TLR Series Battery Charger

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					  TLR Series
Battery Charger

               Instruction &
             Operation Manual

              Three Phase Input




           Publication No: US-TLR-IOM-01 November 2003
                                                                                                              TLR/TLRF Charger



                                                 TABLE OF CONTENTS


        SAFETY INSTRUCTIONS ...................................................................................iv

        CHARGER SPECIFICATIONS .............................................................................1

        BATTERY CHARGER OPTION LIST............................................................... 1-2

1.0     FUNCTIONAL PURPOSE ....................................................................................3
1.1       Description .....................................................................................................................3
1.2       Specifications .................................................................................................................3
1.3       Controls ..........................................................................................................................4
1.4       Indicators........................................................................................................................4
1.5       Environmental ................................................................................................................4
1.6       Protection .......................................................................................................................4
1.7       General...........................................................................................................................5
1.7.1     Magnetics .......................................................................................................................5
1.7.2     Wiring .............................................................................................................................5
1.7.3     Enclosure .......................................................................................................................5
1.7.4     Testing............................................................................................................................5
1.8       Output Response ...........................................................................................................5

2.0     INSTALLATION AND WIRING.............................................................................6
2.1       Installation ......................................................................................................................6
2.2       Inspection .......................................................................................................................6
2.3       Hook-Up .........................................................................................................................6
2.3.1     Connecting to the Load and Battery...............................................................................7
2.3.2     Connecting for Parallel Operation ..................................................................................7
2.3.3     Connecting the AC Supply .............................................................................................7

3.0     OPERATIONAL INSTRUCTIONS ........................................................................8
3.1       General...........................................................................................................................8
3.2       Start-Up ..........................................................................................................................8
3.3       Power-Off .......................................................................................................................8
3.4       Operation........................................................................................................................9

4.0     FUNCTIONAL CHECKS.....................................................................................10
4.1       Battery "State of Charge" Test .....................................................................................10
4.2       Periodic Checks ...........................................................................................................10
4.2.1     Float/Equalize Voltages................................................................................................10
4.2.2     The Battery...................................................................................................................10

5.0     DESCRIPTION OF OPERATION .......................................................................11




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6.0      ADJUSTMENTS ................................................................................................. 12
6.1        Tools ............................................................................................................................ 12
6.2        Float Voltage ................................................................................................................ 12
6.2.1      Checking Float Voltage ................................................................................................ 12
6.2.2      Adjusting Float Voltage ................................................................................................ 12
6.3        Equalize Voltage .......................................................................................................... 13
6.3.1      Checking Equalize Voltage .......................................................................................... 13
6.3.2      Adjusting Equalize Voltage .......................................................................................... 13
6.4        Current Limit................................................................................................................. 13
6.4.1      Checking System Current Limit.................................................................................... 13
6.4.2      Adjusting System Current Limit.................................................................................... 13

7.0      TROUBLESHOOTING PROCEDURES ............................................................. 14
7.1        Bridge Assembly Check ............................................................................................... 15
           Diagnostic Chart #1...................................................................................................... 16
           Diagnostic Chart #2...................................................................................................... 17
           Diagnostic Chart #3...................................................................................................... 18
           Diagnostic Chart #4...................................................................................................... 19

8.0      CONTROL CARDS CONNECTIONS ................................................................. 20
8.1        Regulator Control Card - E1......................................................................................... 20
8.2        Six Pulse Firing Control - E2 ........................................................................................ 21
8.3        Transformer - T1 Secondary Voltage (VRMS) ............................................................ 22

9.0      ADDITIONAL OPTIONS..................................................................................... 23
9.1        Ground Detection Alarm Circuits.................................................................................. 23
9.1.1      Two Light Circuit with Test Switch .............................................................................. 23
9.1.2      Ground Detection Switchable Voltmeter ...................................................................... 23

10.0     OTHER ALARM CIRCUITS................................................................................ 24
10.1       End of Discharge Alarm (Light Optional)...................................................................... 24
10.2       High DC Voltage Shutdown ......................................................................................... 24
10.2.1     Adjustment High/Low Voltage DC Alarm ..................................................................... 24
10.3       Combined Alarm-Status Monitor (CASM) - Main Charger Drawing ............................. 25
10.4       0-72 Hr. Manual Equalize Timer with Switch and Indicating Light ............................... 26
10.5       0-72 Hr. Auto Equalize Timer After AC Failure with Indicating Light............................ 26

11.0     PLUG-IN MODULES TO MAIN CONTROL CARD ............................................ 27
11.1       Auto Charge Control (ACC) ......................................................................................... 27
11.2       Battery Temperature Compensation ............................................................................ 27
11.3       Battery Current Limit and Load Share......................................................................... 27
11.3.1     Battery Current Limit .................................................................................................... 27
11.3.2     Load Share................................................................................................................... 28

12.0     MAINTENANCE ................................................................................................. 29

SPARE PARTS LIST .................................................................................................... 30
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                                                                       TLR/TLRF Charger

APPENDIX A - SLR/TLR CASM ALARM CARD OUTLINE .........................................31

                                APPENDIX B – DRAWINGS

    Cabinet Outline Floor & Rack Mounted TLR Type “C”
    Cabinet Outline Floor Mounted SLR/TLR Type “D”
    Cabinet Outline (H) TLR Series Rectifier
    Cabinet Outline TLR Series Rectifier Type “F” and “G”
    Cabinet Outline TLR Series Rectifier Type “E”
    Schematic Battery Charger Type TLR/TLRF
    Schematic SLR/TLR Battery Current Limit
    Schematic DC Digital Meters – Type DX-35 SLR/TLR
    Schematic SLR/TLR Selective Remote Relay Option
    Schematic SLR/TLR High Volts Shutdown Alarm
    Schematic SLR/TLR Ground Detection Alarm
    Schematic SLR/TLR Ground Detection Switches for DC Voltmeter Indication
    Schematic SLR/TLR Ground Detection Lights with Test Switch
    Schematic SLR/TLR Ground Detection Lights
    Schematic SLR/TLR End of Discharge Alarm
    Layout SLR/TLR Control E1 Plug-in Options
    Schematic – TLR AC Input Ammeter with Current Transformer Option
    Schematic – TLR AC Input Ammeter with Selector Switch Option
    Schematic – TLR AC Input Ammeter Option
    Schematic SLR/TLR Lightning Arrestors
    Schematic – TLR AC Input Voltmeter with Selector Switch Option
    Schematic – TLR AC Input Voltmeter Option Line to Line
    Schematic SLR/TLR DC Center Zero Ammeter
    Schematic SLR/TLR Surge Suppression Option
    Schematic SLR/TLR External Pot. Connection
    Interconnection Diagram SLR/TLR Timer




Publication No. US-TLR-IOM-01                                                         iii
November 2003                    www.enersysinc.com
                       IMPORTANT SAFETY INSTRUCTIONS

READ AND FOLLOW ALL SAFETY INSTRUCTIONS


1. Before using the battery charger, read all instructions and cautionary markings on:
    A) battery charger, B) battery, C) equipment connected to charger battery.

2. This manual contains important safety and operating instructions, and therefore should be
   filed for easy access.

3. Do not touch any uninsulated parts of the battery charger, especially the input and output
   connections, as there is the possibility of electrical shock.

4. During normal operation, batteries may produce explosive gas. NEVER smoke, use an open
   flame, or create arcs in the vicinity of the charger or battery to prevent fire or explosion.

5. When replacing batteries, use the same number and type of batteries as specified in this
   manual.

6. Proper disposal of batteries is required. Refer to your local codes for disposal requirements.

7. Maintain adequate ventilation according to the cabinet outline and clearance from all
   obstructions on all ventilation openings of the battery charger.

8. Keep area in front of battery charger clear to allow full opening of door.

9. Connect or disconnect the battery only when the battery charger is off to prevent arcing or
   burning.

10. De-energize all AC and DC inputs to the battery charger before servicing.

11. Do not operate battery charger if it has been damaged in any way. Refer to qualified service
    personnel.

12. Do not disassemble battery charger: only qualified service personnel should attempt repairs.
    Incorrect reassembly may result in explosion, electrical shock, or fire.

13. Do not install the battery charger outdoors, or in wet or damp locations unless specifically
    ordered for that environment.

14. Remove all jewellery, watches, rings, etc. before proceeding with installation.



                              SAVE THESE INSTRUCTIONS


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                                   www.enersysinc.com                                November 2003
                                                                              TLR/TLRF Charger

This page is a sample. The "Specifications" and “Option List” page in the manual shipped
with each charger will be filled in with the specifications and options for that charger.

                                CHARGER SPECIFICATIONS
       MODEL NO.:
       SERIAL NO.:
       INPUT VOLTAGE:               VAC FREQ.:                  Hz PHASE:
       FLOAT VOLTAGE:                                                               VDC
       EQUALIZE VOLTAGE:                                                                      VDC

                           BATTERY CHARGER OPTION LIST

Customer:                                        Customer PO#:

      OPTION NO.                                      DESCRIPTION
         A001        Input Lightning Arrestors
         A002        Surge Withstand Capability per ANSI C37.90A (1 Phase)
         A003        Surge Withstand Capability per ANSI C37.90A (3 Phase)
         A004        DC Fuse (Standard)
         A005        DC Circuit Breaker (for chargers up to 75ADC and 130VDC)
         A006        DC Circuit Breaker (for chargers up to 75ADC and 260VDC)
         A007        DC Circuit Breaker (for chargers up to 150ADC and 130VDC)
         A008        DC Circuit Breaker (for chargers up to 150ADC and 260VDC)
         A009        DC Circuit Breaker (for chargers up to 300ADC and 260VDC)
         A010        DC Circuit Breaker (for chargers up to 400ADC and 260VDC)
         A011        DC Circuit Breaker (for chargers up to 600ADC and 260VDC)
         A012        Front Panel and Equalize Adjustments
         A013        Equalize Switch with Indicating Light (Standard)
         A014        0-72 Hour Manual Equalize Timer with Switch and Indicating Light
         A015        0-72 Hour Auto Equalize Timer After AC Failure with Indicating Light
         A016        0-72 Hour Timer with Equalize Switch, Light, and Auto Charge Control
         A017        Automatic Charge Control After Battery Discharge with Indicating Light
         A018        Battery Current Limit (for chargers up to 100ADC)
         A019        Battery Current Limit (for chargers up to 200ADC)
         A020        Battery Current Limit (for chargers up to 400ADC)
         A021        Battery Current Limit (for chargers up to 600ADC)
         A022        Blocking Diode (for chargers up to 30ADC)
         A023        Blocking Diode (for chargers up to 75ADC)
         A024        Blocking Diode (for chargers up to 100ADC)
         A025        Blocking Diode (for chargers up to 200ADC)
         A026        Blocking Diode (for chargers up to 400ADC)
         A027        Blocking Diode (for chargers up to 600ADC)
         A028        DC Voltmeter and Ammeter (Analog, 3 Inch, 2% Accuracy)
         A029        DC Voltmeter and Ammeter (Analog, 3 Inch, 1% Accuracy)
         A030        DC Voltmeter and Ammeter (Digital, 3.5-Digit, 1% Accuracy)

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        OPTION NO.                                       DESCRIPTION
           A031       CASM with Common Form-C Relay
           A032       CASM Select with Individual Form-C Relays
           A033       CASM Select with Two Sets of Individual Form-C Relays
           A034       AC Ammeter (Analog, 3 Inch, 2% Accuracy)
           A035       AC Ammeter (Analog, 3 Inch, 1% Accuracy)
           A036       AC Ammeter (Digital, 3.5-Digit, 1% Accuracy)
           A037       AC Ammeter (Analog, 3 Inch, 2% Accuracy) with Phase Selector Switch
           A038       AC Ammeter (Analog, 3 Inch, 1% Accuracy) with Phase Selector Switch
           A039       AC Ammeter (Digital, 3.5-Digit, 1% Accuracy) with Phase Selector Switch
           A040       AC Voltmeter (Analog, 3 Inch, 2% Accuracy)
           A041       AC Voltmeter (Analog, 3 Inch, 1% Accuracy)
           A042       AC Voltmeter (Digital, 3.5-Digit, 1% Accuracy)
           A043       AC Voltmeter (Analog, 3 Inch, 2% Accuracy) with Phase Selector Switch
           A044       AC Voltmeter (Analog, 3 Inch, 1% Accuracy) with Phase Selector Switch
           A045       AC Voltmeter (Digital, 3.5-Digit, 1% Accuracy) with Phase Selector Switch
           A046       Ground Detection Switch for DC Voltmeter Indication
           A047       Ground Detection Alarm Relays with Reset Switch
           A048       Ground Detection Alarm Relays with Reset Switch and Indicating Lights
           A049       Ground Detection Indicating Lights with Ground Test and Lamp Test Switch
           A050       End of Discharge Alarm Relay
           A051       End of Discharge Alarm Relay with Indicating Lights
           A052       Parallel Charger Operation with 2% Load Sharing
           A053       High DC Voltage Shutdown
           A054       Battery Zero-Center Ammeter (Analog, 3 Inch, 2% Accuracy)
           A055       Battery Zero-Center Ammeter (Analog, 3 Inch, 1% Accuracy)
           A056       Battery Zero-Center Ammeter (Digital, 3.5-Digit, 1% Accuracy)
           A057       Temperature Compensation
           A058       Switchboard Wire to Replace PVC Wire (1 Phase)
           A059       Switchboard Wire to Replace PVC Wire (3 Phase)
           A060       Drip-Proof Shield (for A or B Cabinet)
           A061       Drip-Proof Shield (for C, D, E, F, G, or CB10820 Cabinet)
           A062       Engraved Functional Nameplates
           A063       Fungus Proofing
           A064       Export Packing (for A or B Cabinet)
           A065       Export Packing (for C or D Cabinet)
           A066       Export Packing (for E, F, G, or CB10820 Cabinet)
           A067       Production Test Data (added to the Manual)
           A068       Certified Production Test Data (added to the Manual)
           A069       Factory Inspection (Daily Rate)
           A070       Price Per Manual (First One Free)
           A071       Key-Lockable Cabinet Door
           A072       Tags on Drawings
           A073       Custom Drawings
           A074       Specified Voltage Designation

Note:     X = Item Supplied

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                                                                          TLR/TLRF Charger



1.0     FUNCTIONAL PURPOSE

1.1     Description
         The Series TLR/TLRF Battery Charger is SCR controlled to provide a suitable highly
         stable DC power source for charging vented and valve regulated nickel cadmium, lead
         calcium, lead selenium and lead antimony batteries.

         The included features are:
              •   constant voltage charging
              •   current limit control
              •   equalize control
              •   slow start
              •   minimum maintenance

1.2     Specifications
         The following specifications and descriptions listed apply to all standard TLR/TLRF
         chargers.

         Input Ratings
         VOLTAGE:         208, 240, 480, 600 VAC, 60 Hz - 220, 380, 415 VAC, 50 Hz
         TOLERANCE:       +/-10% of input voltage
         FREQUENCY:       60 Hz +/- 6% 50 Hz +/- 6%
         PHASE:           Three

         Output Ratings

         VOLTAGE:                 NOMINAL                    MAXIMUM
                                    12 VDC                    16.0 VDC
                                    24 VDC                    32.0 VDC
                                    48 VDC                    63.0 VDC
                                   130 VDC                   154.0 VDC
                                   260 VDC                   308.0 VDC
         DC VOLTAGE RANGE:        FLOAT             - 75% to 120% of nominal DC
                                  EQUALIZE          - 75% to 120% of nominal DC
         VOLTAGE STABILITY (static)                 +/- 0.5%
         CONDITIONS:                                1% to 100% full load
                                                    +/- 10% input voltage variation
                                                    +/- 6% input frequency variation
         OUTPUT RIPPLE:                    Typically 2% of nominal DC voltage when
                                           connected to a battery with Ah capacity
                                           four times higher than charger current rating

         CURRENT LIMIT:                    Adjustable 20% to 120% of rated DC current

         CURRENT STABILITY:                +/- 2% at current limit


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1.3   Controls

            •     "Equalize" Control
            •     "Float" Voltage Potentiometer
            •     "Equalize" Voltage Potentiometer
            •     "Current Limit" Potentiometer

1.4   Indicators

      Voltmeter:           3" scale Moving Coil 2%
      Ammeter:             3" scale Moving Coil 2%
      "AC ON":             LED, green indicator
      "Equalize":          LED, amber indicator

1.5   Environmental

      Ambient Temperature,          -10o C to +50o C (14o F to 122o F)
      Operational:                  CSA approved to +40o C (104o F)

      Storage:                      -25o C to +70o C (-13o F to 158o F)

      Altitude:                     to 1000 m
                                    1000 m to 4000 m, derate 6.7%/ 1000 m

      Humidity:                     95% Non-condensing

      Cooling:                      Convection (output below 400A)
                                    Fan-assisted semiconductors (output 400A and greater)

1.6   Protection

      AC input thermal-magnetic overload device
      DC output fuse
      AC and DC surge suppression
      Soft Start Circuit
      Reverse battery protection
      DC current limit at 110% of rated current




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                                                                          TLR/TLRF Charger




1.7     General

       1.7.1      Magnetics

                  Class:                             180o C
                  Insulation temperature rating:     200o C (392o F)
                  Insulation voltage breakdown:      2500 V minimum

       1.7.2      Wiring

                  Insulation:       600 Volts
                                    All wires tagged for identification
                                    Ratings per NEC, NFPA No. 70. CEC

       1.7.3      Enclosure

                  Type:             NEMA (EEMAC) 1 - ventilated
                  Cabinet Finish:   Epoxy Paint
                  Color:            ASA 61 Grey
                  Panels:           Cadmium Blue

       1.7.4      Testing

                  Tested in accordance with NEMA PE 5 and CSA C22.2 No.107.1-M91

1.8     Output Response

         Load              Single Element (L/LC)
         Change            Filter to Batt. Load

                            10 - 100%       -5%             75 ms
                            100 - 10%       +5%             150 ms




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2.0   INSTALLATION AND WIRING

2.1   Installation

      Refer to cabinet outline drawing in Appendix B for cabinet dimensions and minimum
      clearances. Avoid locating the unit near heat generating equipment and areas which
      are subject to dirt or moisture. All cabinets must be mounted vertically. DO NOT
      BLOCK VENTILATION SLOTS. Charger must have minimum ventilation space as
      specified in the outline drawing.

               NOTE: TLR/TLRF chargers in floor-mount cabinets can be easily
                     transported by fork lift.

2.2   Inspection

      Before making any connections to the charger, the following steps should be followed:

           1) Check the rating plate to ensure that the AC input supply and battery
              correspond to the charger's parameters.

           2) All incoming power sources to the charger are switched off.

           3) The charger AC and DC protection are deactivated.

           4) All debris in, and around the cabinet, has been removed.

2.3   Hook-Up

      Cable entry into the cabinet is normally through the bottom. Conduit may be
      connected through the top, back or sides as required, if bottom entry is impractical or
      undesired. Refer to the Charger schematic at the end of the manual for correct input
      connections.

               NOTE: Phase rotation must be connected correctly since the Charger
                     is phase sensitive.

      Install and wire the battery according to the layout diagram provided by the battery
      manufacturer.

      When making connections to the charger, use cables adequately sized for the
      maximum DC output current listed on the charger rating plate. For connections, refer
      to the system schematic diagram.

      If the battery is located a long distance away from the charger, the cables should be
      sized for minimum voltage drop at maximum DC output current.




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                                                                              TLR/TLRF Charger


         2.3.1       Connecting to the Load and Battery

         With the charger power sources and AC and DC protection off, make the following
         connections:

                 •   wire the +DC terminal and the load positive terminal to the battery positive
                     terminal.

                 •   wire the -DC terminal and the load negative terminal to the battery negative
                     terminal.

         CAUTION: TO AVOID ACCIDENTS, OBSERVE CORRECT POLARITY.

         Refer to the option schematics, as non-standard connections may be required.

                     NOTE: The DC load must be connected at the battery terminals and not at
                           the charger terminals. This is vital for high current draw applications.

         2.3.2       Connecting for Parallel Operation

                     NOTE:     The following procedure applies to parallel TLR/TLRF battery
                               chargers ONLY.

                     1. Connect the +DC terminal on each charger output to the +VE terminal on
                        the battery separately ensuring that the cable length from each charger is
                        approximately the same (for proper load sharing).
                     2. Connect the -DC terminal on each charger output to the -VE terminal on
                        the battery separately ensuring that the cable length from each charger is
                        approximately the same (for proper load sharing); the -VE cable should
                        be approximately the same length as the +VE cable.

                     3. Connect the +VE load terminal to the +VE battery terminal and the -VE
                        load terminal to the -VE battery terminal.

         2.3.3       Connecting the AC Supply
                     Check the AC line for input voltage, frequency and phase to match the
                     specifications as listed on the charger rating plate 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 breaker. Connect the AC line to the
                     terminals indicated in the correct sequence. Be sure to connect ground to
                     the proper terminal - GND.

                     CAUTION:      CHARGED CELLS CONTAIN LARGE AMOUNTS OF
                                   STORED ENERGY AND CARE MUST BE EXERCISED
                                   WHEN USING ANY METAL TOOLS AROUND THE
                                   BATTERY TO AVOID SHORTING.




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November 2003                        www.enersysinc.com
3.0   OPERATIONAL INSTRUCTIONS

3.1   General

      The battery charger output voltage and current are factory set to meet battery load
      specifications, thus no further adjustments are usually required. In the event that
      adjustments become necessary, consult section 6.0 ADJUSTMENTS for details.

3.2   Start-Up

      Proper operation of the battery charger requires that all input, output, battery or load (if
      any) wiring be correctly connected as specified in section 2.0 INSTALLATION AND
      WIRING.

                NOTE:      On filtered chargers, excessive current will flow from the battery
                           into the capacitors when the DC protection is inserted/closed. To
                           avoid this, the charger should be turned on so that the output
                           voltage and the battery voltage are approximately equal. At this
                           point, the DC protection may be inserted/closed.

      With the wiring complete, activate the output protection (non-filtered chargers). The
      battery or load voltage should be indicated on the output voltmeter.

      Turn "ON" the AC input breaker and the charger should slowly increase output power
      until either the voltage setting or current limit is reached.

                NOTE:      If the unit does not start refer to Diagnostic Chart #3.

      The charger will start up in the "Float" mode but may switch to "Equalize" depending
      on the type of charge control supplied. Switch the charger into "Equalize" to
      commission charge the battery for the length of time specified by the battery
      manufacturer.

3.3   Power-Off

      Shut off the charger with the AC breaker and observe that no output current exists.

                NOTE:      Battery voltage will be displayed on the meter as long as the DC
                           output fuse is installed and not blown (or optional circuit breaker is
                           closed).




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                                                                         TLR/TLRF Charger


3.4     Operation

         Standard Unit

         During normal operation the charger will be in "Float" mode. To activate an "Equalize"
         charge, the "Equalize" push button must be momentarily depressed (latching). To
         return the charger to "Float", depress the push button (unlatched). Other "Equalize"
         charge controls are explained in section 9.0 ADDITIONAL OPTIONS.

         CAUTION: Never leave the charger in the "equalize" mode for longer than
                  recommended by the battery manufacturer. Excessive "equalize"
                  charging will cause the battery to overcharge and gas (through
                  electrolysis). This will consume water, reducing the electroltye level
                  and may be detrimental to battery life.




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November 2003                     www.enersysinc.com
4.0   FUNCTIONAL CHECKS

4.1   Battery "State of Charge" Test

      The approximate state of charge of the battery can be determined by a simple check:

               1) Switch the charger to "Equalize".

               2) Observe that the unit enters current limit (on the output ammeter).

               3) If the charger remains in current limit for longer than 36 seconds, the
                  battery requires "Equalize" charging. If the battery is already adequately
                  charged, the charger will leave the current limit mode; this is shown by a
                  decrease in the charger output current.

4.2   Periodic Checks

      4.2.1   Float/Equalize Voltages

      The "Float" and "Equalize" voltages should be checked periodically (semi-annually) for
      compliance to the requirements of the battery manufacturer. If adjustments are
      required, refer to section 6.0 ADJUSTMENTS.

      4.2.2    The Battery

      The battery is an important part of your system and should be regularly maintained, as
      outlined by the battery manufacturer. Special attention should be given to the
      electrolyte level of vented cells.




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                                                                               TLR/TLRF Charger


5.0     DESCRIPTION OF OPERATION

         The AC input voltage is applied to the primary winding of the power transformer via the
         AC breaker. Transformer T1 galvanically isolates the AC mains voltage from the
         secondary voltages and steps the AC voltage up or down to the required levels.

         The secondary power windings are connected to a phase controlled full wave bridge
         rectifier comprising of six thyristors. The phase-controlled bridge converts the
         unregulated AC voltage to a regulated DC voltage. The bridge is connected via an
         inductor L1 and ammeter (or shunt) to the negative, and via the output protection to
         the positive output terminal.

         For control of voltages and current, two independent feedback loops are used. Only
         one of these control loops is active at a time.

         The DC voltage is fed back to the control card which controls the voltage setting, both
         for the "Float" and "Equalize" mode. Both voltage levels can be adjusted on the control
         card. Normally the rectifier is operating in "Float" mode. The "Equalize" mode is used
         for battery recharge. If the output current demands exceed the nominal rating, the
         rectifier will shift from constant-voltage to current-control mode. The voltage developed
         across shunt SH (proportional to the output current) is sensed and processed by a
         current-limit amplifier on the control card. The charger regulates its output voltage and
         current by controlling the thyristor bridge.

         The bridge is designed as a full-wave rectifier, and the thyristors determine the amount
         of current delivered to the output. The thyristor is off until a trigger pulse is applied to
         the gate. Once triggered, the thyristor remains in conduction until the current through
         it is zero. By phase-angle control, i.e., varying the delay of the trigger pulses, the firing
         angle of the thyristors can be varied and the required amount of energy is made
         available at the output terminals. If high current is required, the trigger pulse will start
         earlier during the half-cycle of the sine wave and vice versa. The AC voltage is also
         compensated for by this method.




Publication No. US-TLR-IOM-01                                                                      11
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6.0   ADJUSTMENTS

      The battery charger is shipped factory-set for the specified system battery, so no
      further adjustments should be necessary at start-up. However, should adjustments
      become necessary, the following section should be used as a guide.

      NOTES:
                       1.   All adjustment potentiometers are located on the main control card
                            inside the cabinet; however, optional external “Float” and “Equalize”
                            potentiometers must be used if provided.

                       2.   If the charger is equipped with an ACC (Automatic Charge Control)
                            option, the charger must be turned off and the ACC piggy-back card
                            removed from the main control card before adjusting the “Float”
                            voltage and/or System current limit. Once adjustment(s) are complete,
                            the charger must be turned off again and the ACC card re-inserted
                            before adjusting the “Equalize” voltage.

6.1   Tools
              •       Trimpot alignment tool or flat bladed mini screwdriver
              •       Precision voltmeter or digital multimeter (accuracy +/-1% or better)
      The voltmeter should be connected across the charger DC output terminals.

6.2   Float Voltage

      6.2.1       Checking Float Voltage

      Verify that the charger is in “Float” mode, by observing that the "Equalize" lamp is
      extinguished. If the charger is in "Equalize" mode, return to “Float”.

      NOTE:              With the charger at less than full load, the "Float" voltage should be per
                         the battery manufacturer's specifications.

      If the voltage is correct, proceed to paragraph 6.3.

      6.2.2       Adjusting Float Voltage
                  •     Verify that the charger is not producing full output current (not in Current
                        Limit).
                  •     Reduce the load if necessary.
                  •     Observe the voltmeter while making adjustments.
                  •     To increase output voltage, adjust Float potentiometer clockwise (CW) in
                        small increments until the voltage is attained.
                  •     To decrease output voltage, adjust Float potentiometer counterclockwise
                        (CCW) in small increments until the desired voltage is attained.
                  •     Allow the voltage to stabilize after each increment before continuing.



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                                                                               TLR/TLRF Charger


6.3     Equalize Voltage

         6.3.1   Checking Equalize Voltage

         Switch the charger to "Equalize" by depressing the "Equalize" push button/lamp. The
         "Equailize" lamp will be illuminated. Allow the output voltage and current to stabilize.

                  NOTE:         With the charger at less than full load, the Equalize voltage should
                                be per the battery manufacturer's recommendations.

         6.3.2    Adjusting Equalize Voltage

                  • Verify that the charger is not producing full load current (not in Current
                    Limit).
                  • Reduce the load if necessary.
                  • Observe the voltmeter while making adjustments.
                  • To increase output voltage, adjust "Equalize" potentiometer CW in small
                    increments, until the desired voltage is attained.
                  • To decrease output voltage, adjust "Equalize" potentiometer CCW in small
                    increments, until the desired voltage is obtained.
                  • Allow the voltage to stabilize after each increment before continuing.
                  • When properly set, return the charger to "Float" mode by depressing the
                    "Equalize" push button.
                  • Observe that the "Equalize" lamp is extinguished.

6.4     Current Limit

         6.4.1    Checking System Current Limit

                  • Increase the load current while observing the DC voltmeter (the load must
                    be taken from the load terminals if battery current limit option is supplied).
                  • Note the current at which the output voltage begins to decrease.

         NOTE:     Current limit is factory set to 110%.

         If it is desired to adjust the current limit to a lower value or to adjust a new control card,
         use the following procedure.

         6.4.2    Adjusting System Current Limit

                  • Turn the Current Limit Potentiometer fully CW.
                  • Apply a load slightly in excess of the desired current limit setting, (from
                    load terminals if battery current limit option is supplied).
                  • Observing the ammeter, adjust the current limit potentiometer for desired
                    setting.




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7.0   TROUBLESHOOTING PROCEDURES

      The troubleshooting Diagnostics Charts have been prepared to aid in fault isolation in
      the event of charger failure. In case of malfunction, check the following:

               a) All inter-cell and inter-tray battery connections. These connections are
                  positive to negative (in series) and must be secured according to the
                  battery manufacturer’s specifications.

               b) Connections between the battery and charger. The connections are
                  positive to positive, negative to negative (in parallel) and must be securely
                  tightened.

               c) Individual cell voltages. In normal "Float" mode, these voltage readings
                  should be 1.40 to 1.42 Volts per cell for nickel cadmium batteries, or 2.17
                  to 2.25 Volts per cell for lead acid. If there is more than the battery
                  manufacturer’s requirement between the cell with the highest and lowest
                  reading, charge the battery in "Equalize" for 24 hours to equalize
                  voltages, and recheck.

               d) AC input voltage and frequency. Must match design input of the charger
                  as shown on the rating plate.

      If all external connections are correct, cell voltages are within tolerance, and AC input
      voltage and frequency match the charger's, then use the diagnostic charts provided
      and troubleshoot the charger. Perform the step in each box then proceed to the next
      step indicated by your result.


                             SYMPTOM                              CORRECTIVE ACTION
       DC fuse is blown immediately                              Refer to diagnostic chart 1
       Mains circuit breaker opens immediately                   Refer to diagnostic chart 2
       No output power                                           Refer to diagnostic chart 3
       Rectifier continuously operating in current limit mode
                                                                 Refer to diagnostic chart 4
       or incorrect output voltage


      NOTE:        Care must be exercised at all times to avoid contact with live circuits.




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                                                                          TLR/TLRF Charger


7.1     Bridge Assembly Check

         For smaller chargers, three SCR/SCR modules are used. All SCR/SCR connections
         are made via module terminals. To check for a short-circuit, first remove the AC power
         coming from the input by opening the AC circuit breaker. Also disconnect the battery
         by removing/opening the DC protection. Use an ohmmeter or multimeter on low
         resistance scale and check both directions across components. If a short is indicated,
         disconnect wires to isolate the faulty component. A good SCR alone will indicate an
         open-circuit in both directions.

         To check the gate, disconnect the white gate lead and check the gate to cathode
         (white to red) resistance with the ohmmeter/multimeter. Resistances vary but typically
         are 30 to 100 ohms in either direction. Also check gate to anode resistance - it should
         be essentially an open-circuit.

         With reference to the main schematic diagram, components should check out as
         follows:


          FROM         TO       RESISTANCE READING                    ALTERNATE

         AC X1         (+)      Q1 High Resistance        Reverse Meter Leads Q1 High

         AC X2         (+)      Q2 High Resistance        Reverse Meter Leads Q2 High

         AC X3         (+)      Q3 High Resistance        Reverse Meter Leads Q3 High

         AC X1         (-)      Q1 High Resistance        Reverse Meter Leads Q4 High

         AC X2         (-)      Q2 High Resistance        Reverse Meter Leads Q5 High

         AC X3         (-)      Q3 High Resistance        Reverse Meter Leads Q6 High

         G1            (+)      Q1 Gate 30-100 Ohm        Reverse Meter Leads Q1 Gate 30-100 Ohm

         G2            (+)      Q2 Gate 30-100 Ohm        Reverse Meter Leads Q2 Gate 30-100 Ohm

         G3            (+)      Q3 Gate 30-100 Ohm        Reverse Meter Leads Q3 Gate 30-100 Ohm

         G4           AC X1     Q4 Gate 30-100 Ohm        Reverse Meter Leads Q4 Gate 30-100 Ohm

         G5           AC X2     Q5 Gate 30-100 Ohm        Reverse Meter Leads Q5 Gate 30-100 Ohm

         G6           AC X3     Q6 Gate 30-100 Ohm        Reverse Meter Leads Q6 Gate 30-100 Ohm




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November 2003                     www.enersysinc.com
                       Diagnostic Chart #1
                     OUTPUT BREAKER/FUSE
                     OPENS IMMEDIATELY WHEN
                     BATTERY IS CONNECTED.
                     (AC POWER NOT APPLIED)



                     CHECK CONNECTIONS
                     BETWEEN BATTERY AND
                     RECTIFIER-CHARGER
                     (POSITIVE TO POSITIVE)
                     (NEGATIVE TO NEGATIVE)




                          CONNECTIONS                   NO
                            CORRECT
                               ?
                                   YES                RE-CONNECT

                     CHECK BATTERY CELL TO
                     CELL CONNECTIONS
                     (POSITIVE OF ONE TO
                     NEGATIVE OF THE NEXT)



                          CONNECTIONS                   NO
                            CORRECT
                               ?
                                   YES                RE-CONNECT

                     DISCONNECT BATTERY?




                     CHECK FREEWHEEL DIODE,
                     BRIDGE DIODES AND SCRs
                     RESIST WITH OHMMETER



                           DIODES/SCRs                 YES
                             SHORTED
                                ?

                                   NO                 REPLACE DEFEC-
                                                      TIVE DIODE/SCR
                     CHECK FILTER CAPACITORS          OR MODULE
                     FOR SHORT-CIRCUIT
     NO CAPACITORS   (IF APPLICABLE)



                           CAPACITOR(s)                YES
                             SHORTED
                                ?
                                    NO                REPLACE
                                                      DEFECTIVE
                     CHECK REMAINING WIRING           CAPACITORS
                     AS DETAILED IN
                     MAIN CHARGER SCHEMATIC




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                                                                             TLR/TLRF Charger

                                Diagnostic Chart #2

  AC BREAKER OPENS WHEN
  POWER IS APPLIED




  DISCONNECT CABLES FROM
  T1 SECONDARY AND REMOVE
  MAIN CONTROL CARD

                                       BREAKER
                                                               YES
       APPLY AC POWER                  OPENS
                                         ?

                                                                      REPLACE TRANSFORMER T1
                                             NO
  DISCONNECT AC POWER
  AND BATTERY.
  CHECK SCRs/DIODES FOR
  SHORTS WITH OHMMETER




         COMPONENTS       YES   REPLACE
         SHORTED                DEFECTIVE
            ?                   COMPONENTS

                NO

  RECONNECT CABLES TO
  T1 SECONDARY


                                      BREAKER                        CHECK FILTER CAPACITOR
                                       OPENS           YES
       APPLY AC POWER                                                (IF APPLICABLE)
                                         ?                           FOR SHORT-CIRCUIT

                                             NO

     DISCONNECT AC POWER                                              NO CAPACITORS




  INSTALL MAIN CONTROL CARD

                                       BREAKER       YES
                                        OPENS
                                          ?
                                                                                        CAPACITORS
                                                                                   NO   SHORTED
                                     NO         REPLACE MAIN CONTROL CARD                   ?
       APPLY AC POWER
                                                                                                YES

                                                     APPLY AC POWER            REPLACE CAPACITORS


   RECONNECT BATTERY TO                      NO                              YES
   RECTIFIER-CHARGER                                       BREAKER
                                                            OPENS
                                                              ?

                                                                           CHECK REMAINING WIRING
                                                                           AS DETAILED IN MAIN
                                                                           CHARGER SCHEMATIC



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November 2003                   www.enersysinc.com
Diagnostic Chart #3                      NO OUTPUT WITH INPUT AND OUTPUT
                                              FUSE/BREAKER CLOSED



                                              IS MAIN CONT. CARD E1            NO          RECONNECT
                                              PROPERLY CONNECTED                          CONTROL CARD
                                                        ?
                                                             YES
                                  YES         CORRECT TYPE AND                  NO
   CHECK FOR CORRECT LINE                                                                CONSULT BATTERY
                                              NUMBER OF CELLS                                MANUAL
   VOLTAGE AT T1 TERMINALS                              ?



         AC VOLTAGE               NO             CHECK PRIMARY                 OK          CHECK FAULTY
     PRESENT AND CORRECT                        CIRCUIT WIRING ON                           PROTECTOR
              ?                                 TRANSFORMER T1

                     YES
                                                        NOT ON
CHECK RED LED ON FIRING CARD E2                                          REPLACE T1



            IS LED         YES          INCORRECT PHASE ROTATION, OR LOSS OF PHASE.
              ON                          POWER-DOWN AND ROTATE ANY TWO PHASES.
               ?                                  RESTART UNIT NORMALLY

                     NO

     CHECK FOR SECONDARY                          VOLTAGES          NO                   REPLACE
         VOLTAGE ON                               PRESENT                             TRANSFORMER T1
       TRANSFORMER T1                                 ?



                                          OPEN AC BREAKER. MEASURE DC
                                        VOLTAGE ACROSS OUTPUT TERMINALS



                                                                      NO              TRACE WIRING FOR
                                   YES            BATTERY
         OPEN OUTPUT                                                                   OPEN-CIRCUIT TO
       BREAKER OR FUSE                            VOLTAGE                            BATTERY TERMINALS
                                                  PRESENT
                                                     ?


CHECK GATE TO CATHODE ON SCRs                  PROPER VALUES             NO               REPLACE
OR MODULES FOR PROPER VALUES                      PERSENT                             SCRs OR MODULES
PER SECTION 7.1 WITH MAIN                            ?
CONTROL CARD E1 REMOVED
                                                            YES

                                    CHECK ALL SCRs OR MODULES IN BRIDGE FOR
                                       PROPER WIRING PER MAIN SCHEMATIC



 CHECK WIRING AND                                                                        REPLACE AND
                                                     SCRs OR             YES            RECONNECT MAIN
 CORRECT PER MAIN CHARGER               NO
 SCHEMATIC. CLOSE INPUT AND                         MODULES                            CONTROL CARD E1.
 OUTPUT BREAKER/FUSE.                               PROPERLY                         RESTART UNIT NORMALLY
 RESTART UNIT NORMALLY                                WIRED
                                                        ?


                                                                                     CALL FOR SUPPORT




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                                                                                 TLR/TLRF Charger

                                          Diagnostic Chart #4




           RECTIFIER-CHARGER
           OPERATES AT CURRENT
           LIMIT CONTINUOUSLY




          CHECK FLOAT OR
          EQUALIZE VOLTAGE
          (SECTION 6.2 OR 6.3)




                   VOLTAGE              YES
                     LOW                                 REFER TO SECTION 6.2 OR 6.3
                      ?




                 NUMBER                  YES             CONSULT BATTERY MANUAL
                 AND TYPE                                AND RE-ADJUST FLOAT VOLTAGE
                 OF CELLS                                FOR CORRECT NO. OF CELLS
                 INCORRECT

                          NO


           CHECK FOR DEFECTIVE
           BATTERY CELLS




                   CELL(S)               YES
                  DEFECTIVE                              REPLACE CELL(S)
                      ?



                          NO
                                                         RE-ADJUST CURRENT
                                                         LIMIT PER SECTION 6.4


         LOAD IN EXCESS OF
         RECTIFIER-CHARGER OUTPUT




         REDUCE LOAD AND
         RE-ADJUST CURRRENT LIMIT
         PER SECTION 6.4




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November 2003                       www.enersysinc.com
8.0   CONTROL CARDS CONNECTIONS

8.1   Regulator Control Card - E1

             MH1    -    1       COMMON
                    -    2       NOT USED
                    -    3       VSENSE +
                    -    4       NOT USED
                    -    5       CAPACITOR VOLTAGE LIMIT
                    -    6       CAPACITOR VOLTAGE LIMIT
                    -    7       SP VOLTAGE
                    -    8       SLOW START
                    -    9       NOT USED
                    -    10      VOLTAGE LIMITER (NEGATIVE)

             MH2    -    1       EQUALIZE/HIGH RATE CONTROL
                    -    2       BATTERY SHUNT +
                    -    3       BATTERY SHUNT -
                    -    4       BATTERY TEMPERATURE COMPENSATION THERMISTOR
                    -    5       BATTERY TEMPERATURE COMPENSATION THERMISTOR
                    -    6       SYSTEM SHUNT +
                    -    7       SYSTEM SHUNT -
                    -    8       EQUALIZE/HIGH RATE LED
                    -    9       AUTO CHARGE CONTROL PUSHBUTTON
                    -    10      +20 VDC
                    -    11      - DC
                    -    12      AC FAIL
                    -    13      RECTIFIER FAIL
                    -    14      AC ON LED +
                    -    15      EQUALIZE/HIGH RATE LED +




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                                                                  TLR/TLRF Charger


8.2     Six Pulse Firing Control - E2

                 Connector A

                  2a            OUTPUT SENSE             2b    OUTPUT SENSE +

                  4a            X1 +CATHODE              4b    X1+GATE

                  6a            X2 +CATHODE              6b    X2 +GATE

                  8a            X3 +CATHODE              8b    X3 +GATE

                  10a           NOT USED                 10b   NOT USED

                  12a           NOT USED                 12b   NOT USED

                  14a           X1 -CATHODE              14b   X1 -GATE

                  16a           NOT USED                 16b   NOT USED

                  18a           NOT USED                 18b   NOT USED

                  20a           NOT USED                 20b   NOT USED

                  22a           X2 –CATHODE              22b   X2 -GATE

                  24a           NOT USED                 24b   NOT USED

                  26a           NOT USED                 26b   NOT USED

                  28a           X3 -CATHODE              28b   X3 -GATE

                  30a           NOT USED                 30b   NOT USED

                  32a           NOT USED                 32b   NOT USED




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November 2003                       www.enersysinc.com
            Connector B

             2a         START DELAY                        2b       NOT USED

             4a         NOT USED                           4b       NOT USED

             6a         NOT USED                           6b       COMMON

             8a         NOT USED                           8b       NOT USED

             10a        NOT USED                           10b      NOT USED

             12a        NOT USED                           12b      NOT USED

             14a        SP VOLTAGE                         14b      NOT USED

             16a        COMMON                             16b      NOT USED

             18a        COMMON                             18b      NOT USED

             20a        NOT USED                           20b      NOT USED

             22a        +18VDC                             22b      NOT USED

             24a        NOT USED                           24b      NOT USED

             26a        NEUTRAL (CONTROL WDG. ON T1)       26b      NOT USED

             28a        C3 (CONTROL WINDING ON T1)         28b      NOT USED

             30a        C1 (CONTROL WINDING ON T1)         30b      NOT USED

             32a        C2 (CONTROL WINDING ON T1)         32b      NOT USED




8.3   Transformer - T1 Secondary Voltage (VRMS)


                   DC Nominal          Secondary                Secondary
                    Voltage           X1,X2,X3 (L-L)            C1/C2/C3-N
                       12                  20 V                     17
                       24                  32 V                     17
                       48                  56 V                     17
                      130                 136 V                     17
                      260                 266 V                     17




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                                                                              TLR/TLRF Charger



9.0     ADDITIONAL OPTIONS

9.1     Ground Detection Alarm Circuits

         9.1.1   Two Light Circuit with Test Switch
                 (Option A048 and A049)
         A double-pole, double-throw, momentary center off switch is added to the two light
         circuit so that the lights are not continuously connected in the circuit. With the switch in
         the "GND TEST" position the lights are connected between each output terminal and
         ground. The other position serves to test the lights.

         9.1.2   Ground Detection Switchable Voltmeter
                 (Option A046)
         This method uses the existing panel DC voltmeter and two double-throw switches to
         utilize the voltmeter in both functions. Switch SW8 establishes the meter function
         (output voltage or ground detection) & SW9 switches the voltmeter between (+) or (-)
         terminal to chassis ground reversing the meter polarity to maintain up-scale
         indications. The voltmeter, used in the ground detection mode, will indicate the DC
         voltage potential between the corresponding output terminal and chassis ground. For
         cases of partial grounds, the voltmeter will indicate the difference of the terminal DC
         voltage and the voltage of the partial ground.




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November 2003                      www.enersysinc.com
10.0   OTHER ALARM CIRCUITS

10.1   End of Discharge Alarm (Light Optional)
       (Option A050 and A051)

       This alarm provides a low-limit threshold voltage set at the lowest safe voltage to
       which the batteries may be discharged. The remote relay contacts may be used to
       operate a load disconnect.

       For adjustment, refer to section 10.2.1 Adjustment High/Low Voltage DC Alarm.

       The factory setting for this alarm unless otherwise specified is:
                    Lead Acid               1.75V/C
                    Nickel Cadmium          1.05V/C

10.2   High DC Voltage Shutdown
       (Option A053)

       This alarm disables and locks out the battery charger whenever the DC voltage
       exceeds the set level. This option is designed to protect the batteries and load from a
       potential dangerous over voltage condition.

       The high DC voltage detector control E13 senses the DC voltage and activates the on-
       board relay at the alarm setting. External relay K21 and light DS20 are energized. The
       contact K21/4 closes which latches the alarm. Contacts K21/2 and K21/3 remove
       voltage from the control card E1, shutting it off. To restart the charger momentarily
       depress the reset switch S14.

       Refer to section 10.2.1 Adjustment High/Low Voltage DC Alarm for the adjustment
       procedure.
       The factory setting unless otherwise specified are:
                    Lead Acid             2.5 V/C
                    Nickel Cadmium        1.70 V/C

       10.2.1 Adjustment High/Low Voltage DC Alarm
       Adjust P1 fully CCW and P2 fully CW. Once at the desired alarm point, adjust P1 CW
       until the on-board relay drops out. NOTE: 3 second delay. Raise the voltage to the
       desired low volts reset level. Turn P2 CCW until the on-board relay picks up. NOTE:
       3 second delay.

       Similarly if the high volts setting requires adjustment, the “Equalize” voltage must be
       readjusted. In some cases it may be impossible to reach the desired level. If this is the
       case, the battery bank should be substituted with a resistive load and parallel
       capacitance. Adjust P1 fully CCW and P2 fully CW. Once at the desired alarm point,
       adjust P2 CCW until the on-board relay drops out. NOTE: 3 second delay. Lower the
       voltage to the desired high volts reset level. Turn P1 CW until the on-board relay picks
       up. NOTE: 3 second delay. Adjust the equalize voltage back to desired setting.

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                                                                             TLR/TLRF Charger


10.3    Combined Alarm-Status Monitor (CASM) - Main Charger Drawing
        (Option A031)

         The CASM circuit combines the monitoring of the AC Fail alarm, High and Low Volts
         DC alarm, Ground Fault (Pos & Neg.) alarms, Rectifier Fail alarm and provides
         common alarm contacts for the group of alarms. Front panel LEDs, which are latching,
         are provided along with a lamp test/reset push button.

         AC Fail Alarm
             •    No adjustment, fixed to -30%, +10% of nominal AC input voltage
             •    10% hysteresis
             •    Alarm delay 4 seconds

         High Volts (DC) Alarm
              •   Adjustment 0-150% of nominal DC Voltage
              •   Adjustment potentiometer R20
              •   No hysteresis
              •   Alarm delay 4 seconds

         Low Volts (DC) Alarm
             •   Adjustment 0-150% of nominal DC Voltage
             •   Adjustment potentiometer R40
             •   No hysteresis
             •   Alarm delay 4 seconds

         Ground (+)/(-) Alarm *
             •   No adjustment, fixed to 10mA (100 Ohm/V)
             •   No hysteresis
             •   Alarm delay 4 seconds

         Rectifier Fail Alarm
              •    No adjustment, digital input (signal from control card)
              •    No hysteresis
              •    Alarm delay 15 seconds

         Common alarm relay output (TB2)

              Contact Ratings:
              AC: 125V 1A      125VA 1.0PF
              DC: 120V 0.5A 60W RES MAX

         * In systems with a grounded battery, the ground (+)/(-) fault alarm may be disabled by
         removing the ground connection (X1-8 on the alarm card).

         The combination alarm status monitor (alarm card) is also available with individual
         relays for each alarm (Option A032). This relay board (Km) provides customer
         connections (Form 'C' contacts) for Ground Fault -VE (Gnd. Neg.), Rectifier Fail, Low
         Volts DC, Ground Fault -VE (Gnd. Pos.), AC Fail and High Volts DC.



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10.4   0-72 Hr. Manual Equalize Timer with Switch and Indicating Light
       (Option A014)

       The equalize timer is an adjustable timer with a three digit seven segment display. The
       time out period can be set by the user and stored in nonvolatile memory.

       Setting Mode

       Holding the push button more than 5 seconds will force the timer into setting mode
       with the display flashing. The display will increment between 0 & 72 hours. Releasing
       the push button for more than 5 seconds will end the setting mode. The last number
       on the display will be stored into the memory.

       Timer Equalize Mode

       Pressing the push button will force the timer into Timer/Equalize mode. The preset
       time out which is stored in the memory will appear on the display. The timer starts
       counting down from the preset time to zero. Pressing the push button during this
       period will cancel Equalize. Equalize has to be cancelled before entering the Set Mode
       to change the preset value.

       AC Line Failure

       The AC line failure during the Equalize period will not disturb the timer which
       accumulated time. When AC power is restored, the timer will maintain correct time out.
       The display will shut off during power failure to prevent the battery from power drain.

10.5   0-72 Hr. Auto Equalize Timer After AC Failure with Indicating Light
       (Option A015)

       Operation of this timer is the same as the 0-72 Hr. Manual Equalize Timer above but
       with the addition of an AC line failure mode.

       If AC line failure occurs for longer than 10 seconds, either in the Float or Equalize
       mode, after the power is restored, Equalize will be activated and the timer will start
       counting from the preset time which is stored in the memory. If the AC failure time is
       less than 10 seconds, the timer will resume the counting of the remaining time as soon
       as the AC power is restored. During the AC line failure, the display shuts off to prevent
       the battery from power drain.

       Pressing the push button during the Equalize period will cancel this mode and return
       the charger to Float. In order to enter the Set mode to change the preset value during
       Equalize period, Equalize has to be cancelled first.




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                                                                              TLR/TLRF Charger


11.0    PLUG-IN MODULES TO MAIN CONTROL CARD

11.1    Auto Charge Control (ACC)
        (Option A017)

         This option will allow the charger to automatically recharge the battery in the Equalize
         mode after a discharge. If the charger remains in current limit for 36 seconds, an
         internal timer is activated. This timer will not start timing until the charger is no longer
         in current limit. The Equalize period is factory set at 10 hours. Should periodic
         Equalize charging of the batteries be required, it can be activated by momentarily
         depressing the Timed Equalize push button. The charger will automatically return to
         Float after 10 hours. Equalize can be cancelled by depressing and holding the push
         button for 3 seconds.

         NOTE: Equalize cannot be cancelled if the charger is in current limit.

         Adjustment

         Potentiometer P1 on this plug-in board adjusts the point at which the ACC is activated
         by the charger current limit circuit. This is factory set but if adjusting a new card is
         required, load the charger until the current limit is just reached and adjust P1 until LED
         DS1 just comes on.

11.2    Battery Temperature Compensation
        (Option A057)

         The sensor used is a 10kOhm NTC thermistor mounted in a plated copper "terminal".
         It is normally mounted on an inter-cell connector of the battery. This provides true
         battery temperature sensing. The output voltage is changed at a rate of 0.22%/ oC over
         the range of -20o C to +50o C (-4o F to 122o F) with reduced compensation at the
         extremes.

         Adjustment

         No adjustment is required.

11.3    Battery Current Limit and Load Share

         11.3.1   Battery Current Limit
                  (Option A018, A019, A020, and A021)
                  The battery current limit amplifier, in conjunction with a series connected
                  battery shunt, permits control of the battery charge currents independent of
                  the charger system current limit circuit. This function is normally applied when
                  the total current output of the unit is too large for the battery (i.e., small
                  battery).




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November 2003                      www.enersysinc.com
              Checking Battery Current Limit

                   •   Remove all loads from the charger except the battery.
                   •   Switch the charger to Equalize and monitor the output current. This
                       current should follow the battery manufacturer's recommendations.

     NOTE: If the battery is completely charged, additional load at the battery terminals
           may be required.

     If it is desired to adjust the current limit to a different value or to adjust a new plug-in
     board, use the following procedure.

     Adjustment

          •    Turn the current limit potentiometer P1 fully CW on the plug-in board.
          •    Apply a load slightly in excess of the desired current limit (at the battery
               terminals).
          •    Observing the output ammeter, adjust P1 CCW just until the desired current
               limit setting is established.
          •    Increasing the load should maintain the same current (approximately).

     11.3.2   Load Share
              (Option A052)

     Load Share allows two or more chargers to operate in parallel within +/-5% of each
     other without any additional wiring.

     Adjustment

     Adjust the current between the two paralleled chargers. The load share point is
     factory set, but if adjusting a new plug-in board is required, the following procedure
     should be used.

          •    Remove the battery and adjust the load to 50% total.
          •    Bring the chargers to Float, and then to Equalize; ensure both chargers have
               the same Equalize voltage using a digital multi-meter.
          •    Adjust potentiometer P2 slightly on one charger and then on the other, to
               fine tune the output currents until they are approx. equal (i.e., 25% of the
               load per charger).




28                                                               Publication No. US-TLR-IOM-01
                               www.enersysinc.com                                November 2003
                                                                          TLR/TLRF Charger


12.0    MAINTENANCE

         Series TLR/TLRF battery chargers do not employ any moving parts other than the
         adjusting potentiometers, meters and relays used for the alarms. Other than blowing
         dust off the charger, no maintenance other than periodical electrical checks and
         adjustments should be required during the life of the unit.

         All magnetic components, resistors, capacitors & semi-conductors are conservatively
         rated for long life.

         The approximate state of charge of the battery should be regularly checked; this can
         be accomplished by the following procedure:

              1)    Initiate an Equalize charge by depressing the "Equalize" push button/ lamp.

              2)    Observe that the charger enters current limit (on DC output ammeter).

              3)    If the charger remains in current limit for longer than 36 seconds, then the
                    battery requires "Equalize" charging. If the battery is already adequately
                    charged, the charger will leave the current limit mode, (observed by
                    decreasing battery current or charger output).

              4)    Cancel the manual "Equalize" if battery does not require charging.

         In addition, the battery should be regularly maintained as outlined by the battery
         manufacturer. Special attention should be given to the electrolyte level of the vented
         cells.

         Also, the "Float" and "Equalize" voltages should be checked periodically (semi-
         annually) for compliance to the settings described in section 6.0 ADJUSTMENTS.




Publication No. US-TLR-IOM-01                                                                29
November 2003                     www.enersysinc.com
                                        SLR/SLRF & TLR/TLRF
                                         BATTERY CHARGER
                                         SPARE PARTS LIST



                       CIRCUIT          DESCRIPTION:
     QUANTITY          SYMBOL           RECOMMENDED SPARE PARTS

                                      START UP SPARE PARTS

     1                 F1               DC FUSE (NOT USED IF DCB OPTION IS INSTALLED)
     1                 F2               CONTROL FUSE 2A
     1                 F3               CONTROL FUSE 1A
                                        ADDITIONAL FUSES REQUIRED FOR SOME
         OPTIONS


                                      OPERATING SPARE PARTS

     1 SET/ASSY.       BA               RECTIFIER ASSY.
     1                 E1               CONTROL MODULE
     1                 RC1              SURGE SUPPRESSOR
                                        FUSES LISTED ABOVE


                                      LONG TERM SPARE PARTS

     1                C1, C2            FILTER CAPACITOR (SLRF/TLRF UNITS ONLY)




         TO ORDER PARTS SPECIFY:

           1.      Charger Model Number
           2.      Charger Serial Number
           3.      Component Symbol and Quantity if individual parts only are required.
           4.      Job # on Rating Plate if available.




30                                                                 Publication No. US-TLR-IOM-01
                                   www.enersysinc.com                              November 2003
                                                                      TLR/TLRF Charger


APPENDIX A - SLR/TLR CASM ALARM CARD OUTLINE


Front View (Simplified)




                                                      PUSHBUTTON S1 “RESET / LEDs TEST”




                                                     POT. P1 “HIGH VOLTS” ALARM ADJUSTMENT


                                                      POT. P2 “LOW VOLTS” ALARM ADJUSTMENT



                                                     LED 1 “AC FAILURE”


                                                     LED 2 “HIGH DC VOLTS”


                                                     LED 3 “LOW DC VOLTS”


                                                     LED 4 “GROUND FAULT POS.”


                                                     LED 5 “GROUND FAULT NEG.”


                                                     LED 6 “RECTIFIER FAILURE”




Publication No. US-TLR-IOM-01                                                        31
November 2003                   www.enersysinc.com
     Cabinet Outline Floor & Rack Mounted TLR “C” Type




                                                          THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
                                                          DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.




32                                  Publication No. US-TLR-IOM-01
        www.enersysinc.com                          November 2003
                                                                     TLR/TLRF Charger


                    Cabinet Outline Floor Mounted SLR/TLR Type “D”




 THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
 DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.



Publication No. US-TLR-IOM-01                                                   33
November 2003                     www.enersysinc.com
                         Cabinet Outline (H) TLR Series Rectifier




 THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
 DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.



34                                                          Publication No. US-TLR-IOM-01
                                  www.enersysinc.com                        November 2003
                                                                          TLR/TLRF Charger

                           Cabinet Outline TLR Series Rectifier Type “F” and “G”




 THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
 DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.


Publication No. US-TLR-IOM-01                                                        35
November 2003                     www.enersysinc.com
                             Cabinet Outline TLR Series Rectifier Type “E”




     THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
     DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.



36                                                               Publication No. US-TLR-IOM-01
                                    www.enersysinc.com                           November 2003
                                                              TLR/TLRF Charger

                    Schematic Battery Charger Type TLR/TLRF




                                                                  THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
                                                                  DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.




Publication No. US-TLR-IOM-01                                                                                    37
November 2003                   www.enersysinc.com
                        Schematic SLR/TLR Battery Current Limit




 THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
 DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.




38                                                         Publication No. US-TLR-IOM-01
                                 www.enersysinc.com                        November 2003
                                                               TLR/TLRF Charger


            Schematic DC Digital Meters – Type DX-35 SLR/TLR




  THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
  DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.




Publication No. US-TLR-IOM-01                                             39
November 2003                     www.enersysinc.com
     Schematic SLR/TLR Selective Remote Relay Option




                                                               THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
                                                               DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.




40                                         Publication No. US-TLR-IOM-01
                www.enersysinc.com                         November 2003
                                                          TLR/TLRF Charger



            Schematic SLR/TLR High Volts Shutdown Alarm




                                                                 THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
                                                                 DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.




Publication No. US-TLR-IOM-01                                                                                   41
November 2003                   www.enersysinc.com
     Schematic SLR/TLR Ground Detection Alarm




                                                             THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
                                                             DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.




42                                     Publication No. US-TLR-IOM-01
            www.enersysinc.com                         November 2003
                                                                     TLR/TLRF Charger


          Schematic SLR/TLR Ground Detection Switches for DC Voltmeter Indication




                                                                              THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
                                                                              DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.




Publication No. US-TLR-IOM-01                                                                                                43
November 2003                   www.enersysinc.com
                  Schematic SLR/TLR Ground Detection Lights with Test Switch




 THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
 DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.




44                                                         Publication No. US-TLR-IOM-01
                                 www.enersysinc.com                        November 2003
                                                          TLR/TLRF Charger



              Schematic SLR/TLR Ground Detection Lights




 THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
 DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.



Publication No. US-TLR-IOM-01                                        45
November 2003                    www.enersysinc.com
     Schematic SLR/TLR End of Discharge Alarm




                                                         THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
                                                         DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.




46                                  Publication No. US-TLR-IOM-01
          www.enersysinc.com                        November 2003
                                                             TLR/TLRF Charger



                 Layout SLR/TLR Control E1 Plug-in Options




                                                                 THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
                                                                 DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.




Publication No. US-TLR-IOM-01                                                                                   47
November 2003                   www.enersysinc.com
           Schematic – TLR AC Input Ammeter with Current Transformer Option




 THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
 DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.




48                                                        Publication No. US-TLR-IOM-01
                                  www.enersysinc.com                      November 2003
                                                                       TLR/TLRF Charger


                     Schematic – TLR AC Input Ammeter with Selector Switch Option




 THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
 DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.




Publication No. US-TLR-IOM-01                                                       49
November 2003                     www.enersysinc.com
                     Schematic – TLR AC Input Ammeter Option




 THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
 DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.




50                                                        Publication No. US-TLR-IOM-01
                                 www.enersysinc.com                       November 2003
                                                            TLR/TLRF Charger

                    Schematic SLR/TLR Lightning Arrestors




 THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
 DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.




Publication No. US-TLR-IOM-01                                          51
November 2003                    www.enersysinc.com
          Schematic – TLR AC Input Voltmeter with Selector Switch Option




 THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
 DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.



52                                                        Publication No. US-TLR-IOM-01
                                 www.enersysinc.com                       November 2003
                                                                TLR/TLRF Charger


       Schematic – TLR AC Input Voltmeter Option Line to Line




 THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
 DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.




Publication No. US-TLR-IOM-01                                              53
November 2003                     www.enersysinc.com
                              Schematic SLR/TLR DC Center Zero Ammeter




 THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
 DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.



54                                                         Publication No. US-TLR-IOM-01
                                 www.enersysinc.com                        November 2003
                                                             TLR/TLRF Charger



                Schematic SLR/TLR Surge Suppression Option




 THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
 DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.




Publication No. US-TLR-IOM-01                                           55
November 2003                     www.enersysinc.com
                            Schematic SLR/TLR External Pot. Connection




 THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
 DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.




56                                                          Publication No. US-TLR-IOM-01
                                 www.enersysinc.com                         November 2003
                                                                        TLR/TLRF Charger


                                Interconnection Diagram SLR/TLR Timer




                                                                             THIS DRAWING IS FOR REFERENCE ONLY. STANDARD
                                                                             DRAWINGS ARE IN MANUAL SHIPPED WITH CHARGER.




Publication No. US-TLR-IOM-01                                                                                               57
November 2003                       www.enersysinc.com
            NOTES




58                        Publication No. US-TLR-IOM-01
     www.enersysinc.com                   November 2003
                                                                            Publication No: US-TLR-IOM-01 November 2003



                     EnerSys Inc.             EnerSys EMEA              Represented by:
                     P.O. Box 14145           Brussels, Belgium
                     Reading, PA 19612-4145   Tel: +32 (0)2 247 94 47
                     USA                      EnerSys Asia
                     Tel: +1-610-208-1991     Guangdong, China
                                              Tel: +86 755 2689 3639
www.enersysinc.com                                                                                          Printed in USA