SPP PowrPak Series Industrial Battery Chargers - Exide Technologies

LIMITED WARRANTYPOW’R PAK MOTIVE POWER BATTERY AND CHARGER(MODELS M21 AND M89 WITH …PP… DESIGNATION )This limited Warranty and Warranty Adjustment Agreement is entered into between GNB Industrial Power (“GNB”) and the OriginalUser with respect to CHAMPIONÒ Pow’r Pak Motive Power Batteries and Chargers for industrial electric vehicle motive power use.WARRANTY: GNB warrants to the Original User, subject to the Conditions and Limitations described below, that a CHAMPIONÒPow’r Pak Motive Power Battery, when used in an industrial electric vehicle motive power application, will be free from defects inmaterial and workmanship for a period of:For Original Users in the United States of America, Canada, and Puerto Rico: Freight charges paid by:One (1) year for 5 and 7 plate sizes GNBThree (3) years for all other plate sizes GNB for the first year, Original User thereafterFor Original Users in all other countries:One (1) year for all plate sizes Original Userfrom the initial date of shipment, as shown on the shipping documents.In discharge of this Warranty, GNB will, at its choice, repair or replace any cells or parts of the battery that are found to be defectiveor if necessary, replace the battery. GNB will bear all parts and labor costs of such repair. The repaired or replacement batteryshall complete the remaining unused portion of the warranty for the original battery.GNB warrants to the Original User, subject to the Conditions and Limitations described below, that a CHAMPIONÒ Pow’r PakMotive Power Charger, when used in an industrial electric vehicle motive power application, will be free from defects in material andworkmanship for a period of One (1) year from the date of shipment, as shown on the shipping documents, with the exception ofprimary switch contacts, fuses, bulbs, and filters (unless they are found to be defective prior to use). Replacement and exchangeparts will be warranted for a period of Ninety (90) days.WARRANTY ADJUSTMENT AGREEMENT: From expiration of the above mentioned Warranty, GNB further warrants to theOriginal User, subject to the Conditions and Limitations described below, that the battery will for a period of:For Original Users in the United States of America, Canada, and Puerto Rico: Freight charges paid by:One (1) year for 5 and 7 plate sizes Original UserTwo (2) years for all other plate sizes Original UserFor Original Users in all other countries:One (1) year for all plate sizes Original Userfurnish not less than 80% of its published rated capacity in ampere-hours at the 6-hour rate to an average final voltage of 1.7 voltsper cell, when tested under GNB’s supervision, in accordance with BCI-I-2, latest revision.In discharge of this Warranty Adjustment Agreement, GNB will either (a) repair the battery to deliver 80% or more of its publishedrated capacity or (b) credit the Original User a pro-rated amount to be used for purchase of another CHAMPIONÒ battery of equalor greater capacity. If the battery is repaired, the Original User will be billed for all labor and parts expenses minus the pro-ratedcredit for cells used in the repair. The pro-rated credit is determined by multiplying the net purchase price of the original battery (orthe current list price of cells used in repair) by a fraction, the denominator being the number of months in the period of the Warrantyand Warranty Adjustment Agreement and the numerator being the number of whole months remaining in the Warranty AdjustmentAgreement period.CONDITIONS: GNB shall have no obligation unless the Original User establishes that the following conditions have beenconsistently met at all times:1. The battery meets the size, design, and capacity requirements for the electric vehicle in which the battery is used and meetsGNB’s specified requirements for the number of batteries required for the Original User’s service application. The OriginalUser is responsible to report, in writing, any changes in the originally intended application and service duty to their local GNBsales representative.2. Batteries must always be charged with the integral Pow’r Pak charger. Use of any other brand of charger or modified chargingregime shall void this Warranty.

IMPORTANT OPERATING AND SAFETY INSTRUCTIONSSAVE THESE INSTRUCTIONSWorking in the vicinity of a lead-acid battery is dangerous. Batteries generate explosive gases duringnormal charger operation. For this reason it is of the utmost importance that each time before usingyour charger, read and follow the instructions provided exactly.a) Before using the battery charger, read all the instructions, precautions, CAUTION, WARNING,and DANGER markings on the charger, battery and all products using the battery.b) Do not touch uninsulated parts of the DC output connector or the battery terminals, as there is apossibility of electric shock.c) To reduce risk of battery explosion, follow these instructions and those marked on the battery.d) Batteries produce hydrogen gas while charging, which can explode if ignited. Never smoke, usean open flame or create sparks near a battery. Ventilate the area well when the battery is in aenclosed place and when it is charging.e) Connect or disconnect the battery plug only when the charger is disconnected from the ACpower supply, to prevent arcing or burning.f) Only qualified personnel should operate or service this equipment.g) De-energize all AC and DC power connections before servicing this unit. If injury does occur,apply the prescribed treatment for electrical shock and obtain medical attention immediately.h) The charger is NOT for outdoor use. Do not expose the charger to rain or snow or charge afrozen or wet battery.i) This charger is factory set to charge lead-acid batteries only. It is NOT intended to supplypower to an extra low-voltage electrical system or to charge dry-cell batteries. Charging dry-cellbatteries may cause them to burst and cause injury to persons and damage to property.J) Do not operate this unit if it has received a sharp blow, been dropped or otherwise damaged.Consult a qualified GNB service center.k) Do not disassemble the charger. Have the charger examined by a GNB service representativeor local qualified service facility. Incorrect reassembly of the charger may result in an explosion,electric shock or fire.I) If it is necessary to remove battery from vehicle to charge it, always disconnect the battery plugfrom the vehicle first. Make sure all accessories in the vehicle are off in order to prevent an arc.Instr. 4722-65-92608-00 Page 3

1. INTRODUCTIONThe GNB SPP “SCR POW’R PAK” series chargersare designed to make battery charging an easy,economical and precise operation. Chargers aremade for single phase, 120 Volt, 60 Hertz or 240Volt, 50 Hertz operation. Here are the GNBadvanced design features in the new SPP chargers:Recharge is fully automatic. A solid state controlcard provides an inteligent charge algorithm to fullycharge the battery. The algorithm is based on a IIEIprofile of four stages.The first stage of the profile is a diagnose profile inorder to test if the battery needs a recharge. If thecharger decides the battery needs a recharge thecharger moves into the Main charge. Upon reachingthe gassing voltage of typical 2.37V per cell, thecharger moves into a constant voltage stage at thegassing voltage until the charge current drops belowa predefined level (Finish rate current.If this current is detected the charger moves into aconstant current finish rate stage with a low currentuntil the control detects a low voltage rise over time.If this is detected the charger will terminate thecharge.A push button on the front allows the user to selectan Equalize charge. This equalize is started at theend of a complete charge profile. If Equalize isselected in the Diagnose mode, the charger movesdirectly into the Main charge stageAll stages are time controlled. An overall securitytimer protects the battery from over charge.2. INSTALLATIONThe SPP charger is mounted in the pocket providedat the side of the battery tray. It should be insertedsuch that the front vent holes at the top face theoutside of the battery tray.WARNING: THE CHARGER SHOULD EASILY FITIN THE POCKET PROVIDED IN THE BATTERYTRAY. IF IT DOES NOT, DO NOT FORCE THECHARGER AS DAMAGE TO THE CHARGERMIGHT RESULT.3. AC SUPPLYThis charger must be electrically grounded to reducethe risk of electric shock. The charger is equippedwith an AC supply cord having an equipmentgrounding conductor and a grounding type plug andis designed for either 120 Volt, 60 Hertz or 240 Volt,50 Hertz operation. This plug must be connected toan appropriate outlet that is properly installed andgrounded in accordance with the National ElectricCode (USA) or the Canadian Electrical Code(Canada) and all local codes and ordinances.WARNING: IMPROPER CONNECTION OF THEGROUNDING CONDUCTOR CAN RESULT IN ANELECTRIC SHOCK. DO NOT REMOVE THEGROUNDING PIN FROM THE AC PLUG.Specifications for AC supply power are:V/ICurrentVoltageVoltage: 120 or 240 Volts (tolerance ±5%) 1PhFrequency: 60 or 50 Hertz (tolerance ±5%) 1PhCharger ModelInput SupplySPP06385S1120V, 60Hz, 7ASPP06480S1120V, 60Hz, 7ASPP09415S1 120V, 60Hz, 8.7ASPP12200S1120V, 60Hz, 7ASPP12385S1120V, 60Hz, 12ASPP12480S1120V, 60Hz, 12ASPP12385S1-50HZ240V, 50Hz, 7ASPP12480S1-50HZ240V, 50Hz, 7ADiagnoseMain ChargeTimeConst.VoltageFinishRateThe charger is equipped with a safety interlock whichenables the charger when the battery isdisconnected from the charger.The use of an extension cord with the charger is notrecommended. If an extension cord must be used,keep the length to a minimum and use an extensioncord suitable for the current and use. Make sure thatthe pins of the plug on the extension cord are thesame number, size and shape as that of the plug onthe battery charger. aaaaaaaaaaaaaaaaaaaaaaaaaaInstr. 4722-65-92608-00 Page 4

WARNING: THE USE OF AN IMPROPER ORDAMAGED EXTENSION CORD COULD RESULTIN A RISK OF FIRE OR ELECTRIC SHOCK.LOCATE ALL CORDS SO THAT THEY WILL NOTBE STEPPED ON, TRIPPED OVER OROTHERWISE SUBJECTED TO DAMAGE ORSTRESS.6.1 FRONT PANEL CONTROLS ANDINDICATORSDISPLAYA.C. ON (yellow lamp)FUNCTIONIndicates AC power isavailable to the input andEqualize indication (Flashing).4. DC CONNECTIONSCharging (green lamp)Indicates Charge stagesThe output is provided with a commonly usedSB175A black connector. Check to be sure thepolarity of the battery connector is the same as thecharger plug. A reversed connection may causecharger damage and/or DC fuse blowing.WARNING: ALWAYS SHIELD EYES WHENWORKING NEAR BATTERIES. DO NOT PUTWRENCHES OR OTHER METAL OBJECTSACROSS THE BATTERY TERMINALS ORBATTERY TOP. ARCING OR EXPLOSION OFTHE BATTERY CAN RESULT.5. APPLICATIONThese chargers may be used only for the number ofcells for which they are designed. The solid statecontrol card is able to determine if a recharge isrequired. The various models and batteries are listedin Table 1.No. OfCells inSeries66912121212126. OPERATIONTable 1 - Charging SpecificationGNB Model NumberSPP06385S1SPP06480S1SPP09415S1SPP12200S1SPP12385S1SPP12480S1SPP12385S1-50HZSPP12480S1-50HZDCAmps3030301530303030BatteryAmperehours385480415200385480385480The SPP charger will automatically determine if thebattery requires recharge. If during step 4 below, thecharger terminates the charge, the battery is fullycharged and ready for use.The following is a list of controls and indicators plusa step-by-step instruction for daily battery charging.Fault (red lamp)EQUALIZE START/STOP PUSHBUTTON6.2 CHARGING THE BATTERYIndicates charger/battery fault.Starts the equalize mode (3.5hours). Pushbutton must bepressed longer than 3 seconds1. Connect the battery connector to the charger plug.2. Connect the AC power cord to a grounded outlet.3. Charger “A.C. ON” and will light.4. After 10 seconds the green LED Charging will flashat 1 Hz (5 minute Diagnose mode).5. If in Main charge or Constant voltage, the green LEDwill be solid on. In finish rate charge the green LEDwill flash two times and is off for two seconds. End ofcharge is indicated by a steady flashing of every twoseconds.6. Unplug the AC power cord from the outlet anddisconnect the battery plug.6.3 CHARGE INTERRUPTIf the charge cycle must be interrupted:1. Unplug the AC power cord from the outlet.2. Disconnect the battery plug.6.4 EQUALIZING THE BATTERYCAUTION - DO NOT MISUSEAfter the battery is fully charged and equalize isrequired:1. Press the “EQUALIZE” pushbutton, for 3seconds. The Yellow AC LED will flashAfter a complete charge cycle Equalize will beinitiated. Equalize will be performed for 3.5hours2. If Equalize needs to be interrupted, hold theswitch for at least 3 seconds. (not if inEqualize)Instr. 4722-65-92608-00 Page 5

7. PARTS LIST MODEL: SPP06385S1/SPP06480S1DESCRIPTION NUMBER QTYAC Line CordInput Fuse (F1)Control CardTransformer (T1)SCR/Diode (Q1/2,D1/2)Varistor (Z1/Z2)Shunt (SH)1645-66-31072-213281-66-01107-104111-66-12399-304611-66-88300-013541-66-01801-693551-66-01422-024158-66-07374-031111221Output Fuse (F2) 3290-66-02899-05 1Output Connector 3112-66-01495-04 1MODEL: SPP09415S1MODEL: SPP12200S1DESCRIPTION NUMBER QTY DESCRIPTION NUMBER QTYAC Line CordInput Fuse (F1)Control CardTransformer (T1)SCR/Diode (Q1/2,D1/2)Varistor (Z1/Z2)Shunt (SH)Output Fuse (F2)Output Connector1645-66-31072-213281-66-01107-124111-66-12399-304611-66-87198-023541-66-01801-693551-66-01422-024158-66-07374-033290-66-02899-053112-66-01495-04111122111AC Line CordInput Fuse (F1)Control CardTransformer (T1)SCR/Diode (Q1/2,D1/2)Varistor (Z1/Z2)Shunt (SH)Output Fuse (F2)Output Connector1645-66-31072-213281-66-01107-104111-66-12399-304611-66-88300-013541-66-01801-693551-66-01422-024158-66-07374-033290-66-02899-053112-66-01495-04111122111MODEL: SPP12385S1/SPP12480S1MODEL: SPP12385S1-50HZ/SPP12480S1-50HZDESCRIPTION NUMBER QTY DESCRIPTION NUMBER QTYAC Line CordInput Fuse (F1)Control CardTransformer (T1)SCR/Diode (Q1/2,D1/2)Varistor (Z1/Z2)Shunt (SH)Output Fuse (F2)Output Connector1645-66-31072-213281-66-01107-154111-66-12399-304611-66-87200-033541-66-01801-693551-66-01422-024158-66-07374-033290-66-02899-053112-66-01495-04111122111AC Line CordInput Fuse (F1)Control CardTransformer (T1)SCR/Diode (Q1/2,D1/2)Varistor (Z1/Z2)Shunt (SH)Output Fuse (F2)Output Connector1645-66-31072-213281-66-01107-104111-66-12399-304611-66-87200-043541-66-01801-693551-66-01422-024158-66-07374-033290-66-02899-053112-66-01495-04111122111Instr. 4722-65-92608-00 Page 6

SALES • SERVICE • RECYCLINGTOLL FREE 1-888-563-6300Champion ® is a registered trademark of Federal-Mogul CorporationGNB Industrial PowerMotive Power829 Parkview BoulevardLombard, IL 60148-3249U.S.A.Tel: 877.GNB.INFOFax: 630.691.7869GNB Industrial PowerMotive Power8301 Keele StreetMaple, OntarioCanada L6A 1T2Tel: 905.669.9326Fax: 905.669.7688Exide TechnologiesChloride Motive PowerP.O. Box 1, Salford RoadOver Hulton, Bolton BL5 1DDUnited KingdomTel: 44.1204.661.230Fax: 44.1204.652.100www.gnb.comREV 18Printed on recycled paperA