AMERICAN BATTERY ABC11B-120-10 Owner's manual

MANUAL NUMBER: 64073
REV: 2
DATE: October 3, 2006
INSTALLATION, OPERATION & MAINTENANCE
SERIES ABC11B-120-XX
BATTERY CHARGERS
AMERICAN BATTERY CHARGING, INC.
P.O. BOX 17040
28 MAPLE AVENUE
SMITHFIELD, RHODE ISLAND 02917
TELEPHONE [phone]
TELEFAX 401-231-6155
E-mail: [email protected]

TABLE OF CONTENTS
1.0 GENERAL DESCRIPTION
1.1 DESCRIPTION
1.2 SPECIFICATIONS
2.0 INSTALLATION
3.0 OUTPUT ADJUSTMENTS
3.1 "FLOAT" VOLTAGE ADJUSTMENT
3.2 "HIGH-RATE" VOLTAGE ADJUSTMENT
3.3 "CURRENT LIMIT" ADJUSTMENT
4.0 DESCRIPTION OF OPERATION
4.1 RECTIFIER CIRCUIT
4.2 CONTROL UNIT
4.3 SEQUENCE OF OPERATION
4.4 ACCESSORY DEVICE – EMI/RFI FILTER
4.5 ACCESSORY DEVICE – MULTI-ALARM WITH AUTO-CHARGE
5.0 MAINTENANCE AND TROUBLE SHOOTING PROCEDURES
5.1 MAINTENANCE
5.2 TROUBLESHOOTING PROCEDURES

1.0 GENERAL DESCRIPTION
1.1 Description
The American Battery Charging rectifiers described in this manual are designed
to supply a constant voltage output for any load within their ratings. Beyond
approximately 110% of the rated load the output voltage will drop rapidly,
thereby protecting the rectifier and the system to which it is connected, this
makes the ABC rectifier ideal for use as a battery charger since it supplies a
constant current to a discharged battery.
ABC11B chargers are two rate float battery chargers for charging standby and
on-line batteries.
1.2 Specifications
1.2.1 Input
AC Input Voltage: Models are provided with taps for specific ranges of AC input
The bold type indicates the voltage setting for a particular model when shipped.
The Table below lists the particular models, AC input voltages and the
recommended external AC line protection. Caution: To reduce the risk of fire,
use only on circuits with branch circuit protection in accordance with the National
Electric Code, NFPA 70.
Model Solar P/N AC input range External protection
Tolerance +/- 10%
ABC11B-120-10 1060367-100 100/110/120VAC 40A
ABC11B-120-15 1060367-200 100/110/120VAC 60A
ABC11B-120-20 1060367-300 100/110/120VAC 70A
ABC11B-120-25 1060367-400 100/110/120VAC 90A
ABC11B-120-10 1060367-500 208/220/230/240VAC 20A
ABC11B-120-15 1060367-600 208/220/230/240VAC 25A
ABC11B-120-20 1060367-700 208/220/230/240VAC 40A
ABC11B-120-25 1060367-800 208/220/230/240VAC 50A
ABC11B-120-10 1060367-900 380/400/415VAC 15A
ABC11B-120-15 1060367-1000 380/400/415VAC 15A
ABC11B-120-20 1060367-1100 380/400/415VAC 20A
ABC11B-120-25 1060367-1200 380/400/415VAC 25A
ABC11B-120-10 1060367-1300 440/460/480VAC 15A
ABC11B-120-15 1060367-1400 440/460/480VAC 15A
ABC11B-120-20 1060367-1500 440/460/480VAC 15A
ABC11B-120-25 1060367-1600 440/460/480VAC 20A
AC Input Frequency: 50 Hertz Models: 47-63 HZ

If the available nominal AC voltage matches another one of the taps provided,
the main transformer T1 must be rewired to the appropriate tap. The taps are
located on the left side of the main transformer T1. T1 is located at the top of the
charger cabinet and the taps are labeled with the particular voltage. Disconnect
wire #3 from the standard tap connection and reconnect to the alternate tap if
required. See Figure 1.2.1.
FIGURE 1.2.1: MAIN TRANSFORMER T1, AC INPUT TAPS
1.2.2 Output
Output voltage suitable for charging valve regulated or flooded lead-acid or
nickel-cadmium batteries. Maximum output voltage is 145VDC.
Voltage Stability: +/- 1/2" from no-load to full load with an AC input voltage
variation of +/- 10% and an AC input frequency variation of +/- 5% with battery
connected.
Current: Models of 10, 15, 20 and 25 amps. Limited to approximately 110%
overload capacity.
1.2.3 Controls
"Float - High Rate" Manual Switch (Located on the front panel)

"Float" Voltage Potentiometer (Located on E1 control board)
"High-Rate" Voltage Potentiometer (Located on E1 control board)
1.2.4 Meters and Indicators
Ammeter: Moving-Coil, 3 1/2" scale, 2% accuracy
Voltmeter: Moving-Coil, 3 1/2" scale, 2% accuracy
"AC ON" LED Indicator
"High-Rate" LED Indicator
1.2.5 Operating Environment
Natural convection cooled
Operating Temperature range: -10 degree C (+14 degrees F) to
+50 degrees C (+122 degrees F)
Maximum humidity: 95%
Maximum altitude: 4100 feet (1250 M) above sea level
Derated models available for higher temperatures or altitudes.
1.2.6 Protection
AC Input 2-pole circuit breaker
DC Output 2-pole circuit breaker
AC and DC Surge Suppressors
Soft Start Circuit
1.2.7 Wiring
Insulation: 600 Volts All wires tagged for identification
Ratings per NEC, NFPA No. 70
1.2.8 Enclosures
Type: NEMA 1 - Ventilated
Color: RAL 7032 Polyester powder coat
1.2.9 Testing Tested in accordance with NEMA PE-5

2.0 INSTALLATION
2.1 Location
Locate the battery charger in the desired location (refer to dimensional drawing
in last section of manual). Avoid locations near heat generating equipment, or
subject to extremes of dirt or moisture.
2.2 Wall Cabinets
Install the wall-mounted unit with suitable bolts, according to unit weight, wall
material and structure. Use eight 1/4" diameter bolts. With bolts in place, install
the unit over the bolts with keyslot mounting holes. Open the cabinet door for
access to the bolts for tightening.
2.3 Cable Routing
Cable entry to the cabinet is normally from the bottom. Conduit may be
connected through the top, back or sides as required if bottom entry is
impractical or undesirable. Refer to the dimensional drawing in the last section
of the manual and Figure 2.3.
Figure 2.3: Cable entry for AC input at P1 and charger output at TB521

2.4 Ventilation
The design of the cabinet provides satisfactory for convection cooling. Allow a
minimum of 3 inches (75mm) clearance on each side, and 6 inches (150mm) on
top for ventilation.
2.5 Connecting Battery to Charger
Connect the charger and load to the battery using separate cables. The charger
output terminals are at TB521. The DC load terminals are at TB522. Use two
sets of cables to connect these to the battery. The charger to battery cables will
carry the charger output current. The DC load cables will carry the maximum DC
loads.
Connect the TB521 positive to the battery positive terminal.
Connect the TB521 negative to the battery negative terminal.
Connect the TB522 positive to the battery positive terminal.
Connect the TB522 negative to the battery negative terminal.
NOTE: If correct polarity is not observed at TB521, the charger will not operate.
2.6 Connecting Charger to AC Supply Mains
Locate the input/output terminal strip (P1). Check the AC line for input voltage,
frequency and phase to match the specifications as listed on the battery
charger's nameplate, located on the cabinet front. The AC line must be sized to
allow for the maximum current capacity as indicated by the rating of the input
fuse or breaker. Connect the AC line to the terminals indicated. Connect ground
to proper terminal: GND.
2.7 Energizing
Energize the charger DC BREAKER. The battery should be connected to the
chargers DC output and the breaker energized, before the AC power is
energized.
Energize the AC line then energize the charger AC BREAKER. The "AC ON"
lamp should light, and the charger should be operating.

3.0 Output Adjustments
ABC11B-series battery chargers have been adjusted at the factory. See Figure
3.0 for voltage and current limit adjustment potentiometers. For charging
batteries, "Float" and "High Rate" voltages have been set according to the
following table. Alternate voltage settings are indicated for other battery types.
The charging voltage may be adjusted if needed according to the following
instructions. The selection of "Float" or "High Rate" is controlled by the "High
Rate" switch (S1), or the automatic charge control circuit.
Figure 3.0: E1 control adjustment potentiometers
The "Float" voltage is adjusted to a specific voltage in order to maintain a fully
charged battery in a fully charged condition. The "High Rate" voltage is adjusted
to a specific voltage higher than "Float". This voltage should be set to force-
charge the battery. A battery should be "High Rate" charged whenever
discharged.
CAUTION: The "Float/High Rate" switch (S1) controls the "High Rate" charge.
Never leave the switch in the "High Rate" position for long periods of time
(consult the battery manual). Excessive "High Rate" charging will cause cells to
gas (through electrolysis) and dissociate the water in the electrolyte into
hydrogen and oxygen. Never let the electrolyte level drop below the minimum
level line.

It is recommended that all settings be checked before putting the charger into
service. The following procedure should also be followed if the voltages require
resetting in the future or when a new control card, E1, is installed.
3.1 "Float" Voltage Adjustment
3.1.1 Precision Voltmeter
Attach a precision voltmeter of the correct range in parallel with the rectifier's
voltmeter. (Accuracy should be better than +/- 0.5%)
3.1.2 Switch to "Float"
Switch the charger's switch (S1) to "Float". The "High Rate" lamp should be out.
If the charger's high-rate LED is lit, the automatic timer has initiated a high-rate
charge cycle. Allow the charger to "High Rate" charge until the "High Rate" lamp
goes out. This may take from 4 to 30 hours. When the lamp goes out, proceed
to Paragraph 3.1.3.
3.1.3 Checking "Float" Voltage
The current should be considerably lower than the output current listed on the
rectifier nameplate. The "High Rate" lamp should be out. Check that the voltage
is at the desire level. Consult the battery manufacturers recommendations. If
the voltage is incorrect, adjust as per Paragraph 3.1.4.
3.1.4 Adjusting "Float" Voltage
If the voltage is incorrect, adjust potentiometer (FLT) located on the printed
circuit card (E1), using a small screwdriver. Turn the adjusting screw counter-
clockwise to reduce voltage. Adjust in small increments, allowing voltage to
stabilize after each adjustment. When properly set, proceed to 3.2.1.
3.2 "High Rate" Voltage Adjustment
CAUTION: Set "Float" voltage per paragraph 3.1 before adjusting "High Rate"
voltage.
3.2.1 Checking "High Rate" Voltage
Switch the charger to the "High Rate" mode with switch (S1). The "High Rate"
LED should be lit. Allow the "High Rate" voltage and current to stabilize. The
DC output current must be less than the maximum value as shown on the
nameplate. If it is not, wait until the level drops. Check that the voltage is at the
desired level. Consult the battery manufacturers recommendations. If the

voltage is incorrect, adjust per Paragraph 3.2.2
3.2.2 Adjusting "High Rate"
If the voltage is incorrect, adjust the potentiometer (HR), located on the printed
circuit card (E1), using a small screwdriver. The potentiometer is labeled "High
Rate". Turn the adjusting screw clockwise to increase voltage, and counter-
clockwise to reduce voltage. Adjust in small increments, allowing voltage to
stabilize after each adjustment. When properly set, return the switch (S1) to
"Float".
3.3 "Current Limit" Adjustment
The "Current Limit" potentiometer (CL), is located on the printed circuit card (E1).
It is factory set normally at 110% of rated output.
CAUTION: The "Current Limit" potentiometer (P3), is set at the factory and
sealed. Do not change this adjustment. An improper setting may damage the
rectifier.
If it is desired to adjust the current limit to a lower value, or to adjust a new
control card (E1), the following procedure may be used.
3.3.1 Adjusting "Current Limit"
Turn the "Current Limit" potentiometer (CL), fully counter-clockwise. Energize
the AC line. Slowly adjust potentiometer (CL) clockwise until the ammeter
reading is equal to the DC current rating on the nameplate. Adjust current limit
only with rectifier under full load. CAUTION: Under no circumstances should the
rectifier current exceed the nameplate value. Damage may occur if miss-
adjusted.
4.0 DESCRIPTION OF OPERATION
4.1 Rectifier circuit
4.1 When the rectifier is connected to an appropriate AC voltage source, the
voltage is connected to the input transformer, (T1). The transformer steps the
voltage up or down, as required for the specific DC output voltage. The
transformer also isolates the commercial AC line from the battery circuit. The
main secondary, X1-X2, of the transformer is connected to the full wave bridge
rectifier.
The bridge is the heart of the power circuit. This assembly is a standard full-
wave silicon bridge, incorporating three diodes and two SCR's (silicon controlled