Professional Documents
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CAUTION
WARNING
CAUTIO
A battery on charge gives off a mixture of oxygen
PHASE FUSE
N
and hydrogen gas, which is explosive. Ventilate the
charger room to prevent gas accumulation. C&D
RATING
LIFT ALL
chargers are convection cooled. To provide ample HIGH 208 LOW
ventilation to carry off excess heat, keep chargers VOLTAGE VOLTS VOLTAGE
at least four inches from a wall and from other
chargers and obstructions.
3-4-5 3-4-5 3-4-5
CAUTION 6-7-8 6-7-8 6-7-8
Electrical connections can work loose during 10-12-15 10-12-15 10-12-15
CAUTION
shipping. Check all connections for tightness 20-25-30 20-25-30 20-25-30
before connecting the charger to the AC Make sure the charger positive 35-40-45
terminal is
supply voltage.
35-40-45 35-40-45
connected to the charger connector terminal
marked (+) and the negative terminal to the
WARNING one marked (-).
GROUND
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
CONNECTION
codes and they match the current and voltage
requirements of the charger or chargers. The
charger nameplate shows AC volts, phase and
current requirements at nominal line and rated
output and recommended external fusing. In
addition, check the tag on the charger for proper
input voltage.
CAUTIO
N CAUTIO
DO NOT ATTEMPT N
TO RECONNECT
VOLTAGE WITHOUT
DANGER
SHOCK HAZARD WARNING DANGER
ARC HAZARD HIGH VOLTAGE
DO NOT TOUCH
UNINSULATED BATTERY CONNECT OR DISCONNECT CHARGER
TERMINALS OR DISCONNECT BATTERY FROM AC VOLTAGE SUPPLY
CONNECTORS PLUG ONLY WHEN AND BATTERY BEFORE
CHARGE CYCLE IS SERVICING OR DISMANTLING
COMPLETE
TABLE OF CONTENTS
Contents Page
Receiving and
Section 1 Receiving and installation 1
installation
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
RECEIVING AND
1
INSTALLATION
1.1 Receiving
Inspect your C&D charger for any
shipping and handling damage as
MFG DA
CAUTIO soon as it arrives. Describe any
damage on the receiving slip and
Industrial Batteries and Chargers
1400 UNION MEETING ROAD • BLUE BELL PA 19422
VOLTS PHASE 3
with installation. Use caution when AMPS 208/240/480
19/17/8.5HZ 60JM-280
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
FLAMMABLE MATERIALS SHOULD requires 1.5 pints of water to relevel,
NOT BE PERMITTED IN THE will produce 34.5 cubic (1.5 x 23)
CHARGING ROOM. NEVER MOUNT feet of hydrogen.
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
hydrogen is generated at different of capacity.
3
0.24
=
100 Pies cúbicos de hidrógeno / ciclo de carga
Celdas x Capacidad x
0.24
18 x 720 x = 31.1 Pies cúbicos de hidrógeno / ciclo de carga
100
1.5 Mechanical installation Los cargadores se pueden atornillar a pisos Figura 1.3 para las dimensiones del gabinete del
no combustibles o bancos de acero. Para cargador. El montaje en la pared requiere los soportes
un ahorro máximo de espacio, se pueden opcionales descritos en la Sección 6.6.
apilar hasta tres unidades. Consultar
DIMENSIONAL DRAWINGS
F H
DC Cable Entrance Hole 1.75 (44.45 mm)
DA EC D EC
A
CABINET A B C D E F G H J
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 Cada cargador requiere un interruptor de Las instalaciones eléctricas deben ser realizadas por
desconexión de seguridad con fusible o un electricista calificado.
un disyuntor. Utilice un dispositivo de y cumplir con todos los códigos eléctricos locales,
protección de línea con el valor de fusible nacionales y federales. Es vital para el funcionamiento
de línea recomendado que se muestra confiable del cargador que se le proporcione una
en la placa de identificación del cargador buena conexión a tierra.
(Figura 1.1).
CAUTIO
N
Electrical connections can work loose during shipping. Check all connections
1.9 DC cables and cable C&D envía cada cargador con un cable de
connectors salida de CC estándar de ocho pies de
largo que termina con un conector de
cable apropiado. Como opción, hay otras
longitudes disponibles. Si es necesario
instalar cables más largos, deben tener el
tamaño adecuado para evitar el
sobrecalentamiento y garantizar el
cumplimiento de los códigos eléctricos. NO DEBE SUPERAR LOS 35 PIES.
LONGITUD DE CABLE DE CC DE 15 A Al especificar conectores de cable de repuesto, es
25 PIES DEBE SER UN TAMAÑO DE importante recordar que los cargadores monofásicos de
CABLE MÁS GRANDE QUE EL CABLE C&D producen corrientes de pico más altas que los
ESTÁNDAR. LONGITUD DE CABLE sistemas trifásicos de C&D de clasificación similar. La
DESDE 25 corriente DC máxima que fluye desde un cargador
A 35 PIES DEBE SER DOS TAMAÑOS monofásico
DE CABLE MÁS GRANDES. LONGITUD es típicamente 1.3 veces la lectura del amperímetro del
DE CABLE DE CC panel.
C&D recomienda que los conectores SB-350 de mayor
capacidad se especifiquen como equipo de
retroadaptación para todos los cargadores monofásicos
de más de 135 amperios.
6
CAUTIO
N
Asegúrese de que el terminal positivo del cargador esté conectado al
CAUTIO
N
Debido a las altas corrientes involucradas, es imperativo que los conectores
se mantengan adecuadamente. Consulte a su representante de C&D para
7
1.10 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
RANGER II
2 CONTROL WARNIN
G
Battery chargers present an electrical hazard to those who work with or
2.1 Description
service them. Read and understand all warnings and cautions in this
manual as well as those affixed to the charger. Exercise extreme care to
the week.
Automatic equalize can be set through
the programmable parameters (see If you have selected never or always,
Section 2.2). Use the Scroll key until the the next menu will be:
display reads.
To return to the idle display, press the
➔
PP:ofEqulz
number cycles,mode
the day[ of the]week, entering parameters. When equalization
➔
➔
Use the Arrow keys to select Use PP:
the Arrow keys totm
Set WTR set[ the length
]
➔
PP: options.
watering Water mode [ ➔ ] of the watering cycle. The watering
➔
cycle can last from 15 seconds to
NOTE: If the automatic watering three minutes.
parameter is set to every 5 cycles
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
➔
2.2.6 Main power override turn on. Press the Arrow key to activate
➔
the watering
PP: CTL output
WATERto be forced
[ on
] for an
➔
➔
in non-conventional modes.
PP: CTL STAGE 2 [ ]
➔
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
➔
current Set the rated current of the charger as it current from 0 to 500 amperes in five
PP: Rated
on theAMPS
charger[ nameplate.
]
➔
2.2.11 Setting the charge mode If the charger is set for Flooded Low
➔
MM/DD/YY format.
Press the Scroll key to set the
The current date is set by pressing the
current date.
Arrow keys until the current date
9
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
net inactive.
2.2.17 Setting the baud rate If the network is activated, set the baud
➔
2.3 Operations When the charge begins, the display will show
the elapsed time charging, volt- age and
2.3.1 Manual starting
1. CONNECT THE CHARGER TO THE current in amperes. When the
AC SUPPLY LINE. The digital display
will show the number of cells for which
the charger has been set as well as the
charge mode selected (see 2.2.11) and
the time of day.
2. CONNECT THE BATTERY. The
charge cycle will begin within five
seconds, if no other delay time has
been selected. The RANGER II control
display will show the time remaining
until the start of charge. If the battery is
fully charged, the charger will move
from charging to post-charge, or if
manual equalize is selected, to equalize.
10
battery is 80
percent
charged, an
“(80%)” will
appear after
the elapsed
time display.
If manual or
automatic
equalize is
selected, an
“(E)” will
appear in the
upper left hand
corner. When
voltage and
current have
stabilized
“(EXT)” will
appear after
the elapsed
time display.
When
equalization
has begun, an
“(EQU)” will
appear on the
display after
the elapsed
time.
When the
charge is
complete, the
RANGER II will
show the
ampere-hours
and kilowatt-
hours returned
to the battery.
11
CAUTIO
N
Always be sure charger is turned off—either manually or automatically—before
disconnecting the battery from the charger. Otherwise, hazardous arcing will occur.
➔
its cells. Equalizing batteries at To activate manual equalize, press
MNU: Manual EQU [ ]
➔
regular intervals will restore cell an Arrow key. To deactivate manual
equality, assuring rated performance. equalize, press an Arrow key again.
After 60 seconds, the display will
Manual equalizing is activated by return to the idle charger display.
pressing the Scroll key at anytime
before or during a charge. The
normal equalization program is will resume operation as soon as power
is restored and continue the charging
2.3.4 Operation after loss of sequence until the charge cycle is
AC power (warm start) If the charger has been started completed. An exception to this would
manually, it will return to its previous be if the power outage lasted into the
operating mode as soon as power is next day (beyond 24:00, midnight), in
restored and continue charging the which case the charger would not
battery until the charge cycle is restart until the preset hour that day.
completed. If the charger is set for To reduce the possibility of tripping a
real-time start and the power is breaker in multiple charger installations,
discontinued and then restored before the RANGER II control distributes
the selected start time, charger charger starts randomly. The minimum
operation is unaffected. delay time is 15 seconds and the maxi-
mum delay time is 3 minutes and 30
If the charger is set for real-time start seconds.
and the power loss occurs 1) after start
or 2) before start and extends into the
preselected charge period, the charger
2.3.5 Charge data retrieval When a charge is completed, the additional removed data will be
RANGER II control can display the available: ampere-hours moved on
ampere-hours and kilowatt-hours discharge and on charge temperatures.
required for the charge, followed by
➔
reads:
Scroll key will enable the user to access
information about starting time and
This data can be retrieved and shown
date, open circuit battery voltage, MNU: Charge rptafter
[ the ]
on the display during or
starting and ending battery voltage,
charge cycle.
starting and ending battery current,
ampere-hours and kilowatt-hours of In the event of an error during the
charge, length of charge, ending time charge cycle, a “plain English” error
and date, and the number of non- message is displayed. Refer to
equalized cycles. If the battery being Section 7, Troubleshooting.
charged has a SMARTBATTERY II
installed and the charger is equipped for
SMARTBATTERY II communications,
12
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 IIattached to a
SMARTBATTERY II modules parameters, a choice is given RANGER II control. If the RANGER II
between the programmable cannot communicate with the
parameters and the SMARTBATTERY SMARTBATTERY II, COMerr is displayed
II menu. on the interface. If COMerr is displayed,
The SMARTBATTERY II terminal menu contact your local C&D representative.
is used to retrieve information from
13
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
complete charging information on a For more information on the RMS-1000
fleet of FERRO FIVE SERIES chargers or RMS-2000, ask your local C&D
with RANGER II controls. representative for a brochure.
14
COMPUCHARGE
3 CONTROL
Description
3.1
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
®
3.2 Operation
(contimued) If COMPUCHARGE detects a voltage When AC power is interrupted during
rise that has not stabilized after 12 a charge, charging will restart after a
hours, the charge cycle is stopped and randomly timed start up delay, not
an error message appears on the exceeding two minutes.
display.
WARNIN
G
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
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.
5 36 cells
4 24 cells
3 18 cells
2 12 cells
FIGURE 4.3-Close up of jumpers
for changing cells
17
4.3 Operation
4.3.1 Basic operation The operating panel of a FERRO FIVE when the charge is in progress. When
SERIES charger equipped with the the battery is 80 percent charged, the
SCOUT control contains an LED yellow LED is lit, and the red LED will
display and keypad for operator be extinguished. When the charge is
interface. An LED indicates the charger complete, the green LED will glow.
is ready to operate, another LED If equalize is selected, the charge is
indicates the battery is being charged extended by three hours. The red
and a third LED indicates when gassing LED will flash when the battery is
voltage is reached. An Equal key connected and during the charge.
activates the equalization charge mode During equalization, the yellow LED
and a Stop key allows the charger to be will flash and will continue to do so
turned off 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 connected, the charger will not start.
connects the battery, unless another Refer to Section 7, Troubleshooting.
delay is specified by the user (refer
to Section 4.3.2). In the event of an accidental
disconnect, the system will shut down
When no battery is connected, the green automatically, protecting charger
LED will flash briefly every four seconds components.
to indicate the charger is ready to begin
charge. Once a battery is connected, If AC power is interrupted, charging will
the red LED will flash and glow steadily begin after a randomly timed startup
delay, not exceeding three minutes,
WARNIN
G
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
4.3.3 Changing
maximum charging The maximum charging time is set use with FERRO FIVE FR SERIES or
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
automatic equalization: 4) Move the switches to the desired
equalization cycle as shown in
1) Disconnect the AC power supply Figure 4.5.
at the circuit breaker or fused
safety disconnect. 5) Close the cabinet and reconnect
the AC power supply.
2) Open the cabinet and locate the
printed circuit board mounted directly
behind the control panel.
JP8 7 EQU 10c 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
and power factor of the charger. Efficiency is the measure of the useful
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
DC WATTS
PERC
40
C&D MODEL NO. FR18HK1000 SERIAL NO. NONE
18 CELL, 900 AH. BATTERY POWER FACTOR = AC WATTS = 50420/55200 = 91.9%
AC VOLT AMPS
20
MACHINE EFFICIENCY = DC WATTS = 42600/50420 = 84.5% AC WATTS
PERCENT LOAD
6 OPTIONS
6.1 Remote control In some industrial settings, it is
desirable to control chargers from a
central location, such as a charging
mezzanine. FERRO FIVE SERIES
chargers can be assembled with remote
control boxes. Systems equipped with
remote control units function identically
to the panel-mounted charger controls
described in this manual.
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 COMPUCHARGE or other automatic
to 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.
6.5.2 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. wall mounting brackets as a user-
Cabinets are fitted with a vapor installed option. See Figure 6.3
barrier.
for dimensions.
Lead tagging: C&D can affix
7 TROUBLESHOOTING
7.1 Procedure The following charts are designed to Sections 7.4
help a qualified technician diagnose and through 7.8.
remedy malfunctions in the RANGER II, Also refer to
SCOUT and COMPUCHARGE controls. the wiring
In all cases, acknowledge the error diagrams in
message by pressing the Stop key. Section 9.
NOTE: For RANGER II chargers, the
abort condition clears when the battery
is disconnected.
Principally, the chart covers the control;
more extensive troubleshooting instruc-
tions for the charger are presented in
23
IMPORTANT: This equipment must be serviced by qualified
personnel familiar with both local and national electrical codes.
WARNING: Line voltages are present within the battery charger
cabinet.
When performing the following trouble- shooting procedures, be
sure to observe all appropriate safety precautions.
ALWAYS BE SURE THE CHARGER IS TURNED OFF BEFORE
DISCONNECTING A BATTERY.
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
broken, melted or discolored wire. C&D TECHNOLOGIES
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.
7.3 Replacing components Ammeters, ammeter shunts, 1) Disconnect the charger from the
capacitors, control transformers, AC line and battery.
fuses, line contactors, line contactor
coils, electromechanical timer, power 2) Remove the rectifier assembly.
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
contain user-repairable parts. The entire 6) Place the diode on the heat sink
printed circuit board must be replaced. and hand tighten the diode
A printed circuit board repair shop is connection hardware.
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:
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
LINE CONTACTOR
CONTROL BOARD
AMMETER SHUNT HARNESS
AC INPUT TERMINALS
AC CHANGEOVER
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
31
7.5 FERRO FIVE REVOLUTION SERIES: Troubleshooting a charger with output too high
PROBLEM
1 2 3 4
RANGER SET TOBOARD NOT VR MODE VR CONTACTOR NOT ENERGIZED SHORTE ASSE D DIODE MBLY
CHECK DIODE(S)
RESULT
RESULT
7.6 FERRO FIVE LIBERTY SERIES: Troubleshooting a charger when output does not increase
PROBLEM
1 2 3 4 5
POSSIB LE CAUSE POSSIBLE CAUSE POSSIBLE CAUSE POSSIBLE CAUSE POSSIBL E CAUSE
RANGER BO ARD NOT SET M MODE BOOST CONTACTOR(S) NOT ENERGIZED BAD BOOST CAPACITOR OR BOOST RESISTOR S
TO L
BAD RANGER BOARD OPEN BOO T DIODE(S)
CHARGER OUTPUT OK
OUTPUT STILL LOW GO TO CAUSE 5
REPLACE CONTACTOR(S)
RESULT
RESULT
RESULT
CHARGER WON’T START
CHARGING CHARGER STARTS
CHARGING
POSSIBLE CAUSE
DEFECTIVE LINE
CONTACTOR COIL (LCC)
SOLUTION
CHECK FOR LINE VOLTAGE
ACROSS YEL. & BLUE
WIRE TERMINALS ON LINE
CONTACTOR (LC)
RESULT
RESULT RESULT
LINE VOLTAGE PRESENT;
LINE CONTACTOR (LC) CLOSES; NO VOLTAGE PRESENT;
CHARGER WON’T START LINE VOLTAGE PRESENT; LINE CONTACTOR (LC) WON’T
CHARGING LINE CONTACTOR (LC) CLOSE; CHARGER WON’T
WON’T CLOSE START CHARGING
POSSIBLE CAUSE
POSSIBLE CAUSE POSSIBLE CAUSE POSSIBLE CAUSE
DEFECTIVE DIODE IN
RECTIFIER ASSY. (SR) BLOWN AC FUSE (F1)* DEFECTIVE LINE DEFECTIVE TIMER
OR DC FUSE (F2)* CONTACTOR (LCC) COIL CONTACTS (T)
PROCEDURE
PROCEDURE SOLUTION SOLUTION
DISCONNECT LEADS FROM
POWER TRANSFORMER (PXF)* CHECK VOLTAGE ACROSS
TO RECTIFER ASSY. (SR); REMOVE FUSE FROM
FUSE HOLDER AND ORN. & BLU. WIRE REPLACE TIMER ASSEMBLY
CHECK DIODE WITH OHMMETER TERMINALS OF CONTROL (T AND M)
CHECK WITH OHMMETER
TRANSFORMER (CXF)
SOLUTION
SOLUTION RESULT RESULT RESULT
REPLACE RECTIFIER
ASSEMBLY (SR) OR DEFECTIVE
DIODE AND RECONNECT REPLACE DEFECTIVE VOLTAGE IS NOT BETWEEN VOLTAGE IS NOT CHARGER STARTS
LEADS FUSE 22 - 26 VOLTS BETWEEN 22 - 26 VOLTS CHARGING
RESULT
RESULT POSSIBLE CAUSE POSSIBLE CAUSE POSSIBLE CAUSE
CHARGER STARTS
CHARGING CHARGER STARTS DEFECTIVE LINE DEFECTIVE CONTROL CHARGER CONNECTED FOR
CHARGING CONTACTOR COIL (LCC) TRANSFORMER WRONG VOLTAGE
(CXF)
SOLUTION
SOLUTION SOLUTION
REPLACE LINE
CONTACTOR ASSEMBLY (LC) REPLACE CONTROL CHECK AND RECONFIGURE
TRANSFORMER CONNECTIONS AT CHANGE-
(CXF) OVER BLOCK (TB)*
RESULT
RESULT
CHARGER STARTS
34
CHARGER STARTS CHARGING
R
E
S
U
L
T
C
H
A
R
G
E
R
S
T
A
R
T
S
C
H
A
R
G
I
N
G
35
PROBLEM
POSSIBLE CAUSE
RESULT
PROBLEM
RESULT RESULT
PROBLEM
1 2 3 4
RESULT
RESULT RESULT
OHMMETER
OHMMETER HIGH RESI BOTH DIREADS VERY HIGH RESISTANCE IN ONE DIRECTION, VERY LOW
READS VERY STANCE IN RECTIONS IN THE OTHER
RESULT
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
OPEN D RECTIFIER AS
BLOWN D C OUTPUT (F2)* OPEN CAPACITOR (C) IN POWER TRANSFORMER
BLOWN
(PXF)*
ACCIRCUIT
INPUT FUSE (F1)* IODE IN SEMBLY (SR)
FUSE
†Three-phase chargers have three power transformer circuits so they can deliver an output current (lower) even with one or two c ircuits
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
8.1 FERRO FIVE FR SERIES 120/208/240 and 480 VAC inputs
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 3 100 630 125 300 225 254 698 509 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 5 200 620 125 300 225 254 698 509 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 6 200 620 125 300 225 254 698 509 2765 2468 2746 2382
FR6CE510 200 327 2 30 510 15/12 6 200 620 125 300 225 254 698 509 2765 2468 2746 2382
FR6CE640 200 327 2 30 510 20/15 7 325 625 185 300 206 254 698 509 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 3 200 620 185 300 182 254 698 509 2765 2468 2746 2382
FR6HK1000 300 328 3 30 513 10/10 5 200 620 345 300 208 254 698 509 2765 2468 2746 2382
FR6HK1125 300 328 3 30 513 12/10 5 200 620 345 300 208 254 698 509 2765 2468 2746 2382
FR6HK1700 500 328 3 30 513 15/12 7 200 620 345 300 208 254 698 509 2765 2468 2746 2382
FR9CE255 100 381 2 30 510 8/8 4 100 630 125 300 225 254 698 509 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 5 200 620 185 300 182 254 698 509 2765 2468 2746 2382
FR9HK1160 300 328 3 30 513 15/12 7 200 620 345 300 208 254 698 509 2765 2468 2746 2382
FR12CE255 100 381 2 30 510 15/12 6 100 630 125 300 225 254 698 509 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 5 100 630 185 300 182 254 698 509 2765 2468 2746 2382
FR12HK640 200 327 3 30 513 10/10 5 200 620 185 300 182 254 698 509 2765 2468 2746 2382
FR12HK850 300 328 3 30 513 15/12 7 200 620 185 300 182 254 698 509 2765 2468 2746 2382
FR12HK1000 300 328 3 30 513 15/15 8 200 620 345 300 208 254 698 509 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 8 200 620 185 300 182 254 698 509 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 8 200 620 185 300 182 254 698 509 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 6 200 620 185 300 182 254 698 509 2765 2468 2746 2382
FR18HK750 200 327 3 30 513 20/15 8 200 620 185 300 182 254 698 509 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
38
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 3 100 630 125 300 225 255 698 509 2765 2468 2746 2382
FR6M375 200 327 2 30 510 5 200 620 125 300 225 255 698 509 2765 2468 2746 2382
FR6M450 200 327 2 30 510 5 200 620 125 300 225 255 698 509 2765 2468 2746 2382
FR6M510 200 327 2 30 510 5 200 620 125 300 225 255 698 509 2765 2468 2746 2382
FR6M640 200 327 2 30 510 6 325 625 185 300 206 255 698 509 2765 2468 2746 2382
FR6M750 300 328 2 30 510 6 325 625 185 300 206 255 698 509 2765 2468 2746 2382
FR6L830 300 328 3 30 513 3 200 620 185 300 182 255 698 509 2765 2468 2746 2382
FR6L1000 300 328 3 30 513 3 200 620 345 300 208 255 698 509 2765 2468 2746 2382
FR6L1125 300 328 3 30 513 3 200 620 345 300 208 255 698 509 2765 2468 2746 2382
FR6L1700 500 328 3 30 513 5 200 620 345 300 208 255 698 509 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 3 200 620 185 300 182 255 698 509 2765 2468 2746 2382
FR9L1160 300 328 3 30 513 5 200 620 345 300 208 255 698 509 2765 2468 2746 2382
FR12M255 100 381 2 30 510 6 100 630 125 300 225 255 698 509 2765 2468 2746 2382
FR12M375 200 327 2 30 510 6 200 620 125 300 225 255 698 509 2765 2468 2746 2382
FR12M450 200 327 2 30 510 6 200 620 125 300 225 255 698 509 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 3 100 630 185 300 182 255 698 509 2765 2468 2746 2382
FR12L640 200 327 3 30 513 3 200 620 185 300 182 255 698 509 2765 2468 2746 2382
FR12L850 300 328 3 30 513 3 200 620 185 300 182 255 698 509 2765 2468 2746 2382
FR12L1000 300 328 3 30 513 5 200 620 345 300 208 255 698 509 2765 2468 2746 2382
FR12L1200 300 328 3 30 513 5 200 620 345 300 208 255 698 509 2765 2468 2746 2382
FR15L830 300 328 3 30 513 5 200 620 185 300 182 255 698 509 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 5 200 620 185 300 182 255 698 509 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 10 100 630 125 300 225 255 698 509 2765 2468 2746 2382
FR18M450 200 327 2 30 510 10 200 620 125 300 225 255 698 509 2765 2468 2746 2382
FR18M510 200 327 2 30 510 15 200 620 125 300 225 255 698 509 2765 2468 2746 2382
FR18M640 200 327 2 40 511 20 325 625 185 300 651 255 698 509 2765 2468 2746 2382
FR18EM750 200 327 3 60 616 30 25 325 625 185 300 785 255 698 509 2765 2468 2746 2382
FR18EM850 300 328 3 60 616 30 25 325 625 250 600 785 255 698 509 2765 2468 2746 2382
FR18L750 200 327 3 30 513 5 200 620 185 300 182 255 698 509 2765 2468 2746 2382
FR18L850 300 328 3 30 513 5 200 620 185 300 182 255 698 509 2765 2468 2746 2382
FR18L1000 300 328 3 30 513 6 200 620 345 300 208 255 698 509 2765 2468 2746 2382
FR18L1200 300 328 3 40 514 10 200 620 345 300 208 255 698 509 2765 2468 2746 2382
FR18L1360 300 328 3 40 514 10 200 620 345 300 208 255 698 509 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 6 200 620 185 300 182 255 698 509 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 5 200 620 185 600 196 255 698 509 2765 2468 2746 2382
FR24L750 200 327 3 40 513 6 200 620 185 600 196 255 698 509 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 6 200 620 185 600 196 255 698 509 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 5 200 620 125 300 225 254 698 509 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 6 200 620 125 300 225 254 698 509 2765 2468 2746 2382
EFR6CE640 200 327 2 30 510 15/12 6 200 620 125 300 225 254 698 509 2765 2468 2746 2382
EFR6CE800 200 327 2 30 510 20/15 7 325 625 185 300 206 254 698 509 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 3 200 620 185 300 182 254 698 509 2765 2468 2746 2382
EFR6HK1250 300 328 3 30 513 10/10 5 200 620 345 300 208 254 698 509 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 6 100 630 125 300 225 254 698 509 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 5 100 630 185 300 182 254 698 509 2765 2468 2746 2382
EFR12HK800 200 327 3 30 513 10/10 5 200 620 185 300 182 254 698 509 2765 2468 2746 2382
EFR12HK1060 300 328 3 30 513 15/12 7 200 620 185 300 182 254 698 509 2765 2468 2746 2382
EFR12HK1250 300 328 3 30 513 15/15 8 200 620 345 300 208 254 698 509 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 6 200 620 185 300 182 254 698 509 2765 2468 2746 2382
EFR18HK940 200 327 3 30 513 20/15 8 200 620 185 300 182 254 698 509 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 8 200 620 185 600 196 254 698 509 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.
LEGEND
(OPTIONAL)
CAUTION
LEGEND
(OPTIONAL)
5
5
9.5 Wiring diagrams for FERRO FIVE REVOLUTION SERIES
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
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.
9.5 Wiring diagrams for FERRO FIVE REVOLUTION SERIES
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.
CONNECT RED WIRE TO CXF TERMINALS H3.
CAUTION
5
6
9.5 Wiring diagrams for FERRO FIVE REVOLUTION SERIES
DUAL VOLTAGE CHANGEOVER INSTRUCTIONS
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
CONNECTION
(OPTIONAL)