1.FLX200 SERIES INDUSTRIAL BATTERY CHARGERS INSTALLATION & OPERATING INSTRUCTIONS TABLE OF CONTENTS TITLE 1. Important Operating Instructions 2. Introduction 3. Receiving Instructions 4. Location and Installation of Charger 5. Stacking 6. AC Electrical Supply 6.1 Branch Circuit Protection 6.2 AC Voltage Connections 6.3 Ground Connection 7. DC Output 8. Fault and Display Codes 9. Options 9.1 JIC Switch 9.2 Momentary Remote and Stop Operation 10. FLX200 Standard Charger Operation 11. Charger Functional Description 11.1 LED Descriptions 11.2 Display 11.3 Pause Push Button 11.4 Smart Start Stage 11.5 Auto Balance 11.6 Equalize Stage 11.7 Equalize Pushbutton 11.8 Low Battery Override/Recovery 11.9 Delayed Start of Charge 11.10 Battery Cooldown Operation Stage 11.11 Refresh Charge 11.12 Charge Time 11.13 Incorrect Battery Limits 11.14 Charge Cycle Reset 11.15 AC Power Failure 12. Maintenance Appendix A Fault Codes Appendix B FLX200 Troubleshooting Appendix C Single Phase Technical Data Appendix D Three Phase Technical Data Appendix E Circuit Diagrams Appendix F Cabinet Dimensions Page 2 3 3 3 3-4 5-9 5 9 9 10 10 10 10 10 11 12 12 12 12 12 13 13 13 13 14 14 14 15 15 15 15 15 16 17 18-19 20-21 22-27 28 1 Sales • Service • Recycling 1-888-563-6300 FLX200 SERIES INDUSTRIAL BATTERY CHARGERS 1. 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 DANGER markings on the charger, battery, and all the associated equipment. b) Do not touch un-insulated parts of the DC output connector or the battery terminals, as there is a possibility of electric shock. c) Connect or disconnect the battery plug only when the charger output is off. ALWAYS press the PAUSE pushbutton before unplugging the battery to prevent arcing or burning. d) If the battery is unplugged during charging, the charger will indicate “F18”. To restart the charger, plug in the next battery. Do not connect the next battery before you see indication “- - - -” or “F18”. 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 prescribed treatment 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. The operating environment should not contain any materials that may cause corrosion or contamination that would degrade the performance of a charger. i) Do not operate this unit if it has received a sharp blow, been dropped or otherwise damaged. Take it to a qualified Exide Technologies Motive Power service center. Do not disassemble the charger. Have the charger examined by an Exide Technologies Motive Power service representative or local qualified service facility. Incorrect re-assembly of the charger may result in an explosion, electric shock or fire. j) k) The charger profile is set at the factory for a charger DC cable length of 9 ft and a battery DC cable length of 25 in. If DC cable lengths are adjusted, please contact your local Exide Technologies Motive Power service representative. Sales • Service • Recycling 1-888-563-6300 2 In order to permit free air flow for convection cooling allow four inches minimum between the charger and any wall.2. The bolts can be accessed and secured from the underside of the unit at the front and rear or from inside the unit where the large holes are located directly above mounting holes (see appendix G Sales • Service • Recycling 1-888-563-6300 3 . six inches from other equipment. Lifting Sequence is as follows: a) Secure the base unit to the floor or solid base. If any shipping damage or partial loss is found. solid state. The charger has a comprehensive self-checking diagnostic program to control all charger functions. the sling should be placed under the unit where the base plate is located to avoid damage to the units. check that the charger nameplate data corresponds to the packing slip and to the model specified on the original sales order. Check the contents of the package against the delivery slip before disposing of the shipping package. 4. to make sure that no parts have been loosened or damaged during shipment. cool. normal ambient room temperature (between +32oF/0oC and 104oF/40oC). b) These units can be stacked to a maximum 3 high. INTRODUCTION The GNB® FLX200 battery chargers are fan cooled. c) If a lifting sling is used. microprocessor controlled. two button keypad and LED display report on the charger and battery status. file a claim with the carrier without delay and take any necessary steps to protect your rights. dry and well-ventilated area. STACKING The following recommendations should be taken into consideration when stacking these units: a) The base unit should be secured to the floor or a solid base using appropriate bolts and with accordance to local building codes and regulations. and never store anything beneath or on top of the charger. LOCATION AND INSTALLATION OF CHARGER Proper installation is important in order to achieve good charger performance and long trouble free operation and to prevent damage to the charger and batteries. They are factory set to charge flooded lead-acid batteries. RECEIVING CHARGER Examine the charger thoroughly before using. monitor the quality of charge and check its own safety conditions. 3. 5. Before installing. but an upgrade can be purchased from an Exide Technologies Motive Power service representative to enable the charger to service CHAMPION® sealed lead-acid batteries. The FLX200 chargers are delivered on skids for easy handling using a forklift truck. SCR regulated chargers designed to make battery charging simple. The charger should be located in a clean. Large easy to read LEDs. This will allow you to go through the base plate to the bolts. b) Remove the bolts from the top cover of the base unit. Sales • Service • Recycling 1-888-563-6300 4 . When accessing the mounting holes from the inside. which are located on the flange. it is recommended you use a long handle hexagon key or screwdriver with the hexagon key inserted. A FLOOR PLATE OF AT LEAST 1. e) If stacking three high. d) Secure the two units together using the bolts removed from the top cover of the base unit. CONCRETE OR METAL. c) Use an appropriate lifting sling to lift the second unit on to the base unit. as they will be required to fix the two units together.43mm GALVANIZED OR 1. inch the second unit over the base unit and align the holes before resting the second unit on top.6mm UNCOATED STEEL EXTENDED AT LEAST 150mm BEYOND THE EQUIPMENT ON ALL SIDES MUST BE INSTALLED. Use the access between the two units or inside the second unit using the tools as recommended above. INSTALL BATTERY CHARGER ON A FLOOR OF NON-COMBUSTIBLE MATERIAL SUCH AS STONE. WARNING: TO REDUCE THE RISK OF FIRE. WARNING: THESE PROCEDURES MUST BE FOLLOWED EXACTLY TO AVOID INJURY OR RISK OF ELECTRIC SHOCK. use the above procedure for stacking the third unit. IF THIS IS NOT AVAILABLE. BRICK. but do not discard these.for mounting hole locations). CAUTION: TO REDUCE THE RISK OF FIRE. 6.1 BRANCH CIRCUIT PROTECTION The charger comes with an internal supplementary protective device rated to accommodate the highest possible current and voltage for that model. Three phase chargers cannot be powered with a single phase source.6. Sales • Service • Recycling 1-888-563-6300 5 . 60 Hertz (± 2%) AC power source. ANSI/NFPA 70. Figure 2 (page 7) for single-phase input with 208/240/480 transformers or Figure 3 (page 8) for three-phase input transformers. The following transformer options are available: TABLE 1 – INPUT VOLTAGE CHOICES Single phase 120/208/240 VAC 60Hz* 208/240/480 VAC. USE ONLY ON CIRCUITS PROVIDED WITH BRANCH CIRCUIT PROTECTION CONSISTENT WITH THE CURRENT INDICATED ON THE FRONT PANEL-RATING LABEL AND IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE. 60Hz *Only the AC input wire configuration for multi-input chargers can be changed. 60Hz* 600 VAC. Follow Figure 1 (page 6) for single-phase input with 120/208/240 VAC transformers. 60Hz* 600 VAC. A qualified electrical contractor should perform this adjustment. 60Hz Three phase 208/240/480 VAC. AC ELECTRICAL SUPPLY The charger must be connected to either a single phase or three phase. 120 VAC 60Hz CONFIGURATION (120/208/240VAC INPUT) 0 120 208 240 Mains Input (Black) N (Black) L PCB N (Blue) L (Brown) 208 VAC 60Hz CONFIGURATION (120/208/240VAC INPUT) 0 120 208 240 Mains Input (Black) N (Black) L PCB N (Blue) L (Brown) 240VAC 60Hz CONFIGURATION (120/208/240VAC INPUT) 120 0 208 240 Mains Input (Black) N (Black) L PCB N (Blue) L (Brown) Sales • Service • Recycling 1-888-563-6300 6 . The mains input are the only user configurable connections. PCB connections must NOT be altered from factory setting.FIGURE 1: 120/208/240 VAC. SINGLE-PHASE INPUT WARNING: IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE DAMAGE TO THE CHARGER AND BATTERY NOTE: Live connection ‘L’ Must be connected to the breaker. The mains input are the only user configurable connections. 208 VAC 60Hz CONFIGURATION (208/240/480V INPUT) 0 208 240 480 Mains Input (Black) N (Black) L PCB N (Blue) L (Brown) 240 VAC 60Hz CONFIGURATION (208/240/480V INPUT) 0 208 240 480 Mains Input (Black) N (Black) L PCB N (Blue) L (Brown) 480 VAC 60Hz CONFIGURATION (208/240/480V INPUT) 208 0 240 480 Mains Input (Black) N (Black) L PCB N (Blue) L (Brown) Sales • Service • Recycling 1-888-563-6300 7 .FIGURE 2: 208/240/480 VAC. PCB connections must NOT be altered from factory setting. SINGLE-PHASE INPUT WARNING: IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE DAMAGE TO THE CHARGER AND BATTERY NOTE: Live connection ‘L’ Must be connected to the breaker. THREE-PHASE INPUT WARNING: IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE DAMAGE TO THE CHARGER AND BATTERY NOTE: PCB connections must NOT be altered from factory setting. 208VAC 60 Hz CONFIGURATION (208/240/480V INPUT) N 208 240 480 208 240 480 208 240 480 Mains Input (Black) L1 (Black) L2 (Black) L3 PCB L (Brown) N (Blue) 240VAC 60 Hz CONFIGURATION (208/240/480V INPUT) N 208 240 480 208 240 480 208 240 480 Mains Input (Black) L1 (Black) L2 (Black) L3 PCB L (Brown) N (Blue) 480VAC 60 Hz CONFIGURATION (208/240/480V INPUT) N 208 240 480 208 240 480 208 240 480 Mains Input (Black) L1 (Black) L2 (Black) L3 PCB L (Brown) N (Blue) Sales • Service • Recycling 1-888-563-6300 8 .FIGURE 3: 208/240/480 VAC. L2. CAUTION: USE MINIMUM 75°C WIRING FOR SUPPLY CONNECTIONS. Continue the AC wiring to the breaker terminals L1 (N) and L2 (L) (single phase input) or L1. route the AC conduit through the knockout hole provided. and L3 (three phase input). ALUMINUM OR COPPER CONDUCTORS ONLY. The charger comes with a threaded M6 hole. Sales • Service • Recycling 1-888-563-6300 9 .2 AC VOLTAGE CONNECTIONS To connect the input AC voltage. IMPROPER GROUNDING CAN RESULT IN THE RISK OF AN ELECTRIC SHOCK. For proper connection. To ensure good continuity. After electrical connection is completed. torque the screws to approximately 25 inch-pounds.3 GROUND CONNECTION It is a requirement to ground the chassis while the charger is connected to AC power. USE COPPER-CLAD ALUMINUM. WARNING: DO NOT OPERATE THE UNIT WITHOUT PROPER GROUNDING. 6.6. clearly marked on the chassis. the charger is ready for operation. GROUND THE CHARGER PROPERLY USING THE THREADED M6 HOLE (GND) PROVIDED. keep the contact area clean. The DC fuse must be replaced with a fast acting fuse capable of protecting semiconductors. The DC output fuse is a "fast-acting" fuse used to protect the power semiconductors of a charger.7. the door can be opened but only AC power at the input of the switch is present while everything downstream is dead. The charger will not operate in a reversed polarity condition.1 JIC SWITCH ASSEMBLY All FLX200 battery chargers can come with a factory installed JIC switch assembly option for extra operator protection. Sales • Service • Recycling 1-888-563-6300 10 . DC OUTPUT The DC charging cable has a commonly used battery plug or receptacle. See Appendix C and D for correct fuse sizes.2 MOMENTARY REMOTE STOP OPERATION The FLX200 charger has a complete remote control option. In the "OFF" position. which can be factory installed or field retrofitted. In the "ON" position. The polarity of the charger plug must be the same as the battery connector. 8. FAULT AND DISPLAY CODES Refer to Appendix A and B (on pages 16 and 17) for a complete list of fault codes. Contact your local Exide Technologies Motive Power representative for more details. 9. OPTIONS 9. AC power is supplied to the charger but the door cannot be opened. The BLACK DC cable must be connected to the battery negative terminal (-) and the RED DC cable must be connected to the battery positive terminal (+). NOTE: Use only identical replacement fuses available from your Exide Technologies Motive Power service representative. 9. R: Red Y: Yellow G: Green = = = Fault.tr A.V. flashing red is a none critical fault. tr2 = I2 entered 3.V.V. tr4 = di/dt.V.t.t. flashing yellow when < 2. G G.Ah. NOTE: In LoBt.V.Ah.Ph A. charge complete. Equalise and Termination charge function display will only be displayed for 10 seconds. 2 and 3 = Smart start = Cool down period = low battery override = Display will alternate with the two-displayed information = Remaining time = Termination method.V.t.tr A.t.Ph A.Ah. 1.V.Ah.T.Ah.tr for 5 seconds then default display A.5 hour timer operated.t.t A.Ah.Ph A.t.V.t Y* Y Y G* G R*.37VPC. tr1 = dv/dt.tr A.tr A. FLX200 STANDARD CHARGER OPERATION CHARGE CONDITION DISPLAY DEFAULT A A/ #StSt A CooL / rt rEdy rEdy / F A / rEFr EqAL A / EqAL StSt / A StSt / V Lobt / A Lobt / V F F dELy / rt Charge continues FUNCTION BUTTON DISPLAY SELECTION LED I1 CONSTANT VOLTAGE I2 COOL DOWN PERIOD TERMINATION TERMINATION/ FAULT CODE REFRESH CHARGE SETTING EQUALISE EQUALISE CHARGE AUTO BALANCE Lobt CHARGE PERIOD Lobt OFF PERIOD CRITICAL FAULT CODE NONE CRITICAL FAULT CODE DELAYED START OF CHARGE A. StSt.10.V.t. Sales • Service • Recycling 1-888-563-6300 11 .Ah.Ah.e.5 hour timer operated tr3 = Constant voltage stage entered 3. Current flowing. tr5 = Smart Start * = flashing LED.Ah.V.V.tr A. not permanently.Ah. # Display if due to smart start. Y Charge stage G*. display will alternate with the two codes = Phase of charge i.t.Ah. Y G Y* R R* A V Ah t F Ph StSt Cool LoBt / rt tr = Output current = Volts per cell = Returned ampere hours = Time of recharge = Fault code. 11. When the constant voltage stage U1 is entered then the display shows ‘StSt’ alternating with current. then the charge cycle will be suspended and a battery voltage test to determine if the battery was in a sulphated or heavily discharged condition will be instigated. If the battery voltage decays quickly the battery is determined to be sulphated and the charger will continue to Stage 1 High Rate or I1 current level with a ‘sulphated battery’ fault set. 11.2 DISPLAY The display by default shows the charging current during the charge cycle. The FUNCTION button can select charge information. The battery can then be safely unplugged for up to 10 minutes. time or Amp-Hours by pressing the FUNCTION button. the display will show VPC only. the charger will continue with the present charge cycle. If the time to reach the gassing voltage level is equal to or less than 5 minutes. If the battery is still connected after this time. At this time. the gassing voltage is maintained until the current level is equal to the Finish Rate or 32% of the maximum output current. the charger will terminate and Auto Balance stage will be entered. If the time to reach the constant voltage level is greater then 5 minutes and less than 45 minutes. CHARGER FUNCTIONAL DESCRIPTION 11. The display may be changed to show voltage. During the suspension. Description High Rate Current 80% Charged Cool Down Charge Complete Fault – See page 16 for codes Sales • Service • Recycling 1-888-563-6300 12 . When the Auto Balance stage is entered.3 PAUSE PUSH BUTTON This PAUSE push button will halt the charge cycle. If the battery voltage does not fall quickly.11. the decay in battery voltage is monitored.4 SMART START STAGE The charger begins the charge cycle at the high rate current and continues until the gassing voltage is reached. the green LED will be illuminated and the display will show ‘StSt’. Charge will then terminate and Auto Balance stage will be entered.1 LED Descriptions LED Yellow Flashing Yellow Solid Green Flashing Green Solid Red 11. The display may show additional messages as the charge cycle progresses or a fault occurs. down to a minimum of 1. When no current is flowing.2 OPERATION If ‘Low Battery Override’ has been enabled and a battery (voltage > 1. The equalize charge can be set in the service mode to be initiated at ‘x’ number of cycles. 11.00 VPC .00 VPC) is connected to the charger.35VPC with a time limit of 1 hour if 2. the display will show ‘StSt’. amps will be displayed and the yellow LED will be illuminated. The green LED will remain illuminated. EXCESSIVE EQUALIZING MAY DAMAGE THE BATTERY. when the FUNCTION button is depressed > 5 second at anytime whilst a battery is connected.the level at which the charger will recognize a battery connection.5 hours at 32% of the maximum output current with a voltage limit. the charger will pass current at 75% of maximum current output the charger rated output current level. on at 2.8. Sales • Service • Recycling 1-888-563-6300 13 .5 AUTO BALANCE The charger maintains a current equal to 32% of the maximum output that is activated by voltage.70 VPC.7 EQUALIZE PUSHBUTTON Equalize charge can be enabled/disabled. 11. X = 0 to 255. When current is flowing. This is achieved by holding the FUNCTION push button for 5 seconds when the incorrect battery fault has been detected. The FUNCTION button can select charge information. AS SPECIFIED IN THE BATTERY MAINTENANCE INSTRUCTIONS.6 EQUALIZE STAGE Equalize charge consists of 3.15VPC and off at 2.11. CAUTION: DO NOT EQUALIZE MORE OFTEN THAN REQUIRED BY THE CONDITION OF THE BATTERY.1 CONFIGURATION There is the ability to manually override the low ‘Incorrect Battery’ threshold of 1. 11. The following table summarizes the action taken when Equalize is set manually during different charge modes… Charge Mode During recharge After charge termination Smart Start termination Action Equalize active after termination Equalize active immediately Equalize active after termination 11.35VPC is not reached.8 LOW BATTERY OVERRIDE/RECOVORY 11.8. Only one equalize charge per recharge cycle is permitted. 11. the battery recovery mode will cease and charge will start from stage 1 with smart start disabled. The green LED will remain illuminated.If less than 3. The FUNCTION button can select charge information.11 REFRESH CHARGE STAGE The Refresh Charge activates every 24 hours after the standard charge cycle. Sales • Service • Recycling 1-888-563-6300 14 . maximum of 5 minutes. During the 5-minute off period the display will show the battery volts per cell alternating with ‘Lobt’. the countdown will cease and the display will show F19. 11. whereupon the cool down timer countdown will resume. the charger will illuminate the green LED and enter the refresh stage. current will flow for 5 minutes and the charge will be suspended for 5 minutes. During this period the display will show ‘Lobt’. this is permanently set for every charge cycle.70 VPC at the end of the 5-minute rest period.9 DELAYED START OF CHARGE A charge delay can be set in the service mode. Once the cool down period is complete. If 3. If equalize is activated during cool down. If the battery voltage is greater than 1.70 VPC at the end of the 5-minute rest period.0VPC. 11. the cool down timer will be suspended until Equalize is complete. the green LED will flash and the display will show ‘CooL’ alternating with the remaining cool down time. The cycle is repeated until the battery voltage is greater than 1. The FUNCTION button can select charge information and display this momentarily. the charge will be suspended equal to the ‘on’ time. During the refresh off period the display will show ‘rEdy’. The Refresh Charge stage lasts for 10 minutes and consists of Finish Rate or 32% of the maximum output current. The time is 0 to 48 hours in 1-hour steps. if the battery remains connected to the charger. The 24-hour refresh delay starts after termination of recharge or Equalize.10 BATTERY COOLDOWN OPERATION STAGE The cool down period begins after charge termination and is equal to the time spent on charge. During the cool down period. The display will show ‘dELy’ and alternate with the time remaining before charge starts.0 VPC is reached within the 5 minutes of charge. If the battery is disconnected before completion of the cool down period. Blow out with clean compressed air when necessary. 12. MAINTENANCE The charger requires minimum maintenance. 11. The chargers are designed with a breaker and fuse for the AC input and DC output respectively.70 VPC and > 2. the charger will resume the cycle at the point of termination as soon as AC power is restored. Should this fuse fail or breaker trip. the cycle will be terminated after 3. Do not allow excessive dust to accumulate on the components inside.During the 10-minute Refresh Charge period the display will toggle between ‘rEFr ’ and the output current.12 CHARGE TIME The amount of time a battery charges will vary depending on the depth of discharge (DOD). ENSURE THE CHASSIS IS SECURELY GROUNDED per the local/federal Electrical Code. The yellow LED is illuminated and the green LED will remain illuminated and the FUNCTION button can select charge status. Normal charge cycles will average about 8 hours total. The charger will remain in the Refresh Charge stage until the battery is disconnected.13 INCORRECT BATTERY LIMITS Incorrect battery detection limits will be < 1. 11. If the battery voltage comes within this window the charger will automatically commence charging. Never replace the fuse or breaker with one of a higher capacity than the one originally fitted. Sales • Service • Recycling 1-888-563-6300 15 . the cause must be determined before they are corrected or replaced.15 AC POWER FAILURE If the AC power fails during a charge cycle. Once the battery has reached 80% charged. 11.14 CHARGE CYCLE RESET A charge cycle is reset when a battery is disconnected and a battery is reconnected.5 hours or less if terminated by dV/dt. 11.25 VPC (off charge). 90vpc) Sulphated battery Charger over heating Mains failed during charge No output current Incorrect battery < 1.25 Bulk charge time-out Second stage time-out (Profile Dependant) Incorrect Mains Frequency Control hardware (MCU) Thermistor fault Battery overheating (if temp probe fitted) Auto balance charge time-out Battery disconnected without pausing charge Battery disconnected in cool down period Key: C = critical fault charge stopped fault code displayed permanently S = suspend fault charge suspended until criteria fulfilled fault code displayed permanently R = retry fault charge retries after 20 seconds fault code display alternating with standard display N = non-critical fault charge continues fault code display alternating with standard display Sales • Service • Recycling 1-888-563-6300 16 .90vpc after 30 seconds of charge) Deep discharged battery (<1.APPENDIX A – FAULT CODES CODE F01 F02 F03 F04 F05 F06 F07 F07 (+Y led on) F09 F10 F11 F12 F13 F16 F17 F18 F19 STATUS N N N S S R C C C C C C S S C C C DESCRIPTION Over discharged battery (<1.70 Incorrect battery > 2.90vpc after 30 seconds of charge > 1. Contact your local Exide Technologies Motive Power representative. Check battery for low voltage. Battery may require servicing.9 volts per cell initially but rose above this level within the first minute. Check Fan for operation on initial power up. Contact your local Exide Technologies Motive Power representative. Electrical Supply failure during charge. Check battery for High Temperature. Ensure adequate ventilation. Check battery condition. Confirm charger capacity is correctly matched to battery Press the PAUSE button before disconnecting the battery.9 volts per cell after the first minute of charge. Make sure battery voltage matches charger. Contact your local Exide Technologies Motive Power representative. Check battery condition. Battery did not reach gassing volts within the time limit. Allow battery to cool. (Power Cut) Check DC Fuse. Allow the battery to cool before use. Check Breaker. Confirm charger capacity is correctly matched to battery. Contact your local Exide Technologies Motive Power representative. Check battery condition. Battery less than 1. SCRs. F09 Battery Failure Second Stage Time-Out Incorrect Mains Frequency Board Failure Temperature Sensor Failure Auto Balance Stage Time Out Battery Overheating Battery Disconnection Battery Disconnection in Cool Down F10 F11 F12 F13 F17 F16 F18 F19 Sales • Service • Recycling 1-888-563-6300 17 . Check battery condition and Equalize. Check battery condition. Make sure the battery voltage matches the charger voltage. Connection to Battery. Make sure battery voltage matches charger.APPENDIX B – FLX200 TROUBLESHOOTING SYMPTOM No Display F01 F02 F03 F04 F05 F06 POSSIBLE CAUSE No AC Power Deeply Discharged Battery Over discharge Sulphated Battery Charger Overheating Mains Failure No Output Current Incorrect Battery F07 Low Voltage High Voltage EXPLANATION / ACTION Check Input Power. Contact your local Exide Technologies Motive Power representative. Check the mains supply. Mains fuse on Control Board Battery Voltage less than 1. Check battery voltage with a voltage meter. I2 limit not reached within time limit. Check battery condition and Equalize Make sure your battery gets a full charge every cycle. Check battery condition and Equalize. Check battery voltage with a voltage meter. 7 51.53 5.2 35.7 12.2 25.7 18.1 33.8 134 145 163 169 198 136 158 163 216 238 238 36 44 46 57 70 52 54 65 80 43 61 66 74 77 90 62 72 74 98 108 108 *DC FUSE MUST BE A FAST ACTING FUSE CAPABLE OF PROTECTING SEMICONDUCTORS.3 46.8 42.8 25.73 7.3 9.6 13.7 49.8 28.1 14.9 16.83 10.3 16.1 21.84 10.34 7.23 9.3 14.3 45.9 20.5 19.9 63.1 M4 M4 M4 M4 M4 M4 M4 M4 M4 M5 M5 M5 79.3 12 13.92 3.6 32.9 21.4 12.8 53.93 7.4 24.7 42.9 17 18 21.3 16 17 29.2 2.6 13.9 57.5 18.18 7.8 26.89 10.APPENDIX C – SINGLE PHASE TECHNICAL DATA SINGLE PHASE Model Numbers Amp Hour DC Volt DC Amp DC* Fuse AC AMPS (RMS) @ AC VOLTS @ 2.5 33.9 39.4 14. Sales • Service • Recycling 1-888-563-6300 18 .8 14.3 24.5 19.5 22.5 10.92 7.82 6.9 36.81 11.4 19.6 19.9 11.9 18.3 14.6 34.1 11.37 9.7 20.6 17.7 19.3 30.1 15 16.4 28.2 14.7 29.9 27.7 12.4 11 13.8 16.9 48.3 40.4 21.6 7.6 M4 M4 M4 M4 M4 M4 M4 M4 M4 3.22 9.7 15.7 20.4 31.6 45.3 22.9 55.3 9.94 11.9 27.7 32.6 4.93 4.1 29.16 12.2 26.6 18.2 13.7 19.1 14 15.8 30.1 5.7 38.5 32.9 23.9 6.8 22.81 9.9 21.6 27 28.9 14.2 24.8 15.34 9.36 13 13.85 9.2 96.21 10.9 40.4 19.7 5.6 23.6 6.7 5.7 25.92 5.8 101 125 154 114 119 143 178 94.38 7.9 31.7 15.3 27.9 11.9 13.47 5.8 37.4 17.83 6.1 14.9 23.2 23.3 59.0 VPC 120 Vac 208 Vac 240 Vac 480 Vac 600 Vac SHIPPING DATA Cabinet Size WEIGHT Lbs KG FLX200-06-260S1 FLX200-06-475S1 FLX200-06-600S1 FLX200-06-865S1 FLX200-06-965S1 FLX200-09-475S1 FLX200-09-600S1 FLX200-09-865S1 FLX200-09-965S1 FLX200-12-260S1 FLX200-12-475S1 FLX200-12-600S1 FLX200-12-750S1 FLX200-12-865S1 FLX200-12-965S1 FLX200-18-260S1 FLX200-18-475S1 FLX200-18-600S1 FLX200-18-750S1 FLX200-18-865S1 FLX200-18-965S1 260 475 600 865 965 475 600 865 965 260 475 600 750 865 965 260 475 600 750 865 965 12 12 12 12 12 18 18 18 18 24 24 24 24 24 24 36 36 36 36 36 36 40 75 95 135 150 75 95 135 150 40 75 95 115 135 150 40 75 95 115 135 150 63 125 160 200 250 125 160 200 250 63 125 160 180 200 250 63 125 160 180 200 200 Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum 11.3 36.4 16 12.9 35 39. 13 7.7 32.8 19 33.1 25.SINGLE PHASE TECHNICAL DATA CONTINUED SINGLE PHASE Model Numbers Amp Hour DC Volt DC Amp DC* Fuse AC AMPS (RMS) @ AC VOLTS @ 2.92 9.9 13.4 45.8 21.9 35 17.9 52 29.5 30.59 13.3 15.5 28.4 14.9 38.2 16.0 VPC 120 Vac 208 Vac 240 Vac 480 Vac 600 Vac SHIPPING DATA Cabinet Size WEIGHT Lbs KG FLX200-24-260S1 FLX200-24-475S1 FLX200-24-600S1 FLX200-36-260S1 FLX200-40-260S1 260 475 600 260 260 48 48 48 72 80 40 75 95 40 40 63 125 160 63 63 Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximu Nominal Maximum 20.2 7.6 41 48.6 21.6 42.5 12.7 17.49 16.9 18 M4 M5 M5 M5 M5 132 198 242 242 242 60 90 110 110 110 *DC FUSE MUST BE A FAST ACTING FUSE CAPABLE OF PROTECTING SEMICONDUCTORS.3 8.4 35. Sales • Service • Recycling 1-888-563-6300 19 .8 31.2 22.7 14.8 27. 9 8.5 10 11 12 12 12.1 9.1 6.2 4.5 5.6 6.5 9.1 8.4 6.2 9.8 3.4 8.3 4.3 5.APPENDIX D – THREE PHASE TECHNICAL DATA THREE PHASE Model Numbers Amp Hour DC Volt DC Amp DC* Fuse AC AMPS (RMS) @ AC VOLTS @ 2.6 6.9 16 17 20 21 24 26 28 30 2.4 5 5.7 8 8.1 8.6 8 8.3 6.6 6.6 2.4 3.2 4.5 6.7 7.5 10 11 11 12 12 13 14 16 17 4.5 15 16 18 19 12 12 12 13 15 16 19 20 22 23 24 26 27 28 30 32 36 39 9.5 9.4 10 11 12 13 14 15 M4 M4 M4 M4 M4 M4 M5 M5 M4 4.3 5.5 7.3 9.5 9.9 8.4 7.9 9.1 8.7 5 5.3 5.7 10 18 19 23 24 28 30 33 35 5.8 10 11 13 13 3.4VPC 120 Vac 208 Vac 240 Vac 480 Vac 600 Vac SHIPPING DATA Cabinet Size WEIGHT Lbs KG FLX200-06-475T1 FLX200-06-600T1 FLX200-06-750T1 FLX200-06-865T1 FLX200-06-965T1 FLX200-06-1050T1 FLX200-06-1200T1 FLX200-06-1450T1 FLX200-09-600T1 FLX200-12-475T1 FLX200-12-600T1 FLX200-12-750T1 FLX200-12-865T1 FLX200-12-965T1 FLX200-12-1050T1 FLX200-12-1200T1 FLX200-12-1450T1 FLX200-18-260T1 FLX200-18-475T1 FLX200-18-600T1 FLX200-18-750T1 FLX200-18-865T1 475 600 750 865 965 1050 1200 1450 600 475 600 750 865 965 1050 1200 1450 260 475 600 750 865 12 12 12 12 12 12 12 12 18 24 24 24 24 24 24 24 24 36 36 36 36 36 75 95 115 135 150 165 185 225 95 75 95 115 135 150 165 185 225 40 75 95 115 135 80 100 125 160 160 180 200 250 100 80 100 125 160 160 180 200 250 63 80 100 125 160 Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum 6.5 13 14 16 17 10 11 11 11 13 14 16 17 19 20 21 22 23 24 26 27 32 33 8.7 10 11 12 M4 M4 M4 M4 M5 M5 M5 M5 M4 M4 M4 M4 M5 101 101 123 132 143 163 246 299 134 134 145 145 180 238 238 288 365 158 180 180 209 275 46 46 56 60 65 74 112 136 61 61 66 66 82 108 108 131 166 72 82 82 95 125 *DC FUSE MUST BE A FAST ACTING FUSE CAPABLE OF PROTECTING SEMICONDUCTORS.9 7.6 6.8 6.5 14.6 6 6 6.1 8.3 5.9 11 12 12 13 13.8 7.5 4 4.7 7. Sales • Service • Recycling 1-888-563-6300 20 .3 3.7 8.4 8. 4 38.5 43.7 59.5 72.8 63.5 53.2 25. Sales • Service • Recycling 1-888-563-6300 21 .7 32.6 55.5 72.5 58 64.6 40 42.3 24.THREE PHASE TECHNICAL DATA CONTINUED THREE PHASE Model Numbers Amp Hour DC Volt DC Amp DC* Fuse AC AMPS (RMS) @ AC VOLTS @ 2.9 11 11 13 14 15 16 17 18 18 20 21 22 25 27 M5 M5 M5 M5 M6 M5 M5 M5 M5 M5 M5 M5 M5 M5 M5 M5 M5 297 297 321 398 466 242 264 288 299 304 326 363 464 330 352 374 396 135 135 146 180 212 110 120 130 136 138 148 165 211 150 160 170 180 *DC FUSE MUST BE A FAST ACTING FUSE CAPABLE OF PROTECTING SEMICONDUCTORS.6 37.6 46.4 48.5 44.4VPC 120 Vac 208 Vac 240 Vac 480 Vac 600 Vac SHIPPING DATA Cabinet Size WEIGHT Lbs KG FLX200-18-965T1 965 36 36 36 36 36 48 48 48 48 48 48 48 48 72 72 72 72 150 165 185 225 265 75 95 115 135 150 165 185 225 75 115 135 150 160 180 200 250 300 80 100 125 160 160 180 200 250 80 125 160 160 Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum FLX200-18-1050T1 1050 FLX200-18-1200T1 1200 FLX200-18-1450T1 1450 FLX200-18-1700T1 1700 FLX200-24-475T1 FLX200-24-600T1 FLX200-24-750T1 FLX200-24-865T1 FLX200-24-965T1 475 600 750 865 965 FLX200-24-1050T1 1050 FLX200-24-1200T1 1200 FLX200-24-1450T1 1450 FLX200-36-475T1 FLX200-36-750T1 FLX200-36-865T1 FLX200-36-965T1 475 750 865 965 36.4 8.5 51.7 77.3 56.4 69.3 32 33 35 37 39 41 47 50 56 59 21 22 27 28 32 34 38 40 42 45 46 49 52 55 63 67 32 33 48 51 57 60 63 67 16 17 17 18 19 21 24 25 28 30 11 11 13 14 16 17 19 20 21 22 23 25 26 28 32 33 16 17 24 26 28 30 32 33 13 13 14 15 16 17 19 20 22 24 8.8 30.7 77.8 47.3 36.2 39.4 38.7 59.2 65.2 68.7 54. CMP . DRAWING No: 4 . Charger Division. Unit 2 Pisces.WD . Mosley Road. M17 1PF.E Sales • Service • Recycling 1-888-563-6300 CON 5 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 bk 1 N L2 L3 bl br T1 PCB1 CON1 FS1 br bl bl 4 3 2 1 gy bl gy 22 . Materials: Adheasive: Size: Text: Colour: White Polypropylene 60u PP198 TC Clear Overlaminate 60u PP20 AP51 A5 (210mm x 147mm) As shown Black on white CMP Batteries Ltd.01 . Manchester. Trafford Park.APPENDIX F – CIRCUIT DIAGRAMS Component No: CLT6006 For 208V input connect to 208V connections on T1 For 240V input connect to 240V connections on T1 For 480V input connect to 480V connections on T1 DRAWING TITLE: GNB [UL] 3phase wiring diagram KEY L1 L2 L3 OR L1 L1 L2 L3 YL/G L1 L2 L3 bl bk br gy rd wh YL/G BLUE BLACK BROWN GREY RED WHITE YELLOW / GREEN 208V 240V 208V 240V 208V 480V 480V 480V 240V wh '2' wh '1' wh '0' rd rd rd wh bl bl '0' bl '1' bl '2' wh '2' bl '2' wh '1' bl '1' wh '0' bl '0' wh Shunt FS2 bl rd _ bk Drawn by: Trev Peacock Trev Peacock Trev Peacock Trev Peacock 13 12 02 10 12 03 19 12 03 17 03 04 Checked by: - + MOD No: C000007 C000044 C000045 C000068 REV: B C D E If any errors are apparent within this diagram please inform CMP engineering.2600 . Charger Division. DRAWING No: 4 .Component No: CLT6005 DRAWING TITLE: GNB [UL] Single phase wiring diagram Fuse / Breakers KEY bl bk br gy rd wh YL/G BLUE BLACK BROWN GREY RED WHITE YELLOW / GREEN For 120V input connect to 120V connections on T1 For 208V input connect to 208V connections on T1 For 240V input connect to 240V connections on T1 For 480V input connect to 480V connections on T1 N L OR N L OR L N YL/G 120V 240V 208V 0V 240V 0V br bl bl PCB1 CON1 FS1 4 3 2 1 gy OR br 208V 240V 480V 0V bl bl gy wh rd rd rd wh bl T1 wh wh wh CON 5 8 7 6 5 4 3 2 Shunt FS2 bl rd _ bk Drawn by: Trev Peacock Trev Peacock Trev Peacock Trev Peacock 17 04 03 10 12 03 19 12 03 17 03 04 Checked by: - + MOD No: C000007 C000044 C000045 C000068 REV: B C D E If any errors are apparent within this diagram please inform CMP engineering.2600 .E Sales • Service • Recycling 1-888-563-6300 bk 1 23 . Manchester.CMP . Mosley Road.02 . Trafford Park. Unit 2 Pisces.WD . Materials: Adheasive: Size: Text: Colour: White Polypropylene 60u PP198 TC Clear Overlaminate 60u PP20 AP51 A5 (210mm x 147mm) As shown Black on white CMP Batteries Ltd. M17 1PF. C C000045 C000068 Sales • Service • Recycling 1-888-563-6300 bk 1 24 . Trafford Park.03 .WD . Unit 2 Pisces. Mosley Road. Materials: Adhesive: Size: Text: Colour: CMP Batteries Ltd.CMP .2600 .Component No: CLT6006C DRAWING TITLE: GNB [UL] 3phase wiring diagram 600V Fuse/Breaker KEY bl bk br gy rd wh YL/G BLUE BLACK BROWN GREY RED WHITE YELLOW / GREEN Transformer determines voltage operation. L1 L2 L3 OR L1 L1 L2 L3 L1 L2 L3 YL/G 600V 240V 600V N 600V L2 L3 br bl T1 F2 PCB1 CON1 br bl bl 4 3 2 1 gy FS1 wh '2' wh '1' wh '0' rd rd rd wh bl 9 8 7 6 5 4 3 2 White Polypropylene 60u PP198 TC Clear Overlaminate 60u PP20 AP51 A5 (210mm x 147mm) As shown Black on white bl '0' bl '1' bl '2' bl gy CON 5 16 15 14 13 12 11 10 wh '2' bl '2' wh '1' bl '1' wh '0' bl '0' wh Shunt FS2 bl rd _ bk Drawn by: Trev Peacock Trev Peacock Trev Peacock 01 10 03 19 12 03 17 03 04 Checked by: - + MOD No: REV: A B C If any errors are apparent within this diagram please inform CMP engineering. Manchester. Connect to T1 for 600V input voltage operation. DRAWING No: 4 . M17 1PF. Charger Division. 04 . Manchester. Mosley Road. Charger Division. M17 1PF. Trafford Park.WD . Sales • Service • Recycling 1-888-563-6300 bk 1 25 . Materials: Adheasive: Size: Text: Colour: White Polypropylene 60u PP198 TC Clear Overlaminate 60u PP20 AP51 A5 (210mm x 147mm) As shown Black on white CMP Batteries Ltd. Unit 2 Pisces.C Drawn by: Trev Peacock Trev Peacock Trev Peacock 01 10 03 01 10 03 17 03 04 Checked by: MOD No: C000045 C000068 REV: A B C If any errors are apparent within this diagram please inform CMP engineering.Component No: CLT6005JIC DRAWING TITLE: GNB [UL] Single phase wiring diagram single phase JIC KEY bl bk br gy rd wh YL/G BLUE BLACK BROWN GREY RED WHITE YELLOW / GREEN For 120V input connect to 120V connections on T1 For 208V input connect to 208V connections on T1 For 240V input connect to 240V connections on T1 For 480V input connect to 480V connections on T1 N L OR N L OR L N N L 120V 240V 208V 0V 240V 0V br bl bl PCB1 CON1 FS1 4 3 2 1 gy OR br 208V 240V 480V 0V bl bl gy wh rd rd rd wh bl T1 wh wh wh CON 5 8 7 6 5 4 3 2 Shunt FS2 bl rd _ bk DRAWING No: 4 .2600 .CMP . Trafford Park.2600 .C C000045 C000068 Sales • Service • Recycling 1-888-563-6300 CON 5 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 bk 1 N br T1 bl PCB1 CON1 FS1 br bl bl 4 3 2 1 gy bl gy 26 . Unit 2 Pisces.05 .CMP .WD . Manchester. Mosley Road. Materials: Adhesive: Size: Text: Colour: White Polypropylene 60u PP198 TC Clear Overlaminate 60u PP20 AP51 A5 (210mm x 147mm) As shown Black on white CMP Batteries Ltd. Charger Division. DRAWING No: 4 .Component No: CLT6006JIC DRAWING TITLE: GNB [UL] 3phase wiring diagram JIC KEY L1 L1 L2 L3 OR L1 L2 L3 L1 L2 L3 L1 L2 L3 YL/G NOTE ISOLATOR AND BREAKER MAY BE COMBINED For 208V input connect to 208V connections on T1 For 240V input connect to 240V connections on T1 For 480V input connect to 480V connections on T1 L2 L3 bl bk br gy rd wh YL/G BLUE BLACK BROWN GREY RED WHITE YELLOW / GREEN 240V 208V 208V 240V 480V 208V 480V 480V 240V wh '2' wh '1' wh '0' rd rd rd wh bl bl '0' bl '1' bl '2' wh '2' bl '2' wh '1' bl '1' wh '0' bl '0' wh Shunt FS2 bl rd _ bk Drawn by: Trev Peacock Trev Peacock Trev Peacock 01 10 03 01 10 03 17 03 04 Checked by: - + MOD No: REV: A B C If any errors are apparent within this diagram please inform CMP engineering. M17 1PF. C Drawn by: Trev Peacock Trev Peacock Trev Peacock 01 10 03 19 12 03 17 03 04 Checked by: MOD No: C000045 C000068 REV: A B C If any errors are apparent within this diagram please inform CMP engineering. M17 1PF. Charger Division. Materials: Adhesive: Size: Text: Colour: CMP Batteries Ltd. L1 L2 L3 bl bk br gy rd wh YL/G BLUE BLACK BROWN GREY RED WHITE YELLOW / GREEN 600V 240V 600V 600V N L2 L3 br bl T1 F2 PCB1 CON1 br bl bl 4 3 2 1 gy FS1 wh '2' wh '1' wh '0' rd rd rd wh bl 9 8 7 6 5 4 3 2 White Polypropylene 60u PP198 TC Clear Overlaminate 60u PP20 AP51 A5 (210mm x 147mm) As shown Black on white bl '0' bl '1' bl '2' bl gy CON 5 16 15 14 13 12 11 10 wh '2' bl '2' wh '1' bl '1' wh '0' bl '0' wh Shunt FS2 bl rd _ bk DRAWING No: 4 .Component No: CLT6006CJIC DRAWING TITLE: GNB [UL] 3phase wiring diagram 600V JIC KEY L1 L2 L3 OR L1 L1 L1 L2 L2 L3 L3 L1 L2 L3 YL/G NOTE ISOLATOR AND BREAKER MAY BE COMBINED Transformer determines voltage operation. Manchester. Unit 2 Pisces.CMP . Sales • Service • Recycling 1-888-563-6300 bk 1 27 .WD . Mosley Road. Trafford Park.06 .2600 . Connect to T1 for 600V input voltage operation. 93” 20.65” 42.62” 23. E 12.69” Sales • Service • Recycling 1-888-563-6300 28 . D 17.54” 21.65” 26.62” DIM.69” 23.00” DIM.62” DIM. A 19.48” 21.APPENDIX F – DIMENSIONS CABINET Size M4 Size M5 Size M6 DIM.87” 23.93” 19. C 16.48” DIM. B 26.99” 16. com .A.6300 Exide Technologies Motive Power Canada Tel: 800.S.SALES – SERVICE – RECYCLING TOLL FREE 1-888-563-6300 in the USA 1-800-268-2698 in Canada Exide Technologies Motive Power U.563.2698 V19CIL5200ULF 2004-03 www. Tel: 888.exide.268.