Railway Equipment 520603-2V150 User manual

MODEL 520603-2V150
VOLTAGE MONITOR
The Cragg Railcharger® Battery Voltage Monitor is
a free standing unit that features the ability to
monitor two DC voltage sources and has optional
temperature and current monitoring ability.
CRAGG RAILCHARGER
®
Instruction Manual for Digital
Voltage Monitor
15400 Medina Rd.
Plymouth, MN 55447
[phone]
[phone] Fax
E-mail: [email protected]

Voltage Monitor – Instruction Manual
Model 520603-2V150
P/N 520603-
2V150 REV. A, 9/10 © 2010 RAILWAY EQUIPMENT CO.
ii
Contents
1.0 WARNINGS, CAUTIONS, AND NOTES.................................................................................... 1
2.0 OPERATION.............................................................................................................................. 2
2.1 Front Panel Features and Components................................................................................. 2
2.1.1 Figure 1. Front Panel of Voltage Monitor.......................................................................... 3
2.1.2 Digital Display…………………………………………………………………………………… 3
2.1.3 Push Buttons…………………………………………………………………………………….. 5
2.1.4 LED Status Indicators....................................................................................................... 5
2.1.5 External Wiring Connector................................................................................................ 5
3.0 STANDARD FEATURES........................................................................................................... 7
4.0 SPECIFICATIONS..................................................................................................................... 8

Voltage Monitor– Instruction Manual
Model 520603-2V150
P/N 520603-
2V150 REV. A, 9/10 © 2010 RAILWAY EQUIPMENT CO.
1
1.0 WARNINGS, CAUTIONS, AND NOTES
Please read the entire instruction manual before using the voltage monitor.
Also, read the warnings, cautions, and notes in Table 1. Failure to observe the warnings and
cautions can lead to equipment damage or personal injury.
If you have any questions concerning the manufacture, design, function, installation, operation
or maintenance, contact Railway Equipment Company before proceeding.
Table 1. Warnings, Cautions, and Notes
Symbol Description
WARNING indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate personal injury. It may also be used to alert against unsafe practices.
NOTE NOTE indicates explanatory information that applies to the next step in the procedure. It
is used to clarify and expand upon the importance of the procedural step when needed.
If incorrectly wired, monitor can be damaged. Be sure to observe correct polarity on all
DC wire connections, check the AC wiring instructions, and connect the ground wire.

4/8/2013 Voltage Monitor – Instruction Manual
Model 520603-2V150
P/N 520603-
2V150 REV. B 9/11 © 2011 RAILWAY EQUIPMENT CO.
2
2.0 OPERATION
The model 520603-2V150 voltage monitor is equipped to monitor up to two DC voltage
sources. The unit is powered by the voltage source that it monitors on channel one. The
channel one voltage range is 10 to 48 VDC. Because the unit is powered by the voltage it
monitors on channel one, the display will not illuminate until a voltage source is applied across
pins one (+) and two (-). The unit power usage is a constant 2.5 Watts. The unit is reverse
polarity protected, and the input power is protected by an internal resettable fuse.
Channel two has a voltage range of 1 to 150 VDC, but is only available for use if channel one is
powered. There is 2,500 volts isolation between channels.
The monitor has easy front panel access for set up and wiring. There are form C relay outputs
that are over current protected with replaceable blade type automotive fuses.
To get started, power from the source to be monitored (10 to 48 VDC range) should be applied
across WAGO pins 1(+) and 2(-) using 18 to 14 gauge wire. This provides power to channel
one.
The display idle screen will show voltage. If the applied voltage is between the high and low
voltage parameters, the Channel 1 OK LED will be on, and the channel one relay will be
powered.
2.1 Front Panel Features and Components
This section describes the features and components that are on the front panel of the
voltage monitor (see Figure 1).

4/8/2013 Voltage Monitor – Instruction Manual
Model 520603-2V150
P/N 520603-
2V150 REV. B 9/11 © 2011 RAILWAY EQUIPMENT CO.
3
2.1.1 Figure 1. Front Panel of Voltage Monitor
2.1.2 Digital Display
The idle screen displays the input voltage. If only channel one has input voltage, only
channel one will be displayed. If both channels are monitoring voltage sources, both
will be displayed. If the optional current or temperature probes are being used, the
lower screen will alternate between displaying channel two voltage, temperature, and
current. With only channel one powered, the following screens will be scrolled through
when the MODE button is depressed:
PASSWORD ___- The password to adjust parameters is 5. It is entered by pressing
the INCREASE button until 5 appears in the parameter field.
MAX VCH1
SET __._ - This displays the high voltage setpoint parameter for channel one. It can
be adjusted from 0 to 50.0 VDC by use of the INCREASE or DECREASE push
buttons. If the input voltage rises above the setpoint, the channel one output relay will
change state and the channel one CHANNEL OK LED will go out. Factory default is
50.0 VDC.
LOW VCH1
SET __._ - Low voltage setpoint for channel one, adjustable from 0 to 50.0 VDC.
If the input voltage falls below the setpoint, the output relay will change state and the
CHANNEL OK LED will go out. Factory default is 0 VDC.
DELAY CH1
SET ___ - Delay time in seconds before a voltage falling outside the parameters
will trigger a fault. This parameter is adjustable from 1 to 600 seconds. Factory
default is 10 seconds.
If a voltage input is added on channel two, in addition to the input on channel one,
the following additional screens to appear as the MODE button is used:
MAX VCH2
SET __._ - High voltage setpoint for channel two. Voltage range is 0 to 150.0 VDC
Factory default is 150.0 VDC.
LOW VCH2
SET __._ - Low voltage setpoint for channel two. Voltage range is 0 to 150.0 VDC.
Factory default is 0 VDC.
DELAY CH2
SET ___ - Delay time in seconds for channel two. Range is 0 to 600 seconds.
Factory default is 10 seconds.
There is an optional amp probe available which can be set up to trip the same relay
as a voltage fault will trip on Channel two. The addition of the current probe will
cause the following additional screens to appear:

4/8/2013 Voltage Monitor – Instruction Manual
Model 520603-2V150
P/N 520603-
2V150 REV. B 9/11 © 2011 RAILWAY EQUIPMENT CO.
4
HIGH AMP
SET ___ - Parameter for amp setting above which channel two will change relay
State. Amp range is -120 to +120 amps. Factory default is +120 amps.
LOW AMP
SET ___ - Amp setting below which channel two will trip. Amp range is -120
to +120 amps. Factory default is -120 amps.
There is also an optional temperature probe that can control the channel two
output. If the probe is used, the temperature can be displayed as Fahrenheit
or Celsius. To select either Fahrenheit or Celsius, enter 10 on the PASSWORD
screen. With 10 as your password, two additional screens will show up as the
parameter screens are toggled through. One screen is: F OR C _____. The
INCREASE or DECREASE buttons can be used to select which temperature scale
will be displayed. The next screen will be REV. LEV ______. This screen will
display the software revision level installed on the monitor. The addition of the
temp probe adds the following screens:
HIGH TEMP
SET ___ - Temperature setting above which channel two relay will change
state. Available temperature range is -40 to +300 degrees F (-40 to 148.9
degrees C). Factory default is +300 F (148.9 C).
LOW TEMP
SET ___ - Temperature setting below which channel two relay will change
state. Available temperature range is -40 to +300 degrees F (-40 to 148.9
degrees C). Factory default is -40 F (-40 C).
The following Fault Counter Screens will appear only if the fault count in each is
Greater than 0:
CH 1 HI V
COUNT ___ - Number of high voltage incidents on Channel 1. Press DECREASE
to clear.
CH 1 LO V
COUNT ___ -Low voltage incidents on Channel 1. Press DECREASE to clear.
CH 2 HI V
COUNT ___ - High voltage incidents on Channel 2. Press DECREASE to clear.
CH 2 LO V
COUNT ___ - Low voltage incidents on Channel 2. Press DECREASE to clear.
HI TEMP
COUNT ___ - High temperature incidents on Channel 2. Press DECREASE to
clear.
LOW TEMP
COUNT ___ - Low temperature incidents on Channel 2. Press DECREASE to

4/8/2013 Voltage Monitor – Instruction Manual
Model 520603-2V150
P/N 520603-
2V150 REV. B 9/11 © 2011 RAILWAY EQUIPMENT CO.
5
clear.
HI AMP
COUNT ___ - High amperage incidents on Channel 2. Press DECREASE to
Clear.
LOW AMP
COUNT ___ - Low amperage incidents on Channel 2. Press DECREASE to clear.
2.1.3 Push Buttons
Below the digital display are three control push buttons:
INCREASE – This is used to increase the value of the displayed parameter, if enabled.
DECREASE – This button will decrease the value of the displayed parameter, if
enabled.
MODE – This control is used to increment through the available screens.
2.1.4 LED Status Indicators
Two LEDs are used to indicate Channel OK, one for each input channel.
2.1.5 External Wiring Connector
Near the bottom of the front panel there is a twelve position socket with a removable
connector for external wiring. The connection locations are shown below:
PIN CONNECTION INPUT NUMBER
1 INPUT 10-48 VDC # 1 +VOLTAGE
2 COM 0V # 1 -VOLTAGE
3 NORMALLY CLOSED # 1 OUTPUT RELAY
4 FUSED COMMON # 1 OUTPUT RELAY
5 NORMALLY OPEN # 1 OUTPUT RELAY
6 NO CONNECTION
7 NO CONNECTION
8 INPUT 1-150 VDC # 2 + VOLTAGE
9 COM 0V # 2 – VOLTAGE
10 NORMALLY CLOSED # 2 OUTPUT RELAY
11 FUSED COMMON # 2 OUTPUT RELAY
12 NORMALLY OPEN # 2 OUTPUT RELAY

4/8/2013 Voltage Monitor – Instruction Manual
Model 520603-2V150
P/N 520603-
2V150 REV. B 9/11 © 2011 RAILWAY EQUIPMENT CO.
6
2.1.6 CURRENT SENSOR
The current sensor connector is located on the right center of the front panel. The
sensor is optional, consisting of a plug end wired to a split current coil that can monitor
the current level of a circuit monitored by channel two. By setting the current
parameters, the current level can be used to trigger a fault condition on channel two,
either independently, or in conjunction with channel two voltage, and/or with the
temperature sensor described in 2.1.7.
2.1.7 TEMPERATURE SENSOR
On the top of the monitor case is a temperature sensor jack. The temp sensor is
An optional thermocouple that can be placed to monitor battery, equipment, or air
temperature. By setting the temp parameters, the temperature level can be used to
trigger a fault condition on channel two, either independently, or in conjunction with
channel two voltage, and/or with the current sensor described in 2.1.6.

4/8/2013 Voltage Monitor – Instruction Manual
Model 520603-2V150
P/N 520603-
2V150 REV. B 9/11 © 2011 RAILWAY EQUIPMENT CO.
7
3.0 STANDARD FEATURES
The standard features of the Voltage Monitor are listed as follows:
Two Channel Battery Voltage Monitor with Relay Outputs
For Lead Acid and NiCad Batteries
Programmable Voltage Parameters
LED Status Indicators
Digital Amperage Meter (when optional Amp Probe is used)
Digital Voltage Meter
Digital Temperature Meter (when optional Temp Probe is used)
Programmable High and Low Relay Trip Limits for Voltage, Current, and Temperature
Meets or Exceeds AAR/AREMA Specifications
Panel Mount Ready
2-Year Warranty

4/8/2013 Voltage Monitor – Instruction Manual
Model 520603-2V150
P/N 520603-
2V150 REV. B 9/11 © 2011 RAILWAY EQUIPMENT CO.
8
4.0 SPECIFICATIONS
Two channels with over and under absolute set points.
Input power is 8 to 48 VDC @ 2.5 Watts. Input power is channel 1 sense input.
The monitor has 2500 Volt isolation between channels.
Channel 2 voltage range is 1 to 150 VDC.
Channel 1 and 2 sensitivity is 100 MV per step.
The inputs are protected against reverse polarity.
The input power is protected by an internal resettable fuse.
The monitor outputs are form C relay with blade type fuse connected to a removable Wago
terminal for each channel.
Input and output connections are on the removable connector on the bottom front of the
monitor.
The digital display is a 2 line by 8 character unit.
An optional temperature sensor with 25 foot cable is available.
An optional current sensor with a range of -120 to +120 Amps is available.