Fire Control Instruments
14-16 Southwest Park
Westwood, MA 02090, USA
Phone: (781) 471-3000
FAX: (781) 471-3099
CHG-120 Battery Charger
Instruction Manual
FCI P/N 9000-0572
Document 52459
11/22/04
PN 52459:A
Revision:
A
ECN 04-691
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Adherence to the following will aid in problem-free
installation with long-term reliability:
Installation Precautions
WARNING - Several different sources of power can be con-
nected to the fire alarm control panel. Disconnect all sources
of power before servicing. Control unit and associated equip-
ment may be damaged by removing and/or inserting cards,
Like all solid state electronic devices, this system may
operate erratically or can be damaged when subjected to light-
ning-induced transients. Although no system is completely
immune from lightning transients and interferences, proper
modules, or interconnecting cables while the unit is energized. grounding will reduce susceptibility. Overhead or outside
Do not attempt to install, service, or operate this unit until this
manual is read and understood.
aerial wiring is not recommended, due to an increased sus-
ceptibility to nearby lightning strikes. Consult with the Techni-
cal Services Department if any problems are anticipated or
encountered.
CAUTION - System Reacceptance Test after Software
Changes. To ensure proper system operation, this product
must be tested in accordance with NFPA 72 Chapter 7 after
any programming operation or change in site-specific soft-
ware. Reacceptance testing is required after any change, ad-
dition or deletion of system components, or after any modifica-
tion, repair or adjustment to system hardware or wiring.
Disconnect AC power and batteries prior to removing or in-
serting circuit boards. Failure to do so can damage circuits.
Remove all electronic assemblies prior to any drilling, filing,
reaming, or punching of the enclosure. When possible, make
all cable entries from the sides or rear. Before making modifi-
cations, verify that they will not interfere with battery, trans-
former, and printed circuit board location.
All components, circuits, system operations, or software func-
tions known to be affected by a change must be 100% tested.
In addition, to ensure that other operations are not inadvert-
ently affected, at least 10% of initiating devices that are not
directly affected by the change, up to a maximum of 50 de-
vices, must also be tested and proper system operation veri-
fied.
Do not tighten screw terminals more than 9 in-lbs.
Over-tightening may damage threads, resulting in reduced
terminal contact pressure and difficulty with screw terminal
removal.
Though designed to last many years, system components
can fail at any time. This system contains static-sensitive
components. Always ground yourself with a proper wrist strap
before handling any circuits so that static charges are re-
moved from the body. Use static-suppressive packaging
to protect electronic assemblies removed from the unit.
This system meets NFPA requirements for operation at
0-49° C/32-120° F and at a relative humidity of 85% RH (non-
condensing) at 30° C/86° F. However, the useful life of the
system's standby batteries and the electronic components
may be adversely affected by extreme temperature ranges
and humidity. Therefore, it is recommended that this system
and all peripherals be installed in an environment with a nomi-
nal room temperature of 15-27° C/60-80° F.
Follow the instructions in the installation, operating, and
programming manuals. These instructions must be followed
to avoid damage to the control panel and associated
equipment. FACP operation and reliability depend upon
proper installation by authorized personnel.
Verify that wire sizes are adequate for all initiating and
indicating device loops. Most devices cannot tolerate more
than a 10% I.R. drop from the specified device voltage.
FCC Warning
Canadian Requirements
WARNING: This equipment generates, uses, and can
radiate radio frequency energy and if not installed and
used in accordance with the instruction manual, may
cause interference to radio communications. It has
been tested and found to comply with the limits for class
A computing device pursuant to Subpart B of Part 15 of
FCC Rules, which is designed to provide reasonable
protection against such interference when operated in a
commercial environment. Operation of this equipment in
a residential area is likely to cause interference, in which
case the user will be required to correct the interference
at his own expense.
This digital apparatus does not exceed the Class A
limits for radiation noise emissions from digital
apparatus set out in the Radio Interference Regulations
of the Canadian Department of Communications.
Le present appareil numerique n'emet pas de bruits
radioelectriques depassant les limites applicables aux
appareils numeriques de la classe A prescrites dans le
Reglement sur le brouillage radioelectrique edicte par le
ministere des Communications du Canada.
LimWarLg.p65 01/10/2000
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Notes
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Table of Contents
Introduction to the Charger....................................................................................... 1
Overview................................................................................................................... 1
Specifications............................................................................................................ 2
Compliance with NFPA Codes and UL Standards................................................... 2
Charger Maintenance................................................................................................ 2
Installing the Charger................................................................................................. 3
Overview................................................................................................................... 3
Installation Precautions and Standards ..................................................................... 3
Battery Precautions............................................................................................... 3
Installation Standards............................................................................................ 4
Charger Connections, Jumpers, and Switches .......................................................... 4
Connecting AC Power to the Charger ...................................................................... 5
Connecting Batteries to the Charger......................................................................... 6
Mounting the Charger............................................................................................... 8
Mounting the Charger into a CAB-X3 Series Cabinet ......................................... 8
Mounting the Charger into a BB-55 Battery Box................................................. 9
Connecting the Charger to a Load .......................................................................... 10
Connecting the Charger to a Multiple Load ....................................................... 10
Adding the Charger for Additional Current.........................................................11
Configuring the Charger ......................................................................................... 12
Delay loss of AC Reporting................................................................................ 12
Disable Ground Fault Detection......................................................................... 12
Trouble and Form-C Relay Connections (Optional) .............................................. 13
Installing Optional Meters ...................................................................................... 14
Installing an AM-1.............................................................................................. 14
Installing a VM-1................................................................................................ 14
Operating the Charger.............................................................................................. 15
Overview................................................................................................................. 15
Starting the Charger ................................................................................................ 15
Understanding the LED Status Indicators............................................................... 15
Normal Operation ................................................................................................... 16
CHG-120 Instruction 11/22/04 PN: 52459:A FCI P/N:9000-0572
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Notes
vi
CHG-120 Instruction 11/22/04 PN: 52459:A FCI P/N:9000-0572
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1. Introduction to the Charger
Overview
The CHG-120 battery charger is designed to charge lead-acid batteries that provide
emergency standby power for a Fire Alarm Control Panel (FACP). Two 12-volt batteries
are always used in series to supply 24 VDC nominal. The following list gives answers to
some common questions about the charger:
Note: Throughout this manual,
the term “charger” refers to a
CHG-120.
•
What types of FACPs can be used with the charger? Any 24 VDC FACP that uses
lead-acid 25 AH to 120 AH batteries and that has the feature to disable the FACP
battery charger.
•
•
Where does the charger mount? You can mount the charger into a CAB-X3 Series
Cabinet or into a BB-55 Battery Box.
How many outputs does the charger provide? The charger provides two output
circuits for connection to multiple loads (such as a power supply, amplifier, auxiliary
amplifier, and so forth).
•
•
What options are available with the charger? You can configure the charger to
disable the charger’s ground fault detection, to delay AC loss reporting (8 or 16 hours),
and to operate with 120 VAC or 240 VAC.
How long does it take the charger to charge batteries? Typically, it takes 9 hours to
charge 25 AH batteries, 20 hours to charge 60 AH batteries, and up to 48 hours to
charge 120 AH batteries. Refer to “Specifications” on page 2 for details.
Figure 1 identifies features of the charger:
Note: For detailed descriptions of charger connections, jumpers, and
switches, see “Charger Connections, Jumpers, and Switches” on page 4.
Nine LED status
indicators
Heavy duty primary
AC power
connections
Open collector trouble daisy chain
connections
Voltage Selection Switch
for 120 VAC or 240 VAC
operation
External trouble
input
Form-C trouble relay to
other devices
Two output circuits to
load (power supply,
auxiliary power supply,
amplifiers, etc.)
15 A replaceable fuses provide
short circuit and overload
protection
25 AH – 120 AH battery
connections
Optional Ammeter
connection
Figure 1 Charger Features
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Introduction to the Charger
Specifications
The charger also provides the following features:
AM-1 ammeter (0-10A) ordered separately
VM-1 voltmeter (0-50 V) ordered separately
Disable local ground fault detection
•
•
•
•
Selectable loss of AC delay (8 or 16 hours)
Specifications
Table 1 contains electrical specifications for the charger:
Primary AC power in (TB1)
120 VAC, 60 Hz, 2 A
240 VAC, 50 Hz, 1 A
5 A at 30 VDC
27.6 VDC
Form-C relay (TB3)
Float charge voltage
Maximum charging current
Fuses F1-F3 (PN 12057)
Battery sizes
4.5 A
15 A
25 AH to 120 AH
Charging Time (to charge two fully discharged
batteries
25 AH – 9 hours
55 AH/60 AH – 20 hours
120 AH – 38 hours
Table 1 Charger Specifications
Compliance with NFPA Codes and UL Standards
The charger complies with the following standards:
•
•
NFPA 72-1993 National Fire Alarm Code
UL 864 Standard for Control Units for Fire Alarm Systems and UL 1481 Power
Supplies for Fire Alarm Systems
•
CAN/ULC-S527-M87
Charger Maintenance
The charger does not require regular maintenance. While installing the charger, however,
make sure to maintain proper polarity when connecting power leads and battery
connections. To ensure optimal operation of the charger, observe the following:
Overload and reverse-polarity protection Fuses F1, F2 and F3 (15 A, PN 12057) provide
overload and reverse-polarity protection. Replace a blown fuse with a fuse with the same
rating and type.
Periodic Inspection Periodically inspect the batteries for corrosion and make sure that
corrosive effects to the batteries do not affect the charger or cabinet.
Troubleshooting Most problems with a charger are due to faulty batteries or loose
connections. If you encounter problems, inspect the charger, the battery, and all
connections for loose wiring or short circuits.
Replacing Batteries Only replace batteries with the same charge rate and capacity as
other batteries in the set. For example, if replacing one of four 60 AH batteries, make sure
the replacement battery has the same charge rate and capacity as the other three batteries.
2
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2. Installing the Charger
Overview
This section contains instructions and illustrations for installing the charger, divided into
the following topics:
Section
Topic(s) Covered
Page
InstallationPrecautions and Precautions to take when installing the charger
3
Standards
and recommended installation standards.
Charger Connections,
Jumpers, and Switches
Location and references to connections,
jumpers, and switches used to configure,
maintain, and operate the charger.
4
Connecting AC Power to
the Charger
How to connect AC power to the charger.
5
6
Connecting Batteries to the
Charger
How to connect batteries to the charger in two
configurations: using two batteries and using
four batteries.
Mounting the Charger
How to mount the charger to a CAB-X3.
How to mount the charger to a BB-55.
8
Connecting the Charger to
a Load
Instructions and illustrations for wiring a charger
to a multiple load and for wiring a charger for a
large system installation.
10
Configuring the Charger
Configuring the charger for the following
options:
Delaying loss of AC reporting (DACT); and
Disabling ground fault detection
12
13
Trouble and Form-C Relay
Connections (Optional)
Instructions and illustrations for connecting the
following:
Open Collector Trouble In (JP5)
Trouble Out (JP4)
Master Trouble In (JP6)
Form-C Trouble Relay (TB3)
Installing Optional Meters
How to install an optional ammeter, voltmeter,
or both.
14
Table 2 Installation Topics
Installation Precautions and Standards
Battery Precautions When installing the charger, observe the following precautions:
!
†
†
†
†
†
Observe polarity when making connections.
Do not connect the Battery Interconnect Cable until instructed.
Batteries, although sealed, contain hazardous acid chemicals.
Charging batteries can cause flammable hydrogen gas.
Take care when handling batteries: batteries are heavy—take care in lifting and
handling them.
†
Mounting batteries requires proper mounting hardware. Follow the battery
manufacture’s installation instructions
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Installing the Charger
Charger Connections, Jumpers, and Switches
Installation Standards An installer should be familiar with the following standards:
•
•
•
•
NEC Article 300 Wiring Methods.
NEC Article 760 Fire Protective Signaling Systems.
Applicable Local and State Building Codes.
Requirements of the Authority Having Jurisdiction.
Charger Connections, Jumpers, and Switches
Figure 2 show all connections, jumpers, and switches needed to maintain, configure, and
operate the charger:
JP4 – Open Collector Trouble Out
and JP5 – Open Collector Trouble In
(see “Trouble and Form-C Relay
LED Status Indicators – Nine LEDs to
indicate status of the charger (see
“Understanding the LED Status
Indicators” on page 15)
Connections (Optional)” on page 13)
JP6 – Master Trouble In
(see “Trouble and Form-C
Relay Connections
(Optional)” on page 13)
TB1 – AC Power (120 VAC
or 240 VAC (see
“Connecting AC Power to
the Charger” on page 5)
TB3 – Form-C Trouble Relay
(see “Trouble and Form-C
Relay Connections (Optional)”
on page 13)
TB2 – Output Circuits
1 and 2 (see
“Connecting the
Charger to a Load” on
page 10)
SW1 – Voltage Selection
Switch for selecting 120
VAC or 240 VAC operation
(See Figure 3 on page 5)
TB2 – Battery
Connections (see
“Connecting Batteries to
the Charger” on page 6)
Resistor R104 – Cut to
disable ground fault
detection (refer to “Disable
Ground Fault Detection” on
page 12)
Resistor R100 – Used
with JP8 to delay loss of
AC reporting (refer to
“Delay loss of AC
Fuses F1, F2, and F3 – Replaceable
plugged fuses (see “Charger
Maintenance” on page 2)
Reporting” on page 12)
JP3 (AM-1 connector) and JP9 for
enabling an optional AM-1
ammeter. (see “Installing an AM-1”
on page 14)
Figure 2 Charger Connections, Switches, and Jumpers
4
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Connecting AC Power to the Charger
Installing the Charger
Connecting AC Power to the Charger
Caution: Before connecting AC power to the charger—make sure to set the Voltage Select
Switch (SW1) on the charger (Figure 2) to match your AC power source (120 VAC or 240
VAC). Figure 3 shows the voltage selection positions for SW1:
Note: The charger is rated
for 120 VAC or 240 VAC
operation. Therefore, 115V
on SW1 indicates 120 VAC
operation; and 230V,
indicates 240 VAC
operation.
SW1 set to 120 VAC
operation
SW1 set to 240 VAC
operation
Figure 3 Using SW1 to Select AC Voltage
Figure 4 shows the steps for connecting the charger to the main AC power source.
Plastic
Earth ground (EARTH)
insulating cover
(PN 02114)
TB1
TB1
Step 2: Connect the Earth ground line to
TB1.
Step 1: Remove the plastic insulating cover
from TB1.
Primary Hot line in (HOT)
Earth ground (EARTH)
Earth ground (EARTH)
Neutral line in (NUTRL)
Neutral line in (NUTRL)
TB1
TB1
Step 4: Connect the Primary Hot line to TB1.
Check all connections, then replace the
plastic insulating cover.
Step 3: Connect the Primary Neutral line to
TB1.
Figure 4 Connecting AC Power to the Charger
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Installing the Charger
Connecting Batteries to the Charger
Connecting Batteries to the Charger
Overview you can connect 25 AH –120 AH batteries to the charger. This section provides
illustrations and instructions for connecting two batteries or for connecting four batteries.
Connecting Two Batteries Figure 5 shows how to connect two 25 AH batteries to the
charger:
TB1
TB2
CHG-120
Warning: Do not
connect the Battery
!
Power Supply
Interconnect Cable
at this time.
Refer to “Starting the
Charger” on page 15.
Figure 5 Connecting 25 AH Batteries
Table 3 contains instructions for connecting batteries to the charger:
Step
Action
1
2
Remove all power sources to the charger.
Connect the battery negative cable to the TB2 terminal (on the charger
labeled “Battery –” as shown in Figure 5.
3
4
Connect the battery positive cable to the TB2 terminal (on the charger)
labeled “Battery +” as shown in Figure 5.
Proceed to the section “Connecting the Charger.” Do not connect the Battery
Interconnect Cable at this time—refer to “Starting the Charger” on page 15.
Table 3 Connecting 25 AH Batteries
6
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Connecting Batteries to the Charger
Installing the Charger
Connecting Four Batteries Figure 6 shows how to connect four 55 AH batteries to the
charger:
TB1
TB2
Warning: Do not
Charger
!
connect the Battery
Interconnect Cable
at this time.
Power Supply
Refer to “Starting the
Charger” on page 15.
Figure 6 Connecting Four Batteries to a Charger
Table 4 contains instructions for connecting four batteries to the charger:
Step
Action
1
2
Remove all power sources to the charger.
Tie the batteries in pairs by connecting the battery negative terminals and the
battery positive terminals as shown in Figure 6.
3
4
5
Connect the battery negative cable to the TB2 terminal (on the charger labeled
“Battery –”) as shown in Figure 6.
Connect the battery positive cable to the TB2 terminal (on the charger) labeled
“Battery +”) as shown in Figure 6.
Proceed to the section “Connecting the Charger.” Do not connect the Battery
Interconnect Cable at this time—refer to “Starting the Charger” on page 15.
Table 4 Connecting 55 AH Batteries
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Installing the Charger
Mounting the Charger
Mounting the Charger
Mounting the Charger into a CAB-X3 Series Cabinet You can mount a charger into the
bottom row of a CAB-X3 Series Cabinet, as long as the charger is within 20 feet of the
load. Typically, a charger mounts into the lower right corner of the CAB-X3—beside the
power supply (Figure 7, position 2). If using an additional CAB-X3, you can mount the
charger in the lower left corner (Figure 7, position 2). Figure 7 shows the two mounting
positions of a charger into a CAB-X3.
Mounting
hooks
Position 1: Lower right corner.
Position 2: Lower left corner.
Figure 7 Mounting a Charger into a CAB-X3 (CAB-C3 shown)
To mount a charger into a CAB-X3 Series Cabinet, follow these instructions:
Step
Action
1
Place the charger chassis mounting slots in line with the mounting holes in the cabinet. If
mounting in position 2, place the charger chassis onto the mounting hooks in the cabinet.
2
Insert the self-tapping screws through the charger chassis mounting slots and into the
mounting holes in the cabinet.
Chassis mounting
slot
Self-tapping screw
3
Tighten the self-tapping screws.
8
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Mounting the Charger
Installing the Charger
Mounting the Charger into a BB-55 Battery Box You can also mount a charger into a
BB-55 battery box, as long as the BB-55 is within 20 feet of the load. Note that a charger
takes up half the space of the BB-55. This means you only have room left for two 25 AH
batteries in the BB-55. Figure 8 shows the mounting position of a charger in a BB-55.
Optional bracket for
mounting an optional
AM-1 or VM-1
Self-tapping screws
Figure 8 Mounting a Charger into a BB-55
To mount a charger into a BB-55 battery box, follow these instructions:
Step
Action
1
2
Place the charger chassis mounting slots in line with the mounting holes in the BB-55.
Insert the self-tapping screws through the charger chassis mounting slots and into the
mounting holes in the BB-55.
Chassis mounting
slot
Self-tapping screw
3
Tighten the self-tapping screws.
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Installing the Charger
Connecting the Charger to a Load
Connecting the Charger to a Load
This section provides two applications for connecting a charger to a load. While connecting
a charger to a load, observe the following precautions:
•
•
Make sure all power sources are off to the charger and the load.
Follow polarity when making connections.
Connecting the Charger to a Multiple Load You can connect a charger to multiple
loads, such as a main power supply, auxiliary power supply, amplifiers, and so forth, as
shown in Figure 9.
Power Supply
Note: Figure 10 shows a
wiring diagram for tying the
load to battery terminals to
obtain additional current. For
example, the first AA-120
draws 7 A, the daisy-chained
Generic Audio Amplifiers
draw 7 A, and the second
AA-120 draws 7 A of
additional current from the
batteries.
CHG-120
Generic Audio
Amplifier
Figure 9 Typical Wiring for a Charger to a Multiple Load
To connect a charger as shown in Figure 9, follow these steps:
Step
Action
1
Connect the battery+ and battery– terminals of the power supply to the charger
output circuit (TB2: Out 1+ and Out 1–) as shown in Figure 9.
2
3
Connect the battery+ and battery– terminals of the amplifier to the charger
output circuit (TB2: Out 2+ and Out 2–) as shown in Figure 9.
Connect the batteries to the charger (for battery connections see Figure 5 or
Figure 6).
10
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Connecting the Charger to a Load
Installing the Charger
Adding the Charger for Additional Current Due to internal fuses, the maximum alarm
current that can be drawn from the batteries and passed through the charger’s two output
circuits is limited to 10 amps maximum (each circuit). The PS-12600 batteries, however,
are capable of supplying up to 45 amps of current in alarm. The remaining 25 amps of
alarm current can be drawn directly from the battery terminals to supply Notification
Appliance Circuits, control modules and other alarm devices as illustrated in Figure 10:
First
AA-120
Charger
Power Supply
First
Generic
Audio Amp
Second
Generic
Audio Amp
55 AH/60 AH
12 VDC
55 AH/60 AH
12 VDC
Second
AA-120
55 AH/60 AH
12 VDC
55 AH/60 AH
12 VDC
Figure 10 Typical Connections for Drawing Additional Current
To connect a charger as shown in Figure 10, follow these steps:
Step
Action
1
Connect the Battery+ and Battery– terminals of the power supply to the charger
Battery output (TB2: Batt 1+ and Batt 1–) as shown in Figure 10.
2
3
4
5
6
Connect the Battery+ and Battery– terminals of the first AA-120 to the charger
output circuit (TB2: Out 2+ and Out 2–) as shown Figure 10.
Connect the Battery+ and Battery– terminals of the first Generic Audio Amp to
the charger output circuit (TB2: Out 1+ and Out 1–) as shown in Figure 10.
Connect the Battery+ and Battery– terminals of the second Generic Audio Amp to
the Battery+ and Battery– terminals of the first Audio Amp as shown in Figure 10.
Connect the Battery+ and Battery– terminals of the second AA-120 to the
batteries as shown in Figure 10.
Connect the batteries to the charger.
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Installing the Charger
Configuring the Charger
Configuring the Charger
You can configure the charger to do the following:
•
•
•
Set the charger input power (see Figure 3 on page 5).
Delay AC loss reporting (for Central Station applications); and
Disable charger ground fault detection.
Figure 11 shows how to configure the charger for delaying the loss of AC reporting and for
disabling ground fault detection:
Disable ground fault detection
cut and remove R104
Delay loss of AC (16 hrs) cut and
remove R100, in addition to
cutting JP8
Delay loss of AC (8 hrs) cut JP8
Figure 11 Configuring the Charger
Delay loss of AC Reporting If using a Digital Alarm Communicator (DACT), you must
delay the reporting of an AC loss condition to a central station. This delays activation of the
trouble bus and Form-C trouble contacts when AC fails. You can configure the charger for
an 8-hour or a 16-hour delay as follows:
•
•
8-hour delay – Cut and remove jumper JP8 on the charger (Figure 11).
16-hour delay – Cut jumper JP8; then, cut and remove resistor R100 (Figure 11).
Disable Ground Fault Detection To disable local (charger) earth fault detection, cut and
remove resistor R104 (Figure 11). Figure 12 contains a simplified block diagram that
shows ground fault detection disabled on a charger connected to multiple power supplies:
On the charger,
disable ground fault
detection (cut R104).
Charger
On Power Supply #1,
enable ground fault
detection.
On Power Supply #2 and
#3, disable ground fault
detection.
Power
Power
Power
Supply
Supply
Supply
# 2
# 3
# 1
Figure 12 Disabling Ground Fault Detection
12
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Trouble and Form-C Relay Connections (Optional)
Installing the Charger
Trouble and Form-C Relay Connections (Optional)
Table 5 contains descriptions of optional connectors on the charger:
Function
Connector
Use open collector input and output to daisy
chain a trouble signal through the charger
without affecting charger operation.
JP5 Open Collector Trouble In
JP4 Open Collector Trouble Out
Receive trouble signals from another device,
such as a Control Module.
JP6 Master Trouble In
Transmit a charger trouble signal to another
device.
TB3 Form-C Trouble Relay
Table 5 Charger Trouble and Form-C Relay Connections
Figure 13 shows charger trouble and Form-C relay connections:
Figure 13 Connections for Optional Devices
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Installing the Charger
Installing Optional Meters
Installing Optional Meters
You can also order and install a ammeter (AM-1) or voltmeter (VM-1) for use with the
charger. If mounting an AM-1 or a VM-1, mount the meter to a BB-55 as shown in Figure
14. Table 6 contains descriptions and part numbers for these optional meters:
Item
Part Number
Description
Ammeter
AM-1
0-10 A ammeter with a 3-ft. cable for connection to the
charger (JP3). Mounts into a BB-55 battery box only.
Voltmeter
VM-1
0-50 V voltmeter with 3-ft. positive and negative leads
for connection to the charger output circuit. Mounts
into a BB-55 battery box only.
Table 6 Optional Meters
Installing an AM-1 To install an AM-1, follow these steps:
1. Cut jumper JP9 on the charger (Figure 13).
2. Connect the AM-1 harness to JP3 on the charger (Figure 11)—making sure to observe
proper polarity.
3. Mount the AM-1 into a mounting slot on the front of the BB-55 (Figure 14):
AM-1 or VM-1
(BB-55 only)
BB-55 Mounting Slot
Figure 14 Mounting an AM-1 or VM-1 to a BB-55 Battery Box
Installing a VM-1 You can connect a VM-1 across a charger output circuit. For example,
to install a VM-1 to measure voltage from charger output circuit 1, follow these steps:
1. Connect the positive lead to TB2 Out 1 (+). See Figure 13.
2. Connect the negative lead to TB2 Out 1 (–). SeeFigure 13.
3. Mount the VM-1 into a mounting slot on the front of the BB-55 battery box.
14
CHG-120 Instruction 11/22/04 PN: 52459:A FCI P/N:9000-0572
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3. Operating the Charger
Overview
This section contains information on starting the charger, interpreting the LED Status
Indicators on the charger, and normal operation of the charger.
Starting the Charger
Warning: Before starting the charger, do the following:
!
†
†
Follow the installation instructions in Section 2, “Installing the Charger.”
Verify proper polarity on all connections between the charger and the batteries, load,
and optional meters.
†
†
Make sure there are no short circuits between leads and between battery terminals.
Make sure the Battery Interconnect Cable(s) is not connected.
To start the charger, follow these steps:
4. Connect AC power to the charger. The AC On LED and Trouble LED go on.
5. Connect the batteries to the charger
6. Connect the Battery Interconnect Cable. The Trouble LED goes off.
7. Connect the charger to the load (such as a power supply, an amplifier, and so on).
Understanding the LED Status Indicators
The charger provides nine LED Status Indicators, which are identified in Figure 15. Also
refer to Table 7 for conditions, such as troubles, that cause LEDs to light.
AC On Primary AC on
Trouble Charger in trouble condition (see Table 7)
Ground Fault Earth fault condition detected
HI Charge Charging current greater than 400 mA
LO Charge Charging current less than 400 mA (loss of AC)
27V Battery voltage greater than 27 VDC
25V Battery voltage between 25-27 VDC
23V Battery voltage between 23-25 VDC
Low Battery Battery voltage less than 23 VDC
Green LED
Yellow LED
Figure 15 LED Status Indicators
CHG-120 Instruction 11/22/04 PN: 52459:A FCI P/N:9000-0572
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Operating the Charger
Normal Operation
Table 7 shows the conditions that cause the charger LEDs to come on:
LED
AC On
H
H
H
H
H
H
I
H
H
H
H
H
Trouble
H
H
H
H
Ground Fault
HI Charge
I
I
I
I
I
I
I
LO Charge
(Loss of AC)
H
H
H
I
27 V
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
25 V
23 V
Low Battery
H
H
Legend:
H LED on.
I LED on or off, depending on battery voltage. Refer to “Normal Operation.”
Table 7 LED Status Indicators
Normal Operation
The CHG-120 charges batteries at 4.5 A. When batteries are fully charged, the charger
maintains a float charge of 27.6 VDC at a trickle charge rate of less than 400 mA. While
charging the batteries, the HI and LO Charge LEDs switch on and off approximately every
20 seconds. Also, one of the 23 V, 25 V, 27 V, or Low Battery LEDs also comes on,
depending on the battery voltage.
16
CHG-120 Instruction 11/22/04 PN: 52459:A FCI P/N:9000-0572
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Index
A
LED status indicators 4, 15
AC loss reporting 1, 4, 12
AC Power 4
M
meters
AC power connections 5
AM-1
installation 14
AM-1 ammeter 2
AM-1 connector 4
B
installation 14
mounting 1
BB-55 9
CAB-X3 8
N
NFPA Codes 2
normal operation 16
O
batteries 1
battery
25 AH connection 6
connecting four 7
battery charger 1
battery connections 4, 6
battery replacement 2
battery sizes 2
C
operation 15
normal 16
options 1
outputs 1, 4
Overview 1
P
Precautions 3
primary power 1, 2
protection
overload & reverse-polarity 2
R
relay 2, 4
connections 13
S
charger 1
additional current 11
connecting to FACP 11
connecting to load 10
connecting to multiple load 10
operation 15
starting 15
Charger Maintenance 2
charger voltage 2
charging current 2
Charging Time 2
compatibility 1
configuring charger 12
connections 4
F
Specifications 2
starting charger 15
switches 4
T
trouble
connections 13
Trouble In 4
Trouble Out 4
troubleshooting 2
U
FACP compatibility 1
Features 1
Fuses 2
fuses 4
UL Standards 2
V
G
VM-1
ground fault detection 1, 4, 12
I
inspection 2
installation 3
precautions 3
standards 4
installation 14
VM-1 voltmeter 2
Voltage Select Switch 5
voltage selection 4
J
jumpers 4
L
LED
status 16
CHG-120 Instruction 11/22/04 PN: 52459:A FCI P/N:9000-0572
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Limited Warranty
The manufacturer warrants its products to be free from defects in materials and workmanship
for eighteen (18) months from the date of manufacture, under normal use and service. Products
are date-stamped at time of manufacture. The sole and exclusive obligation of the manufacturer
is to repair or replace, at its option, free of charge for parts and labor, any part which is
defective in materials or workmanship under normal use and service. For products not under
the manufacturer's date-stamp control, the warranty is eighteen (18) months from date of
original purchase by the manufacturer's distributor unless the installation instructions or catalog
sets forth a shorter period, in which case the shorter period shall apply. This warranty is void
if the product is altered, repaired, or serviced by anyone other than the manufacturer or its
authorized distributors, or if there is a failure to maintain the products and systems in which
they operate in a proper and workable manner. In case of defect, secure a Return Material
Authorization form from our customer service department. Return product, transportation
prepaid, to the manufacturer.
This writing constitutes the only warranty made by this manufacturer with respect to its
products. The manufacturer does not represent that its products will prevent any loss by fire
or otherwise, or that its products will in all cases provide the protection for which they are
installed or intended. Buyer acknowledges that the manufacturer is not an insurer and assumes
no risk for loss or damages or the cost of any inconvenience, transportation, damage, misuse,
abuse, accident, or similar incident.
THE MANUFACTURER GIVES NO WARRANTY, EXPRESSED OR IMPLIED, OF
MERCHANTABILITY, FITNESS FOR ANY PARTICULAR PURPOSE, OR OTHERWISE
WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF. UNDER
NO CIRCUMSTANCES SHALL THE MANUFACTURER BE LIABLE FOR ANY LOSS
OF OR DAMAGE TO PROPERTY, DIRECT, INCIDENTAL, OR CONSEQUENTIAL,
ARISING OUT OF THE USE OF, OR INABILITY TO USE THE MANUFACTURER'S
PRODUCTS. FURTHERMORE, THE MANUFACTURER SHALL NOT BE LIABLE FOR
ANY PERSONAL INJURY OR DEATH WHICH MAY ARISE IN THE COURSE OF, OR
AS A RESULT OF, PERSONAL, COMMERCIAL, OR INDUSTRIAL USE OF ITS
PRODUCTS.
This warranty replaces all previous warranties and is the only warranty made by the
manufacturer. No increase or alteration, written or verbal, of the obligation of this warranty
is authorized.
LimWarLg.p65 01/10/2000
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