 300 328 3 30 513 25/20 10 200 620 345 300 208 254 698 509 2765 2468 2746 2382
EFR18HK1500 300 328 3 40 514 30/25 15 200 620 345 300 208 254 698 509 2765 2468 2746 2382
EFR18HK1700 300 328 3 40 514 30/30 15 200 620 345 300 208 254 698 509 2765 2468 2746 2382
EFR18HK2000 500 382 3 50 515 35/30 15 200 620 345 300 208 254 698 509 2765 2468 2746 2382
EFR24HK640 200 327 3 30 513 20/15 08 200 620 185 600 196 254 698 509 2765 2468 2746 2382
EFR24HK940 200 327 3 40 513 25/20 10 200 620 185 600 196 254 698 509 2765 2468 2746 2382
EFR24HK1125 300 328 3 40 514 30/30 15 200 620 345 600 209 254 698 509 2765 2468 2746 2382
EFR24HK1375 300 328 3 40 514 35/30 15 200 620 345 600 209 254 698 509 2765 2468 2746 2382
EFR24HK1700 300 328 3 40 514 35/30 15 200 620 345 600 209 254 698 509 2765 2468 2746 2382
EFR36HK690 200 327 3 40 514 25/25 12 200 620 185 600 196 254 698 509 2765 2468 2746 2382
EFR36HK940 200 327 3 40 514 30/30 15 200 620 185 600 196 254 698 509 2765 2468 2746 2382
40
9 WIRING DIAGRAMS
9.1 Wiring diagram guide for FERRO FIVE FR, LIBERTY, and REVOLUTION SERIES charger models
9.2 Wiring diagram guide for FERRO FIVE EFR SERIES models
MODEL EFR
NO.
EFR6AC470 NBC-2243
EFR6CE470 NBC-2244
EFR6CE560 NBC-2244
EFR6CE640 NBC-2244
EFR6CE800 NBC-2244
EFR6CE940 NBC-2244
EFR6HK1040 NBC-2247
EFR6HK1250 NBC-2247
EFR9CE640 NBC-2244
EFR12CE320 NBC-2244
EFR12CE470 NBC-2244
EFR12CE560 NBC-2244
EFR12CE690 NBC-2244
EFR12CE800 NBC-2244
EFR12CE940 NBC-2244
EFR12HK690 NBC-2247
EFR12HK800 NBC-2247
EFR12HK1060 NBC-2247
EFR12HK1250 NBC-2247
EFR12HK1500 NBC-2247
EFR18CE320 NBC-2244
EFR18CE560 NBC-2244
EFR18CE640 NBC-2244
EFR18CE800 NBC-2244
EFR18HK940 NBC-2247
EFR18HK1060 NBC-2247
EFR18HK1250 NBC-2247
EFR18HK1500 NBC-2247
EFR18HK1700 NBC-2247
EFR18HK2000 NBC-2247
EFR24HK640 NBC-2247
EFR24HK940 NBC-2247
EFR24HK1125 NBC-2247
EFR24HK1375 NBC-2247
EFR24HK1700 NBC-2247
EFR36HK690 NBC-2247
EFR36HK940 NBC-2247
42
CHANGEOVER INSTRUCTIONS
CAUTION
AC FUSES MUST BE CHANGED WHEN CHANGING
VOLTAGE. SEE LABEL IN CHARGER.
9.5 Wiring diagrams for FERRO FIVE REVOLUTION SERIES
LEGEND
CAUTION
LEGEND
LEGEND
WIRE NUMBERS USED: 1-17, 20-30, 34, 35, 37-39, 41, 42, 44-47, 50, 51,
54-56, 59, 60, 72-78.
CHANGEOVER INSTRUCTIONS
AND 5 & 7.
ON CXF CONNECT TERMINALS H1 & H3 and H2 & H4.
CAUTION
1. ALL 3 PHASES ON VOLTAGE CHANGEOVER BOARD MUST BE
RECONNECTED WHEN CHANGING VOLTAGE.
2. AC FUSES MUST BE CHANGED WHEN CHANGING VOLTAGE.
SEE LABEL IN CHARGER.
LEGEND
WIRE NUMBERS USED: 1-17, 20-30, 34, 35, 37-39, 41, 42, 44-47, 50, 51, 54-56,
59, 60, 72-78.
FOR 480 VOLT INPUT CONNECT – TERMINALS 2 & 4 ON TB1, TB2, TB3.
CONNECT RED WIRE TO CXF TERMINALS H2.
FOR 575 VOLT INPUT CONNECT – TERMINALS 3 & 4 ON TB1, TB2, TB3.
9.5 Wiring diagrams for FERRO FIVE REVOLUTION SERIES (continued)
CAUTION
FOR 480 VOLT INPUT: CONNECT TERMINALS 2 & 4 ON TB1 AND RED WIRE
TO CXF H2.
FOR 575 VOLT INPUT: CONNECT TERMINALS 3 & 4 ON TB1 AND RED WIRE
TO CXF H3.
CAUTION
LEGEND