MODEL SJ SERIES BATTERY CHARGERS

PRINTED IN U.S.A.

INSTRUCTION & OPERATION MODEL SJ SERIES BATTERY CHARGERS SETEMBER 2001 (REVISED APRIL 2014)

DOCUMENT NO. SIG-00-00-18 VERSION B.1

Siemens Industry, Inc. Rail Automation 9568 Archibald Ave., Suite 100, Rancho Cucamonga, California 91730

1-800-793-SAFE Copyright © 2013 - 2014 Siemens Industry, Inc. All rights reserved

ii SIG-00-00-18 SETEMBER 2001 (Revised April 2014) Version No.: B.1

PROPRIETARY INFORMATION Siemens Industry, Inc. has a proprietary interest in the information contained herein and, in some instances, has patent rights in the systems and components described. It is requested that you distribute this information only to those responsible people within your organization who have an official interest. This document or the information disclosed herein, shall not be reproduced or transferred to other documents or used or disclosed for manufacturing or for any other purpose except as specifically authorized in writing by Siemens Industry, Inc.

TRANSLATIONS

The manuals and product information of Siemens Industry, Inc. are intended to be produced and read in English. Any translation of the manuals and product information are unofficial and can be imprecise and inaccurate in whole or in part. Siemens Industry, Inc. does not warrant the accuracy, reliability, or timeliness of any information contained in any translation of manual or product information from its original official released version in English and shall not be liable for any losses caused by such reliance on the accuracy, reliability, or timeliness of such information. Any person or entity that relies on translated information does so at his or her own risk.

WARRANTY INFORMATION

Siemens Industry, Inc. warranty policy is as stated in the current Terms and Conditions of Sale document. Warranty adjustments will not be allowed for products or components which have been subjected to abuse, alteration, improper handling or installation, or which have not been operated in accordance with Seller's instructions. Alteration or removal of any serial number or identification mark voids the warranty.

SALES AND SERVICE LOCATIONS

Technical assistance and sales information on Siemens Industry, Inc. products may be obtained at the following locations:

SIEMENS INDUSTRY, INC. RAIL AUTOMATION SIEMENS INDUSTRY, INC.RAIL AUTOMATION 2400 NELSON MILLER PARKWAY 939 S. MAIN STREET LOUISVILLE, KENTUCKY 40223 MARION, KENTUCKY 42064 TELEPHONE: (502) 618-8800 TELEPHONE: (270) 918-7800 FAX: (502) 618-8810 CUSTOMER SERVICE: (800) 626-2710 SALES & SERVICE: (800) 626-2710 TECHNICAL SUPPORT: (800) 793-7233 WEB SITE: http://www.rail-automation.com/ FAX: (270) 918-7830

FCC RULES COMPLIANCE

The equipment covered in this manual has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his/her own expense.

iii SIG-00-00-18 SETEMBER 2001 (Revised April 2014) Version No.: B.1

DOCUMENT HISTORY

Version Release Date

Sections Changed

Details of Change

1.0 10-2-2000 - - - - - Initial review copy A 10-27-2000 - - - - - Initial Release B 09-18-2001 ALL Data on SJ30, SJ40, and SJ60 added

B.1 Apr 2014 ALL Convert to Siemens Format

iv SIG-00-00-18 SETEMBER 2001 (Revised April 2014) Version No.: B.1

Table of Contents

Section Title Page PROPRIETARY INFORMATION .................................................................................................................. ii TRANSLATIONS ........................................................................................................................................... ii WARRANTY INFORMATION ....................................................................................................................... ii SALES AND SERVICE LOCATIONS ........................................................................................................... ii FCC RULES COMPLIANCE ......................................................................................................................... ii DOCUMENT HISTORY ................................................................................................................................ iii NOTES, CAUTIONS, AND WARNINGS ...................................................................................................... vii ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS .......................................................................... viii SECTION 1 ................................................................................................................................................ 1-1

1.0 INTRODUCTION ............................................................................................................................. 1-1

1.1 GENERAL .................................................................................................................................... 1-1

1.2 OPERATION ................................................................................................................................ 1-1

1.3 FRONT PANEL CONTROLS, INDICATORS, AND CONNECTORS .......................................... 1-2

1.4 TEMPERATURE PROBE ............................................................................................................ 1-2

1.5 SPECIFICATIONS ....................................................................................................................... 1-5

1.6 SURGE PROTECTION ............................................................................................................... 1-7

1.7 ORDERING INFORMATION ....................................................................................................... 1-7

SECTION 2 ................................................................................................................................................ 1-1

2.0 INSTALLATION & ADJUSTMENT .................................................................................................. 2-1

2.1 AC POWER SOURCE ................................................................................................................. 2-1

2.2 INSTALLATION ........................................................................................................................... 2-1

2.3 FLOAT VOLTAGE ADJUSTMENT WITH BATTERY CONNECTED .......................................... 2-4

v SIG-00-00-18 SETEMBER 2001 (Revised April 2014) Version No.: B.1

List of Figures

Section Title Page Figure 1-1 Model SJ40 Battery Charger .................................................................................................. 1-1 Figure 1-2 Front Panel Control, Indicator, and Connector Locations ...................................................... 1-3 Figure 1-3 SJ60 Front Panel .................................................................................................................... 1-3 Figure 1-4 Battery Charger Temperature Probe ...................................................................................... 1-4 Figure 1-5 Cell Quantity Selector ............................................................................................................. 1-7

vi SIG-00-00-18 SETEMBER 2001 (Revised April 2014) Version No.: B.1

List of Tables

Section Title Page Table 1-1 Float Voltage Minimum Adjustment Range for Multiple Battery Cells ..................................... 1-2 Table 1-2 Front Panel Control, Indicator, and Connector Indications ...................................................... 1-4 Table 2-1 Minimum Wire Size (AWG) for 0.2-Volt Total Drop in Battery Cables ..................................... 2-3

vii SIG-00-00-18 SETEMBER 2001 (Revised April 2014) Version No.: B.1

NOTES, CAUTIONS, AND WARNINGS Throughout this manual, notes, cautions, and warnings are frequently used to direct the reader’s attention to specific information. Use of the three terms is defined as follows:

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY. WARNINGS ALWAYS TAKE PRECEDENCE OVER NOTES, CAUTIONS, AND ALL OTHER INFORMATION.

CAUTION

REFERS TO PROPER PROCEDURES OR PRACTICES WHICH IF NOT STRICTLY OBSERVED, COULD RESULT IN A POTENTIALLY HAZARDOUS SITUATION AND/OR POSSIBLE DAMAGE TO EQUIPMENT. CAUTIONS TAKE PRECEDENCE OVER NOTES AND ALL OTHER INFORMATION, EXCEPT WARNINGS.

NOTE

Generally used to highlight certain information relating to the topic under discussion.

If there are any questions, contact Siemens Industry, Inc. Application Engineering.

viii SIG-00-00-18 SETEMBER 2001 (Revised April 2014) Version No.: B.1

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS Static electricity can damage electronic circuitry, particularly low voltage components such as the integrated circuits commonly used throughout the electronics industry. Therefore, procedures have been adopted industry-wide which make it possible to avoid the sometimes invisible damage caused by electrostatic discharge (ESD) during the handling, shipping, and storage of electronic modules and components. Siemens Industry, Inc. has instituted these practices at its manufacturing facility and encourages its customers to adopt them as well to lessen the likelihood of equipment damage in the field due to ESD. Some of the basic protective practices include the following:

• Ground yourself before touching card cages, assemblies, modules, or components.

• Remove power from card cages and assemblies before removing or installing modules.

• Remove circuit boards (modules) from card cages by the ejector lever only. If an ejector lever is not provided, grasp the edge of the circuit board but avoid touching circuit traces or components.

• Handle circuit boards by the edges only.

• Never physically touch circuit board or connector contact fingers or allow these fingers to come in contact with an insulator (e.g., plastic, rubber, etc.).

• When not in use, place circuit boards in approved static-shielding bags, contact fingers first. Remove circuit boards from static-shielding bags by grasping the ejector lever or the edge of the board only. Each bag should include a caution label on the outside indicating static-sensitive contents.

• Cover workbench surfaces used for repair of electronic equipment with static dissipative workbench matting.

• Use integrated circuit extractor/inserter tools designed to remove and install electrostatic-sensitive integrated circuit devices such as PROM’s (OK Industries, Inc., Model EX-2 Extractor and Model MOS-40 Inserter (or equivalent) are highly recommended).

• Utilize only anti-static cushioning material in equipment shipping and storage containers.

For information concerning ESD material applications, please contact the Technical Support Staff at 1-800-793-7233. ESD Awareness Classes and additional ESD product information are also available through the Technical Support Staff.

INTRODUCTION _________________________________________________________________________________________________________

1-1 SIG-00-00-18 SETEMBER 2001 (Revised April 2014) Version No.: B.1

SECTION 1 INTRODUCTION

1.0 INTRODUCTION

1.1 GENERAL

The Model SJ20, SJ30, SJ40, and SJ60 Battery Chargers, see Figure 1-1, are designed for reliable long-term charge maintenance of lead-acid and nickel-cadmium batteries. These units are ideally suited to applications where remote installation, extreme temperatures and minimal human oversight are expected.

Figure 1-1 Model SJ40 Battery Charger The Model SJ series Battery Chargers are dual-mode float units featuring automatic temperature compensation. Each model provides a front-panel digital display for charge current and voltage readings. Cell count and battery type are switch selectable from the front panel.

1.2 OPERATION

The Model SJ series Battery Chargers provide two operating modes:

INTRODUCTION _________________________________________________________________________________________________________


• Constant Current Mode - In this mode the charger supplies full rated output current to quickly recharge a depleted battery. The front-panel Current Limit indicator lights when the charger is in current limit mode.

• Constant Voltage Mode - The charger switches to constant voltage mode when the battery voltage recovers to the constant voltage (float voltage) setting. In constant voltage mode, the charger maintains battery charge by supplying the current necessary, to the battery or any other system load, to hold the battery voltage constant. When system power demand increases to the current limit point, the charger switches back to constant current mode and the cycle repeats. Mode changeover is automatic.

In the lead-acid mode, internal circuitry limits float voltage and temperature compensation to prevent battery gassing. The individual lead-acid cell float voltage limit is 2.36 VDC. The float voltage minimum-adjustment range for both types of batteries is specified in Table 1-1.

Table 1-1 Float Voltage Minimum Adjustment Range for Multiple Battery Cells

Float Voltage Minimum Adjustment Range

Number of Cells Nickel-cadmium Lead-acid

5 7.20 to 7.75 11.00 to 11.75 6 8.64 to 9.30 13.20 to 14.10 7 10.08 to 10.85 15.40 to 16.45 8 11.52 to 12.40 17.60 to 18.80 9 12.96 to 13.95 10 14.40 to 15.50 11 15.84 to 17.05 12 17.28 to 18.60

1.3 FRONT PANEL CONTROLS, INDICATORS, AND CONNECTORS

The model SJ20 front panel is typical of each of the SJ Series Battery chargers. The SJ Series front-panel controls, indicators, and connectors are identified in Figure 1-2 and described in Table 1-2. The SJ60 Battery Charger front panel differs from the SJ20 by the inclusion of an additional 70 amp. circuit breaker. The SJ60 front panel is shown in Figure 1-3.

1.4 TEMPERATURE PROBE

The SJ Series Battery Chargers employ an external probe (see Figure 1-4) to sense the internal temperature of the battery. The temperature sensor, located at the distal end of the probe, is placed in direct physical contact with the negative battery terminal. The probe connector is plugged into the charger’s front panel Temperature Probe connector.

INTRODUCTION _________________________________________________________________________________________________________


Figure 1-2 Front Panel Control, Indicator, and Connector Locations

Figure 1-3 SJ60 Front Panel

BATTERY CONNECTORS

AC INPUT CONNECTORS

AC INPUT FUSES LINE VOLTAGE SELECT SWITCH

VOLTAGE DISPLAY PUSH

BUTTON

BATTERY TYPE INDICATORS

CURRENT LIMIT INDICATOR

TEMP PROBE STATUS

INDICATOR

TEMP PROBE CONNECTOR

BATTERY TYPE SELECTOR

FLOAT VOLTAGE ADJUSTMENT

DC OUTPUT CIRCUIT

BREAKER

DIGITAL DISPLAY

CASE GROUNDING LUG

CELL QUANTITY SELECTOR

CASE GROUNDING LUG

DC OUTPUT CIRCUIT BREAKERS

INTRODUCTION _________________________________________________________________________________________________________


Figure 1-4 Battery Charger Temperature Probe

Table 1-2 Front Panel Control, Indicator, and Connector Indications Control/Indicator/Connector Nomenclature Description

AC Input Connectors AC Input AREMA binding posts marked AC1 and AC2 for 115/230 volt, 60 Hz input connection

AC Input Fuses (two fuses) 6A (SJ20) Fused protection for AC input, fuses in parallel for 115V, in series for 230V 20A (SJ30)

12A (SJ40) 30A (SJ60)

Line Voltage Select Switch 115V / 230V Slide switch for selecting AC input voltage, 115V or 230V

DC Output Circuit Breaker (SJ20, SJ30, SJ40)

70 Circuit breaker protection for DC output, 70 amp, push to reset

DC Output Circuit Breakers (SJ60)

70/70 Dual circuit breaker protection for DC output., 70 amp, push to reset

Probe Connector Temperature Sensor

INTRODUCTION _________________________________________________________________________________________________________


Table 1-2 Continued Control/Indicator/Connector Nomenclature Description

Battery Connectors DC Output AREMA binding posts for battery connections, marked + and 2

Current Limit Indicator Current Limit Lights when charger is in current limit mode Temp Probe Status Indicator Tempprobe Inactive Lights to indicate faulty or missing tempera-

ture probe Temp Probe Connector Temperature Probe Connection for temperature probe Battery Type Selector n/a Slide switch for selecting battery type.

Indicators to right of switch identifies the battery type selected.

Battery Type Indicators Lead Acid / Nicad Indicator lights to identify battery type selected

Cell Quantity Selector Cells DIP switch for cell quantity selection. Number of cells labeled to left of each switch position (figure 1-5). Slide switch handle toward cell quantity label to select. (Limited to 8 cells for lead-acid. If more than 8 cells are selected, charger functions as though only 8 cells are selected.)

Digital Display Current Three-digit LED display. Displays current by default. Press voltage display push button to display voltage reading.

Voltage Display Push Button Push for Voltage Press to view voltage reading on three-digit display

Float Voltage Adjustment Float Voltage Adj. Use to adjust the constant voltage level at which the battery will be maintained. View voltage reading on display while adjusting.

Case Grounding Lug n/a Ground lug for connecting case to earth ground

1.5 SPECIFICATIONS

Parameter Battery Charger SJ20 SJ30 SJ40 SJ60

Cell Selection Range

Lead-acid 5 to 8 cells 11 to 18 cells 5 to 8 cells 5 to 8 cells

Nicad 5 to 12 cells 19 to 26 cells 5 to 12 cells 5 to 12 cells

Input Current

115 VAC (±15%), 60Hz

8.2 amps 24.6 amps 16.4 amps 24.6 amps

230 VAC (±15%), 60Hz

4.1 amps 12.3 amps 8.2 amps 12.3 amps

Output Voltage

Lead- acid battery mode

10 to 18.8 VDC 22 to 42.4 VDC 10 to 18.9 VDC 10 to 18.8 VDC

INTRODUCTION _________________________________________________________________________________________________________


Nicad battery mode

6.5 to 19.0 VDC 24.7 to 41.0 VDC 6.5 to 19.0 VDC 6.5 to 19.0 VDC

Output Current 20 amps DC 30 amps DC 40 amps DC 60 amps DC Current Limit (Continuous Operation)

21.5 amps (±5%) 32 amps (±5%) 43 amps (±5%) 64 amps (±5%)

Load Regulation (no load to full load)

Less than 10 mV deviation




Line Regulation (low line to high line)





Output Ripple (0 to maximum current)

Less than 1.0 Vp-p with battery load




Float Voltage, Minimum Adjustment Range: (see Table 1-2)

Lead-acid mode

2.20 – 2.35 VDC per cell




Nicad mode





Ammeter Display Accuracy

99.9 amps full-scale ±5%




Voltmeter Display Accuracy

99.9 volts full-scale ±0.1 volt




Temperature Compensation using temperature probe with 12-foot cable

-40 °F to +160 °F (-40 °C to +70 °C)

-40 °F to +160 °F (-40 °C to +70 °C)

-40 °F to +160 °F (-40 °C to +70 °C)

-40 °F to +160 °F (-40 °C to +70 °C)

Weight 27 pounds (approximate)

60 pounds (approximate)



Dimensions

Height (rack mount flanges included)

9.4 inches (23.88 centimeters)




Depth (terminals included)





Width 10 inches (25.4 centimeters)

10 inches (25.4 centimeters)



INTRODUCTION _________________________________________________________________________________________________________


1.6 SURGE PROTECTION

Figure 1-5 Cell Quantity Selector The battery charger is provided with transient suppression devices across the input and output terminals. However, Siemens recommends that all connections to the charger that may be subject to surges from external sources be protected with appropriate surge protection.

1.7 ORDERING INFORMATION

To order, specify the description, model number, and applicable part number from the following chart:

Description Model Number Part Number 20 Amp Battery Charger SJ20 Z927-04861-0000 30 Amp Battery Charger SJ30 Z927-04863-0030 40 Amp Battery Charger SJ40 Z927-04863-0040 60 Amp Battery Charger SJ60 Z927-04863-0060

Temperature Probe, 12 foot - Mag-Con 3250775319 Temperature Probe, 25 foot - Mag-Con 3250775328

Cells12111098765

NOTE: SWITCHES SHOWN SET FOR 6 CELLS.

INTRODUCTION _________________________________________________________________________________________________________


This Page Intentionally Left Blank

INSTALLATION & ADJUSTMENT _________________________________________________________________________________________________________


SECTION 2 INSTALLATION & ADJUSTMENT

2.0 INSTALLATION & ADJUSTMENT

2.1 AC POWER SOURCE

The SJ Series Battery Chargers require a 60 Hz AC power source of 115 volts or 230 volts.

2.2 INSTALLATION

1. Mount the charger in a weather-tight enclosure as close as possible to the AC power source and the batteries to be charged.

2. Before making any connections to the charger, verify the following:

• The line voltage select switch is set to the proper line voltage (115V or 230V) • The battery type selector switch is set to the appropriate battery type (lead-acid or

Nicad) • The cell quantity switches are set to the proper number of cells

NOTE

1. If more than one cell quantity switch is inadvertently set, the switch corresponding to the lowest cell quantity takes precedence and all others are ignored.

2. If set to more than 8 cells while in the lead-acid battery mode, the charger will default to 8 cells selected.

3. Prepare the AC input cables using the appropriate wire gauge for the charger input current

rating listed below.

NOTE

Terminate the AC input cables wires with ¼-inch I.D. ring terminals.

Input Voltage Current 115V 12A 230V 6A



WARNING

THERE IS NO “ON/OFF” SWITCH; THE CHARGER IS ON WHEN AC POWER IS APPLIED! MAKE ALL CONNECTIONS WITH THE AC POWER SHUT OFF AT THE SOURCE (e.g. CIRCUIT BREAKER).

4. Turn the AC power off at the source. 5. Connect the AC input cables to the charger, but do not connect the temperature probe at

this time. 6. Turn the AC power on. 7. Using a small screwdriver, adjust the front panel Float Voltage Adj. potentiometer until the

digital voltage display matches the desired float voltage for 25°C.

NOTE

1. Consult the battery manufacturer for the appropriate float voltage. 2. This adjustment is done without the temperature probe to temporarily disable the temperature compensation function. The float setting will then be correct for all temperatures

8. Turn the AC power off at the source. 9. Prepare the charger-to-battery cables using a wire gauge appropriate for both the expected

current and the wire length required (see table 2-1).

NOTE

1. Terminate the wires with ¼-inch I.D. ring terminals. 2. The wire used should be large enough to minimize the voltage drop caused by wire resistance. If lighter wire is used, the battery may require longer charge times and the float voltage may be lower than indicated by the front panel display.



Table 2-1 Minimum Wire Size (AWG) for 0.2-Volt Total Drop in Battery Cables Cable length Minimum AWG#

15. 20A 30A 40A 60A 5ft 10 8 7 5

10ft 7 5 4 2 20ft 4 2 1 00

10. With AC power off, connect cables from the battery to the charger DC Output terminals.

WARNING

SHUT OFF AC POWER AT THE SOURCE BEFORE MAKING ANY CONNECTIONS TO THE BATTERY CHARGER.

CAUTION

OBSERVE PROPER POLARITY WHEN CONNECTING BATTERY CHARGER CABLES TO BATTERY TERMINALS.

NOTE

Reversed polarity of the battery connections will cause the charger output circuit breaker(s) to open. If this occurs, turn off AC power, correct the polarity, and then reset the breaker(s) by pushing the breaker button(s) back in.

11. Install the temperature probe with the temperature sensor in direct contact with the negative

terminal of the battery.

NOTE

This allows the probe to sense the internal battery temperature. 12. Connect the temperature probe to the charger. 13. Recheck all connections and cables and verify all selector switch settings. 14. Apply AC power to the charger.



The charger is now installed and ready for service. 15. Verify the float voltage directly at the battery with an external meter.

2.3 FLOAT VOLTAGE ADJUSTMENT WITH BATTERY CONNECTED

The float voltage can be adjusted with the battery connected, within the following limitations: • The charger must be operating in constant voltage mode • The charger must be actively supplying a charge current of approximately one or more amps When these conditions are met, the charger output voltage may be adjusted using the Float Voltage Adj. potentiometer as described in step 8 of paragraph 2.1.

NOTE

1. Battery and system loading will affect the charger output voltage. Accurate setting of the float voltage is only possible when the voltage is not held up by the battery or pulled down due to current limit. 2. Float voltage adjustment at temperature extremes may not be possible without disconnecting the battery.

Siemens Industry, Inc. Rail Automation

2400 Nelson Miller Parkway Louisville, Kentucky 40223

(502) 618-8800

Siemens Industry, Inc. Rail Automation

California R&D Division 9568 Archibald Ave., Suite 100

Rancho Cucamonga, California 91730 (909) 532-5300

MODEL SJ SERIES BATTERY CHARGERS

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