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Precision Trading SUPERCHARGER 60 R3.0 60 R3.0 manual

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Table of contents for the manual

  • Page 1

    Operator Manual, Supercharg er 60 R3.0 Page 1 of 62 TABLE OF CONTENTS 1. INTRODUCTION AND SYSTEM DESCRIPTION .................................................................. 5 2. CONDENSED OPERATING INSTRUCTIONS ....................................................................... 8 2.1 Constant Cur rent Charge (normal mode ) ..................[...]

  • Page 2

    Operator Manual, Supercharg er 60 R3.0 Page 2 of 62 4.20 DS5A - FULL: .................................................................................................................. ........................ 21 4.21 DS5B - DISCH: ................................................................................................................. ....[...]

  • Page 3

    Operator Manual, Supercharg er 60 R3.0 Page 3 of 62 8.8 DISCH ARGE VOLTAGE CUT-OFF. ................................................................................................... 38 8.9 FULL DISCHA RGE. ............................................................................................................... ............... 39 8.10 CURREN[...]

  • Page 4

    Operator Manual, Supercharg er 60 R3.0 Page 4 of 62 TABLE OF FIGURES Figure 1 - Bl ock Diagram ...................................................................................................................................... 7 Figure 2 - Fr ont Panel ..............................................................................................[...]

  • Page 5

    Operator Manual, Supercharg er 60 R3.0 Page 5 of 62 1. INTRODUCTION AND SYSTEM DESCRIPTION Congratulations! You now own the finest batte ry Charger-Analyzer available today. The Supercharger is a precision instrument desi gned to charge and analyze NICKEL-CADMIUM, LEAD-ACID and other rechargeable batteri es exactly as recommended by the battery man[...]

  • Page 6

    Operator Manual, Supercharg er 60 R3.0 Page 6 of 62 The TIMER provides all the required timing func tions related to the charge and discharge durations. Digital time and speed selectors provide the external inputs, while the four digit readout of the CLOCK provides the elapsed time display. The CURRENT CONTROL interprets the programme d current val[...]

  • Page 7

    Operator Manual, Supercharg er 60 R3.0 Page 7 of 62 Figure 1 - Block Diagram[...]

  • Page 8

    Operator Manual, Supercharg er 60 R3.0 Page 8 of 62 2. CONDENSED OPERATING INSTRUCTIONS CAUTION: Disconnect power and batteries befor e performing any internal maintenance. Failure to observe this caution may result in serious damage to the unit and injury to the operator. NOTE 1: Depress the RESET button before turning the power on, or before conn[...]

  • Page 9

    Operator Manual, Supercharg er 60 R3.0 Page 9 of 62 2.2 Constant Voltage 2.2.1. Battery Voltage 2.2.1.1. Enter the nominal battery voltage using the cell selector (see chart on page 19). 2.2.1.2. Program the charge (m aximum) current in the Topping Current selector. 2.2.1.3. Program sufficient time in the Total Time selector to allow the battery to[...]

  • Page 10

    Operator Manual, Supercharg er 60 R3.0 Page 10 of 62 2.3 Peak Voltage Charge 2.3.1. Nominal Battery Voltage 2.3.1.1. Enter the nominal battery voltage using the cell selector (see chart on page xxx ). 2.3.1.2. Select transfer from Main to Topping on Peak or stop on Peak. 2.3.1.3. Program the Main and Topping Charge currents as required. 2.3.1.4. Pr[...]

  • Page 11

    Operator Manual, Supercharg er 60 R3.0 Page 11 of 62 2.4 Discharge NOTE 1: Do not place batteries on the Temp-Plate during discharge. Due to the normal heating of the battery a false Overtemp may be generated later during the charge process. NOTE 2: Do not attempt to discharge with the voltage mode selector in the Float or Peak voltage modes. Volta[...]

  • Page 12

    Operator Manual, Supercharg er 60 R3.0 Page 12 of 62 3. SPECIFICATIONS 3.1 CHARGE 3.1.1. CONTROL: SCR, air cooled. 3.1.2. MAXIMUM CURRENT: 50 AMPS. 3.1.3. MINIMUM INCREMENT: 0.1 AMP. 3.1.4. ACCURACY and STABILITY of settings: ±1% of reading, ±0.1 AMP. 3.1.4.1. FLOAT: • The reference voltage is set at th e equivalent of 2.33V/cell (Lead- Acid). [...]

  • Page 13

    Operator Manual, Supercharg er 60 R3.0 Page 13 of 62 3.1.5. MODES: 3.1.5.1. Main and topping for Cons tant Current 3.1.5.2. Constant Voltage 3.1.5.3. Peak Voltage. 3.1.6. TIMER: 3.1.6.1. 1 to 9 hours for MAIN charge time and 1 to 6 0 hours for TOTAL time. 3.1.6.2. Time can also be programmed in minutes by selecting the FAST mode in the TIMER SPEED [...]

  • Page 14

    Operator Manual, Supercharg er 60 R3.0 Page 14 of 62 3.1.12.1. 3 AMPS idling plus ½ the value of the charging curre nt; e.g. when charging 40 AMPS the line current is 23 AMPS (Note: nominal values, line voltage and frequency dependent). 3.2 DISCHARGE 3.2.1. CONTROL: Transistors, air cooled. 3.2.2. MAXIMUM CURRENT: 3.2.2.1. 60 AMPS. Total power dis[...]

  • Page 15

    Operator Manual, Supercharg er 60 R3.0 Page 15 of 62 3.2.6. TERMINAL VOLTAGE: 3.2.6.1. Programmable, in accordance with the number of cells selected, at the equivalent of 1 VOLT/cell. 3.2.6.2. TOLERANCE: ±1% ±0.1 VOLT. 3.2.6.3. NOTE 1: Due to cable/connector losses the voltage registered by the Charger-Analyzer will be lower than the actual batte[...]

  • Page 16

    Operator Manual, Supercharg er 60 R3.0 Page 16 of 62 3.3.2.4. NOTE: The colon flashes at the rate of one cycle per second regardless of the selected mode. 3.3.3. ACCURACY AND STABILITY: 3.3.3.1. ±0.01% 3.3.4. POWER FAILURE PROTECTION: 3.3.4.1. An internal rechargeable battery ma intains (for several hours) the clock and other vital circuits for a [...]

  • Page 17

    Operator Manual, Supercharg er 60 R3.0 Page 17 of 62 3.5 DIGITAL PANEL METERS 3.5.1. VOLTMETER: 3.5.1.1. Accuracy (system): ±0.25% of r eading, ±0.1V in the 200V scale, ±0.01V in the 20V scale, ±0.005V in the 2V scale. 3.5.1.2. Input impedance: 1 M-OHM. 3.5.1.3. Scale 2V, 20V and 200V (1.999V, 19. 9V and 199.9V) for external measurements and 20[...]

  • Page 18

    Operator Manual, Supercharg er 60 R3.0 Page 18 of 62 4. CONTROLS AND DISPLAYS 4.1 M1 - Ammeter 4.1.1. 0 to 199.9ADC DIGITAL PANEL METER. 4.1.2. Positive sign indicates charge current. 4.1.3. Minus sign indicates discharge current. 4.2 M1 - Voltmeter 4.2.1. 0 to 1.999VDC, 0 to 19.99VDC and 0 to 199.9VDC DIGITAL PANEL METER. 4.2.2. Indicates battery [...]

  • Page 19

    Operator Manual, Supercharg er 60 R3.0 Page 19 of 62 4.8 SW4 - CELL SELECTOR: 4.8.1. Two digit selector to program the battery terminal voltage as a function of the number of cells. 4.8.2. Rate: 1.75 volts per cell for charge a nd 1.0 volts per cell for discharge. 4.8.3. Used also in the Float and Peak Voltage modes to enter nom inal battery voltag[...]

  • Page 20

    Operator Manual, Supercharg er 60 R3.0 Page 20 of 62 Figure 2 - Front Panel[...]

  • Page 21

    Operator Manual, Supercharg er 60 R3.0 Page 21 of 62 4.12 DS1A - RESET: 4.12.1. Indicates that the unit is in standby. 4.13 DS1B - CYC END: 4.13.1. Flashing (with pulsating beeper) cycle end. Indicates that the unit has completed its cycle. 4.14 DS2A - DUAL: 4.14.1. Indicates that the DUAL rate mode (MAIN and TOPPING) is selected. 4.15 DS2B - MAIN:[...]

  • Page 22

    Operator Manual, Supercharg er 60 R3.0 Page 22 of 62 4.25 DS7B - OVR HEAT: 4.25.1. Indicates that the discharge bank is overheated. 4.26 DS8A - VOLT FLT: Indicates voltage fault. 4.26.1. Continuous: battery connected with polarity reversed. 4.26.2. Flashing: (during charge) battery voltage in excess of 1.75 volts per cell or in excess of 85 volts, [...]

  • Page 23

    Operator Manual, Supercharg er 60 R3.0 Page 23 of 62 5. MODES OF OPERATION 5.1 CONSTANT CURRENT CHARGE 5.1.1. DUAL RATE: 5.1.1.1. The battery is charged at the main rate for a preset time, at the end of which, the current is switched automa tically to the topping rate for the remainder of the total time selected. 5.1.1.2. Charging is automa tically[...]

  • Page 24

    Operator Manual, Supercharg er 60 R3.0 Page 24 of 62 5.2 CONSTANT VOLTAGE CHARGE. 5.2.1. The battery is charged at the topping rate for a preset time. 5.2.2. When the battery voltage is within 0.5V of the selected float vol tage, the charging current begins to diminish, and se ttles to the level of current required to maintain the battery at the se[...]

  • Page 25

    Operator Manual, Supercharg er 60 R3.0 Page 25 of 62 5.3 PEAK CHARGE. 5.3.1. Transfer from Main to Topping on Peak voltage. 5.3.1.1. The battery is charged at the main rate for a preset time. 5.3.1.2. When the battery voltage reaches the programmed peak voltage, the charging current transfers from main to topping. 5.3.1.3. Charging is automa ticall[...]

  • Page 26

    Operator Manual, Supercharg er 60 R3.0 Page 26 of 62 5.4 DISCHARGE. NOTE: For battery voltages greater than 32V, the discharge current is automatically limited to 30A. A current fault condition will result if more than 30A is programmed. 5.4.1. ANALYSIS (AUTO CUT-OFF): 5.4.1.1. The battery is discharged at the selected rate for a preset time. 5.4.1[...]

  • Page 27

    Operator Manual, Supercharg er 60 R3.0 Page 27 of 62 6. OPERATING INSTRUCTIONS 6.1 GENERAL 6.1.1. Verify RESET 6.1.1.1. Verify that the reset button is depressed before turning power on. 6.1.2. Connect the Battery 6.1.2.1. Connect the battery cable to the batteries and the Temp-Plate. 6.1.2.2. If only one ba ttery is used, connect the free plug to [...]

  • Page 28

    Operator Manual, Supercharg er 60 R3.0 Page 28 of 62 6.2 CONSTANT CURRENT CHARGE. 6.2.1. Main Charge 6.2.1.1. Program Main charging rat e and time duration. 6.2.1.2. Verify that the Timer Speed is consistent with the required elapsed time. 6.2.2. Topping Charge 6.2.2.1. Program Topping chargi ng rate and total time of charge (Total time = Main + To[...]

  • Page 29

    Operator Manual, Supercharg er 60 R3.0 Page 29 of 62 6.3.4. RUN 6.3.4.1. Start the Charger-Analyzer in the Single Rate mode. The charger will start to reduce the charging current when the battery voltage is within 0.5V of the float level. 6.3.4.2. The charge will terminate autom a tically (CYCLE END) when the TOTAL TIME selected is reached. 6.3.4.3[...]

  • Page 30

    Operator Manual, Supercharg er 60 R3.0 Page 30 of 62 6.5 DISCHARGE NOTE: Do not discharge batteries on the Te mp-Plate. Normal battery heating of the Temp-Plate during discharge will generate a false battery Overtemp fault when attempting to recharge it. 6.5.1. Current and Time 6.5.1.1. Program the discharge rate and tim e duration. 6.5.1.2. Verify[...]

  • Page 31

    Operator Manual, Supercharg er 60 R3.0 Page 31 of 62 6.6 Float/Peak Voltage Chart CHART RELATING THE COMPUTED FLOAT AND PEAK VOLTAGES TO THE SELECTED NOMINAL BATTERY VOLTAGE 6.6.1. The Cell Selector becomes a Nominal Battery Voltage selector in other than the Constant Current settings of the Voltage Mode Selector. 6.6.2. NOTE: Nominal battery volta[...]

  • Page 32

    Operator Manual, Supercharg er 60 R3.0 Page 32 of 62 6.7 OPERATING NOTES AND PRECAUTIONS 6.7.1. Make sure that the instrument is in th e reset position before turning power on or off, or before connecting or disconnecting batteries. 6.7.2. When a cycle is terminated either automatically or by resetting, wait about two to three seconds before re-sta[...]

  • Page 33

    Operator Manual, Supercharg er 60 R3.0 Page 33 of 62 7. INSTALLATION 7.1 BENCH SPACE. 7.1.1. The Charger-Analyzer system occupies 19" x 17" (48.3 cm x 43.2 cm) of table top space for the charger and 10" x 25" (25 cm X 63.5 cm) for the Temp-Plate. 7.1.2. Allow also at least 6" (15.2 cm) of separation from the wall and adjace[...]

  • Page 34

    Operator Manual, Supercharg er 60 R3.0 Page 34 of 62 Figure 4 - Line Voltage Wiring, 208/230V Figure 5 - Line Voltage Wiring, 230/245V[...]

  • Page 35

    Operator Manual, Supercharg er 60 R3.0 Page 35 of 62 8. VERIFICATION OF PERFORMANCE The Charger-Analyzer has been designed, manufactur ed and tested to give thousands of hours of trouble free operation, but if you find that your unit is not performing properly (or as expected), please refer first to the operating inst ructions for re-assurance that[...]

  • Page 36

    Operator Manual, Supercharg er 60 R3.0 Page 36 of 62 8.3 TIMER VERIFICATION. 8.3.1. Settings: 8.3.1.1. Set the Main and Topping Charge Current Selectors to zero. 8.3.1.2. Set both Time Selectors to zero. 8.3.1.3. Set the Timer Speed Switch to the test (center) position. 8.3.2. NOTE: Current and voltage readings must remain at zero during the follow[...]

  • Page 37

    Operator Manual, Supercharg er 60 R3.0 Page 37 of 62 8.4 BATTERY OVERTEMP CUT-OFF. 8.4.1. Settings: 8.4.1.1. Set current selectors to zero. 8.4.1.2. Set the timer speed switch in the normal position (to t he right). 8.4.1.3. Set time selectors to 1/01 and cell selector to 20. 8.4.1.4. Connect the battery cable to the unit but make no battery or Tem[...]

  • Page 38

    Operator Manual, Supercharg er 60 R3.0 Page 38 of 62 8.6 REVERSE POLARITY TEST. 8.6.1. Connect the battery cable to a voltage source (CAL-100 or low current power supply and reverse the polarity). Start at zero and advance towards -0.5V 8.6.2. The unit will show a fault through the alar m and the voltage fault light at about - 0.25V (-0.20V to -0.3[...]

  • Page 39

    Operator Manual, Supercharg er 60 R3.0 Page 39 of 62 8.9 FULL DISCHARGE. 8.9.1. Settings: 8.9.1.1. Set the Current selectors to zero. 8.9.1.2. Set the Time selectors to 1/01. 8.9.1.3. Set the Cell selector to 20. 8.9.2. Start the unit in the full discharge mode (red). Unit will run. I ncrease the discharge current selector to any value above 1 AMP [...]

  • Page 40

    Operator Manual, Supercharg er 60 R3.0 Page 40 of 62 8.12 FLOAT VOLTAGE: 8.12.1. Settings: 8.12.1.1. Set the Voltage Control Selector to Float 8.12.1.2. Set the Current Selectors to zero. 8.12.2. Connect the Battery Cable to the battery and note the battery voltage. 8.12.3. Using the chart in figure 3 (page 19) fi nd in the FLOAT column the closest[...]

  • Page 41

    Operator Manual, Supercharg er 60 R3.0 Page 41 of 62 8.14 METERS 8.14.1. Verify the battery voltage and charge/discharge current readings by comparing against a CAL-100 Calibrator or a refere nce voltmeter and a reference ammeter (or reference shunt). 8.14.2. See 8.1 for adjustments.[...]

  • Page 42

    Operator Manual, Supercharg er 60 R3.0 Page 42 of 62 9. CALIBRATION • NOTE 1: The Charger-Analyzer must be verified (and calibrated if required) at least once every 12 months, or earlier if deviation from performance is observed. (see first note on section 7). • NOTE 2: Perform adjustments only when changing parts and components that r equire r[...]

  • Page 43

    Operator Manual, Supercharg er 60 R3.0 Page 43 of 62 • NOTE 3: Insert an external shunt/ammeter in series with any of the battery leads (Use the Single Cell adaptor to facilitate the connection or simply use the CAL-100 which is a calibrator designed specifically to test and certify Charger-Analyzer Battery Charger-Analyzers. • NOTE 4: The char[...]

  • Page 44

    Operator Manual, Supercharg er 60 R3.0 Page 44 of 62 Figure 6 - Meters Board Adjustments[...]

  • Page 45

    Operator Manual, Supercharg er 60 R3.0 Page 45 of 62 Figure 7 - Control S witch Board Adjustments 9.2.3. CONTROL SWITCH (see fig 8). NOTE: For voltage measurements use pin 14 on the Current Control Board as reference common. 9.2.3.1. R10 - AMPLIFIER ZERO. • Static test (no battery or Calibrator). • Adjust a reading of 0.000V " 0.003V at E3[...]

  • Page 46

    Operator Manual, Supercharg er 60 R3.0 Page 46 of 62 • Set the Cell Selector at 20, connect a voltage source set to approximately 21V and start the Charger-Analyzer in AUTO Discharge • Adjust for a Discharge CUT-OFF (Capacity Failure) at 20.0 volts. • NOTE: This step requires that the Overvoltage cut-off on the MONITOR circuit board be previo[...]

  • Page 47

    Operator Manual, Supercharg er 60 R3.0 Page 47 of 62 • NOTE 1: Other currents can also be used for High Current calibration (20A minimum). • NOTE 2: Adjustments of R28 and R25 a re interactive. Therefore, It will be necessary to repeat the adjustments once or twice to achieve exact results. • The Voltage reading at E3 (shunt amplifier output)[...]

  • Page 48

    Operator Manual, Supercharg er 60 R3.0 Page 48 of 62 Figure 9 - Monitor Board Adjustments 9.2.4. MONITOR (see fig 12) NOTE: Use pin 14 on the card connector (or the Test Point E0 on the Control Board) as ground reference for voltage measurements. 9.2.4.1. U12 pin 1 - B ATTERY VOLTAGE • This point corresponds to one tent h of t he battery voltage [...]

  • Page 49

    Operator Manual, Supercharg er 60 R3.0 Page 49 of 62 9.2.4.3. R62 – OVERVOLTAGE • (no battery) • Set the Current Selectors to zero and set the Cell Selector to 20 (1.75V/cell) • Connect an external voltage source (Power Supply or CAL-100) to simulate the battery voltage, set at approximately 34V. • Start the Charger-Analyzer in either of [...]

  • Page 50

    Operator Manual, Supercharg er 60 R3.0 Page 50 of 62 Figure 10 - Voltage Control Board Adjustmen ts 9.2.5.2. VOLTAGE CONTROL - See [ Figure 10 ] 9.2.5.2.1. R11, FLOAT VOLTAGE: • Connect a CAL-100 Calibrator or a power supply capable of producing at least 10V (very little current required) to the CAL (-) and CAL (COMMON) test points. The positive [...]

  • Page 51

    Operator Manual, Supercharg er 60 R3.0 Page 51 of 62 • Adjust R11 as required to reduce the charging current to zero at a simulated battery voltage of 28.0V • Note: This test can also be performed directly on a battery (no calibrator required), preferably one that is “soft” (rapid voltage change). Adjust R11 as necessary to maintain the bat[...]

  • Page 52

    Operator Manual, Supercharg er 60 R3.0 Page 52 of 62 Figure 11 - Circuit Board Sequence[...]

  • Page 53

    Operator Manual, Supercharg er 60 R3.0 Page 53 of 62 10. TROUBLESHOOTING AND REPAIRS 10.1 TROUBLESHOOTING The following are hints and directions to help you locate the most probable causes of deviation of performance as establis hed in the procedures of section 8. 10.1.1. UNIT CHARGES ON MAIN BUT DOES NOT CHARGE ON TOPPING AN D DOES NOT DISCHARGE. [...]

  • Page 54

    Operator Manual, Supercharg er 60 R3.0 Page 54 of 62 Do not connect a battery under this condition! 10.1.12. 9.1.12 CURRENT TRACKING IS OFF BY A SMALL CONSTANT AMOUNT. Amplifier zero or low current calibrate out of adjustment (CONTROL board). 10.1.13. 9.1.13 CURRENT TRACKING IS OFF BY A SMALL AMOUNT WHICH INCREASES AS THE PROGRAMMED VALUE IS INCREA[...]

  • Page 55

    Operator Manual, Supercharg er 60 R3.0 Page 55 of 62 10.2 FINDING A SHORTED DISCHARGE TRANSISTOR Since all discharge transistors are wired in pa rallel, a single shorted transistor will short the entire bank. The procedure that follows will allow the finding of the shorted transistor without requiring removal and testing of each device individually[...]

  • Page 56

    Operator Manual, Supercharg er 60 R3.0 Page 56 of 62 Figure 12 - Measuring for a shorted transistor[...]

  • Page 57

    Operator Manual, Supercharg er 60 R3.0 Page 57 of 62 Figure 13 - Location of Current Limiters[...]

  • Page 58

    Operator Manual, Supercharg er 60 R3.0 Page 58 of 62 Figure 14 - Po wer Block Diagram[...]

  • Page 59

    Operator Manual, Supercharg er 60 R3.0 Page 59 of 62 11. REPLACEABLE MODULES AND PARTS 11.1 CIRCUIT BOARDS 9879101001 - METERS (LED) 9879903004 - VOLTAGE CONTROL 9879960001 – CONTROL SWITCH 9879903009 – CLOCK (older units) 9879903010 – TIMER (ol der units) 9879903109 – CLOCK-TIMER (newer units) 9879903011 – CURRENT CONTROL 9879960012 – [...]

  • Page 60

    Operator Manual, Supercharg er 60 R3.0 Page 60 of 62 12. BATTERY TESTING NOTES Note, hazardous condition: Handle batteries with extreme care as they are capable of very high discharge rates if short circuited. Check the Battery Manual, IMM or Aircraft Manufacturer Instructions for information on charging, discharging and testing. The Charge & F[...]

  • Page 61

    Operator Manual, Supercharg er 60 R3.0 Page 61 of 62 13. DISCLAIMER • The Supercharger is a precision system inte nded to be operated by personnel qualified in the servicing of aircraft batteries. • The end user must establish suitability in the intended application. • JFM Engineering’s responsibility is limited to the repair/replacement of[...]

  • Page 62

    Operator Manual, Supercharg er 60 R3.0 Page 62 of 62 14. REVISION INDEX Table 2 - Index of Revisions REVISION DATE NOTES 1.0 21 January 2001 Release 2.0 15 January 2003 New Clock-Timer Board and add itional Peak function 2.1 23 July 2003 Overvoltage is now set at 1.75V/cel l (was 1.70). N umerous ot her text updates (clarifi cations). 3.0 4 October[...]