MSA Power Builder 10002460 User manual

Power BuilderTM
Battery Charger
instructions,5&10unit
The warranties made by MSA with respect to the product are voided if
the product is not assembled, used, and serviced according to the
instructions in this manual. Please protect yourself and your employees
by following the instructions. Please read and observe the WARNINGS
and CAUTIONS inside. We encourage our customers to write or call for
a demonstration of this equipment prior to use, or for any additional
information relative to use or repairs.
Call 1-800-MSA-2222 during regular working hours.
This manual, including Warnings and Cautions inside, must be read and followed
carefully by all persons who will use or maintain the product, including those
who have any responsibility involving its selection, application, service, or
repair. This product will perform as designed only if used and maintained
according to the instructions. Otherwise, it could fail to perform as designed,
and persons who rely on this product could sustain serious personal injury or
death.
TAL 201 (L) Rev. 1 © MSA 2002 Prnt. Spec. 10000005389 (C) Mat. 10002461
Doc. 10000000241
part no.
10002460 - 5 unit.
10002439 - 10 unit.

2TAL 201 (L) Rev. 1 - 10002461
CAUTIONS AND WARNINGS
IMPORTANT
Pay close attention to Warnings and
Cautions in this manual. A WARNING
describes a condition that may cause
severe personal injury or death if
allowed to happen. A CAUTION
describes a condition that may cause
the cap lamp or other property to be
damaged if allowed to happen.
1 The cap lamp and charging sys-
tems will perform as designed
only if used and maintained
according to the manufacturer’s
instructions. Supervisors and
users must read and understand
these instructions before trying to
use or service this product. We
encourage our customers to write
or call their MSA distributor or call
MSA Customer Service for infor-
mation on this product before
using it. To reach the nearest MSA
office, call 1-800-MSA-2222 dur-
ing normal business hours, or 1-
800-MSA-5555 after hours or in
emergencies.
2. Do not alter, modify, or substitute
any components without the
approval of MSA.
3. Inspect and maintain the charger
according to MSA’s instructions.
Repairs must be made by properly
trained personnel only.
4. Even though the battery may be
left “on charge” indefinitely, doing
so may cause internal gases to
vent, which may lead to accumu-
lation of combustible gases in the
lamp room. Install the charger in
an adequately ventilated room.
DESCRIPTION
MSA’s5&10unit Power BuilderTM
chargers are designed to recharge
MSA’s LuminatorTM and Luminator
PlusTM batteries. The charger is
equipped with a variable rate, factory-
set program controlled by a micro-
processor that maximizes recharge
capacity in the shortest amount of
time. The charge indicator is an easy -
to - read LED display; Red and Green
lights show charge status.
The MSA Power Builder Battery
Charger is also a “float” charger,
which means that the battery will not
be overcharged if left in charge mode
over long periods of time.
INSTALLATION
1. The charger assembly may be
installed in the following ways:
• table or bench top,
• configured with multiple
assemblies into a free standing
rack using the mounting kit p/n
10002465,
• mounted to a wall using the 3
holes in the rear of the assem-
bly using 3/8 inch diameter min-
imum bolts securely anchored
into the wall (anchoring system
must be able to support the
charger plus 10 cap lamps
weighing approximately 5 lb.
each).
2. Each charger has a standard 6
foot, 3 conductor cable for con-
nection to the main power supply.
The cord is supplied less plug and
the user is responsible for supply-
ing the proper connection. For
clarification of plug type and AC
circuit requirements please con-
sult with qualified electrical power
personnel or standards.
3. Both chargers are set for 230 VAC
operation. For operation from 115
VAC the following steps must be
taken before charging:
• the voltage selector switch,
located inside the charger panel
on the right side, must be set for
115 VAC.
Operating the charger from 230
VAC while switched for 115 VAC will
permanently damage the charger
transformer and the transformer
will need to be replaced.
• The 5A fuse located adjacent to
the voltage selector switch must
be changed to the 10A fuse
supplied for operation at 115
VAC. See replacing fuse section.
• the plug must be changed (or
adapted for International
usage) to match the mating
outlet. For clarification of plug
type and AC circuit require-
ments please consult with
qualified electrical power per-
sonnel or standards.
Description/Installation
Technical Data
Charging Method Automatic constant current / constant potential
Initial Charging Current 2.5 A max.
Charging Voltage 5.3VDC switching to 5.0VDC (float mode 4.6VDC)
Charging time Approximately 8 hrs. (after 8 hour discharge w/Ultralight lamp)
Supply Voltage 115/230 VAC +/-10%, single phase, 50/60 Hz, fused for 10A/5A
Power Consumption 5 unit - 350 WATTS, 10 unit - 700 WATTS
Dimensions
Length: 1180mm (46.5 in.)
Width: 190mm (6.5 in.)
Height: 260mm (10.25 in.)
Weight (10 Unit): 15 kg (33 lbs.)
Voltage Selector
Fuse Holder
Power Indicator
Battery Station Guides
LED Lights Positive
Charging
Terminal

OPERATION
1. Any battery must be recharged
(regardless of how long it’s been
used,) before the next use in order
to maintain the battery’s rated
capacity and cycle life. Typically,
the approximate recharge time is 8
hours after a 8 hour discharge
using the Ultralight lamp with either
the Luminator or Luminator Plus
Batteries. Longer recharge times
can be expected if the ML-2 lamp,
the remote power accessory, or
longer discharge times are used.
2. When power is supplied to the
charger, the power indication light
located on the front panel should
be on. Refer to the troubleshoot-
ing guide if light does not turn on.
3. To charge the cap lamp , the
headpiece should be fitted over
the projecting key on the front of
the charger and rotated clockwise
until it is in the full stop position.
Place the battery between the
guides located directly above the
station being used. To remove the
cap lamp from charger - reverse
the procedure.
After connection of the cap lamp, the
red LED will illuminate after a short
time, the circuitry will wait 5 seconds
then start the constant current charge
(stage 1) while monitoring the charger
voltage. When the charging voltage
reaches 5.3 VDC the charger switches
to a constant potential of 5.0 volts
(stages 2 &3) for a set period of time
(full charge is reached when the green
LED is on only), the charger then
switches to a “float” mode voltage of
4.6 volts (stage 4) until the battery is
removed. The battery state of charge
is indicated by the Charge Indicator
Guide
Note
The charging requirements for individ-
ual batteries are unaffected by the
state of charge of other batteries on
charge. If the battery is removed or
input power is interrupted, the charger
will reset to stage 1 when reconnect-
ed. The charger will quickly read the
level of charge in the battery then go
on to the appropriate stage where it
left off before the interruption. It is not
advisable to leave the battery partially
charged for any extended length of
time. Doing so will reduce the cycle
life and capacity of the battery.
MAINTENANCE
1. Each charger is supplied with an
extra fuse for 230 VAC operation.
Replace any broken fuses with the
following types which are readily
available through most electrical
supply sources:
• 115 VAC - fuse type -10A, T
10A
• 230 VAC - fuse type -5A,
TDC11 5A
The fuse holder is located on the
front, bottom right side of the
frame. To replace a blown fuse,
unscrew the fuse holder cover
counterclockwise. Remove the
blown fuse, place the new fuse in
the end of the cover and place
back into the holder.
2. Refer to troubleshooting guide if
the charger is not working proper-
ly, or to the cap lamp user instruc-
tions for battery operation.
3. Charging Contact Replacement
Remove top. Disconnect wires to
charging contacts.
Pull apart - disconnecting positive
charging key from retainer disk
Operation/Maintenance
TAL 201 (L) Rev. 1 - 10002461 3
Charge Indicator Guide
Stage LED Display Charge Status
1. Constant Current Mode RED light on only charging
2. Constant Potential Mode RED and GREEN lights on 75% charged
3. Fully Charged GREEN light on only charged, ready for use
4. Float Mode GREEN light on, RED light flashing float charge, ready for
use
LED Lights
Keyed Fitting
Positive
Terminal
Projecting
Key
LED Lights
Positive
Charging
Key
Charging
Post
Retainer
Charging
Post
Base

TAL 201 (L) Rev. 1 - 10002461 5
• replace either negative contact,
charging post retainer, positive
charging key, or charging post
base
• make sure retainer disk is ori-
ented properly
ACCESSORIES AND
REPLACEMENT PARTS
1. Transformer - 10002464
2. Charging module - 10002462
3. Power light module - 10002463
4. Negative Contact - 96529
5. Positive Charging Key - 453977
6. Retainer Washer - 453974
7. Charging Post Base - 96527
8. Charging Post Retainer - 453976
9. Free standing mounting kit -
10002465 (Accessory)
Power Indicator/Charging/Replacing/Accessories/Tools

6TAL 201 (L) Rev. 1 - 10002461
Troubleshooting Guide
CHARGER NOT OPERATING
Is
power on
illuminated? Check mains input
fuse and confirm
voltage is present
and corresponds to
voltage selected
on changeover
switch
Check output from
transformer is
17V a.c.
Check mains input
voltage selector switch
is at correct setting
Replace
transformer
Is
output
voltage
presented
from
transformer?
Has fuse
blown?
Replace
mains
fuse
Check supply to
individual charger
modules
Check mains
supply
Replace charger
module
Check wiring from
transformer to each
charger module
Is 17V a.c.
supply to
each
module
present?
No Yes
Yes
Yes
No
No
No
Yes
FAULT FINDING