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INSTALLATION & OPERATING INSTRUCTIONS CHP 100 SERIES INDUSTRIAL BATTERY CHARGERS
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Page 1: GNB Battery Charger

INSTALLATION & OPERATING

INSTRUCTIONS

CHP 100 SERIES

INDUSTRIAL BATTERY CHARGERS

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PACIFIC CHLORIDE ®

Champion® is a registered trademark of Federal-Mogul Corporation

Exide TechnologiesChloride Motive PowerP.O. Box 1, Salford RoadOver Hulton, Bolton BL5 1DDUnited KingdomTel: 44.1204.661.230Fax: 44.1204.652.100

GNB Industrial PowerMotive Power8301 Keele StreetMaple, OntarioCanada L6A 1T2Tel: 905.669.9326Fax: 905.669.7688

GB-3653 RPT 11/01

GNB Industrial PowerMotive Power829 Parkview BoulevardLombard, IL 60148-3249U.S.A.Tel: 877.GNB.INFOFax: 630.691.7869

Printed on recycled paper

www.gnb.com

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Instr. 4770-65-95005-20Rev. 12/06/01

TABLE OF CONTENTS

TITLE PAGE

1.0 IMPORTANT OPERATING AND SAFETY INSTRUCTIONS 2

2.0 INTRODUCTION 3

3.0 RECEIVING CHARGER 3

4.0 LOCATION AND INSTALLATION OF CHARGER 3

4.1 Stacking 3

5.0 AC ELECTRICAL SUPPLY 3

5.1 AC Fuse Mounting 3

5.2 Input Voltage Change 3

5.3 AC Voltage Connections 7

5.4 Ground connection 7

6.0 DC OUTPUT 7

7.0 APPLICATION 8

7.1 Fault and Display Codes 8

7.2 Options 8

TABLE 2 - SINGLE PHASE RATINGS 9

TABLE 3 - THREE PHASE RATINGS 10

8.0 CABINET OUTLINE/DIMENSIONS 13

9.0 CHP100 CHARGER OPERATION 14

9.1 CHP100 Charger Functional Description 15

10.0 CHARGE TIME 16

11.0 MAINTENANCE 16

APPENDIX A: ELECTRICAL SCHEMATICS 18

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Instr. 4770-65-95005-20 Page 2

CHP100 SERIES INDUSTRIAL BATTERY CHARGERS

1.0 IMPORTANT OPERATING AND SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

a) Before using the battery charger, read all the instructions in addition to the CAUTION, WARNING, and DANGERmarkings on the charger, battery and all the associated equipment.

b) Do not touch uninsulated parts of the DC output connector or the battery terminals, as there is a possibility ofelectric shock.

c) Connect or disconnect the battery plug only when the charger output is off; ALWAYS press the STOPpushbutton before unplugging the battery to prevent arcing or burning.

d) If the battery is unplugged during charging, the charger will indicate “CHG INTERRUPTED XXAH, UNPLUGGEDBATTERY”. To restart charging, wait for five seconds when the display will read “UNIT READY” and plug in thenext battery.

e) Only qualified personnel should operate or service this equipment.

f) De-energize all AC and DC power connections before servicing this unit. If injury does occur, apply the prescribedtreatment for electrical shock and obtain medical attention immediately.

g) The charger is NOT for outdoor use. Do not expose the charger to rain or snow.

h) This charger is factory set to charge lead-acid batteries only. Operating environment should not contain anycontaminations that may cause corrosion or contamination of a charger in degree that can degrade theperformance of a charger or the safety requirements

i) Do not operate this unit if it has received a sharp blow, been dropped or otherwise damaged. Take it to a qualifiedGNB service center.

j) Do not disassemble the charger. Have the charger examined by a GNB service representative or local qualifiedservice facility. Incorrect re-assembly of the charger may result in an explosion, electric shock or fire.

k) The charger profile is set at the factory for a charger DC cable length of 9ft and a battery DC cable length of 25in. If DC cable lengths are adjusted please contact you local GNB service representative.

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Instr. 4770-65-95005-20 Page 3

2.0 INTRODUCTION

The GNB CHP100 battery chargers are convectioncooled, solid state, micro-processor controlled SCRregulated chargers designed to make battery chargingsimple. They are factory set to charge sealed lead-acidbatteries but it may be configured by a GNB servicerepresentative to charge flooded lead-acid batteries.

The charger has a comprehensive self-checkingdiagnostic program to control all charger functions,monitor the quality of charge and check its own safetyconditions. Large easy to read vacuum fluorescentdisplay, three button keypad and LEDs report on chargerand battery status.

3.0 RECEIVING CHARGER

Examine the charger thoroughly before using, to makesure that no parts have been loosened or damagedduring shipment. Check the contents of the packageagainst the delivery slip before disposing of the shippingpackage. If any shipping damage or partial loss isfound, file a claim with the carrier without delay and takeany necessary steps to portect your rights. Beforeinstalling check that the charger namelpate datacorresponds to the packing slip and to the modelspecified on the original sales order.The CHP100 chargers are delivered on skids for easyhandling using a fork lift truck.

4.0 LOCATION AND INSTALLATION OFCHARGER

Proper installation is important in order to achieve goodcharger performance, long troublefree operation and toprevent damage to the charger and batteries. Thecharger should be located in a clean, dry and wellventilated area, where the ambient temperature isbetween +45°F/7.2°C and 90°F/32.2°C. To permit freeair flow for convection cooling allow four inchesminimum between the charger and any wall, six inchesfrom other equipment, and never store anything beneathor on top of the charger.

4.1 STACKING

When stacking chargers on top of each other, ensurethat cabinets are bolted together using properly sizedblack #1/4-20 UNC hardware provided in all four cornerson top cover. The floor mounting must be done with#3/8-16 UNC bolts (steel rack) or #3/8 lag screws andanchors (concrete floor). All charger models with a Z,CHP100-XX-XXXT1Z OR CHP100-XX-XXXS1Z, can bestacked to a maximum of three high.

WARNING: THE ABOVE PROCEDURES MUSTBE FOLLOWED EXACTLY TO AVOID INJURYOR RISK OF ELECTRIC SHOCK.

WARNING: TO REDUCE THE RISK OF FIRE,INSTALL BATTERY CHARGER ON A FLOOR OFNON-COMBUSTIBLE MATERIAL SUCH ASSTONE, BRICK, CONCRETE OR METAL. IFTHIS IS NOT AVAILABLE, A FLOOR PLATE OFAT LEAST 1.43mm GALVANIZED OR 1.6mmUNCOATED STEEL EXTENDED AT LEAST150mm BEYOND THE EQUIPMENT ON ALLSIDES MUST BE INSTALLED.

5.0 AC ELECTRICAL SUPPLY

The charger must be connected to either a single phase,or three phase 50 or 60 Hertz (± 2%) AC power source.The following options are available:

TABLE 1 – INPUT VOLTAGE CHOICESSingle phase Three phasea) 120/208/240VAC, 60Hz e) 208/240/480VAC, 60Hzb) 208/240/480VAC, 60Hz f) 480VAC, 60Hzc) 600VAC, 60Hz g) 600VAC, 60Hzd) 240VAC, 50Hz h) 380VAC, 50Hz

g) 415VAC, 50Hz

Only in a multi-input charger can the AC input wireconfiguration be changed. Follow Figure 1 (page 4) forsingle phase input or Figure 2 and Figure 3 (pages 5-6)for three phase input transformers. This change shouldbe done by a qualified electrical contractor.

5.1 AC FUSE MOUNTING

The charger comes with a fuseblock rated big enough toaccommodate the highest possible current and voltagefor that particular model. When needed, find the properAC fuse rating from Table 2 and Table 3 (see pages 9-12) for the input fuses (F1, F2 in case of a single phaseinput or F1, F2, F3 in case of a three phase input).Fuses with an ampere rating of 30A or less are smallerand need fuse reducers when placed in a 60A fuseblock.

5.2 INPUT VOLTAGE CHANGE

When changing the taps on the input side between 1)120, 208, 240 VAC or 2) 208, 240, 480 VAC (singlephase input), be sure to change the wires and/orjumpers according to Figure 1 (page 4). Once finished,refer to Table 2 (page 9) for the correct size of inputfuses. Similarly when changing input voltage between 1)208, 240, 480 VAC or 2) 380, 415VAC (three phaseinput) follow the schematics on Figure 2 or Figure 3(pages 5-6) whichever is applicable. Following that,check Table 3 (page 10) for the correct size of the inputfuse. Figure 3 applies to 12 cell 475, 600, 750, 865 Ah;18 cell 475, 600, 750, 865, 1050 Ah; and 24 cell 475,600, 750, 865Ah chargers only.

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Instr. 4770-65-95005-20 Page 4

NOTE: Upon completion and proper verification of theinput voltage configuration change, markings on thedoor label and the unit nameplate must be revised

(crossing out factory set markings); re-mark the labelwith a permanent marker to reflect new input voltageconfiguration and fuse size.

120 VAC CONFIGURATION (120/208/240V INPUT)

208 VAC CONFIGURATION (120/208/240V INPUT)

240 VAC CONFIGURATION (120/208/240V INPUT)

208 VAC CONFIGURATION (208/240/480V INPUT)

240 VAC CONFIGURATION (208/240/480V INPUT)

480 VAC CONFIGURATION (208/240/480V INPUT)

L2

L2 L2

L2 L1 L1

L1

BRNBLK BLK

BLK BLK

BRN

BRN

BRN

BRN

L1

L1

BLK BLK

BRN

L1 L2L2

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FIGURE 2: THREE PHASE INPUTWARNING: IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE DAMAGE TO THECHARGER AND BATTERY

Instr. 4770-65-95005-20 Page 5

208VAC CONFIGURATION (208/240/480V INPUT)

240VAC CONFIGURATION (208/240/480V INPUT)

480VAC CONFIGURATION (208/240/480V INPUT)

380VAC CONFIGURATION

415VAC CONFIGURATION

L1 L1

L1L1

L1 L1L2

L2

L2L2 L2L3

L3 L3

L3

L1

L1

L1

L1

L2

L2

L2L2

L2

L3 L3

L3

L3L3

L3

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FIGURE 3: THREE PHASEWARNING: IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVER DAMAGE TO THECHARGER AND BATTERY.

Instr. 4770-65-95005-20 Page 6

208VAC CONFIGURATION (208/240/480V INPUT) (CHARGERS WITH SPEC V16-893XX-XXONLY)

L2

L1 L1L2

L3

L3

240VAC CONFIGURATION (208/240/480V INPUT) (CHARGERS WITH SPEC V16-893XX-XXONLY)

L1

L3

L1

L2

L2 L3

480VAC CONFIGURATION (208/240/480V INPUT) (CHARGERS WITH SPEC V16-893XX-XXONLY)

L3L2

L1 L1L2 L3

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Instr. 4770-65-95005-20 Page 7

5.3 AC VOLTAGE CONNECTIONS

To connect the input AC voltage, route the AC conduitthrough the knockout hole provided. Continue the ACwiring to fuseholder terminals L1 (N) and L2 (L) (singlephase input) or L1, L2, and L3 (three phase input),ensuring that the AC source phases match the phaserotation on the AC input. For proper connection torquethe screws to approximately 25 inch-pounds.

5.4 GROUND CONNECTION

It is a requirement to ground the chassis while thecharger is connected to AC power. The charger comeswith a ground wire attached to the stud, clearly markedon the chassis. To ensure good continnuity keep thecontact area clean. The stud is designed for a 3/16”hardware. See gounding method shown below (Figure4.).

WARNING: DO NOT OPERATE THE UNITWITHOUT PROPER GROUNDING. IMPROPERGROUNDING CAN RESULT IN THE RISK OF ANELECTRIC SHOCK AND ELIMINATESCHARGER WARRANTY.

CAUTION: USE MINIMUM 75°C WIRING. FORSUPPLY CONNECTIONS, GROUND CHARGERPROPERLY USING GROUNDING STUD[SDOACI1](GND) PROVIDED. USE COPPER-CLADALUMINUM, ALUMINUM OR COPPERCONDUCTORS ONLY.

After electrical connection is completed, the charger isready for operation.

FIGURE 4: GROUNDING METHOD

6.0 DC OUTPUT

The DC charging cable has a commonly used batteryplug or receptacle. The polarity of the charger plug mustbe the same as the battery connector. The BLACK DCcable must be connected to the battery negative (-), andthe RED DC cable must be connected to the batterypositive (+). The charger will not operate in a reversedpolarity condition.

The DC output fuse is a "fast-acting" fuse used toprotect the power semiconductors of a charger.

NOTE: Use only identical replacement fuses obtainable from your GNB service representative

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Instr. 4770-65-95005-20 Page 8

7.0 APPLICATION

The charger will automatically charge a battery per theAh rating set at the factory. The charger can be re-setfor anywhere between 45% to 200% of the nameplateAh rating. Ensure that battery and charger are matched.Keep in mind if the charger is set for more than 100% ofAh of the charger the charging time will increaseproportionately to up to 16 hours. For battery sizes notlisted, contact your local GNB service representative.

7.2 OPTIONS

7.2.1 JIC SWITCH ASSEMBLY

All CHP100 battery chargers can come with a factoryinstalled fused JIC switch assembly option for extraprotection of the operator. In the "OFF" position, the doorcan be opened but AC power on the input side is presentwith the ramainder of the charger void of AC power. Inthe "ON" position, AC power is supplied to the chargerbut the door cannot be opened. See applicable drawing4770-65-73041-05, 4770-65-73041-15 or 4770-65-73041-17 for electrical schematic (Appendix B, pages18-27). NOTE: Only HRCI-R type fuses (ECSR orequivalent) with the notched ferrule at one end can beused. A JIC option can only be factory installed and itwill be in a “B”, “C” or “D” size cabinet.

7.2.2 BATTERY WATERING OPERATION

The CHP100 battery charger has an available wateringcontrol, in the form of a relay contact at terminalsTB10-1 to TB10-2 (supplied for customer connection).The relay closes thirty minutes after the charger reachesgassing voltage. It remains closed for approximately tenminutes.

NOTE:These options require a different control card perdrawing 4120-65-68650-05 (see Appendix B, pages 18-27).

RELAY CONTACT RATINGS:- AC: 125V 0.6A 1.0PF maximum- DC: 30V 2A resistive maximum

7.2.3 MOMENTARY REMOTE STOP OPERATION

The CHP100 battery charger has an available remotestop control option that allows the operator to turn off thecharger from a remote site. An external momentarypushbutton rated at or above 2.7 times the number ofcells (Vdc) and at least 0.5Adc is required. Thepushbutton is connected to terminal TB-1, -2. Once thestop button is depressed the charger will stop the chargecycle. To re-start charging battery has to be unpluggedand then re-connected. See drawing 4120-65-68650-20(Appendix B pages 18-27) for electrical schematics.

7.2.4 CHP100 REMOTE CONTROL

The CHP100 has an available remote control kit thatallows the operator to control the charger from a remotecontrol panel (included) away from the charger. RequestInstruction number V16-92625-00 for complete details.

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TABLE 2 – SINGLE PHASE TECHNICAL DATA

Instr. 4770-65-95005-20 Page 9

STANDARD MODELCHP100-XX-XXXX-S1Z

DC AC AMPS @ AC VOLTS CABINET WEIGHT

AMPS 120 208 240 480 TYPE LBS KGS

CHP100-06-260S1Z AMPS 12 7 6 3 A 76 34.540

FUSE 15 10 8 4

CHP100-06-475S1Z AMPS 19 11 9.5 5 A 120 54.474

FUSE 25 15 12 7

(50 Hz) AMPS X X 9.5 X A 130 59.174

FUSE - - 12 -

CHP100-06-600S1Z AMPS 26 15 14 7 B 190 86.293

FUSE 35 20 20 10

(50 Hz) AMPS X X 13.5 X B 205 93.293

FUSE - - 20 -

CHP100-06-865S1Z AMPS C.F. 20 18 9 B 255 116134

FUSE - 25 25 12

CHP100-06-965S1Z AMPS C.F. 23 20 10 B 295 134150

FUSE - 30 25 15

CHP100-09-475S1Z AMPS 26 15 14 6.5 B 160 72.574

FUSE 35 20 20 10

CHP100-09-600S1Z AMPS C.F. 19 16 8 B 210 9593

FUSE - 25 20 10

CHP100-09-865S1Z AMPS C.F. 27 23.5 12 B 260 118134

FUSE - 35 30 15

CHP100-09-965S1Z AMPS C.F. 30 26 13 B 300 136150

FUSE - 40 35 20

CHP100-12-260S1Z AMPS 18.5 10.5 9 5 A 120 54.440

FUSE 25 15 12 7

(50 Hz) AMPS X X 9 X A 130 59.140

FUSE - - 12 -

CHP100-12-475S1Z AMPS X 19.5 17 8.5 B 200 90.774

FUSE - 25 25 12

(50 Hz) AMPS X X 17 X B 212 96.474

FUSE - - 25 -

CHP100-12-600S1Z AMPS X 25.5 22 11 B 225 10293

FUSE - 35 30 15

(50 Hz) AMPS X X 22 X B 235 10793

FUSE - - 25 -

CHP100-12-750S1Z AMPS C.F. 34 29 14.5 B 270 122116

FUSE - 45 40 20

CHP100-12-865S1Z AMPS C.F. 34 29 14.5 B 270 122134

FUSE - 45 40 20

CHP100-12-965S1Z AMPS C.F. 38 34 17 B 305 138150

FUSE - 50 45 25

CHP100-18-260S1Z AMPS C.F. 16 14 7 B 195 88.540

FUSE - 20 20 10

CHP100-18-475S1Z AMPS C.F. 30 26 14 B 240 10974

FUSE - 40 35 20

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TABLE 2 – SINGLE PHASE TECHNICAL DATA

Instr. 4770-65-95005-20 Page 10

STANDARD MODELCHP100-XX-XXXX-S1Z

DC AC AMPS @ AC VOLTSCABINET

WEIGHT

AMPS 120 208 240 480 TYPE LBS KGS

CHP100-18-600S1Z AMPS C.F. 36.5 31.5 16 B 260 11893

FUSE - 50 40 20

CHP100-18-750S1Z AMPS C.F. 48 44 22 C 260 118116

FUSE - 60 60 30

CHP100-18-865S1Z AMPS C.F. 48 44 22 C 325 147134

FUSE - 60 60 30

(50 Hz) AMPS X X 44 X C 340 155134

FUSE - - 60 -

CHP100-24-260S1Z AMPS X 22 19 10 B 300 13540

FUSE - 30 25 15

AMPS X 39 33.5 17 C 315 14374

FUSE - 50 45 25AMPS X X 33.5 X C 340 155

CHP100-24-475S1Z

(50 Hz)74

FUSE - - 45 -

AMPS X 48 41 21 C 380 17293

FUSE - 60 60 30AMPS X X 41 X C 400 182

CHP100-24-600S1Z

(50 Hz)93

FUSE X X 60 X

NOTE: C.F.: CONTACT FACTORY; X: NOT AVAILABLE; -: DATA NOT AVAILABLE

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TABLE 3 – THREE PHASE TECHNICAL DATA

Instr. 4770-65-95005-20 Page 11

AC AMPS @ AC VOLTS CABINET

STANDARD MODEL DC 60Hz 50Hz CABINET WEIGHT

CHP100-XX-XXXX-T1Z AMPS 208 240 480 380 415 TYPE LBS KGS

CHP100-06-475T1Z AMPS 5 4.5 2.2 C.F. C.F. B 170 77.174

FUSE 7 6 3 - -

CHP100-06-600T1Z AMPS 7 6 3.5 C.F. 3.5 B 190 86.293 FUSE 10 8 5 - 5

AMPS 9 8 4 C.F. C.F. B 220 99.8CHP100-06-750T1Z116

FUSE 12 12 6 - -

CHP100-06-865T1Z AMPS 10 9 5 C.F. C.F. B 220 99.8134

FUSE 15 12 7 - -

CHP100-06-965T1Z AMPS 11 10 5 C.F. C.F. B 235 107150

FUSE 15 12 6 - -

CHP100-06-1050T1Z AMPS 12 11 5.5 C.F. C.F. B 245 111163

FUSE 15 15 8 - -

AMPS 12.7 11 5 C.F. C.F. C 260 118CHP100-06-1200T1Z186

FUSE 20 15 7 - -

CHP100-06-1450T1Z AMPS 15 14 7 C.F. C.F. C 290 132225

FUSE 20 20 10 - -

CHP100-09-600T1Z AMPS 12 10 5 C.F. C.F. B 220 99.893

FUSE 15 15 7 - -

CHP100-12-475T1Z AMPS 9 8 4 5.5 5.0 B 215 97.674

FUSE 12 12 6 8 7

CHP100-12-600T1Z AMPS 11.5 10 5 7 7 B 220 10093

FUSE 15 15 7 10 10

CHP100-12-750T1Z AMPS 15 14 7 9.2 9 B / C* 250 113.5116FUSE 20 20 10 12 12

CHP100-12-865T1Z AMPS 16 14 7 10 9 C 255 116134

FUSE 20 20 10 15 12

CHP100-12-965T1Z AMPS 21 18 9 C.F. C.F. C 260 118150

FUSE 30 25 12 - -

CHP100-12-1050T1Z AMPS 22 19 9.5 12 C.F. C 270 122163

FUSE 30 25 12 15

CHP100-12-1200T1Z 186 AMPS 26 22 11 C.F. C.F. C 298 135

FUSE 35 30 15 - -

CHP100-12-1450T1Z 225 AMPS 30 26 14 C.F. C.F. C 310 141

FUSE 40 35 20 - -

CHP100-18-260T1Z 40 AMPS 9 8 4 C.F. C.F. B 215 98

FUSE 12 10 6 - -

CHP100-18-475T1Z 74 AMPS 14 11 5.5 C.F. 8 B 255 116

FUSE 20 15 8 - 12

AMPS 16 14 7 C.F. 10.7 B / C* 300 136CHP100-18-600T1Z93

FUSE 20 20 10 - 15

CHP100-18-750T1Z 116 AMPS 20 18 9 16 15 B / C* 310 141

FUSE 30 25 12 20 20CHP100-18-865T1Z 134 AMPS 24 21 10.5 16 15 C 325 148

FUSE 35 30 15 20 20

CHP100-18-965T1Z 150 AMPS 26 22 11 18 17 C 340 155

FUSE 35 30 15 25 25

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TABLE 3 – THREE PHASE TECHNICAL DATA

Instr. 4770-65-95005-20 Page 12

AC AMPS @ AC VOLTS CABINET

STANDARD MODEL DC 60Hz 50Hz CABINET WEIGHT

CHP100-XX-XXXX-T1Z AMPS 208 240 480 380 415 TYPE LBS KGS

CHP100-18-1050T1Z AMPS 28 24 12 19 17.5 C 380 163163

FUSE 40 35 15 25 25

CHP100-18-1200T1Z AMPS 37 32 16 26 C.F. C 410 186186 FUSE 50 45 20 35 -

AMPS 47.5 41 21 26 27 C 450 204CHP100-18-1450T1Z225

FUSE 60 60 30 35 35

CHP100-18-1700T1Z AMPS 48 44 22 C.F. C.F. D 550 250264

FUSE 60 60 35 - -

CHP100-24-475T1Z AMPS 17 15 7.5 C.F. 10 B / C* 290 13274

FUSE 25 20 10 - 15

CHP100-24-600T1Z AMPS 21 18 9.5 15 12 C 320 14593

FUSE 30 25 12 20 15

AMPS 28 24 12 18 17.2 C 345 157CHP100-24-750T1Z116

FUSE 40 35 15 25 25

CHP100-24-865T1Z AMPS 31 27 14 18 17.6 C 380 173134

FUSE 45 40 20 25 25

CHP100-24-965T1Z AMPS 40 36 18 C.F. 20 C 400 182150

FUSE 60 50 25 - 30

CHP100-24-1050T1Z AMPS 44 38 18.5 24 22 C 425 193163

FUSE 60 50 25 35 30

CHP100-24-1200T1Z AMPS C.F. 46 23 28 C.F. C 440 200186

FUSE - 60 30 40 -

CHP100-24-1450T1Z AMPS C.F. C.F. 27 27 22 C 490 222225

FUSE - - 35 35 30

CHP100-24-1700T1Z AMPS C.F. C.F. 31 31 25 D 525 239264

FUSE - - 40 40 35

CHP100-36-475T1Z AMPS 34 29 14.5 C.F. C.F. C 330 15074

FUSE 45 40 20 - -

CHP100-36-600T1Z AMPS 41 35 18 21 20.5 C 420 19093

FUSE 60 50 25 35 30

CHP100-36-750T1Z 116 AMPS 46 40 20 C.F. 27 C 460 209

FUSE 60 60 30 - 35

CHP100-36-865-T1Z 134 AMPS C.F. 46.5 23 C.F. 27 C 480 218

FUSE - 60 30 - 35

CHP100-36-965-T1Z 150 AMPS C.F. C.F. 27 C.F. 29.4 C 500 227

FUSE - - 40 - 40

CHP100-36-1450-T1Z 225 AMPS C.F. C.F. 37 C.F. 42 D 550 250FUSE - - 50 - 60

AMPS 39 34 17 C.F. 19.5 C 450 204CHP100-40-475-T1Z74

FUSE 50 45 25 - 25CHP100-40-1200-T1Z 186 AMPS C.F. C.F. 33 C.F. C.F. D 500 227

FUSE - - 45 - -

CHP100-48-600-T1Z 93 AMPS 48 42 21 C.F. C.F. D 550 250

FUSE 60 60 30 - -

CHP100-48-865-T1Z 134 AMPS C.F. C.F. C.F. C.F. C.F. D 600 272

FUSE - - - - -

NOTE: C.F.: CONTACT FACTORY; X: NOT AVAILABLE -: DATA NOT AVAILABLE

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Instr. 4770-65-95005-20 Page 13

8.0 CABINET OUTLINE/DIMENSIONS FOR –Z MODEL CHARGERS ONLY

CABINET DIM. A DIM. B DIM. CA 15.10” 20.65” 12.75”B 22.70” 26.50” 22.25”C 32.10” 26.50” 22.25”D 24.30” 42.00” 23.65”

D (Mining) 24.30” 42.00” 23.65”E (Mining) 24.30” 59.00” 31.50”

NOTE: Mining chargers are equipped with a drip cap and four lifting eyebolts for sling lifting. Add anadditional 5.000” to the height. (DIM.C)

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Instr. 4770-65-95005-20 Page 14

9.0 CHP100 CHARGER OPERATIONLED DISPLAY DESCRIPTION

(NONE) UNIT READY PLUG IN THE BATTERY TO COMMENCECHARGING.

(TIME)

(NONE)START TIME: XX:XXSTART EQUAL FAULT

DELAY MODE, PRESS “START” BUTTON TOOVERRIDE.

DELAYSTART EQUAL FAULT

(BATTERY VOLTAGE/CURRENT/AH RETURNED)

CHARGINGXX.XV XX.XA XXXAHSTOP EQUAL FAULT HIGH RATE CHARGING (First stage)

(Orange)HIGH RATE

STOP EQUAL FAULT

(BATTERY VOLTAGE/CURRENT/AH RETURNED)

80% CHARGEDXX.XV XX.XA XXXAHSTOP EQUAL FAULT FINISH RATE CHARGING (Second stage)

(Yellow)FINISH RATE (CV)

STOP EQUAL FAULT

(BATTERY VOLTAGE/CURRENT/AH RETURNED)

80% CHARGEDXX.XV XX.XA XXXAHSTOP EQUAL FAULT FINISH RATE CHARGING (Third stage)

(Yellow)FINISH RATE (CC)

STOP EQUAL FAULT

(NONE) CHARGE INTERRUPTED XAHUNPLUG BATTERY

TO INTERRUPT CHARGING, PRESS “STOP”BUTTON BEFORE UNPLUGGING THE BATTERY.

CHARGECOMPLETE

XXXAMP-HR RETURNEDUNPLUG BATTERY

CHARGING IS COMPLETE. UNPLUG THE BATTERY

(Green)(NONE) XXXAMP-HR RETURNED

UNPLUG BATTERY NO ALARMS ARE PRESENT.

FAULT (Red)

POWER FAILURENEXT WHEN? EXIT

FAULT CONDITION EXISTS. DO NOT UNPLUG THEBATTERY. PRESS “WHEN?” BUTTON TO FINDTHE DATE AND TIME OF FIRST FAULT. PRESS“NEXT” BUTTON TO FIND ANY OTHER FAULTS.SEE SECTION 10.1.19 FOR DETAILS.

(BATTERY VOLTAGE/CURRENT/AH RETURNED)EQUALIZE (Orange)

XX.XV XX.XA XXXAHSTOP EQUAL FAULT

PRESS “EQUAL” BUTTON TO EQUALIZE THEBATTERY. PRESS AGAIN TO CANCEL.

AND80% CHARGED (Yellow)

EQUALIZESTOP EQUAL FAULT

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10.1 CHP100 CHARGER FUNCTIONAL DESCRIPTION

This section gives a brief description of each LED,softkey, and display message on the CHP100 chargercontrol panel.

10.1.2 CHARGING (LED)

This LED indicates that the charger is ON and in HighRate charge mode.

10.1.3 80% CHARGED (LED)

This LED indicates that the battery is 80% charged andthe charger is in Finish Rate charge mode.

10.1.4 CHARGE COMPLETE (LED)

This LED indicates that the charge cycle has completed.The battery can now be safely unplugged.

10.1.5 EQUALIZE (LED)

This LED indicates that the charger is in the equalizemode. Refer to SECTION 10.1.18 for more details.

10.1.6 FAULT (LED)

This LED indicates that a fault occured prior to or duringthe charge cycle. Refer to SECTION 10.1.19 for detaileddescriptions of each fault.

10.1.7 DISPLAY

The display shows the battery voltage, charging current,and amp-hours returned during high rate, finish rate, andequalize modes. Different fault messages are alsodisplayed here. Furthermore it identifies the function ofeach softkey while in different modes. (Normal orProgram)

10.1.8 UNIT READY

This indicates that the AC supply is correct and that theunit is ready to start charging as soon as the battery isplugged in.

10.1.9 START TIME: XX:XX

This message indicates the time the battery charger willstart charging. It alternates with the "DELAY" messagefor 10 seconds, then the cycle starts.(A 10 second delayis automatically initiated as soon as the battery isplugged in).

10.1.10 DELAY

This message indicates that the charger is in the delaymode and charging will not start until the delay time haselapsed. Refer to SECTION 10.1.27 for further details.

10.1.11 XX.XV XX.XA XXXXAH

The first number indicates the battery voltage, thesecond number indicates the charging current, and thethird number indicates the Amp-hours of charge thathave been returned to the battery. This informationalternates with the following messages: “HIGH RATE”while in High Rate mode, “FINISH RATE” while in FinishRate mode, or “EQUALIZE” while in Equalize mode.

10.1.12 START (softkey function)

Press this softkey to override a previously set delay andstart the High Rate charge cycle.

10.1.13 HIGH RATE (Orange LED)

This message indicates that the charger is in the HighRate mode.

10.1.14 FINISH RATE (Yellow LED)

This message indicates that the charger is in the FinishRate mode.

10.1.15 STOP (softkey function)

This softkey will interrupt the charge cycle whendepressed. The battery can now safely be unplugged.

10.1.16 XXXAMP-HR RETURNED (Green LED)

This message indicates that the charge cycle iscomplete and the battery can safely be unplugged.

10.1.17 CHARGE INTERRUPT UNPLUG BATTERY

This message indicates that the "STOP" softkey hasbeen pressed or a fault has occured during charge.Refer to SECTION 10.1.19 for detailed descriptions ofeach fault.

10.1.18 EQUALIZE (softkey function)NOTE: New CHP100 program #3611-66-12267-98

v.1.20 and greater have the choice of either manualequalize (MAN), auto-equalize by number of chargecycles completed (NUM), or auto-equalize on aparticuliar day of the week (DAY).Only in the manual mode will pressing the softkeymake the charger go into the equalize mode. The"EQUALIZE" LED will light. Press the softkey a secondtime to cancel the equalize mode; the LED shouldextinguish. The ‘auto’ modes disable the EQUALsoftkey as equalizing will occur automatically.

10.1.19 FAULT (softkey function)

DO NOT UNPLUG BATTERY or the alarms will clear asthe control resets. Press this softkey to view the alarmsthat have occured since battery plug-in. Press “WHEN?”to find out the date and time of the alarm(s).

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Instr. 4770-65-95005-20 Page 16

10.1.20 NO ACTIVE ALARM

This message indicates that no alarms have occured.

10.1.21 AC VOLTAGE HI/LO ORPHASE LOSS/ROTATION

This fault message indicates that prior to or duringcharge, the AC supply is low, one or more phases aremissing, and/or the phase sequence is incorrect (threephase input units only).

10.1.22 POWER FAILURE

This fault message indicates that the AC supply wasinterrupted.

10.1.23 OUTPUT FUSE BLOWN

This fault message indicates that the charger output fuseis blown.

10.1.24 LOW BATTERY VOLTAGE

This fault message indicates that prior to or duringcharge, the battery voltage is lower than the preset value(1.5 V/C).

10.1.25 HIGH BATTERY VOLTAGE

This fault message indicates that prior to charge, thebattery voltage is greater than the preset value(2.25V/C). If the battery voltage dropped to withinacceptable range, the charger will not start.

10.1.26 DEFECTIVE BATTERY

This fault message indicates that the battery has notreached the gassing voltage after the preset high ratetime has elapsed.

10.1.27 CLOCK AND DELAY SETTINGS

This feature allows the user to set the date and time. Italso allows to setup a delay.

NOTE: The following procedures must be done with theAC power on and the battery unplugged.

To access either feature:a. Press the left softkey three times.b. Press the middle softkey two times.c. Press the right softkey once.

This will make the display show:

XXX/XX/XX XX:XX:XX CLOCK DELAY QUIT

Once you have completed the clock and/or delaysettings, press the 'QUIT' softkey.10.1.27.1 CLOCK

Press the 'CLOCK' softkey then press the appropriatesoftkeys to set the time, the date, and the day of theweek (new on program v.1.20 and greater).

10.1.27.2 DELAY

NOTE: Only the 'TIME' (actual start time of chargerstart-up with the battery plugged in) OR the 'HOURS'(actual delay period in hours and/or minutes from thetime of battery plug in) DELAY mode should be used.Ensure that the unused mode is set to zeros before unitstart-up.

Press the “DELAY” softkey then press:1. “HOURS” and the appropriate softkeys to change the

delay time in hours/minutes or2. “TIME” and the appropriate softkeys to activate the

actual time of day to start the charging process.

NOTE: New CHP100 program #3611-66-12267-98v.1.20 and greater have the ‘POWERSAVE’STARTX/STOPX feature to allow the user to set up to 3start/stop times to save AC energy. However, the totalof the running times must be equal to or greater than thenormal total charging time. Contact factoryrepresentative for settting up this delay mode

11.0 MAINTENANCE

The charger requires minimum maintenance. ENSURETHE CHASSIS IS SECURELY GROUNDED per thelocal/federal Electrical Code. Do not allow excessivedust to accumulate on the components inside. Blow outwith clean compressed air when necessary.

The AC input and DC output of the charger are fusedand should these fuses fail, the cause of the failure mustbe determined and corrected before the fuse(s) is (are)replaced. Never replace the fuse(s) with one of a highercapacity than the one originally fitted with (see Tables 2and 3 pages 9-12).

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APPENDIX A: ELECTRICAL SCHEMATIC DRAWINGSPages 19 - 27

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SALES • SERVICE • RECYCLING

TOLL FREE 1-888-563-6300

Champion® is a registered trademark of Federal-Mogul Corporation

Exide TechnologiesChloride Motive PowerP.O. Box 1, Salford RoadOver Hulton, Bolton BL5 1DDUnited KingdomTel: 44.1204.661.230Fax: 44.1204.652.100

GNB Industrial PowerMotive Power8301 Keele StreetMaple, OntarioCanada L6A 1T2Tel: 905.669.9326Fax: 905.669.7688

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GNB Industrial PowerMotive Power829 Parkview BoulevardLombard, IL 60148-3249U.S.A.Tel: 877.GNB.INFOFax: 630.691.7869

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