C-D Ferro IFR

INSTALLATION AND OPERATING INSTRUCTIONS
FerroCharge®
INDUSTRIAL BATTERY CHARGERS
PM990-1897-00, ISSUE 5
Issue History
ISSUE PAGE(S) DESCRIPTION APP'D / DATE
1 All Original Release 8/4/03

2 56 Correct 575v 3 –ph primary connection 4/16/04
3 53 to 60 Remove optional ammeter and reference to TB3 watering 2/15/05
4 5, 50-52 Add models, add French safety instructions 5/13/05
5 9,50-55, Add Models, Cabinet B, and three transformer diagrams, add
MCM 9/20/06
59,62,65-82 TVS to diagrams, MC4 photos SEE ECN 15704
PM990-1897-00, ISSU E 5 2
Table of Contents
1. IMPORTANT SAFETY INSTRUCTIONS.......................................................................................................................... 7
2. RECEIVING AND INSTALLATION .................................................................................................................................. 8

2.1. RECEIVING ......................................................................................................................................................................... 8
2.2. IDENTIFICATION ................................................................................................................................................................. 8
2.3. STORAGE ........................................................................................................................................................................... 9
2.4. LOCATION .......................................................................................................................................................................... 9
2.5. MECHANICAL INSTALLATION............................................................................................................................................. 9
2.6. ELECTRICAL CONNECTION ............................................................................................................................................... 10
2.6.1. AC Input voltage and voltage changeover .............................................................................................................. 10
2.6.2. AC input voltage cables .......................................................................................................................................... 11
2.6.3. Grounding ............................................................................................................................................................... 12
2.6.4. DC cables and cable connectors............................................................................................................................. 12
2.7. MAINTENANCE ................................................................................................................................................................ 12
3. SCOUT CONTROL.............................................................................................................................................................. 13
3.1. DESCRIPTION ................................................................................................................................................................... 13
3.2. OPERATION ...................................................................................................................................................................... 14
3.2.1. Basic operation ....................................................................................................................................................... 14
3.3. BASIC SETTINGS ............................................................................................................................................................... 14
3.3.1. Setting the number of cells ...................................................................................................................................... 14
3.3.2. Changing the five-second factory-set delay ............................................................................................................ 15
3.3.3. Changing maximum charging time ......................................................................................................................... 16
3.3.4. Cold Storage Setting ............................................................................................................................................... 16
3.3.5. Manual equalizing................................................................................................................................................... 17
3.3.6. Automatic equalizing............................................................................................................................................... 17
4. COMPUCHARGE 3 CONTROL........................................................................................................................................ 18
4.1. DESCRIPTION ................................................................................................................................................................... 18
4.2. OPERATION ...................................................................................................................................................................... 19
4.3. BASIC SETTINGS .............................................................................................................................................................. 19
4.3.1. Setting the precharge delay..................................................................................................................................... 19
4.3.2. Activating cold storage ........................................................................................................................................... 20
4.3.6. Automatic watering ................................................................................................................................................. 22
5. COMPUCHARGE 4............................................................................................................................................................. 23
5.1. DESCRIPTION ................................................................................................................................................................... 23
5.2. OPERATION ...................................................................................................................................................................... 24
5.3. BASIC SETTINGS .............................................................................................................................................................. 24
5.3.1. Setting the Precharge Delay ................................................................................................................................... 24
5.3.2. Setting the Automatic Equalizing Frequency .......................................................................................................... 25
5.3.3. Setting the Equalize Charge Duration .................................................................................................................... 25
5.3.4. Setting the Refresh Charge Interval ........................................................................................................................ 25
5.3.5. Setting the Number of Cells..................................................................................................................................... 25
5.3.6. Setting the Shunt Size .............................................................................................................................................. 26
5.3.7. Setting the Operating Temperature......................................................................................................................... 26
5.3.8. Setting the Gassing Voltage .................................................................................................................................... 26
5.3.9. Setting the Charge Profile....................................................................................................................................... 26
5.3.10. Setting the Hold Time for Opportunity Charging ................................................................................................... 27
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5.3.11. Cooldown Timer at End of Charge ......................................................................................................................... 27
6. RANGER II CONTROL ...................................................................................................................................................... 28
6.1. DESCRIPTION ................................................................................................................................................................... 28
6.2. BASIC SETTINGS .............................................................................................................................................................. 29
6.2.1. Real-time or fixed increment starting...................................................................................................................... 29
6.2.4. Setting cool time...................................................................................................................................................... 30
6.2.5. Monitoring water flow ............................................................................................................................................ 30
6.2.6. Main power override............................................................................................................................................... 31
6.2.7. Water control override............................................................................................................................................ 31
6.2.9. Selecting the shunt size ........................................................................................................................................... 31
6.2.10. Setting the rated output current .............................................................................................................................. 31
6.2.11. Setting the charge mode .......................................................................................................................................... 31
6.2.12. Setting the date........................................................................................................................................................ 32
6.2.13. Setting the correct time ........................................................................................................................................... 32
6.2.14. Setting the day of the week ...................................................................................................................................... 32
6.2.15. Activating daylight savings time ............................................................................................................................. 32
6.2.16. Activating and setting the address .......................................................................................................................... 32
6.2.17. Setting the baud rate ............................................................................................................................................... 33
6.3. OPERATION ...................................................................................................................................................................... 33
6.3.1. Manual starting....................................................................................................................................................... 33
6.3.2. Manual Stopping ..................................................................................................................................................... 33
6.3.4. Operation after loss of AC power (warm start) ...................................................................................................... 33
6.3.5. Charge data retrieval.............................................................................................................................................. 34
6.4. SPECIAL FEATURES WITH A COMPATIBLE BATTERY MODULE ........................................................................................... 34
6.4.1. Installing a compatible battery module communications board ............................................................................. 34
6.4.2. Retrieving data from a compatible battery module................................................................................................. 34
6.5. COMMUNICATIONS PORT ................................................................................................................................................. 35
7. CHARGER OPERATION ................................................................................................................................................... 36
7.1. RECOMMENDED CHARGING PROCEDURES ........................................................................................................................ 36
7.2. OPERATING CHARACTERISTICS ........................................................................................................................................ 37
8. TROUBLESHOOTING ....................................................................................................................................................... 39
8.1. GENERAL TROUBLESHOOTING GUIDELINES..................................................................................................................... 39
8.2. PROCEDURE ..................................................................................................................................................................... 39
8.3. COMPONENT TESTING ...................................................................................................................................................... 44
8.4. REPLACING COMPONENTS ................................................................................................................................................ 45
9. MODELS, RATINGS, AND PARTS LISTS ...................................................................................................................... 46
10. SCHEMATICS AND WIRING DIAGRAMS ................................................................................................................ 52

SCHEMATIC DIAGRAM – 208/240/480 VAC 1- PHASE....................................................................................................................53
SCHEMATIC DIAGRAM – 120/208/240 VAC 1- PHASE....................................................................................................................54
SCHEMATIC DIAGRAM – 208/240/480 VAC 3-PHASE.....................................................................................................................55
SCHEMATIC DIAGRAM – 208/240/480 VAC 3-PHASE THREE TRANSFORMERS.......................................................................56
SCHEMATIC DIAGRAM –480 VAC 3-PHASE THREE TRANSFORMERS......................................................................................57
SCHEMATIC DIAGRAM – 575 VAC 1- PHASE..................................................................................................................................58
SCHEMATIC DIAGRAM – 575 VAC 3- PHASE..................................................................................................................................59
SCHEMATIC DIAGRAM – 575 VAC 3- PHASE THREE TRANSFORMERS....................................................................................60
WIRING DIAGRAM - 1 PHASE - 208/240/480 VAC ...........................................................................................................................61
PM990-1897-00, ISSU E 5 4
WIRING DIAGRAM - 3 PHASE - THREE TRANSFORMERS - 208/240/480 VAC ...........................................................................64
WIRING DIAGRAM - 3 PHASE - THREE TRANSFORMERS - 480 VAC .........................................................................................65
WIRING DIAGRAM - 1 PHASE - 575 VAC .........................................................................................................................................66
WIRING DIAGRAM - 3 PHASE - 575 VAC .........................................................................................................................................67
WIRING DIAGRAM - 3 PHASE - THREE TRANSFORMERS - 575 VAC .........................................................................................68
PM990-1897-00, ISSU E 5 5
Figures and Tables Content
FIGURE 2.1 NAMEPLATE .............................................................................................................................................................. 8

TABLE 2.1 AC INPUT VOLTAGE CODES...................................................................................................................................... 8
FIGURE 2.2 CABINET DIMENSIONS............................................................................................................................................. 9
FIGURE 2.3 AC VOLTAGE RATING LABEL (VOLTAGE CIRCLED) ......................................................................................... 11
FIGURE 2.4 AC FUSE RATING CHART. CIRCLES INDICATE THE PROPER FUSES FOR EACH VOLTAGE....................... 11
TABLE 2.2 ALLOWABLE AC INPUT RANGE............................................................................................................................... 12
FIGURE 3.1 SCOUT CONTROL BOARD...................................................................................................................................... 13
FIGURE 3.2 SCOUT CONTROL BOARD JUMPERS ................................................................................................................... 15
FIGURE 3.3 JUMPERS FOR CHANGING CELLS ....................................................................................................................... 15
FIGURE 3.4 JUMPERS FOR SETTING TURN ON DELAY.......................................................................................................... 16
FIGURE 3.5 JUMPERS FOR SETTING MAXIMUM CHARGING TIME ..................................................................................... 16
FIGURE 3.6 JUMPERS FOR SETTING AUTOMATIC EQUALIZE ............................................................................................. 17
FIGURE 4.1 COMPUCHARGE 3 CONTROL ............................................................................................................................... 18
FIGURE 4.2 JUMPERS FOR SETTING TURN ON DELAY.......................................................................................................... 20
FIGURE 4.3 JUMPERS FOR SETTING COLD STORAGE........................................................................................................... 20
FIGURE 4.4 JUMPERS FOR SETTING THE NUMBER OF CELLS ............................................................................................ 21
FIGURE 4.5 JUMPERS FOR SETTING AUTOMATIC EQUALIZE ............................................................................................. 22
FIGURE 5.1 COMPUCHARGE 4 CONTROL (L) AND INTERFACE (R) BOARDS..................................................................... 23
FIGURE 6.1 RANGER II CONTROL WITH COMMUNICATIONS BOARD................................................................................. 28
FIGURE 7.1 TYPICAL FERRORESONANT CHARGER CURVES............................................................................................... 37
TABLE 8.1 TEST INSTRUMENTS AND TOOLS FOR TROUBLESHOOTING ............................................................................. 39
TABLE 8.2 DIODE CONNECTION TORQUE VALUES ............................................................................................................... 45
PM990-1897-00, ISSU E 5 6
1. IMPORTANT SAFETY INSTRUCTIONS
INSTRUCTIONS IMPORTANTES CONCERNANT LA SÉCURITIÉ
a. Read the instruction manual and all warning labels on the charger and battery before using the charger.
b. Familiarize yourself with the locations of hazardous voltages within the cabinet.
c. Danger: To prevent electric shock do not touch uninsulated live parts of the charger or battery. Danger: risque de chocs
électriques. Ne pas toucher les parties non isolées du connecteur de sortie ou les bornes non isolées de l’accumulateur.
d. Shut off the charger before connecting or disconnecting the battery. Press the STOP key before disconnecting the
battery.
e. The charger must be operated or serviced only by qualified personnel.
f. De-energize the ac input and disconnect the battery before servicing the charger.
g. Do not operate the charger outside its ratings as specified on the data nameplate.
h. FerroCharge chargers are intended for charging lead acid batteries only. Attention : utiliser pour charger uniquement
les accumulateurs du type au plomb. D’autres types d’accumulateurs pourraient éclater et causer des blessures ou
dommages.
i. Do not expose the charger to water or other liquids.
j. FerroCharge chargers are intended for indoor use only.
CAUTION: DO NOT EXPOSE TO RAIN.
ATTENTION: NE PAS EXPOSER À LA PLUIE.
k. Chargers are equipped from the factory with a tag describing the ac input Voltage. If the tag does not match the
available ac line the input must be reconnected and the fuse values changed following the instructions in this manual.
CAUTION – DISCONNECT SUPPLY BEFORE CHANGING FUSES.
ATTENTION - COUPER L’ALIMENTATION AVANT DE REMPLACER LES FUSIBLES.
l. FerroCharge chargers are not intended for use in hazardous locations. Even if equipped with an explosion proof
connector to match the battery, the charger must be located in a non-hazardous location.
m. Check for wear on the dc cables and connector. Replace cables that have cracked insulation. Replace connectors that
overheat, are melted, or with pitted contacts.
Legal Disclaimer
Any data, descriptions or specifications presented herein are subject to revision by C&D Technologies, Inc. without notice. While such information
is believed to be accurate as indicated herein, C&D Technologies makes no warranty and hereby disclaims all warranties, express or implied, with
regard to the accuracy or completeness of such information. Further, because the product(s) featured herein may be used under conditions beyond
its control, C&D Technologies hereby disclaims all warranties, either express or implied, concerning the fitness or suitability of such product(s) for
any particular use or in any specific application or arising from any course of dealing or usage trade. The user is solely responsible for determining
the suitability of the product(s) featured herein for the user’s intended purpose and in user’s specific application.
Seller’s liability for any breach of warranty is limited as set forth in seller’s standard warranty applicable to the product (“the warranty”). The
warranty is exclusive and offered in lieu of all other express, implied or statutory warranties including, without limitation, implied warranties of
merchantability and fitness for a particular purpose. In no event shall the seller’s liability for any damages arising out of any sale of products to
buyer, and regardless of the legal theory on which such damages may be based, exceed the amount that supplier has received as payment for such
products and under no circumstances shall supplier be subject to any consequential, incidental, indirect, special or contingent damages whatsoever,
including but not limited to damages for lost profits or goodwill, even if supplier was advised of the possibility of such damages.
PM990-1897-00, ISSU E 5 7
2. RECEIVING AND INSTALLATION
2.1. Receiving
Inspect the charger for any shipping and handling damage as soon as it arrives. Describe any damage on the receiving slip
and immediately notify the shipper. Verify the model and serial numbers printed on the packing list against the nameplate
(Figure 2.1). If they disagree, contact your representative before proceeding with installation. Use caution when moving
chargers. Use the proper moving equipment. Do not drop or otherwise abuse the charger.
MODEL: IFR18HK1000 SPEC: XXXXXX

SERIAL NUMBER: XXX000000
DC OUTPUT: 36 VOLTS 190 AMPS 18 CELLS LA
RATED 8 HOUR CAPACITY: 1000 (100D6C8) AH
AC INPUT: 208/240/480 VOLTS 3 PHASE
28/24/12 AMPS 60 HERTZ
RECOMMENDED LINE FUSES: 40/40/20
FIGURE 2.1 NAMEPLATE
2.2. Identification
A six-element model number identifies each charger. Each element describes a different charger performance characteristic.
The model number of a FerroCharge charger describes its basic operating characteristics. A typical model number is:
IFR - Product Family

12 - Number of (Lead-Acid) Cells in Battery to be charged
HK - AC Input Voltage Code, See Table 2.1
1000 - Ampere-Hour Rating for 8-Hour Charge
AC INPUT VOLTAGE CODES

Code Input (VAC) and Phase Frequency
(Hz)
AC 120/208/240, 1-Phase 60 Hz
CE 208/240/480, 1-Phase 60 Hz
HK 208/240/480, 3-Phase 60 Hz
M 575, 1-Phase 60 Hz
K 480, 3-phase 60 Hz
L 575, 3-Phase 60 Hz
TABLE 2.1 AC INPUT VOLTAGE CODES
PM990-1897-00, ISSU E 5 8
2.3. Storage
Keep the charger in its original shipping container until it is ready to be installed. The unit can be safely stored in any clean,
dry area where temperatures remain between 40°F and 120°F (5°C and 50°C).
2.4. Location
Battery charging produces heat and a potentially explosive mixture of odorless oxygen and hydrogen gases. Safe charging
requires a clean, dry, well-ventilated area. For long battery life the room temperature should be between 60°F and 90°F
(16°C and 32°C). Refer to the battery manufacturer’s recommendations. The charger is rated to operate in ambient
temperatures between 60°F and 104°F (16°C and 40°C). The charger may be operated for limited periods (up to 4 hours) at
ambient temperatures between 104°F and 122°F (40°C to 50°C).
FerroCharge chargers are natural convection-cooled. Chargers require a MINIMUM of four inches of clearance between
the floor, walls, chargers, and other obstructions for adequate air circulation. EXPLOSIVE, COMBUSTIBLE or
FLAMMABLE MATERIALS SHOULD NOT BE PERMITTED IN THE CHARGING ROOM. NEVER MOUNT A
CHARGER ON OR ABOVE COMBUSTIBLE MATERIALS. NE PAS INSTALLER SUR DES SURFACES
COMBUSTIBLES OU AU-DESSUS DE TELLES SURFACES.
To prevent the accumulation of explosive concentrations of hydrogen and oxygen, the charging area should have sufficient
ventilation to prevent formation of one percent, by volume, of hydrogen. It is important to note hydrogen is generated at
different rates during various times in the charger cycle. Most of the gas forms during the last two to three hours of the
charge when the average cell potential exceeds 2.37 volts. Every pint of water dissociated during recharge releases 23 cubic
feet of hydrogen gas to the atmosphere. To calculate hydrogen formation, multiply the number of pints of water needed to
correctly re-level cells after charging then multiply the number by 23. Thus, a lead-acid motive power battery that requires
1.5 pints of water to re-level, will produce 34.5 cubic (1.5 X 23) feet of hydrogen.
An approximation technique may be used to estimate hydrogen production from batteries charged by chargers equipped with
CompuCharge and Ranger controls. It is estimated a total of 0.24 cubic feet of hydrogen gas will evolve from each cell per
100 ampere-hours of capacity. For example, an 18-cell battery rated at 720 ampere-hours:
Cells x Capacity x 0.24/100 = Cubic feet of hydrogen/charge cycle
18 x 720 x 0.24/100 = 31.1 Cubic feet of hydrogen/charge cycle
2.5. Mechanical installation
Chargers can be bolted to noncombustible floors or steel benches. Consult Figure 2.2 for charger cabinet dimensions. Wall
mounting requires optional brackets, part number KBC05889A, quantity 2.
Cabinet Height Width Depth

A 26.062 In 21.75 In 22.75 In
A 662 mm 552 mm 578 mm
B 26.062 In 32 In 22.75 In
B 662 mm 813 mm 578 mm
FIGURE 2.2 CABINET DIMENSIONS
PM990-1897-00, ISSU E 5 9
2.6. Electrical connection
Each charger requires a fused safety disconnect switch or a circuit breaker. Use a line protection device rated for the
recommended line fuse value shown on the charger nameplate (Figure 2.1). Electrical installations must be performed by a
qualified electrician and satisfy all local, national and federal electrical codes. Proper grounding is required both for safety
and to ensure optimum noise and transient immunity of the control board. Refer to the following sections for more specific
information.
CAUTION
Electrical connections can work loose during shipping. Check all connections for tightness before connecting the charger to the
AC supply voltage.
2.6.1. AC Input voltage and voltage changeover
The voltage circled on the input voltage rating label (Figure 2.3} must match the available line voltage. If the voltages are
different, it will be necessary to change the AC line fuses, the control transformer fuse, and the connection terminals on both
the ferroresonant power transformer and the control transformer. Consult the voltage changeover instruction label inside the
cabinet door and the schematics or wiring diagrams at the back of this manual. BE SURE THE CHARGER IS
DISCONNECTED FROM ITS AC POWER SUPPLY AND THE BATTERY BEFORE ATTEMPTING THIS
MODIFICATION.
CAUTION – DISCONNECT SUPPLY BEFORE CHANGING FUSES.

ATTENTION - COUPER L’ALIMENTATION AVANT DE REMPLACER LES FUSIBLES.
NOTE: AC voltage changeover must be made at the terminals of both the ferroresonant power transformer and the control
transformer.
Input voltage changeover CANNOT BE PERFORMED on chargers manufactured for 575 VAC only operation.
CAUTION
DO NOT ATTEMPT TO
RECONNECT VOLTAGE
WITHOUT READING
INSTRUCTIONS
PM990-1897-00, ISSU E 5 10
THIS CHARGER
CONNECTED FOR
120V-208V-240V
480V-575V
OTHER
FIGURE 2.3 AC VOLTAGE RATING LABEL (VOLTAGE CIRCLED)
CAUTION AC FUSE RATING

USE TYPES NOS, NLS, OR OTS ONLY
208V 240V 480V 575V
3 4 5 3 4 5 3 4 5 3 4 5
6 7 8 6 7 8 6 7 8 6 7 8
10 12 15 10 12 15 10 12 15 10 12
20 25 30 20 25 30 20 25 30 15 20
35 40 45 35 40 45 35 40 45 25 30
50 60 50 60 50 60 35 40
FIGURE 2.4 AC FUSE RATING CHART. CIRCLES INDICATE THE PROPER FUSES FOR EACH VOLTAGE.
2.6.2. AC input voltage cables
Customers or electrical contractors must furnish the AC connection. Cables should be sized for the recommended line fuse
values shown on the charger nameplate. Allowable variations from nominal AC line voltages appear in Table 2.2. Route the
AC conduit through the knockout provided in the charger cabinet. Connect the cables to the fuseblock terminals.
CAUTION – USE MINIMUM 75°C WIRING. USE COPPER CONDUCTORS.

ATTENTION - EMPLOYER DES FILS POUR AU MOINS 75 DEG C
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TABLE 2.2 ALLOWABLE AC INPUT RANGE
Nominal AC Voltage AC Voltage Range
120 106-127
208 184-220
240 212-254
480 424-508
575 508-600*
*The charger will operate up to 632 VAC, but certain kinds of control and protective equipment have a maximum voltage
limit of 600V. The manufacturer or power supplier or both should be consulted to assure proper application.
2.6.3. Grounding
The charger chassis must be grounded to the AC power source per the requirements of the National Electrical Code and
applicable local codes. In order to assure dependable operation, it is imperative that the charger be provided a reliable earth
ground. A solderless connector (lug) is provided on the floor of the cabinet near the AC fuseblock.
WARNING – THERE IS RISK OF ELECTRICAL SHOCK IF THE CHARGER IS NOT PROPERLY GROUNDED
2.6.4. DC cables and cable connectors
Each charger ships with a standard, eight-foot long cable that terminates with an appropriate connector. As an option, other
lengths are available. If it is necessary to install longer cables, they must be properly sized to prevent overheating and ensure
compliance with electrical codes.
When specifying replacement DC output connectors, it is important to remember single-phase chargers produce higher peak
currents than similarly rated three-phase systems. The maximum DC current flowing from a single-phase charger is typically
1.3 times the ammeter reading. Higher capacity SB-350 connectors are recommended as retrofit equipment for all single-
phase chargers rated at over 135 amperes.
DC CABLE LENGTHS FROM 15 TO 25 FEET SHOULD BE ONE CABLE SIZE LARGER THAN THE STANDARD
CABLE. CABLE LENGTHS FROM 25 TO 35 FEET SHOULD BE TWO CABLE SIZES LARGER. DC CABLE
LENGTHS SHOULD NOT EXCEED 35 FEET.
CAUTION
Be sure the charger positive terminal is connected to the charger connector terminal marked (+) and the negative terminal to
the one marked (-).
2.7. Maintenance
Battery chargers work most efficiently and deliver better service life with good heat dissipation. Periodic cleaning with dry,
low-pressure air will remove accumulated dust to assure good heat transfer to the surrounding air. At least twice a year,
check input and output circuit connections and ground connections to make sure they are tight.
The DC cables and DC connector require periodic maintenance. Inspect the DC cables and DC connector to verify a sound,
low-resistance connection, that there is no exposed metal, and that the connector is mechanically intact. Dirty or pitted
contacts should be cleaned and lubricated or replaced following the manufacturer’s recommendations. Cables should be
replaced if the insulation is cut or cracked, or if the copper is exposed.
There are no other maintenance adjustments to the FerroCharge chargers.
CAUTION: Disconnect charger from AC voltage supply before servicing or dismantling.
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3. SCOUT CONTROL
3.1. Description
The SCOUT CONTROL is a microprocessor-based controller that minimizes overcharging by continually monitoring
battery voltage. Other STANDARD features include:
• Automatic start-helps prevent operator errors
• dV/dt termination
• Adjustable start delay
• Automatic equalization
• Safety features-checks for correct battery before charge begins
• Maximum charge time-helps prevent overheating
• Abort feature-when the control senses a problem, the red LED flashes twice every second
FIGURE 3.1 SCOUT CONTROL BOARD
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3.2. Operation
3.2.1. Basic operation
SERIES chargers equipped with the SCOUT control have an LED display and keypad for operator interface. One LED
indicates the charger is ready to operate, another LED indicates the battery is being charged and a third LED indicates
when gassing voltage is reached. The Equal key activates the equalization charge mode and the Stop key allows the
charger to be turned off during a charge.
Chargers equipped with the SCOUT control do not have start switches. Charging automatically begins five seconds
after the operator connects the battery, unless the user specifies another delay (refer to Section 3.3.2).
When no battery is connected, the green LED will flash briefly every four seconds to indicate the charger is ready to
begin charge. Once a battery is connected, the red LED will flash and glow steadily when the charge is in progress.
When the battery is 80 percent charged, the yellow LED is lit, and the red LED will be extinguished. When the charge
is complete, the green LED will glow.
If equalize is selected, the charge is extended by three hours. The red LED will flash when the battery is connected and
during the charge. During equalization, the yellow LED will flash and will continue to do so throughout the equalize
cycle. When the charge is complete, the green LED will flash.
If a battery with a number of cells that do not match the charger rating is connected, the charger will not start. Refer to
Section 8, Troubleshooting.
If AC power is interrupted, charging will restart after a randomly timed start-up delay, not exceeding three minutes,
thirty seconds. The random delay prevents a large inrush from the ac line if all chargers were to start at the same time.
In the event of an accidental battery disconnect, the system will shut down automatically, protecting charger
components.
WARNING
If it is necessary to disconnect the battery during the charge, press the stop key before disconnecting the battery.
FAILURE TO TAKE THIS PRECAUTION CAN CAUSE A SERIOUS ARC HAZARD AND A POTENTIALLY
SERIOUS INJURY.
3.3. Basic settings
3.3.1. Setting the number of cells
The SCOUT control has jumpers to set the number of cells, 6, 12, 18, 24 or 36, to match the charger rating. The SCOUT
is shipped from the factory matched to the charger. ADJUSTMENT OF THIS FEATURE IS NEEDED ONLY WHEN
THE PRINTED CIRCUIT BOARD HAS BEEN REPLACED.
To change the number of cells:
1) Disconnect the ac power supply at the circuit breaker or fused safety-disconnect.

2) Open the instrument panel and locate the printed circuit board mounted directly behind it.
3) Locate the configuration jumpers as shown in Figure 3.2.
4) Move the jumpers to the desired number of cells, as shown in
Figure 3.3.
5) Close the cabinet and reconnect the AC power supply.
PM990-1897-00, ISSU E 5 14
FIGURE 3.2 SCOUT CONTROL BOARD JUMPERS
FIGURE 3.3 JUMPERS FOR CHANGING CELLS
3.3.2. Changing the five-second factory-set delay
The SCOUT control is shipped with a preset, five-second safety-delay. The delay can be changed to 30 seconds, one
hour, or four hours.
To lengthen the factory-set delay:
1) Disconnect the battery and disconnect the ac power supply at the circuit breaker or fused disconnect.
2) Open the cabinet door. Remove the screws at the bottom of the instrument panel. Swing out the instrument panel.
3) Locate the bank of configuration jumpers on the control board as shown in Figure 3.2.
4) Move the jumpers to the desired time pattern: 30 seconds, one hour, or four hours. Refer to Figure 3.4.
5) Close all the panels and doors.
6) Reconnect the ac power supply.
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FIGURE 3.4 JUMPERS FOR SETTING TURN ON DELAY
3.3.3. Changing maximum charging time
The maximum charging time is factory-set at 12 hours. This feature should not need adjustment.
FIGURE 3.5 JUMPERS FOR SETTING MAXIMUM CHARGING TIME
3.3.4. Cold Storage Setting
The SCOUT control may be set to extend the charge by 30 minutes for cold storage or similar applications. A special
combination of the override timer settings is used for this feature.
Place jumpers on both positions 13 and 14, 12hr max and 24hr max, to add 30 minutes of charging time with a 12-hour
maximum charge time. Refer to Figure 3.5.
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3.3.5. Manual equalizing
To initiate an equalization charge the operator connects the battery, waits for the red LED to flash or glow, and then presses
the Equal key on the keypad. At the conclusion of an equalize charge the system automatically returns to the daily charge
mode. The operator may initiate or terminate an equalize charge by pressing the Equal key while the charger is charging. If
the charger is in the equalize part of the charge it will stop when the Equal key is pressed.
3.3.6. Automatic equalizing

The SCOUT control can be set to automatically equalize never, every seventh cycle, or every tenth cycle. To set the
automatic equalization:
1) Disconnect the AC power supply at the circuit breaker or fused disconnect panel.
4) Move the jumpers to the desired equalize cycle. The factory setting is 7 cycles. Refer to Figure 3.6.
FIGURE 3.6 JUMPERS FOR SETTING AUTOMATIC EQUALIZE
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4. COMPUCHARGE 3 CONTROL
4.1. Description
The COMPUCHARGE 3 CONTROL is a microprocessor-based controller that reduces the chance for overcharging by
continually monitoring battery voltage and current. Other COMPUCHARGE 3 control features include:
• dV/dt and dI/dt termination
• Turn-on time delay – Five seconds to seven hours, 45 minutes in 15 minute increments
• Automatic equalize – Never, every seven days, 1, 2, 3, 4, 5, 6, or 7 cycles
• Safety features-checks for correct battery before charge begins
• Maximum charge time-helps prevent overheating
• 4-digit, seven segment easy to read LED display
• Fully charged battery detector – won’t start if detected
• Hot battery detector will terminate charge and resume after 8 hours cooling
• Automatic watering control output
FIGURE 4.1 COMPUCHARGE 3 CONTROL
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4.2. Operation
The operating panel of the COMPUCHARGE 3 control is a sealed membrane with a four character, ½ inch LED display, a
Stop key, an Equal key, and a Scroll key.
The charging cycle is initiated when the battery is connected. The COMPUCHARGE 3 control checks for a battery of the
proper voltage. If the match is correct, the display will show a count down until the charge starts. If a mismatch is detected,
an error code (“bU E”) will appear. (Refer to the troubleshooting section for more information.)
If an equalize charge is selected either automatically or by pressing the Equal key, a dot will appear on the display after the
last character on the right. If automatic equalize is selected it will flash. If manual equalize is selected it will not flash. A
manual equalize may be canceled by pressing the Equal key again.
After the user-selected start up delay the charge cycle begins. (For safety reasons the minimum delay is factory set at five
seconds.) The charge current is displayed during the charge.
The COMPUCHARGE 3 control monitors the change in voltage and current to determine when the charge should be
terminated. When the charge is greater than 80% completed, the last digit on the display will flash.
Pressing the Scroll key at any time during the charge cycle will display the battery voltage (“99.9U”). Pressing the Scroll
key twice displays the Ampere-hours returned (“999r”). The display will return to the charging current after 60 seconds, or if
the Scroll key is pressed a third time.
Charging continues until the battery is fully charged and the cell electrolyte is mixed. If the battery remains connected to the
charger for three days, a refresh charge will be initiated automatically.
Cells nearing the end of their operating life or mistreated batteries may be unable to accept a complete charge. If the charge
termination criteria have not been met after 12 hours, the charge cycle is stopped and an error message is displayed
(“12hE”).
When ac power is interrupted during a charge, charging will restart after a randomly timed startup delay not exceeding two
minutes. The random delay prevents a large inrush from the ac line if a group of chargers were to start at the same time.
If a fully charged battery is inadvertently connected to the charger it will be detected and the charge terminated within three
minutes.
A hot battery that goes into thermal runaway will be detected. The charger will stop for 8 hours, and then resume in the
state where it left off. Typically thermal runaway only occurs as the battery approaches full charge.
4.3. Basic Settings
4.3.1. Setting the precharge delay
The precharge delay may be set to take advantage of lower utility rates. To change the precharge delay, follow these steps:
4) Move the jumpers to the desired setting. When multiple jumpers are used the delay times are additive. For
example, placing jumpers on 15 minutes, 2 hours, and 4 hours will set the delay to 6 hours and 15 minutes. Refer
to Figure 4.2. Extra jumpers are located on the upper right hand corner of the board.
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FIGURE 4.2 JUMPERS FOR SETTING TURN ON DELAY
4.3.2. Activating cold storage
Users with a cold storage application can set the COMPUCHARGE 3 control to adjust its charge termination. Battery
starting temperatures of below 55°F are considered cold storage. To select this option, place jumpers on both the “temp
norm” and “temp cold” pins (use two jumpers). Refer to figure 4.3.
FIGURE 4.3 JUMPERS FOR SETTING COLD STORAGE
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The COMPUCHARGE 3 control is set up to match the charger. It has adjustments for a variable number of cells – 6, 9, 12,
15, 16, 18, 20, 24, 32, 36, and 40.
To change the number of cells:
4) Move the jumpers to the desired number of cells. Refer to Figure 4.4. For 9, 15, 16, 20, 32, and 40 cells multiple
jumpers are required as shown in the following table:
Cells Jumpers on
9 6 and 12 cell
15 12 and 18 cell
16 6, 12, and 18 cell
20 18 and 24 cell
32 24 and 36 cell
40 6 and 24 cell

FIGURE 4.4 JUMPERS FOR SETTING THE NUMBER OF CELLS
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The COMPUCHARGE 3 control can be set to automatically equalize never, every 7 days, or every 1, 2, 3, 4, 5, 6, or 7
cycles.
To change the automatic equalize setting:
3) Locate the bank of configuration jumpers on the control board as shown in Figure 4.1 that start with “EQU”.
4) Move the jumpers to the desired equalize setting. The factory setting is 7 days. Refer to Figure 4.5.
Note: The equalize cycles are designed for maximum flexibility, so multiple jumpers placed in the banks ending in
“cyc” are additive. For example, a jumper on the pin marked “EQU 1 cyc” and a jumper on the pin marked “EQU 2
cyc” would result in an equalize charge every three cycles. A single jumper on the pin marked “EQU 1 cyc” results in
equalize every cycle. “NEVER” takes precedence over all other jumpers. Spare jumpers are located on the control
board.
FIGURE 4.5 JUMPERS FOR SETTING AUTOMATIC EQUALIZE
To begin manual equalize, connect the battery and press the Equal key. Press the Equal key again to take the charger out of
equalize.
4.3.6. Automatic watering

The COMPUCHARGE 3 control has a 24 VAC output to power a solenoid for automatic watering. One side of the solenoid
connects to pin 5 of the control board and the other side of the solenoid connects to X4 on the control transformer (CXF).
Refer to the schematics at the back of this manual.
The watering cycle lasts for 3 minutes at the end of charge. If equalize is set, the watering cycle precedes the equalize cycle.
If the charger is equipped with a watering module, watering is automatic; there are no settings required.
Refer to the instructions supplied with the water module for installation and connections to the charger, and for connections
to the water supply. Refer to the instructions supplied with the battery filling system for installation on the battery.
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5. COMPUCHARGE 4
5.1. Description
The CompuCharge 4 is a microprocessor-based controller that reduces the chance for overcharging by continually
monitoring battery voltage and current. The settings are menu driven and accessible from the front panel membrane
switches. Other CompuCharge 4 features include:
• dV/dt and dI/dt termination
• Turn-on time delay – 5, 10, 30, 60 seconds; 0.1, 0.2, 0.5, 1, 2, 5, 8, and 12 hours
• Manual or automatic equalize – None, 1 to 7 cycles, 7 days, or 14 days. Default is 7 cycles. Equalize duration of 1 to 6
hours, default is 3 hours. Equalize is indicated when the decimal point after the rightmost digit flashes.
• Checks for correct battery voltage before charge begins
• Maximum charge time of 12 hours helps prevent overheating.
• 4-digit, seven segment easy to read LED display for menu setup, current, Voltage, and accumulated Ampere-hours
• Gassing voltage set points of 2.37 or 2.40 Volts per cell
• Operating environment setting for normal or cold temperature
• Refresh charge mode settable for intervals of 3, 6, 8, 12, 15, 20, 24, 30, 40, 48, 60, or 72 hours. The default is 72 hours.
• 100 hour cooldown timer after end of charge helps to select the next battery to use
• Opportunity charging mode that Stops charge at gassing voltage. Settable hold time until full charge commences of 3,
6, 8, or 12 hours
• Fully charged battery detector – won’t continue to charge if detected
• Hot battery detector will terminate charge and resume after 8 hours cooling
• Automatic watering control output
• All display segments light before start of charge to indicate proper operation
FIGURE 5.1 COMPUCHARGE 4 CONTROL (L) AND INTERFACE (R) BOARDS
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5.2. Operation
The operating panel of the CompuCharge 4 control is a sealed membrane with a four character, ½ inch 7-segment LED
display. There are three membrane switches, Stop, Equalize, and Scroll (curved arrow) used to enter the setup menu and
select the setup parameters or to display Volts or Ampere-hours accumulated during the charge cycle.
The 7-segment display shows the number of cells during the idle mode. The charging cycle is initiated when the battery is
connected. The CompuCharge 4 control checks for a battery of the proper voltage. If the match is correct, the display will
show a count down until the charge starts. If a mismatch is detected, the display will show “bV E”. (Refer to the
troubleshooting section for more information.)
After the user-selected start up delay the charge cycle begins. (For safety reasons the minimum delay is factory set at five
seconds.) The charge current is displayed during the charge.
The CompuCharge 4 control monitors the change in voltage and current to determine when the charge should be
terminated. When the charge is greater than 80% completed, the last digit on the display will flash.
Pressing the scroll key at any time during the charge cycle will display the battery Volts per cell (“XX.XV”). Pressing the
key twice displays the Ampere-hours returned (“999r”). The display will return to the charging current after 60 seconds, or
if the key is pressed a third time.
Charging continues until the battery is fully charged and the cell electrolyte is mixed. If the battery remains connected to the
charger, a refresh charge will be initiated automatically after a selected interval.
The CompuCharge 4 has an automatic equalize feature that extends the charge to mix the battery electrolyte and equalize
the cell voltages. The decimal point to the right of the rightmost digit flashes to indicate the charger is in the equalize mode.
Cells nearing the end of their operating life or mistreated batteries may be unable to accept a complete charge. If the battery
is not charged in 12 hours the charger will Stop and the display will show “12hE”.
When ac power is interrupted during a charge, charging will restart after a randomly timed startup delay not exceeding two
minutes. The random delay prevents a large inrush from the ac line if a group of chargers were to start at the same time. A
battery that is mostly charged may show as fully charged after restarting.
If a fully charged battery is inadvertently connected to the charger it will be detected and the charge terminated within three
minutes.
A hot battery that goes into thermal runaway will be detected. The charger will Stop for 8 hours, then resume in the state
where it left off. Typically thermal runaway only occurs as the battery approaches full charge.
If the Stop key is pressed the display will show “StPE”. The battery must be disconnected to clear the display.
5.3. Basic Settings
5.3.1. Setting the Precharge Delay
The precharge delay may be set to take advantage of lower utility rates. To change the precharge delay, follow these steps:
1) Press the Stop key and disconnect the battery to return to the idle mode.
2) Press and hold both the Equalize and Scroll keys for 5 seconds until the display goes to the setup menu. The first
menu item is the delay.
3) Press the Equalize key until the desired setting of 5S (seconds), 10S, 30S, 60S; 0.1, 0.2H (hours), 0.5H, 1H, 2H,
5H, 8H, or 12H is reached
4) Press the Stop key to exit the menu or press the Scroll key to go to the next setting.
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5.3.2. Setting the Automatic Equalizing Frequency
The CompuCharge 4 can be set to automatically equalize none, every 1, 2, 3, 4, 5, 6, or 7 cycles, or every 7 or 14 days.
The decimal point to the right of the rightmost digit flashes to indicate the charger is in the equalize mode.
1) Press the Stop key and disconnect the battery to go to the idle mode.
2) Press and hold both the Equalize and Scroll keys for 5 seconds until the display goes to the setup menu. The
second menu item is the delay.
3) Press the Scroll key until the display shows “E no”, “E XC”, or “EXXd”.
4) Press the Equalize key until the desired setting of None, 1 to 7 cycles, 7 days, or 14 days is reached. Default is 7
cycles.
5.3.3. Setting the Equalize Charge Duration
2) Press and hold both the Equalize and Scroll keys for 5 seconds until the display goes to the setup menu. The third
menu item is the equalize duration.
3) Press the Scroll key until the display shows “EdXh”.
4) Press the Equalize key until the desired setting of 1, 2, 3, 4, 5, or 6 hours is reached. Default is 3 hours.
5.3.4. Setting the Refresh Charge Interval

The CompuCharge 4 can be set to perform a refresh charge if the battery remains connected for 3, 6, 8, 12, 15, 20, 24, 30,
40, 48, 60, 72, or 80 hours.
To change the refresh charge interval:
2) Press and hold both the Equalize and Scroll keys for 5 seconds until the display goes to the setup menu. The fourth
menu item is the refresh interval.
3) Press the Scroll key until the display shows “rXXh”.
4) Press the Equalize key until the desired setting of 3, 6, 8, 12, 15, 20, 24, 30, 40, 48, 60, 72 or 80 hours. The default
is 12 hours.
5.3.5. Setting the Number of Cells

The CompuCharge 4 must be set to match the rating of the charger in which it is installed.
To set the number of cells:
2) Press and hold both the Equalize and Scroll keys for 5 seconds until the display goes to the setup menu. The fifth
menu item is the number of cells.
3) Press the Scroll key until the display shows “C XX”.
4) Press the Equalize key until the desired setting of 6, 9, 12, 15, 16, 18, 20, 24, 32, 36, or 40 is reached.
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5.3.6. Setting the Shunt Size
The CompuCharge 4 must be set to match the rating of the charger in which it is installed.
To set the shunt size:
2) Press and hold both the Equalize and Scroll keys for 5 seconds until the display goes to the setup menu. The sixth
menu item is the shunt size.
3) Press the Scroll key until the display shows “S XXX”.
4) Press the Equalize key until the desired setting of 100A, 200A, 300A, 500A, or 600A is reached.
5.3.7. Setting the Operating Temperature

The default setting is normal or “Tnor”. Users with a cold storage application can set the CompuCharge 4 control to adjust
its charge termination. Battery starting temperatures of below 55°F are considered cold storage.
To set the operating temperature and extend the charge time:
2) Press and hold both the Equalize and Scroll keys for 5 seconds until the display goes to the setup menu. The
seventh menu item is the operating temperature.
3) Press the Scroll key until the display shows “Tnor” or “Tcol”.
4) Press the Equalize key to select normal, Tnor, or cold, Tcol.
5.3.8. Setting the Gassing Voltage

The CompuCharge 4 control may be set to detect a gassing point Voltage of 2.37 or 2.40 Volts per cell.
To set the gassing voltage detector:
2) Press and hold both the Equalize and Scroll keys for 5 seconds until the display goes to the setup menu. The eighth
menu item is the gassing voltage limit.
3) Press the Scroll key until the display shows “G2.37” or “G2.40”.
4) Press the Equalize key to select 2.37 or 2.40.
5.3.9. Setting the Charge Profile

The CompuCharge 4 control may be set for either a conventional or opportunity charging profile. In the opportunity
charging mode the charger will Stop when the voltage reaches the gassing point. If the battery remains connected beyond a
selected interval, a complete charge cycle will be performed.
To set the charge profile:
2) Press and hold both the Equalize and Scroll keys for 5 seconds until the display goes to the setup menu. The ninth
menu item is the charge profile mode
3) Press the Scroll key until the display shows “PrCV” or “PrOP”.
4) Press the Equalize key to select conventional mode, “PrCV” or opportunity mode, “PrOP”.
5) Press the Stop key to exit the menu or press the Scroll key to return to the beginning of the menu settings.
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5.3.10. Setting the Hold Time for Opportunity Charging
In the opportunity charging mode the CompuCharge 4 control may be set to wait for 3, 6, 8, or 12 hours after the charger
Stops after reaching the gassing point to begin a full conventional charge cycle.
To set the hold time:
2) Press and hold both the Equalize and Scroll keys for 5 seconds until the display goes to the setup menu. The ninth
menu item is the charge profile mode
3) Press the Scroll key until the display shows “PrCV” or “PrOP”.
4) Press the Equalize key to select the opportunity charging mode, “PrOP”.
5) Press the Scroll key to display “HXXh”, the hold time.
6) Press the Equalize key to select 3, 6, 8, or 12 hours.
5.3.11. Cooldown Timer at End of Charge

The CompuCharge 4 control displays the hours and minutes, “H.MMC” or hours and tenths of hours, “HH.HC” since the
charge ended up to 100 hours. This feature may be used to select the next battery to place back into use. The rate of change
of the last two digits on the clock determines if they are seconds or minutes. After 100 hours the display will show
“COOL”.
The CompuCharge 4 control has a 24 VAC output to power a solenoid for automatic watering. One side of the solenoid
connects to pin 5 of the control board and the other side of the solenoid connects to X4 on the control transformer (CXF).
Refer to the schematics at the back of this manual.
The watering cycle lasts for 3 minutes at the end of charge. If equalize is set, the watering cycle precedes the equalize cycle.
If the charger is equipped with a watering module, watering is automatic; there are no settings required.
Refer to the instructions supplied with the water module for installation and connections to the charger, and for connections
to the water supply. Refer to the instructions supplied with the battery filling system for installation on the battery.
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6. RANGER II CONTROL
6.1. Description
The RANGER II control uses a “plain-English,” menu-driven display program. When the charger is idle, the display shows
the number of cells, the current date and the time.
Features of the RANGER II control include:

• Bright, two-line vacuum fluorescent display–visible in ambient light
• “Plain English,” menu-driven display–for fast set-up, preview and change of equalize, delayed start and other charge
parameters
• Delayed start–turn-on time delay is selectable from five seconds to 12
hours in one second intervals and time of day start
• Real-time 24-hour clock–with automatic adjustment for daylight savings time.
• Automatic or manual equalize–automatic equalize selectable from one to 50 cycles or day of the week; manual
equalize selectable from front panel
• Automatic three-day refresh cycle- if battery is connected for more than 72 hours, a brief boost charge is provided to
maintain battery in fully charged condition
• Automatic charge termination– when voltages stabilize indicating full charge or if battery overheats
• User programmable cool down step
• A variety of cell and shunt sizes–selectable for six through 36-cell batteries and four shunt sizes
• Output for optional automatic watering device
• Advanced features with compatible battery module:
o Equalize by battery cycles
o Watering by cycles
• Manual equalize and charger reports can be accessed by pressing the Scroll key (curved arrow). Refer to sections
6.3.3 for specific information.
FIGURE 6.1 RANGER II CONTROL WITH COMMUNICATIONS BOARD
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6.2. Basic Settings
Basic control settings such as number of cells, shunt size, delay before starting, etc. are set from the front panel using a
“hidden” menu with restricted access. Before operating your charger, check to be sure these initial settings have not been
changed. Should you need to change any of these settings, you may access them through the RANGER II control panel. The
battery must be disconnected in order to enter the parameters menu.
To access this menu, press both Arrow keys at the same time when the seconds portion of the time display indicates :01
changing to :02.
The Scroll key is used to move from selection to selection, and the Arrow keys are used to enter information. Begin by using
the Arrow key to select “parameters,” then press the
Scroll key to view the first parameter. To return to the idle display, press the Stop key. All parameters are automatically
saved and overwrite existing parameters.
NOTE: An internal, non-rechargeable lithium battery permits the RANGER II

control to retain programmed operating parameters in memory even when the
charger is disconnected from an AC line. This battery has an expected service life of more than 10 years, and, when
required, should be replaced by C&D. In the event of battery malfunction, contact your local C&D representative.
6.2.1. Real-time or fixed increment starting
IMPORTANT: When using real-time starting or fixed increment delay starting, be sure to allow for at least eight hours
of charging before the battery is used again.
Delayed starting lets you delay the time when the charge begins in order to take advantage of lower, off-peak after the
preset start time has passed, the battery will still be charged after a short delay. This allows for unusual situations, such
as extended-shift where the battery would not be available until after the preset time.
NOTE: When using real-time start, if you connect a battery within four hours after the preset time has passed, the
battery will still be charged after a short delay.
Real-time or fixed delay starts can be selected from the programmable parameters menu.
Use the Arrow keys to select either “Start at real time” or “Fixed delay mode.” If you have selected “Start at real time”
press the scroll key and use the arrow keys to enter the start time in HH:MM. If you have selected “Start after delay,”
press the Scroll key, and use the Arrow keys to enter the delay in HH:MM:SS. PP: Delay mode [↑↓]
PP: Delay [↑↓]
The RANGER II control can be set to automatically equalize every 1 to 50 cycles or to equalize all batteries charged on
a particular day of the week.
Automatic equalize can be set through the programmable parameters (see Section 6.2). Use the scroll key until the
display reads: PP: Equlz mode [↑↓]
Press the Arrow keys to select either the number of cycles, the day of the week, never, or always. Depending on your
selection the following displays will appear:
PP: Equlz cycl [↑↓] or PP: Equlz mode [↑↓]
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If you have selected never or always, the next menu will be: PP: Water Mode [↑↓]
To return to the idle display, press the Stop key or the Scroll key to continue
entering parameters. When equalization is scheduled, “C:(E)” is displayed.
If you have selected number of cycles or day of the week, press the Scroll key and use the Arrow keys to enter the
appropriate information. Equalizing cycles can be programmed for two to 50 cycles
NOTE: When a RANGER II charger programmed to equalize by cycles is connected to the optional compatible battery
module it will equalize by battery cycles. Otherwise, it will equalize by charger cycles.

Provisions for automatic watering have been made within the RANGER II control.
NOTE: If a charge mode other than conventional has been selected, these do not apply and the menus will not appear. It
can be set to always, never, and if a communications board has been added for a compatible battery module, every 5
cycles or every 10 cycles.
To select automatic watering, scroll through the programmable parameters until the display shows:
PP: Water mode [↑↓]
Use the Arrow keys to select watering options.
NOTE: If the automatic watering parameter is set to every 5 cycles or every 10 cycles and a battery without a
compatible battery module is connected, the RANGER II will always water the battery.
Once watering has been activated, it is important that it remain activated long enough to ensure all cells have been fully
watered. In order to limit possible overflow due to damage or malfunction, the RANGER II only maintains water flow
for a limited duration. This time is factory set at one minute, but can be adjusted.
To adjust automatic watering time, press the Scroll key until the display reads:
PP: Set WTR tm [↑↓]
Use the Arrow keys to set the length of the watering cycle. The watering cycle can last from 15 seconds to three
minutes.
6.2.4. Setting cool time

After the charge is completed, the charger will pause for a preset period of time to allow the battery to cool. Select a
time from one minute to eight hours.
PP: Set cool time [↑↓]
6.2.5. Monitoring water flow

To monitor the flow of water during a watering cycle, use the Arrow keys to select “enable.”
PP: Flow check [↑↓]
When the flow check is enabled, the water flow is checked soon after the watering triac is turned on. If no flow is
detected, the triac is turned off and a fault appears “(- Flo)”. The flow is also checked at the end of the watering cycle,
and if flow is still detected, the fault will appear “(+ Flo)”. All flow faults appear after the postcharge display.
Disconnecting the battery clears the fault.
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6.2.6. Main power override
Under certain conditions, such as troubleshooting or recovery of an overdischarged battery, it is useful to be able to
override the logic of the main control board and force the charger to turn on. Press the Arrow key to activate this
feature. When activated, this feature energizes the main contactor and only checks for a connected battery. The
contactor will be energized for a maximum of three minutes to preclude damage to a charger or battery caused by
excessive charging with defective or mismatched equipment.
PP: ctl MAIN [↑↓]
6.2.7. Water control override

The water control override feature allows the watering output to be forced on for an indefinite period for
troubleshooting.
It should not be left in the ON position for an extended period of time. Use the Arrow keys to turn it on and off.
PP: CTL WATER [↑↓]
If the charge mode is set for other than conventional, the CTL water display will be replaced by the following:
P: CTL STAGE 2 [↑↓]
Use the Arrow keys to turn the second stage ON or OFF for troubleshooting purposes. Watering mode functions,
including flow check, are not available in non-conventional modes.

The number of cells for the charger and the RANGER II control are designed to match. After entering the programming
menu, as explained above, scroll through the selections until the above display appears. Use the Arrow keys to set the
number of cells to match the charger nameplate rating. You may enter from six to 36 cells in 1-cell increments.
PP: Set CELLS [↑↓]
6.2.9. Selecting the shunt size

The RANGER II control is matched to its shunt size at the factory. There should be no need to change the shunt size
unless a replacement control board is installed. Should you need to change the shunt size, refer to the parts lists on
pages 50 & 51 (section 9). Use the Arrow keys to set the shunt at 100 mV to 100, 200, 300, or 500 amperes. Press the
Scroll key to set the shunt size.
PP: Set SHUNT [↑↓]
6.2.10. Setting the rated output current

Set the rated current of the charger as it is indicated on the charger nameplate. Use the Arrow keys to enter rated
current from 0 to 500 amperes in 5-ampere increments. Press the Scroll key to set rated output current.
PP: Rated AMPS [↑↓]
6.2.11. Setting the charge mode

Use the arrow keys to select ”conventional mode”. The FerroCharge charger can only charge conventional flooded
batteries. The other settings are for battery types that are not compatible with this charger.
PP: Charge Mode [↑↓]
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The ready screen will indicate the mode in use. If the charger is set for conventional mode it will display: READY
(STD): ## cells
Important: If the charger displays any mode other than (STD) the setting must be changed.
If the charger is set for low maintenance battery mode it will display:
READY (LM): ## cells
If the charger is set for sealed battery mode it will display: READY (VR): ## cells
6.2.12. Setting the date

Set the current date by pressing the Arrow keys until the current date is displayed. The display is in MM/DD/YY
format. Press the Scroll key to set the current date.
PP: Set DATE [↑↓]
6.2.13. Setting the correct time

The RANGER II charger has a 24-hour clock, which allows charger operation to begin at a preset time or at a fixed
delay from time of connection. It also allows the charger to report the actual time, date and when the charge was begun
and completed. The 24-hour clock is set when it leaves the factory; however it may need to be adjusted if you live in a
different time zone than the factory. The correct time must be set before placing the charger in operation. Set the
current time HH:MM:SS by pressing the Arrow keys until the current time is shown. Press the Scroll key to set the
correct time.
PP: Set TIME [↑↓]
6.2.14. Setting the day of the week

By keeping track of weekdays, RANGER II can perform equalizing charges on the day most convenient for the user.
For example, you can program the RANGER II so all Friday charges include an equalizing charge. Using the Arrow
keys set the current day of the week. Press the Scroll key to set the day of the week.
PP: Set DAY [↑↓]
6.2.15. Activating daylight savings time

If the charger will be operated in an area using Daylight Savings Time, the automatic daylight savings time feature can
be activated to automatically adjust the clock to daylight savings time and back to standard time on the proper days.
To activate this feature, press an Arrow key until “Auto daylight time” appears on the display. If you do not need
daylight savings time, press an Arrow key until “Always STD time” appears on the display. To activate daylight savings
time, press the Scroll key.
PP: Set DST [↑↓]
6.2.16. Activating and setting the address

If the Asset Management System (AMS) is in use, set the address for this charger. If the AMS is not in use set to net
inactive.
PP: Set NET [↑↓]
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6.2.17. Setting the baud rate
If the network is activated, set the baud rate per the instructions for the AMS.
PP: Set Baud [↑↓]
6.3. Operation
6.3.1. Manual starting

1. CONNECT THE CHARGER TO THE AC SUPPLY LINE. The digital display will show the number of
cells for which the charger has been set as well as the charge mode selected and the time of day.
2. CONNECT THE BATTERY. The charge cycle will begin within five seconds, if no other delay time has
been selected. The RANGER II control display will show the time remaining until the start of charge. If
the battery is fully charged, the charger will move from charging to post-charge, or if manual equalize is
selected, to equalize. When the charge begins, the display will show the elapsed time charging, voltage
and current in amperes. When the battery is 80 percent charged, an “(80%)” will appear after the elapsed
time display. If manual or automatic equalize is selected, an “(E)” will appear in the upper left hand
corner. When voltage and current have stabilized “(EXT)” will appear after the elapsed time display.
When equalization has begun, an “(EQU)” will appear on the display after the elapsed time. When the
charge is complete, the RANGER II will show the ampere-hours and kilowatt-hours returned to the
battery.
In the event of a charging problem or error, an error message will be displayed.

Refer to Section 8, Troubleshooting, for more information on error messages.
NOTE: This error message will clear if the battery is disconnected. This information and other charge parameters are
also available during the charge and can be accessed by pressing the Scroll key twice.
6.3.2. Manual Stopping

To interrupt the charge before it is complete, press the Stop button.
CAUTION:
Always be sure charger is turned off—either manually or automatically—before disconnecting the battery from the
charger. Otherwise, hazardous arcing will occur.

In the course of the normal charge/discharge cycle, a motive power battery develops inequalities of voltage and specific
gravity among its cells. Equalizing batteries at regular intervals will restore cell equality, assuring rated performance.
Activate manual equalizing by pressing the Scroll key anytime before or during a charge. The normal equalization
program is overridden, and so this feature can be used to equalize a fully charged battery. To activate manual equalize,
press an Arrow key. To deactivate manual equalize, press an Arrow key again. After 60 seconds, the display will return
to the idle charger display.
MNU: Manual EQU [↑↓]
6.3.4. Operation after loss of AC power (warm start)

If the charger has been started manually, it will return to its previous operating mode as soon as power is restored and
continue charging the battery until the charge cycle is completed. If the charger is set for real-time start and the power is
discontinued and then restored before the selected start time, charger operation is unaffected. If the charger is set for
real-time start and the power loss occurs 1) after start or 2) before start and extends into the preselected charge period,
the charger will resume operation as soon as power is restored and continue the charging sequence until the charge cycle
is completed. An exception to this would be if the power outage lasted into the next day (beyond 24:00, midnight), in
PM990-1897-00, ISSU E 5 33
which case the charger would not restart until the preset hour that day. To reduce the possibility of tripping a breaker in
multiple charger installations, the RANGER II control distributes charger starts randomly. The minimum delay time is
15 seconds and the maximum delay time is 3 minutes and 30 seconds.
6.3.5. Charge data retrieval

When a charge is completed, the RANGER II control can display the ampere-hours and kilowatt-hours required for the
charge, followed by the word “complete.” Pressing the Scroll key will enable the user to access information about
starting time and date, open circuit battery voltage, starting and ending battery voltage, starting and ending battery
current, ampere-hours and kilowatt-hours of charge, length of charge, ending time and date, and the number of non-
equalized cycles. If the battery being charged has a compatible battery module installed and the charger is equipped for
a compatible battery module communications, additional removed data will be available: ampere-hours moved on
discharge and on charge temperatures. Press the Scroll key until the display reads:
MNU: Charge rpt [↑↓]
This data can be retrieved and shown on the display during or after the charge cycle. In the event of an error during the
charge cycle, a “plain English” error message is displayed. Refer to Section 8, Troubleshooting.
6.4. Special features with a compatible battery module
A RANGER II charger connected with a compatible battery module will operate in the same manner as described in
Sections 6.2 through 6.3, except for the enhancements noted below. While the charger is charging a battery with a
compatible battery module connected, the RANGER II control checks the battery module to see that the last charge was full
and the battery is discharged. It then calculates and displays the percent charged. If the battery module indicates the battery
is already fully charged, the charge cycle is terminated within two minutes. The display will indicate the percent charge.
The charger may enter a cooling cycle if the battery module indicates temperatures within a certain range; if it does so it is
indicated on the display as C:Cooling xx°F, with the hours, minutes and seconds. When the battery temperature is less than
105°F, the RANGER II resumes the charge cycle and will enter the equalize mode, if necessary. After equalization or
watering, the RANGER II checks the battery module again for temperature. It may enter the cooling stage again, indicating
it on the display. Because the battery module keeps track of battery cycles, you can equalize and water by battery cycles,
not charger cycles. If equalization is selected, the display will show “C:E.” During equalization, the percent charge is
displayed. You may specify equalizing parameters as indicated in Section 6.3. When a compatible battery module is
connected to a RANGER II charger, the watering options are always, never, every five battery cycles or every 10 battery
cycles.
NOTE: A battery module capable RANGER II control programmed for watering by battery cycles will always perform the
watering cycle if connected to a battery without a battery module. Changing watering parameters is also described in
Section 6.2.3.
6.4.1. Installing a compatible battery module communications board

The RANGER II control is designed to interface with a compatible battery module, enabling you to get data such as
depth of discharge information, start and end of charge temperatures, minimum volts per cell, low volts per cell and
more. In order for a RANGER II control to interface with a battery module, the charger must have a communications
board installed.
The communications board is installed by inserting it into the RANGER II board at expansion slot A. Firmly seat the
communications board onto the RANGER II board. (Be sure to disconnect both AC power and the battery during this
procedure.)
6.4.2. Retrieving data from a compatible battery module

When entering the programmable parameters, a choice is given between the programmable parameters and the battery
module menu. The battery module terminal menu is used to retrieve information from a compatible battery module
PM990-1897-00, ISSU E 5 34
attached to a RANGER II control. If the RANGER II cannot communicate with the battery module, COMerr is
displayed on the interface. If COMerr is displayed, contact your local C&D Technologies Manufacturing representative.
The following information is displayed; the Scroll key is used to move through
the menu items.
Menu display Description

BT: Present T [C] The current temperature of the battery.
87 °F
BT: Dischrg data [C] Shows minimum volts per cell, ampere-hours removed and time in
2.37V 329AH 14.21 discharge. When this information is retrieved, the equivalent information
in the charge summary report is replaced with this new data.
BT: Discharges [C] The number of discharge cycles from a compatible battery module. When
1000 cycles this information is retrieved, the equivalent information in the charge
summary report is replaced with this new data.
BT: Low VPC [C] The number of low volts per cell cycles and the percent of the total.
25 cycles 2.5%
BT: Lo DOD cycls [C] The number of low depth of discharge cycles for 30% (indicated by “<”)
< 250, 30-70% 700 and 30 to 70% categories.
BT: Hi DOD cycls [C] The number of high depth of discharge cycles for 70-90% and > 90%
70-90% 45, > 5 (indicated by “>”).
BT: SOC T cycls [C] The number of cycles in each of three start of charge temperature
< 250, 500, > 250 categories: < 60°F (indicated by “<”), 60°F-100°F, and > 100°F (indicated
by “>”).
BT: EOC T cycls [C] The number of cycles in each of the three end of charge temperature
< 250, 500, > 250 categories: < 60°F (indicated by “<”), 60°F-100°F, and > 100°F (indicated
by “>”).
BT: Power cycls [C] The number of times the power to the battery module has been cycled.
2
BT: Status [C] The version of the compatible battery module software.
SW Version 1.00
6.5. Communications port

RANGER II controls are designed to be able to interface with a computerized asset management system (AMS). The unique
fiber optic communications bus establishes a link with the AMS, enabling a user to have complete charging information on a
fleet of FerroCharge chargers with RANGER II controls.
The network address should be set to inactive unless there is an AMS. This will hide the baud rate menu. For information
on setup and using an AMS, see the AMS operating manual. For more information on the available asset management
systems, ask your local C&D representative for a brochure.
PM990-1897-00, ISSU E 5 35
7. CHARGER OPERATION
7.1. Recommended charging procedures
Chargers require little attention beyond periodic removal of dust buildup and inspection for loose connections. Refer to
section 2.7, Maintenance. Proper charging procedures are important to prevent damage to chargers, batteries and operators.
Proper charging procedures require lead-acid batteries receive:
• Watering at the end of charge, as needed, to maintain proper electrolyte level and concentration;
• An equalizing charge approximately every seventh charge to correct voltage imbalances among cells;
• Periodic cleaning to remove corrosive spills;
• Freshening charges if batteries remain out of service for three or more days.
Operators should only connect batteries to chargers with matching voltage and sufficient power output. The charger must be
OFF before batteries are connected or disconnected.
Motive power batteries are designed to be discharged daily but should not be discharged by more than 80 percent of their
capacity during an 8-hour work shift. This allows sufficient time for them to charge and cool before they are returned to
service and extends cycle life.
Charging shallow-discharged cells can also lessen battery life. Batteries discharged less than 20 percent should remain in
service for another shift in light duty before being placed on the charger.
High resistance connections can reduce the charger’s ability to properly charge the battery as well as reduce charging
efficiency. Dirty or pitted contact surfaces on either the charger or battery connector should be cleaned and lubricated, or
replaced with the identical part following the manufacturer’s instructions and using the recommended tooling. Discolored
contacts may also indicate loose crimps to the cable. Contacts should also be replaced if this is the case.
PM990-1897-00, ISSU E 5 36
7.2. Operating characteristics
As a battery is placed on charge, there is an inrush of current to the battery. Charging increases battery voltage, and as the
difference between the applied voltage and the battery voltage decreases, the flow of the charger current also decreases.
During the final hours of the charge cycle, the charging rate is significantly reduced. Figure 7.1 shows typical ferroresonant
charging characteristics.
IFR12HK510 Regulation
2.60
2.55
2.50
2.45
Volts per Cell
2.40
2.35
2.30
2.25
2.20
2.15
2.10
2.05
2.00
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Amperes per 100 Ampere-Hours Charger Rating
IFR12HK510 w/12D85-13 98% DoD, 108% Ah Return
25 2.60
20 2.50
Amps per 100 Ah
Charger Rating
Volts per Cell
15 2.40
10 2.30
5 2.20
0 2.10
0 1 2 3 4 5 6 7
Hours
FIGURE 7.1 TYPICAL FERRORESONANT CHARGER CURVES
PM990-1897-00, ISSU E 5 37
As with all electrical apparatus, FerroCharge operating economics are influenced by electric utility rates, the user's choice
of single phase or three-phase power, and the electrical efficiency and power factor of the charger.
Electric utility rates are significantly lower during off-peak periods. However, to take advantage of these rates you may need
a separate electric meter for the off-peak service connection. Your local utility representative can help you determine the
type of off-peak program that best fits your application.
Efficiency is the measure of the useful energy the charger makes available to the cell, as measured at the charger output. It is
calculated by the equation:
Percent efficiency = Output power (kW)/ Input power (kW) x 100
The power factor is the ratio of the true power (Watts) and the apparent power (Volts x Amps) a charger actually requires to
operate. The equation for determining power factor is:
Power factor (PF) = True power/Apparent power = Watts AC/(Volts AC) x (Current AC)
PM990-1897-00, ISSU E 5 38
8. TROUBLESHOOTING
8.1. General Troubleshooting Guidelines
1. Safety is a prime consideration.

a. Think before acting; plan your actions and troubleshooting strategy
b. Wear safety glasses
c. Remove watches, rings, and jewelry before reaching into the cabinet
d. After recording the way you find the charger, press the Stop key, disconnect the battery and disconnect the ac
supply unless a test requires otherwise.
2. Keep a detailed record of the initial charger condition and the control board displays in case you need to request help
later. By referring to the troubleshooting chart for the control board you can probably determine the problem from the
display. Record the charger and battery model numbers and serial numbers. This information will be required when
requesting service or warranty support.
3. Visually inspect the charger displays and condition such as burn marks, smells, etc.
4. Determine the symptoms.
5. Take measurements as required.
6. Diagnose the problem using the troubleshooting charts as a reference.
7. Make the repairs.
TABLE 8.1 TEST INSTRUMENTS AND TOOLS FOR TROUBLESHOOTING

Troubleshooting Equipment
0 to 200-mV scale VOM that reads up to 600 VAC and 250 VDC with minimum accuracy of 0.5 percent
Clamp-on ammeter
SB-175 or SB-350 shorting connector
Wrench set
Screwdriver set
Jumper cables with alligator clips
Note: Diode replacement requires a supply of thermal joint compound and a torque wrench capable of achieving the values
in Table 8.2.
8.2. Procedure
The following charts are designed to help a qualified technician diagnose and remedy malfunctions in the SCOUT,
COMPUCHARGE, and RANGER II controls. In all cases, after recording the error message acknowledge the error message by
pressing the Stop key.
The first two charts cover the control; troubleshooting instructions for the charger are presented in the third chart. Sections 8.3
through 8.4 provide information on testing and replacing components. Also refer to the wiring diagrams in Section 10.
IMPORTANT: Qualified personnel familiar with both local and national electrical codes must service this equipment.
WARNING: Line voltages are present within the battery charger cabinet. When performing the following troubleshooting
procedures, be sure to observe all appropriate safety precautions. ALWAYS BE SURE THE CHARGER IS TURNED OFF
BEFORE DISCONNECTING A BATTERY.
PM990-1897-00, ISSU E 5 39
SCOUT CONTROL TROUBLESHOOTING CHART
DISPLAY STATUS CAUSE ACTION
Yellow LED is lit and red LED is 1. The wrong size battery has been a. Disconnect the battery and check
flashing rapidly connected that the number of cells in the battery
matches the nameplate rating of the
charger.
b. Disconnect the battery and check
that the control board’s jumper
setting configuration for the number
of cells matches the nameplate rating
of the charger. If necessary, change
the number of cells (see Section
3.3.1) by moving the jumpers and
then restoring the power to the
charger.
2. Battery is over-discharged a. Press the Equal key to force the
charger on. While the key is pressed,
the charger will remain on. After
battery voltage rises, release Equal
key, disconnect and reconnect the
battery. The charger should start
automatically in the normal manner.
3. Battery has bad cells a. Check the battery for defective

cells.
Green LED is lit and red LED is 1. The maximum charging time has a. Disconnect the battery to reset the
flashing rapidly been exceeded charger.
b. Check that the charger Ampere-
hour rating matches the battery rating.
c. Check the charger for low dc
output.
d. Check the battery for defective
cells.
Both yellow and green LEDs are lit 1. The Stop key has been pressed a. Disconnect the battery.
and red LED is flashing rapidly
All LEDs are lit constantly 1. Watchdog timer has reset a. Disconnect AC power from the
charger, wait 30 seconds and reapply.
If problem persists, call for service.
All LEDs flashing 1. Low vpc early in the charge cycle a. Check AC line and AC fuses to all
due low charger output power. phases.
b. Check the charger for proper
output voltage and current.
PM990-1897-00, ISSU E 5 40
COMPUCHARGE CONTROL TROUBLESHOOTING CHART
ERROR CODE DESCRIPTION ACTION
bU E 1. Battery voltage does not match the a. Disconnect the battery and check
number of cells programmed (The that the number of cells in the battery
wrong size battery has been matches the nameplate rating of the
connected.) charger.
b. Disconnect the battery and check
that the control board’s jumper
setting configuration for the number
of cells matches the nameplate rating
of the charger. If necessary, change
the number of cells (see Section
4.3.3) by moving the jumpers and
then restoring the power to the
charger.
2. Battery is over-discharged a. Press the Equal key to force the
charger on. While the key is pressed,
the charger will remain on. After the
battery voltage rises, release the
Equal key, disconnect and reconnect
the battery. The charger should start
automatically in the normal manner.
3. Battery has bad cells a. Check the battery for defective
cells.
uS E -or -uT E 1. The charger microprocessor needs a. Charger will reset after five
to reset itself seconds. It will begin from the Ready
state.
bd E 1. During charge, the battery was a. Charger will reset itself after five
disconnected seconds. It will begin from the Ready
state.
hotE 1. The battery temperature is too high a. The charger will stop for 8 hours,
then resume automatically. To clear
the message, disconnect the battery.
Let the battery cool down before
using it.
StPE 1. During the charge, user pressed the a. To clear this message, disconnect
Stop key the battery.
12hE 1. The battery has been on charge a. To clear this message, disconnect
more than 12 hours the battery.
b. Check that the charger Ampere-
hour rating matches the battery rating.
c. Check the charger for low dc
output.
d. Check the battery for defective
cells.
PM990-1897-00, ISSU E 5 41
RANGER II CONTROL TROUBLESHOOTING CHART
DISPLAY CAUSE ACTION
ABORT: discnect 1. Battery not matched to charger a. Verify battery and charger match.
bat (wrong number of cells)
Wrong battery size 2. Battery has short-circuited cells or a. The charger can be “forced” on from this condition
overdischarged by holding the “up” arrow until the voltage reads an
acceptable level.
3. Control board not matched to a. Check and reset board settings to match charger
charger output voltage. Verify other settings.
ABORT: discnect 1. Battery is too large for charger a. Place battery on charger of proper size.
bat 2. Control board failure a. If problem is repeated, contact C&D
Charge > 12 hrs
ABORT: discnect 1. Hot battery a. Allow several hours for cool-down before
bat flt restarting charge.
Hot battery
ABORT: discnect 1. DC current continued to flow after a. Check line contactor and replace if necessary.
PWR contactor turned off
OFF, but charging
ABORT: discnect 1. Charge terminated by operator a. Resume charge if necessary.
bat
Operator STOP
ABORT: discnect 1. Operator disconnected battery a. Reconnect battery and resume charge.
bat
Zero current flt
2. Charger problem a. Refer to flowcharts on next page.
ABORT: press 1. Charger parameters lost a. Remove and then restore AC power; re-enter
{Stop} parameters. If problem recurs, call your local C&D
NVRAM is trashed REPRESENTATIVE.
WDT RST: 1. Watchdog timer reset has a. If problem recurs, call your local C&D
Restarting occurred. The charger will REPRESENTATIVE.
automatically restart.
ABORT: press 1. Real-time clock must be replaced a. Call your local C&D REPRESENTATIVE.
[Stop]
Replace RTC (lobat)
ABORT: press 1. Control program found in an a. Disconnect and reconnect charger. If problem
[Stop] unknown state persists, contact C&D.
State machine flt
PM990-1897-00, ISSU E 5 42
POWERTRAIN AND OTHER CHARGER PROBLEM-TROUBLESHOOTING CHART
Problem Possible Cause Solution

Charger has no display Loss of AC Check AC supply fuses or breakers
Check AC fuses in charger
Check control fuse F3 (1-phase) or F4
(3-phase)
Check control transformer CXF
AC fuses or breaker blow Charger ac input recently reconnected Check that power transformer and
for a different voltage control transformer primary
connections were both changed
correctly. Refer to schematics.
Check that ac fuses were changed for
new line voltage
Wrong fuse or breaker size Check label in charger for internal
fuses and recommended line fuses on
nameplate for external fuses.
Charger will not start charging Loss of AC Check AC fuses or breakers
Check charger AC fuses
Over-discharged battery Check for correct number of cells. On
Scout and CompuCharge controls
press Equal key to force on the
charger to raise battery voltage.
Wrong battery or board set wrong Check that battery matches cells on
charger nameplate
Check that jumpers on control board
are set to match cells on charger
nameplate.
Defective control transformer (CXF) Check primary voltage and secondary
voltages
Defective Line contactor (LC) Check for 24 Vac on coil
Defective control board Check for 24 Vac on line contactor
coil
Charger has no DC output Blown output fuse (DCF) Check for reverse polarity battery.
Were the charger or battery
connectors replaced recently?
Shorted Diode
Charger does not stop Defective control board Press Stop. If charger keeps running,
turn off ac. Restart ac. If charger
starts immediately replace control
board.
If charger goes to delay before
starting the control board may have
“hung up”. Resetting the ac may
correct the problem, but if the
problem persists it may be necessary
to replace the board.
PM990-1897-00, ISSU E 5 43
Low DC output, 3-phase charger One of the power transformers is not Check ac fuses (F1-F3)
working properly Check transformer input and output
voltages.
Defective or disconnected resonant
capacitor
Diode is open in rectifier Check diodes
Loose connection in output wiring Tighten all connections
Low DC output, 1-phase charger Power transformer is not working Defective or disconnected resonant
properly capacitor
Check transformer input and output
voltages
Diode is open in rectifier Check diodes
Loose connection in output wiring Tighten all connections
Override timer shuts down charger Battery is over-discharged or has bad Check battery
cells
Charger has low dc output See chart entry for low output
Flashing lights on Scout control Look at section 8.2 Record display before calling for
service support
Error code displayed on Look at section 8.2 Record display before calling for
CompuCharge control service support
Utility power loss and restoration Both the Scout and CompuCharge controls will restart the charge after a
during the charge cycle random time delay. The Scout control delay is up to 3-1/2 minutes and the
CompuCharge control delay is up to 2 minutes.
8.3. Component testing
Many problems can often be revealed by a visual inspection. In new chargers, look for connections that may have loosened
during shipment. In previously operating systems, look for the whitish powder residue created by burning varnish, or a
broken, melted or discolored wire.
When troubleshooting three-phase chargers, be sure to test both sets of components.
Always read and follow all warning labels and turn off the charger before touching, removing or installing components.
C&D supports FerroCharge chargers with prompt field service and overnight delivery of most components. If you do not
know the name of your nearest representative contact:
C&D Technologies, Inc.

Integrated Power Systems,
Motive Power Division
65 Industrial Park Road, Dunlap, TN 37327
Customer Service, Voice: (800) 440-3504
Customer Service, Fax: (423) 949-3647
Field Service: (800) 299-3907
Web site – http://www.cdpowercom.com
PM990-1897-00, ISSU E 5 44
Device and Procedure Device and Procedure
CAPACITORS: Before starting, be sure the capacitor is DIODES: Test diodes with the ohmmeter set at either the
discharged. Before testing, disconnect both leads to 1OX or 1OOX scale. Before testing, disconnect one lead
isolate the capacitor from the charger circuit. Test to isolate the diode from the charger.
capacitors with a calibrated ohmmeter. Different sizes of • A good diode shows low resistance when tested in
capacitors require different ohmmeter range settings. one direction and high resistance when the ohmmeter
Begin with the highest setting. Be sure to reverse the leads probes are reversed.
for each check. • An open diode shows very high resistance in both
• A good capacitor deflects the ohmmeter needle directions.
toward zero then steadily rises toward infinite • A shorted diode shows zero or low resistance in both
resistance. directions.
• An open capacitor immediately shows Infinite
resistance.
A short capacitor remains at zero resistance.
CONTROL TRANSFORMER: Output should be between FUSES: Remove the fuse from the fuse holder and test it
22 and 26 VAC across the full secondary winding. with an ohmmeter set to any scale.
• A good fuse shows zero resistance.
• An open or "blown" fuse shows infinite resistance.
8.4. Replacing components
Ammeter shunts, capacitors, fuses, control boards, control transformers, line contactors, and power transformers can be user-
replaced. Simply mate the leads of the replacement component with their appropriate connectors.
Printed circuit boards in the controls do not contain user-repairable parts. The entire printed circuit board must be replaced.
It is recommended that the entire rectifier be replaced rather than individual diodes. Users attempting diode replacement
MUST observe the following procedure:
1) Disconnect the charger from the AC line and battery.

2) Remove the rectifier assembly.
3) Clamp the heat sink portion of the assembly in a vise.
4) Remove the faulty diode.
5) Coat the mating surfaces of the diode and the heat sink with a suitable thermal joint compound.
6) Place the diode on the heat sink and hand tighten the diode connection hardware.
7) Torque diode connections to values shown In Table 8.2.
8) Remove excess thermal joint compound.
9) Reinstall the assembly and reconnect leads.
TABLE 8.2 DIODE CONNECTION TORQUE VALUES
DIODE CONNECTION TORQUE VALUES

1/4" studs 25 +2/-2 in- lb.
3/8" studs 112 +4/-3 in- lb.
1/2" studs 137 +4/-4 in- lb.
3/4" studs 260 +5/-3 in- lb.
PM990-1897-00, ISSU E 5 45
9. MODELS, RATINGS, AND PARTS LISTS
Model Input No. Of No. Of Input Output Cells Battery Ah Cabinet

Voltage Phases Xfmrs Current Current Capacity for 8 h
(V) (A) (A) Charge, 100%
DOD
IFR6CE450 208/240/480 1 1 8.5/7.5/4 85 6 450 A
IFR6CE510 208/240/480 1 1 10.5/9/4.5 96 6 510 A
IFR6CE600 208/240/480 1 1 14/12/6 108 6 600 A
IFR6CE750 208/240/480 1 1 15/13.5/7 143 6 750 A
IFR6CE875 208/240/480 1 1 16/14/7 158 6 875 A
IFR6HK875 208/240/480 3 2 9.5/8/4 158 6 875 A
IFR6HK1000 208/240/480 3 2 11.5/10/5 190 6 1000 A
IFR6HK1200 208/240/480 3 2 16/14/7 228 6 1200 A
IFR12AC255 120/208/240 1 1 18/9/8 46 12 255 A

IFR12CE255 208/240/480 1 1 9/8/4 46 12 255 A
IFR12CE450 208/240/480 1 1 18/16/8 85 12 450 A
IFR12CE510 208/240/480 1 1 20.5/18/9 96 12 510 A
IFR12CE600 208/240/480 1 1 24/21/10.5 108 12 600 A
IFR12CE750 208/240/480 1 1 30/26/13.5 135 12 750 A
IFR12CE875 208/240/480 1 1 35/28/14 166 12 875 A
IFR12HK510 208/240/480 3 2 10/9/4.5 96 12 510 A
IFR12HK600 208/240/480 3 2 12/10.5/5.5 108 12 600 A
IFR12HK750 208/240/480 3 2 15.5/13.5/7 135 12 750 A
IFR12HK875 208/240/480 3 2 18/15.5/8 158 12 875 A
IFR12HK1000 208/240/480 3 2 20/17/8.5 190 12 1000 A
IFR12HK1200 208/240/480 3 2 23/20/10 228 12 1200 A
IFR18CE450 208/240/480 1 1 22/19/9.5 85 18 450 A

IFR18CE510 208/240/480 1 1 25/22/11 96 18 510 A
IFR18CE650 208/240/480 1 1 35.5/31.5/15.5 117 18 650 A
IFR18CE750 208/240/480 1 1 41/36/18 135 18 750 A
IFR18HK510 208/240/480 3 2 15/13.5/7 96 18 510 A
IFR18HK650 208/240/480 3 2 20/17/8.5 117 18 650 A
IFR18HK750 208/240/480 3 2 23/20/10 135 18 750 A
IFR18HK875 208/240/480 3 2 26/23/11.5 158 18 875 A
IFR18HK935 208/240/480 3 2 28.5/24.5/12 168 18 935 A
IFR18HK1000 208/240/480 3 2 30.5/26.5/13.5 190 18 1000 A
IFR18HK1100 208/240/480 3 2 32/28/14 198 18 1100 A
IFR18HK1200 208/240/480 3 2 32/28/14 198 18 1200 A
IFR18HK1250 208/240/480 3 3 36/32/16 238 18 1250 B
IFR18HK1400 208/240/480 3 3 40/35/17.5 266 18 1400 B
PM990-1897-00, ISSU E 5 46
Model Input No. Of No. Of Input Output Cells Battery Ah Cabinet
(V) (A) (A) Charge, 100%
DOD
IFR24CE450 208/240/480 1 1 31/27/13.5 85 24 450 A
IFR24CE510 208/240/480 1 1 38/33/17 96 24 510 A
IFR24CE600 208/240/480 1 1 44/38/19 114 24 600 A
IFR24CE680 240/480 1 1 46/23 129 24 680 A
IFR24HK450 208/240/480 3 2 19.5/17/8.5 85 24 450 A
IFR24HK510 208/240/480 3 2 23/20/10 96 24 510 A
IFR24HK600 208/240/480 3 2 24/21/10.5 114 24 600 A
IFR24HK680 208/240/480 3 2 27.5/24/12 129 24 680 A
IFR24HK765 208/240/480 3 2 31/27/13.5 138 24 765 A
IFR24HK850 208/240/480 3 2 35/30/15 153 24 850 A
IFR24HK900 208/240/480 3 2 36/32/16 162 24 900 A
IFR24HK1100 208/240/480 3 3 40/35/17.5 198 24 1100 B
IFR24HK1250 208/240/480 3 3 48/42/21 228 24 1200 B
IFR24K1360 480 3 3 23.5 258 24 1360 B
IFR36HK450 208/240/480 3 2 26.5/23/11.5 85 36 450 A

IFR36HK510 208/240/480 3 3 31/27/13.5 96 36 510 B
IFR36HK600 208/240/480 3 3 35/31/15.5 114 36 600 B
IFR36HK680 208/240/480 3 3 39/34/17 129 36 680 B
IFR40HK510 208/240/480 3 3 35/30/15 96 40 510 B
PM990-1897-00, ISSU E 5 47
Model Input No. of No. of Input Output Cells Battery Ah Cabinet
(V) (A) (A) Charge, 100%
DOD
IFR6M450 575 1 1 4 85 6 450 A
IFR6M510 575 1 1 4.5 96 6 510 A
IFR6M600 575 1 1 6 108 6 600 A
IFR6M750 575 1 1 6.5 143 6 750 A
IFR6M875 575 1 1 7.5 166 6 875 A
IFR6L875 575 3 2 3.5 166 6 875 A
IFR6L1000 575 3 2 4 190 6 1000 A
IFR6L1200 575 3 2 5.5 228 6 1200 A
IFR12M255 575 1 1 3.5 46 12 255 A

IFR12M450 575 1 1 7 85 12 450 A
IFR12M510 575 1 1 7.5 96 12 510 A
IFR12M600 575 1 1 9 108 12 600 A
IFR12M750 575 1 1 11 135 12 750 A
IFR12M875 575 1 1 13 166 12 875 A
IFR12L510 575 3 2 4 96 12 510 A
IFR12L600 575 3 2 4.5 108 12 600 A
IFR12L750 575 3 2 6 135 12 750 A
IFR12L875 575 3 2 7 158 12 875 A
IFR12L1000 575 3 2 7 190 12 1000 A
IFR12L1200 575 3 2 8 228 12 1200 A
IFR18M450 575 1 1 8 85 18 450 A

IFR18M510 575 1 1 9 96 18 510 A
IFR18M650 575 1 1 13.5 117 18 650 A
IFR18M750 575 1 1 15 135 18 750 A
IFR18L510 575 3 2 5.5 96 18 510 A
IFR18L650 575 3 2 7.5 117 18 650 A
IFR18L750 575 3 2 8.5 135 18 750 A
IFR18L875 575 3 2 9.5 158 18 875 A
IFR18L935 575 3 2 10.5 168 18 935 A
IFR18L1000 575 3 2 11 180 18 1000 A
IFR18L1100 575 3 2 12 198 18 1100 A
IFR18L1200 575 3 2 12 198 18 1200 A
IFR18L1250 575 3 3 13 238 18 1250 B
IFR18L1400 575 3 3 14.5 266 18 1400 B
PM990-1897-00, ISSU E 5 48
Model Input No. of No. of Input Output Cells Battery Ah Cabinet
(V) (A) (A) Charge, 100%
DOD
IFR24M450 575 1 1 11.5 85 24 450 A
IFR24M510 575 1 1 14 96 24 510 A
IFR24M600 575 1 1 15.5 114 24 600 A
IFR24M680 575 1 1 19 129 24 680 A
IFR24L450 575 3 2 7 85 24 450 A
IFR24L510 575 3 2 8 96 24 510 A
IFR24L600 575 3 2 9 114 24 600 A
IFR24L680 575 3 2 10 129 24 680 A
IFR24L765 575 3 2 11.5 138 24 765 A
IFR24L850 575 3 2 12 153 24 850 A
IFR24L900 575 3 2 13.5 162 24 900 A
IFR24L1100 575 3 3 14.5 198 24 1100 B
IFR24L1250 575 3 3 17.5 228 24 1200 B
IFR24L1360 575 3 3 20 258 24 1360 B
IFR36L450 575 3 2 9.5 85 36 450 A

IFR36L510 575 3 3 11.5 96 36 510 B
IFR36L600 575 3 3 13 114 36 600 B
IFR36L680 575 3 3 14 129 36 680 B
IFR40L510 575 3 3 12 96 40 510 B
PM990-1897-00, ISSU E 5 49
Model Input (AC) Fuse Rating – Amperes Output Shunt
120 V 208 V 240 V 480 V 575 V * (DC) Fuse Amperes
Rating
Amperes
IFR6CE450 NA 12 10 6 4 200 200
IFR6CE510 NA 15 12 6 6 200 200
IFR6CE600 NA 20 15 8 7 200 200
IFR6CE750 NA 20 20 10 8 200 200
IFR6CE875 NA 20 20 10 8 200 200
IFR6HK875 NA 12 12 6 5 200 200
IFR6HK1000 NA 15 15 7 6 325 300
IFR6HK1200 NA 20 20 10 8 325 300
IFR12AC255 20 12 12 NA NA 100 100

IFR12CE255 NA 12 10 6 5 100 100
IFR12CE450 NA 25 20 10 10 200 200
IFR12CE510 NA 30 25 12 10 200 200
IFR12CE600 NA 30 30 15 12 200 200
IFR12CE750 NA 40 35 20 15 200 200
IFR12CE875 NA 40 35 20 15 200 200
IFR12HK510 NA 15 12 6 6 200 200
IFR12HK600 NA 15 15 8 6 200 200
IFR12HK750 NA 20 10 10 8 200 200
IFR12HK875 NA 25 20 10 10 200 200
IFR12HK1000 NA 30 25 12 10 325 300
IFR12HK1200 NA 30 30 15 12 325 300
IFR18CE450 NA 30 25 12 10 200 200

IFR18CE510 NA 35 30 15 12 200 200
IFR18CE650 NA 45 40 20 20 200 200
IFR18CE750 NA 60 50 25 20 200 200
IFR18HK510 NA 20 20 10 8 200 200
IFR18HK650 NA 25 25 12 10 200 200
IFR18HK750 NA 30 25 15 12 200 200
IFR18HK875 NA 35 30 15 12 200 200
IFR18HK935 NA 40 35 15 15 325 300
IFR18HK1000 NA 40 35 20 15 325 300
IFR18HK1100 NA 45 40 20 15 325 300
IFR18HK1200 NA 45 40 20 15 325 300
IFR18HK1250 NA 50 45 20 20 325 300
IFR18HK1400 NA 50 50 25 20 500 500
* Models with M or L input voltage code only
PM990-1897-00, ISSU E 5 50
Model Input (AC) Fuse Rating – Amperes Output Shunt
120 V 208 V 240 V 480 V 575 V * (DC) Fuse Amperes
Rating
Amperes
IFR24CE450 NA 40 35 20 15 200 200
IFR24CE510 NA 50 45 20 20 200 200
IFR24CE600 NA 60 50 25 20 200 200
IFR24CE680 NA NA 60 30 25 200 200
IFR24HK450 NA 25 25 12 10 200 200
IFR24HK510 NA 30 30 15 12 200 200
IFR24HK600 NA 30 30 15 12 200 200
IFR24HK680 NA 35 30 15 15 200 200
IFR24HK765 NA 40 35 20 15 200 200
IFR24HK850 NA 45 40 20 15 200 200
IFR24HK900 NA 50 45 20 20 325 300
IFR24HK1100 NA 50 50 25 20 325 300
IFR24HK1250 NA 60 60 30 25 325 300
IFR24K1360 NA NA NA 30 25 500 500
IFR36HK450 NA 35 30 15 12 200 200

IFR36HK510 NA 40 40 20 15 200 200
IFR36HK600 NA 50 40 20 20 200 200
IFR36HK680 NA 50 50 25 20 200 200
IFR40HK510 NA 50 40 20 15 200 200

* Models with M or L input voltage code only
PM990-1897-00, ISSU E 5 51
10. SCHEMATICS AND WIRING DIAGRAMS
PM990-1897-00, ISSU E 5 52
TB1 PXF1
BLK
1
LC
RED
2
AC INPUT
{
L1 T1
RES
YEL C1 C2
F1 3
PRI
240VAC 4
GRN
}
L2 T2 POS
BLU
(SHOWN) F2
5
CA
SEC
NAT D1
6 SP
LCC
7 DC OUTPUT
D2 OPTIONAL
DCF AS
1 2 NEG
3 4
LEGEND
RB
AS SHUNT (OPTION)
} DC CONNECTOR
AUX. CONTACTS
CA
C1 & C2
CXF
CATHODE
CAPACITOR (C2 OPTIONAL)
CONTROL TRANSFORMER
D1 & D2 DIODE
CXF DCF DC FUSE
X1 F1-F2 AC FUSE
H4
H2 X2 F3 CONTROL FUSE
X3
K1 BOARD CONNECTOR
H3 LC LINE CONTACTOR
X4
H1 LCC LINE CONTACTOR COIL
1 4 5 7 9 11 12 15 18
F3 PXF1 POWER TRANSFORMER
K1 RB AUX. CONNECTOR BOARD (OPTIONAL)
SP SURGE PROTECTOR
} TO OPTIONAL TB1 TERMINAL BLOCK, AC CHANGEOVER

WATER MODULE TVS TRANSIENT VOLTAGE SUPPRESSOR
DEVICE
JUMPER CONNECTIONS FOR 208V JUMPER CONNECTIONS FOR 480V
TB1 TB1
BLK BLK
1 1
CXF CXF
RED RED
2 L2 H4 2
L2 H4
YEL YEL
3 H2 3
H2
GRN GRN
4 H3 4
H3
BLU L1 BLU
5 H1 5
L1 H1
NAT NAT
6 6
7 7
SCHEMATIC DIAGRAM – 208/240/480 VAC 1- PHASE
PM990-1897-00, ISSU E 5 53
TB1 PXF1
BLK
1
LC
RED
2
AC INPUT
{
L1 T1
RES
YEL C1 C2
F1 3
PRI
120VAC GRN
}
4
L2 T2 POS
BLU
(SHOWN) F2
5
CA
SEC
NAT D1
6 SP
LCC
7 DC OUTPUT
D2 OPTIONAL
DCF AS
1 2 NEG
3 4
LEGEND
RB
AS SHUNT (OPTION)
} DC CONNECTOR
AUX. CONTACTS
CA
C1 & C2
CXF
CATHODE
CAPACITOR (C2 OPTIONAL)
CONTROL TRANSFORMER
D1 & D2 DIODE
CXF DCF DC FUSE
X1 F1-F2 AC FUSE
H4
H2 X2 F3 CONTROL FUSE
X3
K1 BOARD CONNECTOR
H3 LC LINE CONTACTOR
X4
H1 LCC LINE CONTACTOR COIL
1 4 5 7 9 11 12 15 18
F3 PXF1 POWER TRANSFORMER
K1 RB AUX. CONNECTOR BOARD (OPTIONAL)
SP SURGE PROTECTOR
} TO OPTIONAL TB1 TERMINAL BLOCK, AC CHANGEOVER

WATER MODULE TVS TRANSIENT VOLTAGE SUPPRESSOR
DEVICE
JUMPER CONNECTIONS FOR 208V JUMPER CONNECTIONS FOR 240V
TB1 TB1
BLK BLK
1 1
CXF CXF
RED RED
2 L2 H4 2
L2 H4
YEL YEL
3 H2 3
H2
GRN GRN
4 H3 4
H3
BLU L1 BLU
5 H1 5
L1 H1
NAT NAT
6 6
7 7
SCHEMATIC DIAGRAM – 120/208/240 VAC 1- PHASE
PM990-1897-00, ISSU E 5 54
PX F2
LC TB2
L1 T1 B LK
RES
1
{
C1 C3
F1 RED
2
RED
A C IN PUT L2 T2 3
PRI
CA PO S
RED
F2 4
240V S HO W N
SEC
5
YEL D4
L3 T3 O PTIO N AL
6
G RN D C O U TPU T
F3 AS
B LU 2 DCF 1 1 2 NE G
7
S P1 3 4
B LU
8
SEC
B LU
LC C 9
NAT
10
D3
PX F1
TB1
RES
C2 C4
B LK
1
RED
2
D C C O N N EC TO R
RB YEL
SEC
3 D2
A UX . CO NTA C TS
PRI
G RN
4
B LU
5
S P2
NAT
6
SEC
D1
CXF
X1
H4
H2 X2
X3
H3
H1 X4
1 4 5 7 9 11 12 15 18
F4
K1
LE G E ND
JUM PE R C O N NE C TIO N S FO R 208V JU M P ER CO NN EC TIO NS FO R 480V

AS S HU N T (O P TIO N)
T B2 T B2 CA C ATH O D E
C 1-C 4 C AP A C ITO R (C 3 & C 4 O P TIO N AL)
1 1
C XF C O N TR O L TRA N S FO R M E R
2 TB1 2 TB1 D 1-D 4 D IO D E
CXF CXF
3 1 3 1 D CF D C FUS E
L3 L3
H4 H4 F1-F3 A C FUS E
4 2 4 2
H2 H2 F4 C O N TR O L FU SE
5 3 5 3 K1 B O A R D C O N N E CTO R
H3 H3
6 4 6 4 LC LIN E C O N TAC TO R
H1 H1
7 5
L1
7 5
L1 LC C LIN E C O N TAC TO R C O IL
P X F1 & PX F2 P O W ER TRA N S FO R M ER
8 6 8 6
RB A UX . CO N N EC TO R BO A R D (O PTIO NA L)
9 9 S P 1 & SP 2 S UR G E P R O TEC TO R
10 10 TB 1 & TB2 TER M INA L BLO C K
TV S TR A NS IE NT V O LTA G E S U P P RE SS O R
SCHEMATIC DIAGRAM – 208/240/480 VAC 3-PHASE
PM990-1897-00, ISSU E 5 55
PXF1
TB1
RES
C1 C4
BLK
1 CA
RED
2
YEL
SEC
3 D1
PRI
GRN
4
BLU
5
SP1
NAT
6
SEC
7
LC D2
L1 T1 PXF2
{
F1
TB2
RES
C2 C5
A C IN P U T L2 T2
1
BLK
}
F2 RED POS
240V SH O W N 2
SEC
YEL D3
L3 T3 3
PRI
F3 4
GRN D C O U TPUT
AS
BLU 2 DCF 1 1 2 NEG
5
SP2 3 4
NAT
6
SEC
LCC 7
D4
PXF3
TB3
RES
C3 C6
BLK
1
RED
2
DC CO NN ECTO R
RB YEL
SEC
3 D5
AUX. CO NTACTS
PRI
GRN
4
BLU
5
SP3
NAT
6
SEC
7
D6
CXF
X1
H4
H2 X2
X3
H3
H1 X4
1 4 5 7 9 11 12 15 18
F4
K1 LEG END
AS S H U N T (O P T IO N )
CA CATHO DE
C 1 -C 4 C A P A C IT O R (C 3 & C 4 O P T IO N A L )
J U M P E R C O N N E C T IO N S F O R 2 0 8 V J U M P E R C O N N E C T IO N S F O R 4 8 0 V CXF CO NTROL TR ANSFO RM ER
D 1 -D 4 D IO D E
DCF DC FUSE
F 1 -F 3 AC FUSE
T B 1 /T B 2 /T B 3 T B 1 /T B 2 /T B 3 F4 CO NTRO L FUSE
1 CXF 1
CXF K1 BOARD CO NNECTOR
2 L3 L3 LC L IN E C O N T A C T O R
H4 2 H4
LCC L IN E C O N T A C T O R C O IL
3 H2 H2
3 PXF1 & PXF2 POW ER TRAN SFO RM ER
4 H3 4 H3 RB A U X . C O N N E C T O R B O A R D (O P T IO N A L )
5 H1 H1
SP1 & SP2 SURG E PROTECTOR
L1 5 L1
TB1 & TB2 T E R M IN A L B L O C K
6 6 TVS T R A N S IE N T V O L T A G E S U P P R E S S O R
7 7
SCHEMATIC DIAGRAM – 208/240/480 VAC 3-PHASE THREE TRANSFORMERS
PM990-1897-00, ISSU E 5 56
PXF1
TB1
RES
C1 C4
B LK
1 CA
2
PRI
SEC
3 D1
YEL
4
SP1
SEC
LC D2
L1 T1 PXF2
{
F1
TB2
RES
C2 C5
A C IN P U T L2 T2
1
B LK
}
F2 POS
480V 2
PRI
SEC
L3 T3 3 D3
F3 4
YEL D C O UTPUT
AS
2 DCF 1 1 2 NEG
SP2 3 4
SEC
LCC
D4
PXF3
TB3
RES
C3 C6
B LK
1
PRI
DC CO NNECTOR
RB
SEC
3 D5
AUX. CO NTACTS
YEL
4
SP3
LEG END
SEC
D6 AS S H U N T (O P T IO N )
CA CATHODE
CXF
C 1 -C 6 C A P A C IT O R (C 4 - C 6 O P T IO N A L )
X1
H4 CXF CONTRO L TRANSFORM ER
H2 X2 D 1 -D 6 D IO D E
X3 DCF DC FUSE
H3
X4
F 1 -F 3 AC FUSE
H1
1 4 5 7 9 11 12 15 18
F4 CONTRO L FUSE
F4 K1 BO ARD C O NNECTO R
K1 LC L IN E C O N T A C T O R
LCC L IN E C O N T A C T O R C O IL
PXF1 - PXF3 PO W ER TR AN SFO RM ER
RB A U X . C O N N E C T O R B O A R D (O P T IO N A L )
SP1 - SP3 SURG E PROTECTOR
TB1 - TB3 T E R M IN A L B L O C K
TVS T R A N S IE N T V O L T A G E S U P P R E S S O R
SCHEMATIC DIAGRAM –480 VAC 3-PHASE THREE TRANSFORMERS
PM990-1897-00, ISSU E 5 57
TB1 PXF1
BLK
1
LC
2
{
L1 T1
RES
C1 C2
A C IN P U T F1 3
YEL
PRI
}
4
575VAC L2 T2 POS
DC OUTPUT
F2 CA
SEC
D1
SP
LCC
O P T IO N A L
D2
DCF AS
NEG
RB
CXF
H 3 575 X1
H 2 480 X2
X3
H1 X4
1 4 5 7 9 11 12 15 18
F3
K1
T O O P T IO N A L
LEG END W ATER M O DULE
D E V IC E
AS S H U N T (O P T IO N )
CA CATHODE
C1 & C2 C A P A C IT O R (C 2 O P T IO N A L )
CXF CONTROL TRANSFORM ER
D1 & D2 D IO D E
DCF DC FUSE
F 1 -F 2 AC FUSE
F3 CONTROL FUSE
K1 BOARD CONNECTOR
LC L IN E C O N N E C T O R
LC C L IN E C O N N E C T O R C O IL
PXF1 POW ER TRANSFORM ER
RB A U X . C O N N E C T O R B O A R D (O P T IO N A L )
SP SURG E PROTECTOR
TB1 T E R M IN A L B L O C K , A C C H A N G E O V E R
SCHEMATIC DIAGRAM – 575 VAC 1- PHASE
PM990-1897-00, ISSU E 5 58
PXF2
LC TB1
B LK
RES
1
C1 C3
F1
}
2
CA POS
OUTPUT
RED
AC 3
PRI
F2
SEC
IN P U T D4
DC
4 O P T IO N A L
YEL
5 AS
DCF NEG
F3 6
SP1
7
SEC
LC C
D3
PXF1
RES
C2 C4
B LK
DC CO NNECTO R
RB YEL
SEC
D2
AUX. CO NTACTS
PRI
SP2
SEC
D1
CXF
X1
H3
X2
H2
X3
H1
X4
F4 1 4 5 7 9 11 12 15 18
K1 LEG END
AM A M M E T E R (O P T IO N A L )
AS S H U N T ( O P T IO N )
CA CATHODE
C 1 -C 4 C A P A C IT O R ( C 3 & C 4 O P T I O N A L )
CXF CONTROL TRANSFORM ER
D 1 -D 4 D IO D E
DCF DC FUSE
F 1 -F 3 AC FUSE
F4 CONTROL FUSE
T O O P T IO N A L K1 BOARD CONNECTOR
W ATER M O DULE LC L IN E C O N T A C T O R
D E V IC E LC C L IN E C O N T A C T O R C O IL
PXF1 & PXF2 POW ER TRANSFORM ER
RB A U X . C O N N E C T O R B O A R D ( O P T IO N A L )
SP1 & SP2 SURGE PRO TECTOR
TB1 T E R M IN A L B L O C K
SCHEMATIC DIAGRAM – 575 VAC 3- PHASE
PM990-1897-00, ISSU E 5 59
PXF1
TB1
RES
C1 C4
B LK
1 CA
2
PRI
SEC
3 D1
YEL
4
SP1
SEC
LC D2
L1 T1 PXF2
{
F1
TB2
RES
C2 C5
A C IN P U T L2 T2
1
B LK
}
F2 POS
57 5V 2
PRI
SEC
L3 T3 3 D3
F3 4
YEL D C O U TP U T
AS
2 DCF 1 1 2 NEG
SP2 3 4
SEC
LCC
D4
PXF3
TB3
RES
C3 C6
B LK
1
PRI
DC CONNECTOR
RB
SEC
3 D5
A U X . C O N TA C TS
YEL
4
SP3
LEG END
SEC
D6 AS S H U N T (O P TIO N )
CA CATHODE
CXF
C 1-C 6 C A P A C IT O R (C 4 - C 6 O P T IO N A L)
X1
H 3 575 CXF CONTRO L TRANSFORM ER
H 2 480 X2 D 1-D 6 D IO D E
X3 DCF DC FUSE
X4
F 1-F3 AC FUSE
H1
1 4 5 7 9 11 12 15 18
F4 CONTRO L FUSE
F4 K1 BOARD CO NNECTOR
K1 LC LIN E C O N T A C T O R
LCC LIN E C O N T A C TO R C O IL
P X F 1 - P X F3 P O W E R T R A N S FO R M E R
RB A U X . C O N N E C TO R B O A R D (O P T IO N A L)
SP1 - SP3 S U R G E P R O T E C TO R
TB1 - TB3 T E R M IN A L B L O C K
TVS T R A N S IE N T V O LT A G E S U P P R E S S O R
SCHEMATIC DIAGRAM – 575 VAC 3- PHASE THREE TRANSFORMERS
PM990-1897-00, ISSU E 5 60
NOTE:
1 . W IR E N U M B E R S F O R C H A R G E R
W IT H O U T A S H U N T : 1 , 2 , 4 , 5 ,
7 -1 4 , 2 3 , 2 5 , 3 9 & 4 2 .
2 . W H E N S H U N T IS U S E D M O V E
DCF W IR E 2 5 , A D D B U S - B A R , A N D
23 C O N N E C T W IR E S 7 5 & 7 6 .
3 . W H E N C A P 2 IS U S E D A D D
W IR E S : 6 0 & 6 1 .
4 . W H E N A M M E T E R IS U S E D
C O N N E C T W IR E S : 7 0 t h r u 7 1 .
5 . W H E N W A T E R M O D U L E IS U S E D
D1 D2
A D D W IR E S : 7 4 & 7 7 .
R1
R E C T I F IE R CA 6 . W H E N A U X . C O N N E C T O R B O A R D IS U S E D
R2 R E M O V E W IR E 3 1 A N D A D D W IR E S 7 8 th r u 8 0 .
K 1 -1 5 # 1 8 R E D CA RED
26 27
P1 P2 P3 P4 P5 P6
D CF #18 W HT
} DC
35
36
28 18 BLK O UTPUT
GRN
C A #18 RED
RED
TO W ATER
NAT
BLU
BLK
YEL
CAP1 26 15
M O D U LE X3 #18 BRN
( O P T IO N A L ) 72 12
TVS
}
X 2 # 1 8 V IO
10
11
12
7
9
C1 C2
PXF1-S2 #4 BLK
29 11
K1
BLK
AS-2
X1 #18 O R N
60
61
30 9
77
74
TB1-1
TB1-2
TB1-3
TB1-4
TB1-5
TB1-6
CAP2 LCC 1 #18 YEL
3 1 /7 8 7
25
#18 BLU
#18 YEL
T B 3 -2 # 1 8 Y E L
74 5
C1 C2 A S -4 # 1 8 B L K
75 4
A S -3 # 1 8 W H T
76 1
K 1 -1 8 D C O U TPUT
23
28 BLK
DCF
K1-5
X4
25
TB1-1
TB1-7
L C -L 1 C X F -H 1
#18 ORN
WHT
WATER
#18 BRN
TVS
#18 BLU
#18 BLU
BLK
#18 VIO
42 1 F3 2 34
K1-12
K1-11
LCC2
BUS-BAR
BLK BLK
K1-9
4
DC OUTPUT
30
72
32
77
29
BLK
T1 T2
X1 X2 X3 X4
LC JUM PER CXF
L1 L2 1
LCC1
X4 #18 H4 H2 H3 H1 K 1 -1
LC C2
32
BLU #18 W HT 3
AS
WHT
BLK
50 K 1 -4
H 4 #18 4
33
34
76
L1
LC-T1
{
33
LC-T2
1 WHT #18 BLK
INPUT
F1 RED 2
BLK
52
AC
L2
F3-2 #18
F2 2
75
L2 #18
F 3 -1 # 1 8 B L K
BLK
51
RED
4
5
42 T V S ( A L T E R N A T E L O C A T IO N )
31
K 1 -7 # 1 8 Y E L 1 2 3 4 5 6 7 TB1
LC C 1 #18 YEL 10
11
12
7
K 1 -7 # 1 8 Y E L
78
78
O P T IO N A L
VO LTAG E C H AN G EO VER TABLE
RB
GRN
RED
NAT
BLU
BLK
YEL
IN P U T T E R M IN A L B L O C K CO NTRO L TRANS.
VOLTAG E JU M P ER S #10 G A (C X F )
JU M P E R C O N N .
80
} D C C O NN EC TO R
P1
P2
P3
P4
P5
P6
AUX. CO NTACTS
208 VAC T B 1 -1 TO T B 1 -4 , H 1 -H 3
79 T B 1 -2 TO T B 1 -5 , H 2 -H 4
T B 1 -5 TO T B 1 -7
STEP 1- 240 VAC T B 1 -1 TO T B 1 -4 , H 1 -H 3
LEG END (S H O W N ) T B 1 -3 TO T B 1 -6 , H 2 -H 4
F 1 -F 2 FUSE T B 1 -6 TO T B 1 -7
F3 CO NTRO L FUSE STEP 2-
480 VAC T B 1 -3 T O T B 1 -4 , H 2 -H 3
AS SHUNT K1 BO ARD CONNECTO R T B 1 -6 T O T B 1 -7
CA CATHODE LC L IN E C O N T A C T O R
CAP1 & CAP2 C A P A C IT O R LC C L IN E C O N T A C T O R C O IL
CXF CONTROL TRANSFORM ER PXF1 PO W ER TR ANSFO R M ER
D1 & D2 D IO D E RB AUX. CONNECTOR BOARD
DCF DC FUSE TB1 T E R M IN A L B L O C K
WIRING DIAGRAM - 1 PHASE - 208/240/480 VAC
PM990-1897-00, ISSU E 5 61
NOTE:
W IT H O U T A S H U N T : 1 , 2 , 4 , 5 ,
7 -1 4 , 2 3 , 2 5 , 3 9 & 4 2 .
DCF W IR E 2 5 , A D D B U S -B A R , A N D
23 C O N N E C T W IR E S 7 5 & 7 6 .
3 . W H E N C A P 2 IS U S E D A D D
W IR E S : 6 0 & 6 1 .
C O N N E C T W IR E S : 7 0 th ru 7 1 .
D1 D2
A D D W IR E S : 7 4 & 7 7 .
R1
R E C T IF IE R CA 6 . W H E N A U X . C O N N E C T O R B O A R D IS U S E D
R2 R E M O V E W IR E 3 1 A N D A D D W IR E S 7 8 th ru 8 0 .
K 1 -1 5 # 1 8 R E D CA RED
26 27
P1 P2 P3 P4 P5 P6
D C F #18 W H T
} DC
35
36
28 18 BLK OUTPUT
GRN
C A #18 RED
RED
TO W ATER
NAT
BLU
BLK
YEL
CAP1 26 15
M O D U LE X 3 #18 BR N
( O P T IO N A L ) 72 12
TVS
}
X 2 # 1 8 V IO
10
11
12
7
9
C1 C2
PXF1-S2 #4 BLK
29 11
K1
BLK
AS-2
X 1 #18 O RN
60
61
30 9
77
74
TB1-1
TB1-2
TB1-3
TB1-4
TB1-5
TB1-6
CAP2 LC C 1 #18 YEL
3 1 /7 8 7
25
#18 BLU
#18 YEL
T B 3 -2 # 1 8 Y E L
74 5
C1 C2 A S -4 # 1 8 B L K
75 4
A S -3 # 1 8 W H T
76 1
K 1 -1 8 D C O U TPUT
23
28 BLK
DCF
K1-5
X4
25
TB1-1
TB1-7
L C -L 1 C X F -H 1
WHT
#18 ORN
#18 BRN
WATER
TVS
#18 BLU
#18 BLU
BLK
#18 VIO
42 1 F3 2 34
K1-12
K1-11
LCC2
BUS-BAR
BLK B LK
K1-9
4
DC OUTPUT
30
72
32
77
29
BLK
T1 T2
X1 X2 X3 X4
LC JUM PER CXF
L1 L2 1
LCC1
X4 #18 H4 H2 H3 H1 K 1 -1
LCC2
32
BLU #18 W HT 3
AS
WHT
BLK
50 K 1 -4
H 4 #18 4
33
34
76
L1
LC-T1
{
33
LC-T2
WHT
1 #18 B LK
INPUT
F1 RED 2
BLK
52
AC
L2
F3-2 #18
F2 2
75
L2 #18
F 3 -1 # 1 8 B L K
BLK
51
RED
4
5
31
K 1 -7 # 1 8 Y E L 1 2 3 4 5 6 7 TB1
LC C 1 #18 YEL
10
11
12
7
9
K 1 -7 # 1 8 Y E L
78
78
O P T IO N A L
RB
GRN
RED
NAT
BLU
BLK
YEL
V O LT A G E C H A N G EO V ER TA B LE
80
} DC CONNECTOR
P1
P2
P3
P4
P5
P6
AUX. CO NTACTS IN P U T T E R M IN A L B L O C K CONTROL TRANS.
79 VOLTAGE JU M P E R S #10 G A (C X F )
JU M PER CONN.
S TEP 1- 120 VAC
LEG END T B 1 -1 T O T B 1 -4 , H 1 - H 3
(S H O W N )
F 1 -F 2 FUSE T B 1 -3 T O T B 1 -6 , H 2 - H 4
F3 C O N TR O L FU SE S TEP 2-
T B 1 -6 T O T B 1 -7
AS SHUNT K1 BOARD CONNECTOR
CA CATHODE LC L IN E C O N T A C T O R 208 VAC T B 1 -2 T O T B 1 -4 , H 2 - H 3
CAP1 & CAP2 C A P A C IT O R LC C L IN E C O N T A C T O R C O IL T B 1 -5 T O T B 1 -7
CXF CONTROL TRANSFO RM ER PXF1 P O W E R TR ANSFO R M ER
D1 & D2 D IO D E RB AUX. CO NNECTO R BOARD 240 VAC T B 1 -3 T O T B 1 -4 , H 2 - H 3
DCF DC FUSE TB1 T E R M IN A L B L O C K T B 1 -6 T O T B 1 -7
PM990-1897-00, ISSU E 5 62
NOTE:
W IT H O U T A S H U N T : 1 -3 8 ,
4 2 , 5 0 -5 5 , 7 2 .
W IR E 2 5 , A D D B U S -B A R , A N D
C O N N E C T W IR E S 7 5 & 7 6 .
DCF
23 24 3. W HE N CA P3 & CAP4 ARE USED
A D D W IR E S : 6 0 th ru 6 3 .
C O N N E C T W IR E S : 7 0 th ru 7 1 .
A D D W IR E S : 7 4 & 7 7 .
D1 D2 D3 D4 6 . W H E N A U X . C O N N E C T O R B O A R D IS
R3 R1
U S E D R E M O V E W IR E 3 1 A N D A D D
R E C T IF IE R CA W IR E S 7 8 th ru 8 0 .
R4 R2
K 1 -15 # 1 8 R E D RED
}
26 27
P11 P12 P13 P14 P15 P16 P1 P2 P3 P4 P5 P6 P7 P8 P9 P10
D C F #18 W HT TVS DC
35
36
38
38
28 18
OUTPUT
C A #18 R ED
10
11
12
13
14
15
16
17
18
19
20
21
22
9
CAP1 C AP2 TO W ATER 26 15
M O D U LE X3 #18 BR N
(O P T IO N A L ) 72 12
RED-1
RED-2
RED-3
GRN
GRN
BLU-4
BLU-5
BLU-6
X 2 # 1 8 V IO
}
RED
25
NAT
NAT
BLU
BLK
YEL
BLK
YEL
C1 C2 C1 C2
29 11 K1
BLK
AS-2
X1 #18 O R N
60
61
62
63
30 9
77
74
DC OUTPUT
LC C 1 #18 YEL
TB2-10
CAP3 C AP4 3 1 /7 8 7
TB1-1
TB1-2
TB1-3
TB1-4
TB1-5
TB1-6
TB2-1
TB2-2
TB2-3
TB2-4
TB2-5
TB2-6
TB2-7
TB2-8
TB2-9
BLK
#18 BLU
#18 YEL
T B 3 -2 # 1 8 Y E L
74 5
C1 C2 C1 C2 A S -4 # 1 8 B LK
75 4
A S -3 # 1 8 W H T
76 1
28
K1-5
SEE TABLE
L C -L1 C X F -H 1
X4
1 2 DCF
42 F4 34
BLK B LK
TB1-1
TB2-1
25
WHT
RED
BLK
TVS
#18 ORN
WATER
#18 BRN
#18 BLU
#18 BLU
#18 VIO
K1-11
K1-12
LCC2
BUS-BAR
K1-9
4
DC OUTPUT
30
29
72
32
77
BLK
T1 T2 T3
X1 X2 X3 X4
LC
L1 L2 L3
JUM PER CXF
X4 #18 H4 H2 H3 H1 K 1 -1
1
LC C 1 LCC2
32
BLU L C -T 1 W H T #18 W H T 3
AS
F1 WHT
F2 RED
L C -T 2
F3 BLK
H 4 #18 K 1 -4 4
33
34
76
33
RED RED #18 B LK
42
6
31
2
4
F4-2 #18
L3 #18
51
1
53
RED
3
BLK
75
T V S (A L T . L O C A T IO N )
F 4 -1 # 1 8 B L K 54 55 50 52
A C F U S E S M U S T B E C H A N G E D W H E N C H A N G IN G
K 1-7 # 1 8 Y E L V O L T A G E . S E E L A B E L S IN C H A R G E R .
TB1 1 2 3 4 5 6 TB2 1 2 3 4 5 6 7 8 9 10
T3 B LK
LC C 1 #18 Y EL 2 4 0 /4 8 0 U N IT S TE P 1- R E M O V E A LL C H A N G EO V ER JU M P ER S A N D
C O N T R O L T R A N S F O R M E R P R IM A R Y J U M P E R S .
17
18
19
20
21
22
10
11
12
13
14
15
16
K 1 -7 # 1 8 Y E L
7
9
78
78
O P T IO N A L
T3 BLK STEP 2- FO LLO W TABLE BELO W FO R C O R RECT
RB VO LTAG E C H ANG EO VER .
RED-1
RED-2
RED-3
P14 GRN
2 0 8 U N IT
P12 RED
P16 NAT
P15 BLU
P11 BLK
P13 YEL
P7 BLU-1
P8 BLU-2
P9 BLU-3
GRN
P10 NAT
BLK
YEL
VO LTA G E C H AN G EO VER TABLE

80
} DC CONNECTOR
AUX. CONTACTS S P E C IA L C O N N . CO NTRO L TRANS.
P1
P2
P3
P4
P5
P6
79 IN P U T T E R M IN A L B L O C K T O T E R M IN A L (C X F )
V O LT AG E JU M PE R S #10 G A BLO CK JUM PE R CO NN.
208 V AC T B 2 -1 TO T B 2 -6 , F3 TO H 1 -H 3
T B 2 -2 TO T B 2 -7 , T B 2 -9 H 2 -H 4
LEG END T B 2 -4 TO T B 2 -9 ,
F 1 -F 3 FUSE T B 2 -7 TO T B 1 -5 ,
L C -L 1 W H T F4 CONTR OL FUSE T B 1 -1 TO T B 1 -4 ,
F1 1
AS SHUNT K1 BOARD CON NECTOR T B 1 -2 TO T B 1 -5
CA C ATHODE LC L IN E C O N T A C T O R
{
240 V AC T B 2 -1 TO T B 2 -6 , F3 TO H 1 -H 3
INPUT
L C -L 2 R E D C A P 1 -C A P 4 C A P A C IT O R LC C 1 & 2 L IN E C O N T A C T O R C O IL T B 2 -3 TO T B 2 -8 , T B 2 -1 0 H 2 -H 4
AC
F2 2 (S H O W N )
CXF C ON TROL TRANSFORM ER P X F 1 -P X F 2 POW ER TRANSFORM ER T B 2 -5 TO T B 2 -1 0 ,
D 1 -D 4 D IO D E RB AUX. C ON NECTOR BOARD T B 2 -8 TO T B 1 -6 ,
L C -L 3 B L K DCF D C FUSE TB1 & TB2 T E R M IN A L B L O C K T B 1 -1 TO T B 1 -4 ,
F3 3 T B 1 -3 TO T B 1 -6
480 V AC T B 2 -5 TO T B 2 -6 , F3 TO H 2 -H 3
T B 2 -6 TO T B 1 -6 , T B 2 -1 0
T B 1 -3 TO T B 1 -4
PM990-1897-00, ISSU E 5 63
NOTE:
1 . W IR E N U M B E R S FO R C H A R G E R
W IT H O U T A S H U N T : 1 -4 6, 7 2.
W IR E 30 , A D D B U S -B A R , A N D
C O N N E C T W IR E S 7 5 & 76.
27 28 3. W HE N CA P4 TO CA P6 ARE USED
A D D W IR E S : 6 0 th ru 65.
4 . W H E N W A TE R M O D U LE IS U S E D
A D D W IR E S 7 4 & 77
5 . W H E N A U X . C O N N E C T O R B O A R D IS
U S E D R E M O V E W IR E 36 A N D A D D
D1 D2 D3 D4 D5 D6 W IR E S 7 8 th ru 80.
29
R1 R3 R5
R E C T IF IE R CA
R2 R4 R6
K 1-1 5 # 1 8 R E D RED
}
32 31
P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 P13 P 14 P 15 P 16 P 17 P 18
D C F # 18 W H T TVS DC
44
45
40
41
42
43
33 18
OUTPUT
C A # 18 R E D
21
22
23
24
25
26
10
11
12
14
15
16
17
18
19
7
CAP1 CAP2 CAP3 TO W ATER 32 15
M O D ULE X 3 # 18 B R N
(O P T IO N A L) 72 12
GRN
GRN
GRN
RED
X 2 # 1 8 V IO
RED
RED
30
NAT
BLU
NAT
NAT
BLU
BLU
BLK
YEL
YEL
YEL
BLK
BLK
C1 C2 C1 C2 C1 C2
34 11
K1
BLK
AS-2
X1 #18 ORN
64
65
60
61
62
63
35 9
77
74
DC OUTPUT
CAP4 CAP5 CAP6 LCC1 #18 YEL
3 6/78 7
TB3-1
TB3-2
TB3-3
TB3-4
TB3-5
TB3-6
TB1-1
TB1-2
TB1-3
TB1-4
TB1-5
TB1-6
TB2-1
TB2-2
TB2-3
TB2-4
TB2-5
TB2-6
BLK
#18 BLU
#18 YEL
T B 3-2 # 18 Y E L
74 5
C1 C2 C1 C2 C1 C2 A S -4 # 1 8 B LK
75 4
A S -3 # 1 8 W H T
76 1
33
K1-5
L C -L 1 C X F -H 1
X4
46 1 2 39
DCF
F4
B LK BLK
TB1-1
TB2-1
TB3-1
30
WHT
RED
BLK
TV S
#18 ORN
WATER
#18 BRN
#18 BLU
#18 BLU
#18 VIO
K1-11
K1-12
LCC2
BUS-BAR
K1-9
4
DC OUTPUT
35
34
72
37
77
BLK
T1 T2 T3
X1 X2 X3 X4
LC
L1 L2 L3
JU M P E R CXF
X 4 #1 8 H4 H2 H3 H1 K 1 -1
1
L CC 1 LCC2
37
B LU # 18 W H T 3
AS
F1 WHT
F2 RED
F3 BLK
H 4 #1 8 K 1 -4 4
38
39
76
38
RED # 18 B L K
46
36
F4-2 #18
L3 #18
1
RED
3
BLK
75
T V S (A L T . L O C A T IO N ) C A U T IO N
F 4-1 #1 8 B LK
A C F U S E S M U S T B E C H A N G E D W H E N C H A N G IN G
K 1-7 #1 8 Y E L V O LT A G E . S E E LA B E L S IN C H A R G E R .
TB1 1 2 3 4 5 6 7 TB2 1 2 3 4 5 6 7 TB3 1 2 3 4 5 6 7
L C C 1 #1 8 Y E L S T E P 1 - R E M O V E A L L C H A N G E O V E R JU M P E R S A N D
C O N T R O L T R A N S FO R M E R P R IM A R Y JU M P E R S .
27
10
11
12
13
13
14
15
16
17
18
19
20
20
21
22
23
24
25
26
27
K 1-7 # 1 8 Y E L
7
4
78
78
O P T IO N A L
S T E P 2 - F O LLO W T A B L E B E L O W F O R C O R R E C T
WHT
RED
BLK
RB
BLK
BLK
BLK
BLK
BLK
BLK
V O L TA G E C H A N G E O V E R .
GRN
P16 GRN
RED
P14 RED
P10 GRN
NAT
P18 NAT
BLU
RED
P17 BLU
YEL
P15 YEL
BLK
P13 BLK
P12 NAT
P11 BLU
BLK
YEL
VO LTAG E C H AN G EO VER TABLE

80
}
LC-T2
LC-T3
TB3-7
TB2-1
TB3-1
LC-T1
TB1-7
TB2-7
D C C O N N ECTOR
TB1-1
P1
P2
P3
P4
P5
P6
CO N TR O L TRANS.
P7
P8
P9
AU X. C O NTACTS
79 IN P U T T E R M IN A L B L O C K (C X F )
VO LTAG E JUM PERS #10 G A JU M P ER CO NN.
208 V AC T B 1: 1 -4, 2-5 , 5 -7 H 1 -H 3
LEG END T B 2: 1 -4, 2-5 , 5 -7
F 1-F3 AC FUSE T B 3: 1 -4, 2-5 , 5 -7 H 2 -H 4
L C -L 1 W H T F4 C O N T R O L FU S E
F1 1
AS SHUNT K1 B O A R D C O N N E C TO R 240 V AC T B 1: 1 -4, 3-6 , 6 -7 H 1 -H 3
CA C A T H O D E (R E C T IF IE R + O U TP U T) LC L IN E C O N TA C TO R
{
(S H O W N ) T B 2: 1 -4, 3-6 , 6 -7
INPUT
L C -L 2 R E D CAP1 - CAP6 C A P A C ITO R LCC1 & 2 L IN E C O N T A C TO R C O IL H 2 -H 4

T B 3: 1 -4, 3-6 , 6 -7
AC
F2 2
CXF C O N T R O L T R A N S FO R M E R P X F1 - P X F3 P O W E R T R A N S FO R M E R
D1 - D6 R E C T IF IE R D IO D E RB AU X. CO NNECTOR BO ARD 480 V AC T B 1: 3 -4, 6-7 H 2 -H 3
L C -L 3 B LK DCF DC FUSE T B 1 - TB 3 T E R M IN A L B L O C K
F3 3 T B 2: 3 -4, 6-7
TVS T R A N S IE N T V O L T A G E S U P P R E S S O R T B 3: 3 -4, 6-7
WIRING DIAGRAM - 3 PHASE - THREE TRANSFORMERS - 208/240/480 VAC
PM990-1897-00, ISSU E 5 64
D1 D2 D3 D4 D5 D6
R1 R3 R5
R2 R4 R6
R EC TIFIER
P1 P2 P3 P4 P5 P6 DC
O UT PU T
C AP 1 C AP 2 C AP 3 TO W ATER
M O D ULE
(O P TION AL)
K1
C AP 4 C AP 5 C AP 6
D CF
F4
TB3-1
T1 T2 T3
X 1 X2 X3 X4
LC N O T E: C XF
L1 L2 L3
1. W IR E N U M B ER S FO R C H A R G ER H4 H2 H3 H1
W IT H O U T A S H U N T : 1-15, 27-46,
AS
72.
2. W H E N SH U N T IS U SE D M O V E
W IR E 30 , A D D B U S -B AR , AN D
C O N N E C T W IR ES 75 & 76.
3. W H E N C A P4 T O C A P6 AR E U S ED
A D D W IR E S : 60 thru 65.
TB 1 1 2 3 4 TB 2 1 2 3 4 T B3 1 2 3 4
4. W H E N W A TE R M O D U LE IS U SED
A D D W IR E S 74 & 77
5. W H E N AU X. C O N N E C TO R B O AR D IS
U SE D R E M O VE W IR E 36 AN D AD D
W IR E S 78 thru 80.
F1
LEG EN D
INPUT
AS SHUNT
AC
F2
K1 B O A R D C O N N EC TO R
CA C AT H O D E (R E C TIFIE R + O U TP U T) LC LIN E C O N TAC TO R
F3 C A P1 - C A P6 C AP AC ITO R LC C 1 & 2 LIN E C O N TAC TO R C O IL
CXF C O N TR O L TR A N S FO R M ER P XF1 - PXF3 P O W E R T R A N S FO R M ER
D1 - D6 R EC TIFIER D IO D E RB A U X . C O N N EC TO R BO AR D
DCF D C FU SE TB1 - T B3 TE R M IN A L BLO C K
F 1-F3 A C FU SE TVS TR AN SIE N T VO LTAG E S U PP R E SSO R
F4 C O N TR O L FU S E
WIRING DIAGRAM - 3 PHASE - THREE TRANSFORMERS - 480 VAC
PM990-1897-00, ISSU E 5 65
NOTE:
W IT H O U T A S H U N T : 1 , 2 , 4 , 5 ,
7 , 9 , 1 3 -1 4 , 2 3 , 2 5 , 3 9 & 4 2 .
W IR E 2 5 , A D D B U S - B A R , A N D
C O N N E C T W IR E S 7 5 & 7 6 .
DCF 3 . W H E N C A P 2 IS U S E D A D D
23
W IR E S : 6 0 & 6 1 .
C O N N E C T W IR E S : 7 0 th r u 7 1 .
A D D W IR E S : 7 4 & 7 7 .
D1 D2 6 . W H E N A U X . C O N N E C T O R B O A R D IS U S E D
R1 R E M O V E W IR E 3 1 A N D A D D W IR E S 7 8 th r u 8 0 .
R E C T I F IE R CA
R2
K 1 -1 5 # 1 8 R E D CA RED
26 27
D C F #18 W H T
B LK
} DC
35
36
28 18
TO W ATER C A #18 RED OUTPUT
YEL
BLK
CAP1 26 15
M O D ULE X3 #18 BRN
(O P T IO N A L ) 72 12
TVS
}
X 2 # 1 8 V IO
9
C1 C2
PXF1-S2 #4 BLK
29 11 K1
BLK
AS-2
X1 #18 O RN
60
61
30 9
77
74
TB1-1
TB1-4
CAP2 LC C 1 #18 YEL
3 1 /7 8 7
25
#18 BLU
#18 YEL
T B 3 -2 # 1 8 Y E L
74 5
C1 C2 A S -4 # 1 8 B L K
75 4
A S -3 # 1 8 W H T
76 1
K 1 -1 8 D C OUTPUT
23
28 B LK
DCF
K1-5
X4
25
TB1-1
TB1-7
L C -L 1 C X F -H 1
#18 ORN
WHT
WATER
#18 BRN
#18 BLU
#18 BLU
BLK
#18 VIO
42 1 F3 2 34
K1-11
K1-12
LCC2
BUS-BAR
B LK B LK
K1-9
4
DC OUTPUT
30
29
72
32
77
BLK
T1 T2
X1 X2 X3 X4
LC
L1 L2
CXF 1
LCC1
X 4 #18 575 480 K 1 -1
LCC2
32 H3 H2 H1
B LU #18 W HT 3
AS
WHT
BLK
H 3 #18 K 1 -4 4
33
34
76
L1
LC-T1
LC-T2
{
33
WHT
#18 B LK
575 VAC
1
INPUT
F1 RED
BLK
2
L2
F3-2 #18
L2 #18
F2 2
75
RED
F 3 -1 # 1 8 B L K
BLK
4
5
31
K 1 -7 # 1 8 Y E L 1 2 3 4 TB1
LC C 1 #18 YEL
7
9
K 1 -7 # 1 8 Y E L
78
78
O P T IO N A L
RB
YEL
BLK
80
} D C C O N NECTO R
P1
P3
AU X. CO NTACTS
79
LEG END
F 1 -F 2 FUSE
F3 CONTROL FUSE
AS SHUNT K1 BOARD CON NECTOR
CA C ATH ODE LC L IN E C O N T A C T O R
CAP1 & CAP2 C A P A C IT O R LCC L IN E C O N T A C T O R C O IL
CXF CONTROL TRANSFORMER PXF1 POW ER TRANSFORM ER
D1 & D2 D IO D E RB AUX. CO NNECTOR BOARD
WIRING DIAGRAM - 1 PHASE - 575 VAC
PM990-1897-00, ISSU E 5 66
DCF
23 24
D1 D2 D3 D4
R1 R3
R E C T IF IE R CA
R2 R4
K 1 -1 5 # 1 8 R E D CA RED
26 27
D C F #18 W H T
} DC
38
39
40
41
28 18 BLK OUTPUT
CA #18 RED
17
19
10
7
9
C AP1 CAP2 TO W ATER 26 15 K1
M O D U LE X3 #18 BRN
( O P T IO N A L ) 72 12
}
C1 C2 C1 C2 X 2 # 1 8 V IO
RED
29
YEL
YEL
BLK
BLK
11
AS-2
BLK
X1 #18 ORN
60
61
62
63
30 9
77
74
C AP3 CAP4 LC C 1 #18 YEL
3 1 /7 8 7
TB1-3
TB1-5
TB1-1
TB1-4
TB1-7
#18 BLU
#18 YEL
T B 3 -2 # 18 Y E L
74 5
A S -4 # 1 8 B L K
25
C1 C2 C1 C2
75 4
A S -3 # 1 8 W H T
76 1
DC OUTPUT
28 B LK
K1-5
X4
DCF
TB1-3
TB1-9
TB1-1
25
WHT
RED
BLK
#18 ORN
C X F -H 1
WATER
#18 BRN
#18 BLU
#18 BLU
#18 VIO
42 1 F4 2 34
K1-11
K1-12
LCC2
BUS-BAR
B LK
K1-9
LC-L1
BLK
4
DC OUTPUT
30
29
72
32
77
BLK
T1 T2 T3
X1 X2 X3 X4
LC
L1 L2 L3
CXF
X 4 #18 K 1 -1
1
W HT
32
LCC1 LCC2
B LU H3 H2 H1
#18 W H T 3
AS
H 3 #18 B LK
31
K 1 -4
1
3
4
33
34
76
33
LC-T1
LC-T2
LC-T3
RED #18 B LK
WHT
RED
2
BLK
F1
F3
F2
L C -L 1
75
F4-2 #18
L3 #18
F1 1 BLK
W HT F 4 -1 # 1 8 B LK
RED
BLK
42 35
6
{
INPUT
K 1 -7 # 1 8 Y E L
L C -L 2
AC
F2 2 TB1 1 2 3 4 5 6 7
RED
LC C 1 #18 YEL
17
19
10
K 1 -7 # 1 8 Y E L
9
78
78
L C -L 3 O P T IO N A L
F3 3 N O TE:
B LK RB
RED
BLK
BLK
YEL
YEL
W IT H O U T A S H U N T : 1 -7 , 9 , 1 0 , 1 7 ,
80 1 9 , 2 3 - 3 5 , 3 8 -4 2 , 7 2 .
} D C CO NN EC TO R
P11
P12
AU X. C O NTA CTS
P1
P2
P3
79 2 . W H E N S H U N T IS U S E D M O V E
W IR E 2 5 , A D D B U S - B A R , A N D
C O N N E C T W IR E S 7 5 & 7 6 .
LEG END 3. W HEN CAP3 & C AP4 AR E USED

F 1 -F 3 FUSE A D D W IR E S : 6 0 th ru 6 3 .
F4 C ON TR OL FUSE
AS SHUNT K1 BOARD C ON NECTOR 4 . W H E N A M M E T E R IS U S E D
CA C ATH ODE LC L IN E C O N T A C T O R C O N N E C T W IR E S : 7 0 th ru 7 1 .
C A P 1 -C A P 4 C A P A C IT O R LCC1 & 2 L IN E C O N T A C T O R C O IL 5 . W H E N W A T E R M O D U L E IS U S E D
CXF C ON TR OL TRANSFORM ER P X F 1 -P X F 2 POW ER TRANSFO RM ER A D D W IR E S : 7 4 & 7 7 .
D 1 -D 4 D IO D E RB AUX. CO NNECTOR BOARD
6 . W H E N A U X . C O N N E C T O R B O A R D IS U S E D
R E M O V E W IR E 3 1 A N D A D D W IR E S 7 8 th ru 8 0 .
WIRING DIAGRAM - 3 PHASE - 575 VAC
PM990-1897-00, ISSU E 5 67
27 28
D1 D2 D3 D4 D5 D6
29
R1 R3 R5
RECTIFIER CA
R2 R4 R6
K1-15 #18 RED RED
}
32 31
P1 P2 P3 P4 P5 P6
DCF #18 WHT DC
44
45
40
41
42
43
33 18
OUTPUT
CA #18 RED
11
12
10
7
9
CAP1 CAP2 CAP3 TO WATER 32 15
MODULE X3 #18 BRN

(OPTIONAL) 72 12
X2 #18 VIO
30
NAT
NAT
NAT
BLK
BLK
BLK
C1 C2 C1 C2 C1 C2
34 11
K1
BLK
AS-2
X1 #18 ORN
64
65
60
61
62
63
35 9
77
74
DC OUTPUT
CAP4 CAP5 CAP6 LCC1 #18 YEL
36/78 7
TB3-1
TB3-6
TB1-1
TB1-4
TB2-1
TB2-6
BLK
#18 BLU
#18 YEL
TB3-2 #18 YEL
74 5
C1 C2 C1 C2 C1 C2 AS-4 #18 BLK

75 4
AS-3 #18 WHT

76 1
33
K1-5
LC-L1 CXF-H1
X4
1 2 DCF
46 F4 39
BLK BLK
TB1-1
TB2-1
TB3-1
30
WHT
RED
BLK
#18 ORN
WATER
#18 BRN
#18 BLU
#18 BLU
#18 VIO
K1-11
K1-12
LCC2
BUS-BAR
K1-9
4
DC OUTPUT
35
34
72
37
77
BLK
T1 T2 T3
X1 X2 X3 X4
LC
L1 L2 L3
CXF
X4 #18 H3 H2 H1 K1-1
1
LCC1 LCC2
37
BLU NOTE: #18 WHT 3
AS
LC-T1 WHT
LC-T2 RED
LC-T3 BLK
TB3-4 BLK
TB2-1 BLK
TB1-4 BLK
TB3-1 BLK
TB2-4 BLK
TB1-1 BLK
F1 WHT
1. WIRE NUMBERS FOR CHARGER

F2 RED
F3 BLK
H4 #18 K1-4 4
38
39
76
38 WITHOUT A SHUNT: 1-15, 27-46,
RED #18 BLK
46
36
72. 2
F4-2 #18
L3 #18
1
2. WHEN SHUNT IS USED MOVE
RED
3
BLK
75
WIRE 30 , ADD BUS-BAR, AND
13
15
13
14
14
15
4
6
F4-1 #18 BLK CONNECT WIRES 75 & 76.
K1-7 #18 YEL 3. WHEN CAP4 TO CAP6 ARE USED
TB1 1 2 3 4 TB2 1 2 3 4 TB3 1 2 3 4
ADD WIRES: 60 thru 65.
LCC1 #18 YEL
4. WHEN WATER MODULE IS USED
10
11
12
K1-7 #18 YEL
7
9
78
78
OPTIONAL
ADD WIRES 74 & 77
RB
5. WHEN AUX. CONNECTOR BOARD IS
YEL
YEL
BLK
BLK
YEL
BLK
USED REMOVE WIRE 36 AND ADD

80 WIRES 78 thru 80.
} DC CONNECTOR
P1
P2
P5
P6
P3
P4
AUX. CONTACTS
79
LEGEND
F1-F3 AC FUSE
LC-L1 W HT F4 CONTROL FUSE
F1 1
AS SHUNT K1 BOARD CONNECTOR
CA CATHODE (RECTIFIER + OUTPUT) LC LINE CONTACTOR
{
INPUT
LC-L2 RED CAP1 - CAP6 CAPACITOR LCC1 & 2 LINE CONTACTOR COIL
AC
F2 2
CXF CONTROL TRANSFORMER PXF1 - PXF3 POWER TRANSFORMER
D1 - D6 RECTIFIER DIODE RB AUX. CONNECTOR BOARD
LC-L3 BLK DCF DC FUSE TB1 - TB3 TERMINAL BLOCK
F3 3
TVS TRANSIENT VOLTAGE SUPPRESSOR
WIRING DIAGRAM - 3 PHASE - THREE TRANSFORMERS - 575 VAC
PM990-1897-00, ISSU E 5 68

C-D Ferro IFR

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C-D Ferro IFR

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INSTALLATION AND OPERATING INSTRUCTIONS

ISSUE PAGE(S) DESCRIPTION APP'D / DATE

1 All Original Release 8/4/03

2. RECEIVING AND INSTALLATION .................................................................................................................................. 8

10. SCHEMATICS AND WIRING DIAGRAMS ................................................................................................................ 52

FIGURE 2.1 NAMEPLATE .............................................................................................................................................................. 8

MODEL: IFR18HK1000 SPEC: XXXXXX

FIGURE 2.1 NAMEPLATE

IFR - Product Family

AC INPUT VOLTAGE CODES

TABLE 2.1 AC INPUT VOLTAGE CODES

Cells x Capacity x 0.24/100 = Cubic feet of hydrogen/charge cycle

18 x 720 x 0.24/100 = 31.1 Cubic feet of hydrogen/charge cycle

2.5. Mechanical installation

Cabinet Height Width Depth

FIGURE 2.2 CABINET DIMENSIONS

2.6.1. AC Input voltage and voltage changeover

CAUTION – DISCONNECT SUPPLY BEFORE CHANGING FUSES.

FIGURE 2.3 AC VOLTAGE RATING LABEL (VOLTAGE CIRCLED)

CAUTION AC FUSE RATING

2.6.2. AC input voltage cables

CAUTION – USE MINIMUM 75°C WIRING. USE COPPER CONDUCTORS.

2.6.4. DC cables and cable connectors

There are no other maintenance adjustments to the FerroCharge chargers.

CAUTION: Disconnect charger from AC voltage supply before servicing or dismantling.

FIGURE 3.1 SCOUT CONTROL BOARD

3.2.1. Basic operation

3.3. Basic settings

3.3.1. Setting the number of cells

To change the number of cells:

1) Disconnect the ac power supply at the circuit breaker or fused safety-disconnect.

FIGURE 3.3 JUMPERS FOR CHANGING CELLS

3.3.2. Changing the five-second factory-set delay

To lengthen the factory-set delay:

3.3.3. Changing maximum charging time

FIGURE 3.5 JUMPERS FOR SETTING MAXIMUM CHARGING TIME

3.3.4. Cold Storage Setting

3.3.6. Automatic equalizing

FIGURE 3.6 JUMPERS FOR SETTING AUTOMATIC EQUALIZE

FIGURE 4.1 COMPUCHARGE 3 CONTROL

4.3. Basic Settings

4.3.1. Setting the precharge delay

4.3.2. Activating cold storage

FIGURE 4.3 JUMPERS FOR SETTING COLD STORAGE

To change the number of cells:

5) Close all the panels and doors.

FIGURE 4.4 JUMPERS FOR SETTING THE NUMBER OF CELLS

FIGURE 4.5 JUMPERS FOR SETTING AUTOMATIC EQUALIZE

4.3.5. Manual equalizing

4.3.6. Automatic watering

FIGURE 5.1 COMPUCHARGE 4 CONTROL (L) AND INTERFACE (R) BOARDS

5.3. Basic Settings

5.3.1. Setting the Precharge Delay

To change the automatic equalize setting:

5.3.3. Setting the Equalize Charge Duration

To change the automatic equalize setting:

5.3.4. Setting the Refresh Charge Interval

To change the refresh charge interval:

5.3.5. Setting the Number of Cells

To set the number of cells:

To set the shunt size:

5.3.7. Setting the Operating Temperature

To set the operating temperature and extend the charge time: