NRS ELC-12/40-CVM-D Service manual

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NATIONAL
RAILWAY
SUPPLY
Installing, Operating and
Service Instructions for the
ELC-12/40-CVM-D
Solid State Charger
MODEL ELC-12/40-CVM-D
BATTERY CHARGER
PLEASE SAVE THESE IMPORTANT SAFETY AND OPERATING INSTRUCTIONS
For correct operation of the equipment, it is important to read and be familiar
with this entire manual before installing and operating the charger.
DO NOT DISCARD THIS MANUAL AFTER READING.
LOOK FOR THIS SYMBOL TO POINT OUT SAFETY PRECAUTIONS. IT MEANS:
BECOME ALERT—YOUR SAFETY IS INVOLVED. IF YOU DO NOT FOLLOW THESE
SAFETY INSTRUCTIONS, INJURY OR PROPERTY DAMAGE CAN OCCUR.
1. IMPORTANT SAFETY INSTRUCTIONS
a. Before using the battery charger, read all the
instructions and caution markings on the
battery charger, the battery, and all of the
products using the battery.
b. Do not touch the uninsulated parts of the AC
input or the DC wires, the charger's binding
posts, or the battery terminals, as there is a
possibility of electrical shock.
c. Batteries produce hydrogen gas while
operating, which can explode if ignited.
Never smoke, use an open flame, or create
sparks in the vicinity of the battery. Ventilate
the area well when the battery is charging in
an enclosed area.
d. Batteries contain caustic material which may
cause burns. Do not get in eyes, on skin, or
clothing. If the gelled or liquid content of the
batteries contacts the skin or clothing, wash
the area thoroughly with water. In the case
of contact with the eyes, flush immediately
with clean water for 15 minutes and obtain
medical attention.
e. Only qualified personnel should program or
service this equipment.
f. De-energize all AC and DC power
connections before servicing this unit. If
injury does occur, apply standard treatment
for electrical shock and, if necessary, consult
with a physician.
g. The charger is not for outdoor use. Do not
expose the charger to rain or snow.
h. Do not operate the charger if it has received
a sharp blow, been dropped, or otherwise
damaged.
i. Do not disassemble the charger. Have the
charger examined by a NATIONAL
RAILWAY SUPPLY service agent. If the
charger is assembled incorrectly, damage to
the charger and the batteries or an electrical
shock may result.
2. DESCRIPTION
The NATIONAL RAILWAY SUPPLY charger, model
ELC-12/40-CVM-D, is a convection-cooled, solid
state, SCR regulated charger that provides either a
constant current or constant voltage output. The
charger can be set to charge batteries within a
voltage range of 10.00 to 17.00 volts for gel-cell,
liquid lead-acid, nickel cadmium, nickel iron, and
starved electrolytic batteries.

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3. THEORY OF OPERATION
When the charger is connected to the desired AC
voltage source (115 or 230), the transformer creates
auxiliary voltages for the electronic control module.
The electronic control module controls and monitors
the charger so it will perform properly. The
transformer also supplies the power output used for
charging the batteries and provides electrical
isolation between the charger's output and the AC
source.
The charger's output current flows through a shunt
and is sensed by the electronic control module along
with the charger's output voltage. These values are
converted into drive pulses for the SCRs by the
control module. This pulsating charge current (a
pulse occurs each time an SCR is on) is then filtered
by a large capacitor and the batteries to provide a
smooth output.
The charger has an "IE" profile which is: (a) High
rate constant current, and (b) Constant voltage.
When the charger is first started, the SCRs will
conduct for a certain portion of the sinusoidal anode
voltage to provide the required charging current at
the low level of battery voltage. In this start region, a
constant current is applied to the battery. The SCR
conduction will then increase as the battery voltage
increases in order to provide a higher output voltage
while maintaining a constant charging current.
When the battery voltage reaches the float voltage,
the SCRs will start to decrease their output. This
causes the charger to automatically change from a
constant current charge region to a constant voltage
charge region. As the batteries become fully
charged, the output current decreases. A
continuous constant float voltage will be supplied to
the batteries to maintain their charge.
Another feature of the charger is temperature
compensation, which keeps the batteries from
getting under- or over-charged. TEMPERATURE
COMPENSATION ONLY OCCURS WHEN USING
A TEMPERATURE PROBE. The red LED on the
front of the charger will be off when using a
functional temperature probe. If the LED is on,
either a temperature probe is not being used, or the
temperature probe is working improperly.
Temperature compensation uses a temperature
reference of 77F (25C), a voltage reference of 2.23
volts (the voltage of a standard gel-cell battery at
77F), and a compensation value of 3.0 mV per F).
The equivalent equation for the compensated
voltage is:
Vcomp = V –k (t - 77F)
Where V is the voltage of the battery at 77F, t is
the temperature in F, and k = V (.003 / 2.23).
The control module has a temperature
compensation range between 32°F and 95°F (0°C
and 35°C) that does not allow charger voltage to
increase or decrease beyond the calculated values.
Example 1:
If a 13.38 volt battery is charging and the
temperature increases to 95F, then the output
voltage decreases to 13.06 volts.
13.38 - .018 (95F - 77F) = 13.06
Example 2:
If a 14.50 volt battery is charging and the
temperature increases to 95F, then the output
voltage decreases to 14.15 volts.
14.50 - .0195 (95F - 77F) = 14.15
Example 3:
If 15.61 volt batteries are charging and the
temperature decreases to 32F, the output voltage
increases to 16.56 volts.
15.61 - .021 (32F - 77F) = 16.56
4. RECEIVING AND INSTALLING THE
CHARGER
Proper installation of the charger is important in
order to achieve good charger performance and to
prevent damage to the charger and batteries. When
a charger is received, a check for possible in-transit
damage should be made. If any damage is found, it
should be reported as a claim to the carrier. To
permit free air flow for convention cooling, allow two
inches (2") minimum between the charger sides and
other equipment and four inches (4") minimum on
top of the charger.
WARNING: NEVER PLACE ANYTHING ON
TOP OF THE CHARGER WHILE OPERATING.
DAMAGE TO THE CHARGER OR BATTERIES
COULD OCCUR.
WARNING: THE CHARGER MUST BE SET
UP FOR THE PROPER USER SPECIFICATIONS
BEFORE STARTING THE INITIAL CHARGE.
The charger can be mounted on a shelf, countertop,
floor, wall, or relay rack. The charger case includes
four (4) cushioned feet that are designed to prevent
marring of mounting surface and to absorb vibration.
The case has built-in rear mounting flanges at the
rear for wall and rack mounting.
Wall mounting
The mounting flanges each have two (2) keyhole
slots. These are designed to conveniently engage a
¼” (6mm) diameter bolt. The dimensions are pattern
of mounting flange keyhole slots is shown in Figures
4.1 & 4.2

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Figure 4.1 Figure 4.2
Rack Mounting
The charger can be mounted to a
standard Electronic Industries
Association (EIA) 19” (483mm) rack
system using the fasteners provided by
the rack manufacturer. The horizontal
spacing of the vertical rows of holes is
specified by EIA-310 at 18-5/16” (18.312)
(465.1mm). The mounting flanges are
configured for an EIA 19” (483mm) rack
for a forward mounting arrangement
(note: the width from the outer edge of
one mounting flange to the outer edge of
the other mounting flange is 19-15/16”).
Fasteners to match the thread of the rack
should be used in all 7 rack mounting
horizontal slots on each of the 2
mounting flanges (14 rack mounting slots
total) to maximize the mounting integrity.
The fasteners should be torqued to 22
inch-pounds. The dimensions and
pattern of the mounting flange rack
mounting slots is shown in figures 4.2
and 4.3
Figure 4.3

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5. AC ELECTRICAL SUPPLY
The charger must be connected to a single-phase,
50/60/100 Hertz AC power source, which can be
either 115 or 230 VAC depending on the charger
input voltage selection switch setting. Use an
appropriate size wire for the AC power input.
Quarter-inch (1/4") ring terminals are required for
proper connection to the AC input and ground
binding posts (A.A.R.) located on the front of the
charger. Open the small door cover on the front of
the charger by pulling out on the push tabs. Connect
the AC power terminals on the two posts on the right,
as marked on the panel behind the posts. Connect
the AC ground to the terminal lug provided.
WARNING: FAILURE TO PROPERLY
CONNECT THE AC VOLTAGE CONDUCTORS
COULD CAUSE SERIOUS DAMAGE TO THE
CHARGER. BE SURE TO SET THE VOLTAGE
SELECTION SWITCHES ON THE FRONT OF THE
CHARGER TO THEIR PROPER POSITION.
WARNING: DO NOT OPERATE THE
CHARGER WITHOUT PROPER GROUNDING.
IMPROPER GROUNDING CAN RESULT IN THE
RISK OF AN ELECTRIC SHOCK.
6. DC OUTPUT
The DC output wires, 6 AWG or larger, are
connected on the two left-most binding posts as
marked on the panel behind the posts (positive on
the left and negative on the right). The DC cables
should have quarter-inch (¼") ring terminals for
connecting them to the binding posts. Check to
make sure the polarity of the DC output wires are the
same as those connected to the battery. The
charger will not operate in a reversed polarity
condition. WHEN CONNECTING THE DC WIRES
TO THE CHARGER WITH THE AC POWER
DISCONNECTED, A SPARK MAY OCCUR. This is
caused by the output capacitors being charged by
the batteries. If the DC polarity is reversed, a circuit
breaker will protect the charger from internal
damage. Correct the reversed wires and push the
circuit breaker button back in. Close the door cover
on the front of the charger after tightening all of the
binding post nuts.
WARNING: DO NOT TOUCH THE
CHARGER'S TERMINALS OR AN ELECTRICAL
SHOCK COULD OCCUR. A VOLTAGE IS
PRESENT ON THE DC TERMINALS EVEN AFTER
THE AC IS DISCONNECTED BECAUSE OF THE
ENERGY STORED IN THE CAPACITOR.
7. TEMPERATURE PROBE
The external temperature probe is an optional way of
extending battery life by using temperature
compensation. One end of the temperature probe
cable has a three-pin plug, which plugs into a
receptacle labeled TEMP PROBE on the front of the
charger. The other end of the cable has the
temperature sensor sealed in a terminal.
WARNING: IT IS IMPORTANT TO MOUNT
THE TEMPERATURE PROBE ON THE
BATTERIES FOR PROPER TEMPERATURE
COMPENSATION. IF THIS CANNOT BE DONE,
LOCATE THE PROBE AS LOW AS POSSIBLE IN
THE BUNGALOW OR CABINET.
Terminal-Type Probe
The terminal-type probe should be attached to the
negative (-) battery post near the center of the
battery pack. If the threaded stud is long enough
above the battery jumper nut, attach the probe with
another nut. Torque this nut to proper specifications.
If the stud is too short, the nut holding the jumper
wire will need to be removed. Open or remove the
load and charging circuits to the batteries. Remove
the nut holding the jumper and add the probe, then
torque the nut to the proper specifications. Then
close or connect the load and charging circuits back
to the batteries.
Securely fasten the temperature probe cable to
protect the probe from being torn from the
battery. Secure the probe's cable to a fixed object
to ensure the probe will not be pulled loose. Use a
cable tie mount on the battery or on the adjacent
battery, if necessary.
8. OPERATION
The battery charger is adjustable with the three
rotary switches on the front of the charger. The
switches (settable between 10.00 and 17.00)
determine the float voltage for the batteries. SET
THE FLOAT VOLTAGE TO THE BATTERY
MANUFACTURER'S SPECIFIED VOLTAGE FOR
77F. The charger will then electronically charge the
batteries to the voltage specified on the switches. To
set the switches, use a small screwdriver and turn
the switch so that the arrowhead on the slot is
pointing to the desired number. Set the switches in
the following manner: If the desired battery voltage is
13.38 volts, set the top switch to 3, the middle switch
to 3, and the bottom switch to 8 (see the Figure 8.1).
This will provide you with the proper charging
voltage. The tens digit is always a one (1) and
cannot be changed. BE SURE EACH SWITCH IS
SET ON A NUMBER AND NOT BETWEEN
NUMBERS. If a switch is set between numbers, the

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output current will go to zero and the yellow Charging
LED will flash.
The charger does not have a power switch. When
the AC power is applied to the charger, the DC
output will start and the yellow Charging LED will be
on. The Charging LED will go off if the charger stops
outputting current. To turn off the charger,
disconnect the AC power source.
Figure 8.1
9. CURRENT MONITOR/ALARM
The ELC-12/40-CVM-D battery charger includes an
integrated current monitor/alarm that monitors the
output current of the charger. If the charger output
falls below the low current set point, a green LED
indicator is turned off and a Form C, dry contact
alarm relay is actuated. The low current set point
adjustment, LED, and relay terminals are accessible
on the front of the charger (see Figure 9.1).
Figure 9.1
Relay Terminal Remote Wiring
The OPEN, COMMON, and CLOSED relay contacts
have push-in type terminals for remote wiring. The
relay contacts are rated for 1A at 30 Vdc or 0.5A at
120 Vac. A small screwdriver (3/32 inch maximum
blade width) is required to insert or remove a wire
from a relay terminal.
WARNING: BE CAREFUL! IF AN
UNINSULATED METAL TOOL CONTACTS BOTH
THE GROUNDED CHARGER CASE AND A RELAY
TERMINAL PUSH-IN TAB, THIS WILL CAUSE A
POTENTIALLY DAMAGING AND/OR
DANGEROUS ELECTRICAL SHORT.
Current Monitor/Alarm Operation
Table 9.1 outlines the operation of the LED and relay
based on the status of the current monitor. All relay
contact states are with reference to the terminal strip
COMMON.
Current Monitor Status
LED
CLOSED
Relay Contact
OPEN
Relay Contact
Charger output exceeds the low current set point
On
Closed
Open
Charger output falls below the low current set point
(and AC power is present at the charger)
Off
(within 30
seconds)
Open
(within 30
seconds)
Closed
(within 30
seconds)
AC power is removed from the charger
Off
(immediately)
Open
(immediately)
Closed
(immediately)
Table 9.1

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Low Current Set Point
The low current set point adjustment should be set to
a level that is below the charger output when
sourcing the minimum DC load of the system and
floating the fully charged battery set. The low current
set point adjustment is factory-set to approximately
400 mA (fully clockwise), which should work for most
applications. If the minimum DC load of the system
combined with the battery float current is above
approximately 500 mA, leaving the low current set
point adjustment at the factory setting of 400 mA is
recommended. If an adjustment is required, it can
be adjusted between approximately 400 mA and 70
mA.
Adjustment Procedure
A small screwdriver (3/32 inch maximum blade
width) is required to change the low current set point
adjustment.
With AC power applied to the charger input and the
charger DC output connected to the load and fully
charged battery set, monitor the charger output
current until it stops decreasing and levels off at the
minimum system current. Ensure that the low
current set point adjustment is turned fully clockwise,
which will set the low current set point at
approximately 400 mA. If the LED is on and the
CLOSED relay contact is closed when the low
current set point adjustment is turned fully clockwise,
leave it in that position. If the LED is off and the
CLOSED relay contact is open when the low current
set point adjustment is turned fully clockwise, turn it
slowly counterclockwise until the LED turns on and
the CLOSED relay contact closes. Turn the low
current set point adjustment approximately 1/8 of a
turn counterclockwise from this switching point.
Remove AC power from the charger to verify that the
current monitor/alarm is functioning. The LED
should turn off and the CLOSED relay contact should
open.
Current Monitor/Alarm Specifications
RELAY CONTACT RATINGS:
1A at 30 Vdc
0.5A at 120 Vac
TERMINAL CONNECTIONS:
20 –16 AWG wire, strip length of .312 - .359
inches (8 –9 mm)
10. VOLTAGE MONITOR/ALARM
The ELC-12/40-CVM-D battery charger includes an
integrated voltage monitor/alarm that monitors the
DC voltage. Unless the optional VOLTAGE
MONITOR BATTERY SENSE input available on the
front of the charger is remotely wired to the terminals
of the battery, the DC voltage is monitored internally
at the charger output. If the DC voltage rises above
the HIGH VOLTAGE (HV) SET POINT setting, the
green BELOW HV SET POINT LED indicator is
turned off and the Form C, dry contact alarm relay is
actuated. If the DC voltage falls below the LOW
VOLTAGE (LV) SET POINT setting, the green
ABOVE LV SET POINT LED indicator is turned off
and the Form C, dry contact alarm relay is actuated.
The voltage set point switches, LEDs, relay
terminals, and optional battery sense input are
accessible on the front of the charger (see Figure
10.1).
Figure 10.1

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Relay Terminal Remote Wiring
The OPEN, COMMON, and CLOSED relay contacts
have push-in type terminals for remote wiring. The
relay contacts are rated for 1A at 30 Vdc or 0.5A at
120 Vac. A small screwdriver (3/32 inch maximum
blade width) is required to insert or remove a wire
from a relay terminal.
WARNING: BE CAREFUL! IF AN
UNINSULATED METAL TOOL CONTACTS BOTH
THE GROUNDED CHARGER CASE AND A RELAY
TERMINAL PUSH-IN TAB, THIS WILL CAUSE A
POTENTIALLY DAMAGING AND/OR
DANGEROUS ELECTRICAL SHORT.
Table 10.1 outlines the operation of the LEDs and
alarm relay based on the status of the voltage
monitor. All relay contact states are with reference
to the terminal strip COMMON. The voltage
monitor/alarm is DC powered, so, if the charger
loses AC power, the voltage monitor/alarm will
continue to function on battery power until the DC
voltage falls below approximately 7.1 volts, where it
will continue to be in an alarm state until AC power is
returned to the charger and the charger is able to
raise the DC voltage above the LOW VOLTAGE (LV)
SET POINT setting.
Voltage Set Point Adjustments
The HIGH VOLTAGE (HV) SET POINT setting is
adjustable with three (3) rotary switches and the
LOW VOLTAGE (LV) SET POINT setting is
adjustable with three (3) rotary switches, all of which
are available on the front of the charger (see Figure
10.1). For both settings, the top switch sets the tens
of volts, the middle switch sets the volts, and the
bottom switch sets the tenths of volts. Both set
points are settable between 07.8 and 51.3 volts. To
set the switches, use a small screwdriver to turn the
switch so that the arrowhead on the slot is pointing to
the desired number. BE SURE EACH SWITCH IS
SET ON A NUMBER AND NOT BETWEEN
NUMBERS.If a switch is set between numbers, the
corresponding LED will flash, and the voltage
monitor/alarm will not function as intended.
Voltage Monitor Battery Sense Input (Optional)
The voltage monitor/alarm includes an optional
VOLTAGE MONITOR BATTERY SENSE input
available on the front of the charger (see Figure
10.1). If the VOLTAGE MONITOR BATTERY
SENSE input is left disconnected, the DC voltage is
monitored internally at the charger output. The
VOLTAGE MONITOR BATTERY SENSE input can
be remotely wired to the terminals of the battery to
monitor the voltage at this point. The voltage
monitor/alarm detects when the VOLTAGE
MONITOR BATTERY SENSE input is connected to
the battery terminals and automatically monitors this
DC voltage instead of the voltage at the charger
output. Please refer to the wiring diagram in Section
15 for the VOLTAGE MONITOR BATTERY SENSE
input connector detail.
Voltage Monitor/Alarm Specifications
RELAY CONTACT RATINGS:
1A at 30 Vdc
0.5A at 120 Vac
TERMINAL CONNECTIONS:
20 –16 AWG wire, stripe length of .312 - .359 inches
(8 –9 mm)
Voltage Monitor Status
BELOW HV
SET POINT
LED
ABOVE LV
SET POINT
LED
CLOSED
Relay Contact
OPEN
Relay Contact
DC voltage is below the HIGH VOLTAGE
(HV) SET POINT setting and above the LOW
VOLTAGE (LV) SET POINT setting (normal
operation state)
On
On
Closed
Open
DC voltage is above the HIGH VOLTAGE
(HV) SET POINT setting and above the LOW
VOLTAGE (LV) SET POINT T setting (high
DC voltage alarm state)
Off
On
Open
Closed
DC voltage is below the HIGH VOLTAGE
(HV) SET POINT setting and below the LOW
VOLTAGE (LV) SET POINT setting (low DC
voltage alarm state)
On
Off
Open
Closed
Table 10.1

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11. MAINTENANCE
The battery charger requires minimal maintenance.
It should be kept clean and all connections are to be
periodically tightened. BE SURE THE CHASSIS IS
SECURELY GROUNDED. If any problem cannot be
resolved, consult the nearest NRS service agent at
1-800-357-3572.
12. SERVICING
If the battery charger operates improperly, follow the
steps below.
a. Begin by checking the voltage switches to
verify their settings against the specifications
of the batteries.
b. Check the AC voltage selection switch for
the proper setting.
c. Check the fuses to make sure they have not
blown.
d. Check the circuit breaker to see if it has
opened and push it in to reset it, if
necessary.
e. Check the polarity between DC output and
the battery and make sure their connections
are tight.
f. Remove the small cover on the front of the
charger and make sure all of the binding
posts nuts are tight.
g. If the steps above do not solve the problem,
contact your local NRS service agent at
1-800-357-3572.
13. CHARGER SPECIFICATIONS
AC INPUT VOLTAGE:
115 Vac (108-128) or 230 Vac (216-256)
AC INPUT CURRENT:
12.0 amps for 115 Vac (full power)
6.0 amps for 230 Vac (full power)
AC INPUT FREQUENCY:
50/60/100 Hertz (single phase)
AC LINE REGULATION:
For a constant output current at 2.23 volts/cell
22% for 6 cells
AC FUSES:
10 Amp slow blow
DC OUTPUT:
Voltage range 10.00 –17.00 + 0.1 volts
Current maximum 40.0 + 1 amps
DC OUTPUT RIPPLE (at battery terminals):
1.0V p-p at 40.0 amps, 12.0 volts
0.1V p-p at 2.0 amps, 13.38 volts
TEMPERATURE COMPENSATION:
3mV per F per cell
WEIGHT, NET:
60 lbs.

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14. PARTS LIST
The following is a list of parts found in the NRS model ELC-12/40-CVM-D. When replacing a part, USE ONLY
ORIGINAL FACTORY REPLACEMENT PARTS of the correct size and rating.
PART NO. QTY. DESCRIPTION
39022S 1 CASE ASSEMBLY MODEL 27840
18696S 1 SHUNT ASSEMBLY
31462S 1 CONTROL MODULE (W/ ELECTRONIC BOARD #21175)
38309S 1 CURRENT MONITOR MODULE (W/ ELECTRONIC BOARD #27545-01)
38308S 1 CURRENT MONITOR MODULE MOUNT
38811S 1 CONTROL CABLE, CURRENT MONITOR
05322S 2 FUSEHOLDER ASSEMBLY
15028S 2 FUSE, 10 AMP
38924S 1 CIRCUIT BREAKER ASSEMBLY
31457S 1 AC SWITCH ASSEMBLY
27319S 1 AMMETER, 50 AMP
14197S 4 BUSHING, 1"
29741S 1 TEMPERATURE TRANSDUCER, 10' (W/ TERMINAL)
29742S 1 TEMPERATURE TRANSDUCER, 30' (W/ TERMINAL)
14742S 1 HEATSINK ASSEMBLY, W/ SCR, 9” WIRE
15194S 1 HEATSINK ASSEMBLY, W/ SCR, 21” WIRE
23074S 1 SCR ASSEMBLY, 50 AMP, 21” WIRE
23073S 1 SCR ASSEMBLY, 50 AMP, 9” WIRE
32199S 1 OUTPUT CAPACITOR, C, 40,000 UF, 35V
32206S 1 CAP ASSEMBLY, W/ DIODE ASSEMBLY
14759S 1 VARISTOR ASSEMBLY, VR2, 130V
31463S 1 TAP STRIP ASSEMBLY
31309S 1 VARISTOR ASSEMBLY, VR1, 320V
31301S 2 DOOR LATCH, BASE
31302S 2 DOOR LATCH, STUD
38808S 1 VOLTAGE MONITOR MODULE, (W/ ELECTRONIC BOARD #27775)
38856S 1 CABLE CONTROL VOLTAGE MONITOR
15369S 1 REMOTE VOLTAGE SENSE CABLE, 10’
24584S 1 REMOTE VOLTAGE SENSE CABLE, 30’

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15. WIRING DIAGRAM