CAT DBT Battery Charger Model DBT Super Service Operation Manual (A6474X233) - PDF DOWNLOAD

Operation Manual DBT-

Battery Charger Model DBT Super Service

Doc. No.: A6474X233

DBT America 4041 Wurno Road Pulaski, VA 24301

Telephone: 540-980-4530 Fax: 540-994-3763

Internet: www.dbtamerica.com

This manual is intended to provide GENERAL product information for the Model DBT Super Service Battery charger. The illustrations, descriptions and procedures contained in this publication apply only to this unit. DBT America reserves the right to revise models and designs without prior notice.

This battery charger was manufactured under the guidelines, procedures and requirements of the U. S. Federal Coal Mine Health and Safety Act, Code of Federal Regulations, Title 30, Chapter 1, Subpart 0, Part 75 for underground coal mines, and other applicable non-U.S. regulatory agency standards.

At the completion of the manufacturing process, this unit was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this unit, without the consent of DBT America, and these regulatory agencies, or any repair or replacement of parts contrary to DBT America's instructions, may invalidate these approvals and render this unit unsafe to operate.

Strict compliance with all Federal and State Mining laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this unit.

While this manual attempts to anticipate the most important operations and maintenance needs for this unit, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your DBT America Service Representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable. Distribution and access is limited only to authorized personnel. Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

 DBT AMERICA 2003 ALL RIGHTS RESERVED

Table of Contents

Table of contents 1. About this manual About this manual ......................................................................1.3 Before starting to work ............................................................1.3 Who is this operating manual intended for?............................1.3 What is the purpose of this operating manual?.......................1.4 Characters and symbols used.................................................1.5

2. Your safety Your safety ..................................................................................2.3 Personnel ................................................................................2.4 Operation ...........................................................................2.4 Installation and repair.........................................................2.4 Operating conditions ...............................................................2.5 Intended use ......................................................................2.5 Unauthorized use ...............................................................2.5 Safety instructions ...................................................................2.7 General rules:.....................................................................2.7 Storage and transport ........................................................2.9 Installation and start-up......................................................2.9 Operation .........................................................................2.10 Maintenance and repair ...................................................2.10 Overview of the safety instructions .......................................2.13

3. Storage and transport Storage and transport ................................................................3.3 Storage....................................................................................3.3 Storage of the machine and spare parts............................3.3 Transport .................................................................................3.4 Load units; dimensions and weights ..................................3.4 Before transport .................................................................3.5

4. Installation Installation...................................................................................4.3 Points to observe prior to installation ......................................4.3 Who is allowed to carry out installation?............................4.3 Which tools are required for installation?...........................4.3 Notes on installation...........................................................4.3 Pre-installation check list ...................................................4.5

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Table of Contents General information ........................................................... 4.5 Safety features .................................................................. 4.7 Location ............................................................................. 4.5 Overview of the battery charger ........................................... 4.11

5. Operation Operation .................................................................................... 5.3 How to operate the battery charger ........................................ 5.3 Who is allowed to operate the battery charger?................ 5.3 When can charging be started? ........................................ 5.3 Controls and indicators ........................................................... 5.4 Battery charging procedure .................................................... 5.7 Charging ............................................................................ 5.3 Equalizing charge .............................................................. 5.3 Operating instructions........................................................ 5.3 Watering ............................................................................ 5.3 Cleaning............................................................................. 5.3 Shut down procedure............................................................ 5.12 Display fault messages......................................................... 5.12 Electrical system................................................................... 5.15 Input and output ratings ........................................................ 5.15 D.C. voltage....................................................................... 5.3 A.C. voltage ....................................................................... 5.3 Troubleshooting .................................................................... 5.15 General inspection............................................................. 5.3 Service information............................................................ 5.3 Troubleshooting and replacing silicon diodes ................... 5.3 Checking capacitors .......................................................... 5.3

6. Technical data Technical data ............................................................................ 6.3 Components of the battery charger ........................................ 6.3 Technical data sheet ......................................................... 6.3 Tightening torques ................................................................ 6.19

7. For your information For your information.................................................................. 7.3 Our service.............................................................................. 7.3 Service address................................................................. 7.3 Rebuild facility address...................................................... 7.4

Model DBT Super Service Battery Charger

1

About this manual

Before starting to work

About this manual This chapter provides important information making it easier for you to use this manual. You will also be given information on the structure of the manual and the symbols and characters used.

Before starting to work applicable operating manual machine type

Take care to ensure that the operating manual available to you is applicable for the type of equipment or machine used.

This operating manual is intended for: Model DBT Super Service Battery Charger Serial No.: N/A and is only permitted to be used for equipment of this type.

The operating manual must be accessible at all times to all persons working on or with the unit.

It should, if possible, always be available at the place of operation.

new operation manual

Send for a new operation manual immediately if the present manual is no longer complete or has become illegible.

Who is this operating manual intended for?

This operating manual is intended for those persons who work with or on the unit.

Every person working on the face or in the intersection between face and entry or in the entry must read this operating manual.

This includes persons who: are in charge of transport perform assembly / disassembly work operate the machine eliminate faults perform daily routine work on the face or in the entry perform maintenance work perform repair work supervisory personnel who: initiate and/or supervise the activities just indicated.

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1.3

Before starting to work What is the purpose of this operating manual? cost-effectiveness

This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the unit.

Read this operating manual completely and at ease. Pay special attention to the safety instructions. Try to memorize the appearance and the meaning of the safety and instruction symbols.

1.4

service

If any details are not clearly understood, please contact our service department. Our service address is given in the chapter titled “For your information”.

safety

Read the chapter “For your safety” with special attention. The chapter contains important information indicating possible hazards. Observe the information given and follow the procedural instructions.

Model DBT Super Service Battery Charger

Before starting to work Characters and symbols used The following characters and symbols are used for safety instructions and important information in the operating manual.

Try to memorize the symbols and their meanings.

DANGER! Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are: very serious injury or even death.

WARNING! These points contain information on dangerous situations.

Possible consequences are: very serious injury or even death.

CAUTION! This symbol draws attention to dangerous situations. Possible consequences are: light to moderately serious injuries and machine damage.

NOTICE! Points in the text marked with this symbol draw attention to harmful situations. Possible consequences are: damage to the machine or damage in the immediate vicinity.

IMPORTANT! Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you. They do not warn about harmful or dangerous situations.

Items in lists are marked with bullets.

–

Points in sub-lists are marked with a long dash at the start of the line.

) Points in text marked in this way describe individual operations.

Follow these instructions step by step. They will help you carry out your work faster and more importantly, safer.

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1.5

Before starting to work

1.6

Model DBT Super Service Battery Charger

2

Your safety

Personnel

Your safety This chapter provides vital information for your safety.

Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible. state of the art

The battery charger has been manufactured in accordance with the state of the art and generally recognized safety standards and regulations.

You and others can nevertheless be exposed to dangerous situations e.g. as a result of environmental influences, machine damage or operator errors.

Do not make any alterations or modifications which could impair the safety of the unit. All modifications and changes must be approved by DBT America.

Use only original spare parts from DBT America. Note that the use of parts from other manufacturers will void the guarantee.

In addition to this operating manual be sure to also observe the respective legal provisions and regulations in your country.

Observe the safety and accident prevention regulations:

further operating manuals

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of the mine. of the mines inspector and of the mining supervisory authorities

Please read also the operating manuals for the batteries to be charged and equipment to be operated carefully and thoroughly. Clarify any questions before starting work.

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2.3

Personnel

Personnel Operation The battery charger may only be operated by qualified, trained personnel. training

The battery charger is only allowed to be operated by qualified personnel who can provide proof of having been trained on this unit.

Reading of the operation manual, especially the chapter on safety, shall constitute a part of this training.

You must have adequate knowledge of the

electrics, operation

and must be able to prove this knowledge.

Installation and repair As a fundamental rule, installation and repair work may only be carried out by personnel who have been adequately trained for these particular requirements.

Installation and repair work on:

safety components the electrics

may only be carried out by service engineers from DBT America or by specially qualified personnel of the mine.

2.4

Model DBT Super Service Battery Charger

Operating conditions

Operating conditions Intended use The battery charger has been designed and manufactured purely for recharging of mine power storage batteries.

Intended uses include:

the recharging of mine power storage batteries that are specified on the charger nameplate.

Unauthorized use Applications not expressly listed as intended uses are unauthorized uses and are not allowed to be performed with the charger.

the recharging of other types of batteries not specified on the charger nameplate.

DBT America accepts no liability for any damage resulting from any such unauthorized use.

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2.5

Operating conditions

2.6

Model DBT Super Service Battery Charger

Safety instructions

Safety instructions General rules: general

Always work with full concentration.

Familiarize yourself with your working environment.

personal equipment

Always wear your personal protective equipment. This also includes eye and clothing protection.

Inform your colleagues of:

safety equipment

your exact location. the work you are performing. the time that you will probably require.

Start the unit only when it is in a good and safe operating condition and all protective devices, e.g. EMERGENCY STOP devices, cover plates, etc. are correctly installed.

Observe the optical start-up warnings of the unit.

symbol plates emergency stop

lock-out

Observe the symbol plates on the unit.

Press the EMERGENCY STOP switch immediately in the event of fault or irregularities in operation. Report any peculiarity to your superior so that necessary measures can be taken immediately.

Lock-out and disconnect the power system while performing:

cordon off working area

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maintenance work inspection work repair work

Cordon off your working area widely for the battery charger.

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2.7

Safety instructions Personal precautions

2.8

Have someone within range of your voice or close enough to come to your aid when you work near a battery Have plenty of fresh water and soap nearby in case the battery electrolyte contacts skin, clothing, or eyes Wear complete eye protection and clothing protection. Avoid touching eyes while working near a battery If the battery electrolyte contacts skin or clothing, wash immediately with soap and water. If the electrolyte enters the eye, immediately flood the eye with running cold water for at least ten (10) minutes and get medical attention immediately Never smoke or allow a spark or flame in vicinity of a battery Avoid dropping metal tools onto a battery. They may spark or short circuit the battery or other electrical parts that could cause an explosion Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a battery. A battery can produce a short circuit current high enough to weld a ring or the like to metal, causing a severe burn Never charge a frozen battery If it is necessary to remove the battery connections, always remove the grounded terminal from the battery first. Make sure all loads are disconnected and unit is off, so as not to cause an arc Be sure the area around the battery is well ventilated while the battery is being charged When cleaning battery terminals, be careful to keep corrosion from coming in contact with the eyes Study all the battery manufacturer's specific precautions such as do not remove cell caps while charging, recommended rates of charge, and maintenance procedures

Model DBT Super Service Battery Charger

Safety instructions Storage and transport Maintain the prescribed storage periods and observe the instructions for storage.

Do not store materials or parts in the travel way or in your working area.

Inform the persons involved about the intended transport route and the anticipated duration of the transport. transport safety device

Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

Never stand under unsupported parts or suspended loads.

means of attachment

Connect the lifting equipment only to the points of attachment provided for that purpose. Observe the different load limits of the attachment points. Also observe the instructions on the transport sheet.

Only use means of attachment which are in good condition and have been designed for the loads to be handled.

For round components use transport straps, only. Never use chains or steel cables for this purpose.

mobile handling equipment

When using mobile handling systems for transport make sure that the center of gravity is as low as possible.

Installation and start-up environmental acceptability

When working with oils, greases and other chemical substances, observe the safety regulations applicable to the product.

Dispose of cleaning rags, etc. which have been soiled with oil, grease or other chemical substances in an environmentally safe manner.

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2.9

Safety instructions Operation Operate the battery charger only if you have a profound knowledge of the control elements and their functions. It is necessary that you have been task trained on the respective battery charger.

Before start-up, ensure that all covers are on the unit.

Check that all protective devices are installed on the unit and function properly.

Clean the control panel and operator’s area at regular intervals. Ensure that the operating symbols are legible in order to avoid any operator errors and resulting accidents.

Maintenance and repair Be sure to observe the prescribed maintenance and inspection intervals.

Inform the supervisory personnel and the face crew of any maintenance and repair operations. Give them information on the intended operations and the anticipated duration. securing

Secure your working area over a wide range, in order to avoid endangering other persons.

Lock-out and disconnect power from the unit to prevent unauthorized and unintentional restarting.

Protect your work area against falling rocks.

replacing components

Stop, lock-out and disconnect power from unit to prevent from restarting before replacing any defective components.

Pass defective components removed on for servicing without delay in order to prevent these parts being reinstalled elsewhere.

original parts

lifting

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original DBT America spare parts.

Please refer to the spare parts lists for the order numbers.

For raising the battery charger use only:

2.10

crib blocks with adequate load-holding capacity. hoists, jacks or cranes with adequate load-carrying capacity.

Model DBT Super Service Battery Charger

Safety instructions maintenance, repair

Only persons who have and can demonstrate a special knowledge of electrics are allowed to work on the electrical system.

Carry out a visual inspection of all the electrical components at regular intervals. In particular check that:

the wiring and cables are not pinched or trapped. the conduits are not abnormally rigid or hard. the conduits are not damaged. the connectors are securely inserted into the sockets. the connections are tight.

Secure wiring and cables only with the proper clamps. Always fasten the clamps completely and with both sides. Never use nails, wire or similar materials for securing.

After finishing repair work, check all connectors and connections to ensure they are tight.

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2.11

Safety instructions

2.12

Model DBT Super Service Battery Charger

Overview of safety instructions

Overview of the safety instructions This is a summary of all the safety instructions which have to be observed in the following chapters. This summary is intended only to give you an overview of all the instructions. In some cases, there is no logical relationship between the individual instructions.

Chapter 3: Storage and transport DANGER! You could be seriously injured or even killed by falling loads.

Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.

WARNING! Use only load handling devices complying with the technical and legal regulations for the transport of loads.

You could be seriously injured or even killed by falling loads.

Use only suitable load handling devices.

Use only approved lifting equipment!

Chapter 4: Installation CAUTION! Serious damage can be caused to the battery charger as a result of incorrect installation.

The unit should therefore only be installed under the instruction of specialists from DBT America.

IMPORTANT! The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established NOTICE! The machine was inspected prior to shipment from the factory to ensure proper functioning and installation of all components.

However, to ensure that no transit damage has occurred, the following pre-startup checks should be performed:

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perform daily maintenance visually inspect all electrical cables for damage examine complete charger for possible transport damage verify that all the instruction and safety labels are in place and readable.

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2.13

Overview of safety instructions

start up the unit and check for correct operation of emergency stop switch which is located on the operation panel check all control switches to ensure all machine functions are operating properly

NOTICE! The operator must become familiar with all the safety features and their location on the unit prior to installation or operation.

NOTICE! All battery chargers are shipped from the factory with the emergency stop switch disconnected. The switch must be connected and tested by the user prior to installation. When actuated, the emergency stop switch will remove all AC power from the charger.

DANGER! Do not operate the battery charger with any of the covers removed.

You or other personnel could be seriously injured from electrical shock.

Chapter 5: Operation DANGER! Incorrect operation endangers yourself and others!

Incorrect operation of the machine is often the cause of very serious accidents!

Operate the unit only when you have been sufficiently trained on the battery charger and have read and understood this operating manual.

Should anything be unclear, please contact your immediate supervisor.

NOTICE! All battery chargers are shipped from the factory with the emergency stop switch disconnected. The switch must be connected and tested by the user prior to installation. When actuated, the emergency stop switch will remove all AC power from the charger.

IMPORTANT! Before start-up, check that daily maintenance has been performed on the unit.

WARNING! Always wear safety glasses and protective clothing when servicing batteries. Neutralize any acid spills immediately. If acid contacts any part of the body, flush immediately with running water and seek medical attention.

2.14

Model DBT Super Service Battery Charger

Overview of safety instructions WARNING! Care should be taken at all times to avoid electrical shock from the battery or charger. The charger must be turned off before connecting or disconnecting the lead (s) to the battery.

WARNING! Never connect or disconnect the battery and charger unless the charger is turned off. Damage to the plugs and receptacles will occur. Also, an arc will be drawn that could be a safety hazard.

IMPORTANT! All specific gravity readings are based on battery temperature of 25° C. WARNING! This section is intended only to familiarize the user with the electrical components of the battery charger. All electrical maintenance should be performed only by a qualified electrician with the knowledge of the function of the components involved.

WARNING! Before removing any cover and attempting any maintenance or troubleshooting on the battery charger, the main power must be disconnected and locked out at the main power center.

Troubleshooting should be performed only by trained service personnel or experienced electricians.

DANGER! Hazardous A. C. and D. C. voltages are present within the chargers cabinet.

IMPORTANT! If the problem is found to be located in the printed circuit boards, the board should be replaced. No attempt should be made to repair circuit boards in the field.

Chapter 6: Technical data IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled.

The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

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2.15

Overview of safety instructions

2.16

Model DBT Super Service Battery Charger

3

Storage and transport

Storage and transport

Storage and transport This chapter contains important information on the correct storage and transport of the battery charger.

Observance of the instructions and tips will increase the service life and availability of the unit. You will also be able to carry out the transport work quicker and more safely. Careful attention to the points in this chapter will help you to simplify your day-to-day work.

Storage corrosion protection

Components coated with temporary corrosion inhibitor are protected for approximately six months.

Storage of the machine and spare parts no direct exposure to sunlight

dirt and moisture

Store the equipment indoors or cover with a tarpaulin to protect against direct exposure to sunlight. Store the electrical equipment, electronic components, spare parts of rubber or plastic only in closed rooms at temperatures of 60° F (15° C) to 77° F (25°C).

Protect the equipment and all spare parts stored outdoors against moisture and dirt, e.g. using tarpaulins.

short-term storage

During short-term storage (approximately 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components need not be removed. Such components must be particularly protected against excessive temperatures, dirt and moisture.

long-term storage

If the equipment is to be stored more than six months, the equipment must be stored in a well ventilated, dry room. Do not store outdoors

random sample inspection

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After a storage period of approximately two years, a random sample inspection must be performed to determine whether the measures taken and the method of storage has prevented damage.

On request, the inspection can be carried out by DBT America.

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3.3

Storage and transport

Transport Load units; dimensions and weights Observe the transport sheets for the machine and spare parts.

They contain information on:

dimensions weight lifting points, etc.

Additional information on the dimensions and weights can be found in chapter 6 in this operating manual.

WARNING! Use only load handling devices complying with the technical and legal regulations for the transport of loads.

You could be seriously injured or even killed by falling loads.

Use only suitable load handling devices.

3.4

Model DBT Super Service Battery Charger

Storage and transport Before transport temperatures below freezing

During transport of this equipment with floor-mounted vehicles at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads. At very low temperatures and on poor roads, the transport vehicle speed must therefore be limited to a maximum of 15 mph (25 kph) for truck transport.

electronic components

Electrical and electronic components must be removed for overseas transport or prolonged storage outdoors unless these components or the complete equipment is protected against harmful environmental influences by a suitable packaging.

The electrical cables remain in the equipment. They must be carefully protected against transport damage and soiling of the connections.

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3.5

Storage and transport

3.6

Model DBT Super Service Battery Charger

4

Installation

Installation

Installation Points to observe prior to installation Who is allowed to carry out installation?

Installation is only allowed to be carried out by personnel having received adequate training to perform this task.

Work on:

the safety components the electrical equipment and

should only be carried out by DBT America service engineers or by specially trained personnel.

Which tools are required for installation? tool box

You need a number of tools to be able to install the battery charger properly.

We recommend that you deposit a tool box at the battery charger that includes an assortment of mechanical and electrical tools.

In addition, various items of auxiliary equipment and machines are required at the point of installation.

These include i.e.:

hoists with adequate lifting capacity means of attachment with adequate lifting capacity impact wrenches, including accessories jacks with adequate lifting capacity

Notes on installation CAUTION! Serious damage can be caused to the battery charger as a result of incorrect installation.

The unit should therefore only be installed under the instruction of specialists from DBT America.

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4.3

Installation installation plan

The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established.

IMPORTANT! The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established

4.4

Model DBT Super Service Battery Charger

Installation Pre-installation check list NOTICE! The charger was inspected prior to shipment from the factory to ensure proper functioning and installation of all components.

However, to ensure that no transit damage has occurred, the following pre-startup checks should be performed:

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perform daily maintenance visually inspect all electrical cables for damage examine complete charger for possible transport damage verify that all the instruction and safety labels are in place and readable. start up the unit and check for correct operation of emergency stop switch which is located on the operation panel check all control switches to ensure all charger functions are operating properly

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4.5

Installation General information The Model DBT Super Service Battery Charger combines reliable, rugged components with unmatched circuit simplicity.

The ferroresonant design of the charger eliminates he need for complicated control circuits and lowers the parts count Three major components make up the circuit of the charger; a ferroresonant step down transformer; silicon rectifiers; and automatic timer board.

The full wave rectifier includes conservatively rated silicon diodes and surge suppressors to provide a reliable D. C. output.

The DBT charger regulates the D. C. output voltage to produce the proper charging curves for the battery. Its charge rate is dependent on the state of charge of your battery.

The charger is a completely automatic constant voltage charger. Each DBT charger is designed to operate on a specific type of battery with a specific number of cells.

4.6

Model DBT Super Service Battery Charger

Installation Safety features NOTICE! The operator must become familiar with all the safety features and their location on the unit prior to installation or operation.

Safety features include: (Reference Fig. 1) emergency stop switch

The stop switch is located on the control panel of the charger.

Depressing the stop switch button will shutdown all charger functions immediately and remove all AC power from the charger.

NOTICE! All battery chargers are shipped from the factory with the emergency stop switch disconnected. The switch must be connected and tested by the user prior to installation. When actuated, the emergency stop switch must remove all AC power from the charger.

Fig. 1: Emergency stop switch location Dual charger shown

ON/OFF toggle switch

covers

Emergency stop switch

ON/OFF toggle switch

The charger is equipped with covers to reduce the possibility of personnel coming in contact with electrical components. All covers must be installed and securely fastened during operation.

DANGER! Do not operate the battery charger with any of the covers removed.

You or other personnel could be seriously injured from electrical shock.

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4.7

Installation ON/OFF toggle switch

voltage sensing

battery monitoring

The ON/OFF toggle switches (Fig. 1) are located on the control panel of the charger. The switch should be in the “OFF” position when connecting or disconnecting the battery connectors. The switch should only be turned to the “ON” position after the charger plug is fully engaged with the battery receptacle. The switch allows for a 10 second delay after connecting a battery before the charger will begin charging. Once the charging cycle is complete, the switch must be turned to the “OFF” position before disconnecting the battery connector.

Battery voltage sensing determines if there is a proper sized battery connected to the charger. This prevents charging if there is a bad battery connected, no battery connected, bad battery to charger connection or battery voltage and charger mismatch.

The battery voltage and current are continuously monitored.

over charging

Negative battery slope termination to prevent over charge/thermal runaway.

backup timers

backup timers prevent extended charging of a damaged battery. The first timer starts at the beginning of the charge cycle and runs for 9 hours. If the battery has not reached the 80% point, the charger will shutdown. The second timer starts at the 80% point and runs for 6 hours. If the charger does not terminate by then, it will shutdown.

automatic shutdown

Automatic shutdown lockout will not allow a charge to start after a manual or problem shutdown occurs. Automatic shutdown lockout is cleared after the “Shutdown” battery is disconnected. This allows a charge to begin upon connection of a good, proper sized battery.

4.8

Model DBT Super Service Battery Charger

Installation Location

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locate the charging station away from rain, snow, wet conditions or areas of high traffic when possible never place the unit directly above a battery. Gases from the battery will corrode and damage equipment Never allow the battery electrolyte to drop on the unit when reading specific gravity or filling the battery do not operate the unit in a closed area or restrict ventilation in any way Do not set a battery on top of the unit

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4.9

Installation

4.10

Model DBT Super Service Battery Charger

Overview of the battery charger Overview of the battery charger Fig. 2: Overview of the battery charger (Dual charger shown)

Toggle switch #2

Control panel #2

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Toggle switch #1

Skid

Emergency stop switch

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Control panel #1

4.11

Overview of the battery charger

4.12

Model DBT Super Service Battery Charger

5

Operation

How to operate the battery charger

Operation This chapter contains important information on the operation and maintenance of the battery charger. It also includes instructions on the replacement of wear parts.

Read this chapter carefully and thoroughly. In particular, observe the safety instructions in chapter 2 “Your safety”.

How to operate the battery charger DANGER! Incorrect operation endangers yourself and others!

Incorrect operation of the machine is often the cause of very serious accidents!

Operate the unit only when you have been sufficiently trained on the battery charger and have read and understood this operating manual.

Should anything be unclear, please contact your immediate supervisor.

Who is allowed to operate the battery charger?

The battery charger is only allowed to be operated by persons with adequate knowledge of the complete unit.

This also includes: what safety devices are installed on the unit. where these safety devices are located. how these safety devices are to be operated.

When can charging be started?

Charging must not be started until the safe condition and proper function of the complete unit has been checked and the daily maintenance operations have been carried out.

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5.3

How to operate the battery charger Controls and indicators The controls for the battery charger are located on the front panel of the unit (Fig. 3). The charger controls and indicators consist of the following: emergency stop button, on/off toggle switch, stop button, equalize button, led test button, display mode button and indicator lights.

Fig. 3: Battery charger controls and indicators

ON/OFF Toggle switch #1

ON/OFF Toggle switch #2

5.4

Emergency stop button

Model DBT Super Service Battery Charger

How to operate the battery charger emergency stop switch

The emergency stop switch (Fig. 3) is located on the control panel of the charger. Depressing the stop switch button will shutdown all charger functions immediately and remove all AC power from the charger.

NOTICE! All battery chargers are shipped from the factory with the emergency stop switch disconnected. The switch must be connected and tested by the user prior to installation. When actuated, the emergency stop switch must remove all AC power from the charger.

ON/OFF toggle switch

stop button

The ON/OFF toggle switches (Fig. 3) is located on the control panel of the charger. Turn the switch to the “OFF” position and securely connect battery connector to the battery. After connection is made, turn the switch to the “ON” position and after a 10 second delay the charger will start charging. Once the charging cycle is complete, the switch must be turned to the “OFF” position before disconnecting the battery connector.

The stop button (Fig. 3) is located on the control panel of the charger.

Depress the button to stop the charger from charging.

equalize

The equalize button (Fig. 3) is located on the control panel of the charger. When depressed will turn on and off the three hour additional manual equalizing charge. When the equalizing function is turned on, an “E” will be displayed in the leftmost digit of the display. The “E” will flash during the actual equalize charge cycle.

LED test button

The LED test button (Fig. 3) is located on the control panel of the charger. This button is used to ensure that all the LED’s are functioning properly. Press the pushbutton and all of the LED’s should be illuminated. If either of the LED’s do not illuminate, shutdown the charger and contact a qualified maintenance person.

display mode button

The display mode button (Fig. 3) is located on the control panel of the charger. To actuate the display mode switch: press once to display amp hours returned to battery press twice to display accumulated on-charge time press three times to display average volts per cell (VPS) (Multiply by 64 for total voltage) press four times for normal display - charging current while charger is running - cooling time after charge is complete (displayed until toggle switch is turned “OFF”)

charging indicator LED

The charging indicator light (Fig. 3) located on the control panel of the charger will be illuminated when the charger is charging the battery.

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How to operate the battery charger 80% charged indicator LED

The 80% charged indicator light (Fig. 3) located on the control panel of the charger will be illuminated when the battery voltage is greater than 157 VDC (2.45 volts per cell).

complete indicator LED

The complete indicator light (Fig. 3) located on the control panel of the charger will be illuminated when the charge cycle has been terminated normally.

shutdown indicator LED

The shutdown indicator light (Fig. 3) located on the control panel of the charger will be illuminated when the unit has shutdown for a fault.

5.6

Model DBT Super Service Battery Charger

How to operate the battery charger

Battery charging procedure After reading the previous descriptions and locating each control, the operator is ready to operate the battery charger. An experienced operator should monitor a new operator’s indoctrination to the battery charging procedure.

IMPORTANT! Before start-up, check that daily maintenance has been performed on the unit.

WARNING! Always wear safety glasses and protective clothing when servicing batteries. Neutralize any acid spills immediately. If acid contacts any part of the body, flush immediately with running water and seek medical attention.

WARNING! Care should be taken at all times to avoid electrical shock from the battery or charger. The charger must be turned off before connecting or disconnecting the lead (s) to the battery.

Charging ) Battery tray covers should be open during charge. ) Be sure the charger toggle switch is in the “OFF” position (Fig. 4).

Fig. 4: Battery charger ON/OFF toggle switch

Dual charger shown Toggle switch #2

Toggle switch #1

) Check plugs and receptacles to be sure they are clean and in good condition.

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5.7

How to operate the battery charger ) Connect charger plug to battery receptacle and ensure that it is fully engaged.

WARNING! Never connect or disconnect the battery and charger unless the charger is turned off. Damage to the plugs and receptacles will occur. Also, an arc will be drawn that could be a safety hazard.

) Turn toggle switch to the “ON” position (Fig. 4) and the daily charging cycle will begin after a 10 second delay. Check display to be sure battery is charging and charger is operating correctly. Charging indicator LED (Fig. 5) should be illuminated during entire charge cycle. ) Charger is fully automatic and will stop charging when it recognizes a fully charged battery in approximately 8 hours. Charge cycle “COMPLETE” indicator LED (Fig. 5) should be illuminated when charge cycle is complete. ) Full charge specific gravity reading should be 1.280 to 1.290. Higher readings will result due to low water levels. Do not over water battery as lost acid will result in less work per charge and shorten battery life.

Fig. 5: Indicator LED’s

Charging

Complete

IMPORTANT! All specific gravity readings are based on battery temperature of 25° C.

5.8

Model DBT Super Service Battery Charger

How to operate the battery charger Equalizing charge ) Batteries should be equalize charged once weekly. ) During the daily 8 hour charge, with charger running, press the

equalize pushbutton (Fig. 6) to turn on and/or off the 3 hour additional equalize charge time. When the equalizing function is turned on, an “E” will be displayed in the leftmost digit of the display.

The “E” will flash during the actual equalize charge cycle (manual and automatic).

Fig. 6: Equalize pushbutton

Equalize

) When equalizing charge is completed and automatic timer has

turned charger off, read specific gravity of each cell and record. If variations of 10 or 20 points of specific gravity are recorded, call a DBT America service technician. If cells show variations of 0.1 volts or more, call a DBT America service technician.

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How to operate the battery charger Operating instructions ) Do not charge or operate in service if temperature of battery reaches

115° F (46° C). High temperatures are a result of improper charger adjustments, high discharge rates, over discharging, short cycling, and low water levels. ) Keep plugs and receptacles clean and adjusted for tension. If plug is hot, it is not making good contact. Remember the battery has current at all times. Be careful when working on plugs and receptacles. ) Vent caps should only be removed to check water level, temperature, and specific gravity, or to add water. Be sure they are in place and tight at all times. ) Do not weld, grind or allow sparks or allow flame near battery. Do not allow tools or any other metal to be laid on connector of battery. ) Never add anything to the battery except approved water. ) Never add acid to battery.

Watering ) Add approved water to ¼” (6.35 mm) below vent well only (Fig. 7) at

the end of charge. Filling to this level before charging will cause acid overflow. Acid attacks external battery parts. Any acid loss from the battery will result in power loss and shortened life. ) Replace vent caps securely.

Fig. 7: Adding water to battery

Vent cap Water level Cover

6.35 mm

5.10

Model DBT Super Service Battery Charger

How to operate the battery charger Cleaning ) Wash battery at least weekly using soda and water, and then rinse

with plain water (1 lb. (0.35kg) soda to 1 gal. (3.78 l) water mixture).

Vent caps should be in place when washing battery. ) Dirty batteries create grounds, reduce work time, increase battery cost, and shorten life. Correctly charged, watered, and cleaned batteries give longer work time oer shift per charge, reduced cost, and longer life.

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5.11

How to operate the battery charger

Shut down procedure ) Turn toggle switch to the “OFF” position (Fig. 8).

Fig. 8: Battery charger ON/OFF toggle switch

Dual charger shown Toggle switch #2

Toggle switch #1

) Disconnect battery plugs and receptacles. ) Cap battery plugs and receptacles to prevent any dirt or foreign material contamination.

5.12

Model DBT Super Service Battery Charger

How to operate the battery charger

Display fault messages Table 1: Display fault messages Displayed fault code Lo U H.I U diSc Dur. Lo. I

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Failure condition Low battery condition – Less than 109VDC (1.7 VPC) Press and hold stop button for 15+ seconds to override High battery voltage – Higher than 184VDC (2.88 VPC) Battery disconnected from charger during charge Charge time exceeded – Must reach 80% within 9 hours and/or after the 80% point is reached, a 6 hour timer is started. Charge cycle must terminate within 6 hours.

Low charging current – Less than 3 amps

5.13

How to operate the battery charger

5.14

Model DBT Super Service Battery Charger

Electrical system on the battery charger Electrical system The following pages give the location, settings, and adjustments of electrical components that are on the battery charger.

The battery charger receives electrical power through a heavy-duty cable. Be sure that the box connector is correctly identified and is securely connected; also check that the cable entrance is in good mechanical condition. Walk along the cable from the power center to the battery charger and check the condition of the trailing cable. Give special attention to points most apt to cause damage, such as corners, intersections, and where cable may be run over by moving equipment.

Never use cable with exposed wires or splices which heat up or spark under load.

WARNING! This section is intended only to familiarize the user with the electrical components of the battery charger. All electrical maintenance should be performed only by a qualified electrician with the knowledge of the function of the components involved.

WARNING! Before removing any cover and attempting any maintenance or troubleshooting on the battery charger, the main power must be disconnected and locked out at the main power center.

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Electrical system on the battery charger

Fig. 9: Main components of the battery charger

DC output fuse Surge protector

Silicon power diode

Mag amp coil

Capacitors

DC insulator block

AC input block

Main transformer AC input fuse STOP CHARGING

LED TEST

80% CHARGED COMPLETE EQUALIZE

Super Service Mine Duty Battery Charger

DISPLAY MODE

SHUTDOWN Display Mode ? ? ? ?

Push once for amp-hours return Push twice for total charging time Push three times for volts per cell Push four times for normal display

Main controller board/display Cell select board

Emergency stop switch Control transformer (TC2) Contactor (24VAC coil)

Charger main control board

5.16

Control transformer (TC1) ON/OFF toggle switch

Control fuse

Model DBT Super Service Battery Charger

Electrical system on the battery charger

Input and output ratings D.C. voltage The DBT Super Service Battery Chargers are factory set to finish at 2.5 volts/per cell to 2.6 volts/per cell (160 vdc – 166 vdc) for lead acid batteries.

A.C. voltage Taps are provided for various three phase A.C. input voltages with an A.C. input voltage range of +/- 10% of nominal. (See charger schematic for details)

Table 2: Transformer tap settings Input 480VAC, 50HZ, 3PH 575VAC, 50HZ, 3PH

TM 1 and 2

TC1 H1 and H3

TC2 480

1 and 3

H1 and H4

575

Table 3: Capacitor tap settings for finish rate adjustment 6 and 7

5 and 7

Lowest

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4 and 7

6 and 8

Nominal

5 and 8

4 and 8

Maximum

5.17

Electrical system on the battery charger

Table 4: Dip switch settings (Located on back of main board) SW 1 2 3 4 5 6 7 8

Factory Description setting Off On – Single DI/DT compensation Off – Double DI/DT compensation Off On – Normal DV/DT termination Off – Triple DV/DT termination On On – 60HZ operation Off – 50HZ operation On On – Display cool down time after charge complete Off – Do not display cool down time On On – Auto-equalize disabled Off – Auto-equalize enabled On On – Normal current display Off – Double current display On On – Not used – Water signal at charge complete Off – Not used – Water signal at 90% point Off On – 80% point at 2.37 volts per cell (151.7 VDC) Off – 80% point at 2.45 volts per cell (156.8 VDC)

Table 5: Wiring diagram component list Symbol ESS TS SP D K1, K2 K3 CF MB CS TC1 TC2 L1, L2, L3 G + _ MAG TM C1 C2 FA FR

5.18

Description Emergency stop switch Toggle switch Surge protector Silicon power diode Contactor (110VAC coil) Contactor (24VAC coil) Fuse, control (1 amp) Main board, controller Cell select board Control transformer Control transformer AC input line terminal Ground terminal Positive DC terminal Negative DC terminal Mag amp coil Main power transformer Capacitor 1 Capacitor 2 AC input fuses DC output fuses

Model DBT Super Service Battery Charger

Electrical system on the battery charger

Fig. 10: Wiring diagram (single charger)

Note: Refer to your parts manual for full size wiring diagram.

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Electrical system on the battery charger

Fig. 11: Wiring diagram (dual charger)

Note: Refer to your parts manual for full size wiring diagram.

5.20

Model DBT Super Service Battery Charger

Troubleshooting the battery charger Troubleshooting Troubleshooting should be performed only by trained service personnel or experienced electricians.

DANGER! Hazardous A. C. and D. C. voltages are present within the chargers cabinet. equipment

The only equipment required to troubleshoot the charger is a multimeter (volt-ohm meter).

General inspection On servicing new equipment, before setting up any complicated testing or jumping to any conclusions, give the charger a general inspection.

Check the following:

check D. C. output cables, connections, battery type, and number of battery cells with rectifier rating check unit specifications with customer order check input connections, input voltage and A. C. line breaker size check for shipping damage, loose connections, broken wires, etc certain failures can be caused by defective batteries and customer loads; make sure batteries and loads are free from defects check all safety switches

IMPORTANT! If the problem is found to be located in the printed circuit boards, the board should be replaced. No attempt should be made to repair circuit boards in the field.

Service information Information you should have when calling for troubleshooting assistance:

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equipment model number and serial number the actual A. C. input voltage the D. C. output voltage with and without the battery result of the check of A. C. input fuse and D. C. output fuse the actual D. C. output current and voltage when measured with battery connected to charger

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5.21

Troubleshooting the battery charger Table 6: Symptoms and causes Symptom

Possible cause

Remedy

Open A.C. fuse

1. Wrong A.C. input voltage.

1. Correct input voltage.

2. The A.C. input taps on power transformer set incorrectly. (See schematic wiring diagram)

2. Set input taps correctly.

3. An A.C. to d. c. short or A.C. to D.C. short to ground.

3. Correct shorts.

4. Shorted power transformer.

4. Replace transformer.

5. Check for shorted power diodes (SD1). (See page 21)

5. Replace defective diodes.

6. Check for shorted coil on D.C. contactor or defective control transformer.

6. Replace contactor or transformer.

1. Shorted power diode.

1. Replace as required.

2. Shorted battery cells.

2. Repair battery.

3. Shorted output cables.

3. Repair or replace cables.

4. Shorted capacitors.

(See page 21)

4. Replace capacitors.

1. Check A.C. input fuses.

1. Replace fuse(s).

2. Check power diodes.

(See diode troubleshooting procedure, page 21)

2. Replace diode(s).

Open D.C. fuse

Charger operates but output voltage is low

5.22

Model DBT Super Service Battery Charger

Troubleshooting the battery charger Troubleshooting and replacing power silicon diodes If a portable multimeter is used, set the switches on “ohms”, “D.C.”, and “Rx1” scale.

) Isolate one end of the diode by disconnecting the wires attached to

the pigtail end of the diode (only one end of the diode must be disconnected). ) Clip one lead of the ohmmeter to the anode lead of the diode. Clip the other ohmmeter lead to the cathode. ) Note the ohmmeter reading. Then reverse the leads to the diode.

Again, note the ohmmeter reading. If the diode is good, the meter will indicate a high resistance in one direction, and a low resistance with the leads reversed. If the diode is shorted, the meter will read full scale, or zero ("O") resistance with the leads in either direction. If the diode is "open", the ohmmeter needle will not indicate or it will show infinite resistance in either direction, indicating an open circuit. ) All diodes must be checked in the event that more than one diode is defective. ) If the diode is defective, remove it from the heatsink. Clean and smooth the heatsink surface, then using electrically conductive grease, apply to the new diode and replace it in the heatsink.

Checking capacitors When checking capacitors, be sure all power is turned off and the battery is disconnected. Momentarily short circuit the capacitor leads to assure complete discharge. Connect the meter test leads to the capacitor leads or terminals and observe indicated resistance.

A good capacitor will indicate an initial low resistance and gradually increase as the capacitor charges. The final resistance of a good capacitor is usually several hundred thousand ohms approaching a megohm.

Initial high resistance approaching infinity indicates an open capacitor.

Initial and continued low resistance readings indicate a shorted capacitor.

When ordering replacement parts, drawings, or schematics, always give model number, serial number and A.C. input voltage.

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Troubleshooting the battery charger

5.24

Model DBT Super Service Battery Charger

6

Technical data

Components of the battery charger

Technical data This chapter contains the most important technical data on the battery charger. Further data can be found in the spare parts lists. At the end of this chapter you will find information on the bolt tightening torques. Read this chapter through carefully and pay particular attention in particular to the safety instructions.

Components of the battery charger Technical data sheet

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Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP01984 DBT-1500D Dual 480/575/60hz 1500 No approx. 84” approx. 53” approx. 20.5”

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02066 DBT-1375D Dual 480/575/60hz 1320 - 1375 No approx. 84” approx. 53” approx. 20.5”

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02053 DBT-1200D Dual 480/575/60hz 1200 - 1210 No approx. 84” approx. 53” approx. 20.5”

SSVP/01

6.3

Components of the battery charger

6.4

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02075 DBT-1000D Dual 480/575/60hz 1000 - 1020 No approx. 84” approx. 53” approx. 20.5”

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02005 DBT-850D Dual 480/575/60hz 750 - 850 No approx. 84” approx. 53” approx. 20.5”

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02067 DBT-650D Dual 480/575/60hz 585 - 650 No approx. 84” approx. 53” approx. 20.5”

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02068 DBT-550D Dual 480/575/60hz 495 - 550 No approx. 84” approx. 53” approx. 20.5”

Model DBT Super Service Battery Charger

Components of the battery charger

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Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02069 DBT-1500S Single 480/575/60hz 1500 No approx. 84” approx. 35” approx. 20.5”

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02070 DBT-1375S Single 480/575/60hz 1320 - 1375 No approx. 84” approx. 35” approx. 20.5”

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02071 DBT-1200S Single 480/575/60hz 1200 - 1210 No approx. 84” approx. 35” approx. 20.5”

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02052 DBT-1000S Single 480/575/60hz 1000 - 1020 No approx. 84” approx. 35” approx. 20.5”

SSVP/01

6.5

Components of the battery charger

6.6

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02072 DBT-850S Single 480/575/60hz 750 - 850 No approx. 84” approx. 35” approx. 20.5”

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02073 DBT-650S Single 480/575/60hz 585 - 650 No approx. 84” approx. 35” approx. 20.5”

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02074 DBT-550S Single 480/575/60hz 495 - 550 No approx. 84” approx. 35” approx. 20.5”

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02076 DBT-1500D Dual 480/575/60hz 1500 No approx. 84” approx. 53” approx. 20.5” With ground check circuit and 125 VAC outlets

Model DBT Super Service Battery Charger

Components of the battery charger

A6474X233

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02077 DBT-1375D Dual 480/575/60hz 1320 - 1375 No approx. 84” approx. 53” approx. 20.5” With ground check circuit and 125 VAC outlets

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02078 DBT-1200D Dual 480/575/60hz 1200 - 1210 No approx. 84” approx. 53” approx. 20.5” With ground check circuit and 125 VAC outlets

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02079 DBT-1000D Dual 480/575/60hz 1000 - 1020 No approx. 84” approx. 53” approx. 20.5” With ground check circuit and 125 VAC outlets

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02080 DBT-850D Dual 480/575/60hz 750 - 850 No approx. 84” approx. 53” approx. 20.5” With ground check circuit and 125 VAC outlets

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6.7

Components of the battery charger

6.8

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02081 DBT-650D Dual 480/575/60hz 585 - 650 No approx. 84” approx. 53” approx. 20.5” With ground check circuit and 125 VAC outlets

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02082 DBT-550D Dual 480/575/60hz 495 - 550 No approx. 84” approx. 53” approx. 20.5” With ground check circuit and 125 VAC outlets

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02083 DBT-1500S Single 480/575/60hz 1500 No approx. 84” approx. 35” approx. 20.5” With ground check circuit and 125 VAC outlets

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02084 DBT-1375S Single 480/575/60hz 1320 - 1375 No approx. 84” approx. 35” approx. 20.5” With ground check circuit and 125 VAC outlets

Model DBT Super Service Battery Charger

Components of the battery charger

A6474X233

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02085 DBT-1200S Single 480/575/60hz 1200 - 1210 No approx. 84” approx. 35” approx. 20.5” With ground check circuit and 125 VAC outlets

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02086 DBT-1000S Single 480/575/60hz 1000 - 1020 No approx. 84” approx. 35” approx. 20.5” With ground check circuit and 125 VAC outlets

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02087 DBT-850S Single 480/575/60hz 750 - 850 No approx. 84” approx. 35” approx. 20.5” With ground check circuit and 125 VAC outlets

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02088 DBT-650S Single 480/575/60hz 585 - 650 No approx. 84” approx. 35” approx. 20.5” With ground check circuit and 125 VAC outlets

SSVP/01

6.9

Components of the battery charger

6.10

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02089 DBT-550S Single 480/575/60hz 495 - 550 No approx. 84” approx. 35” approx. 20.5” With ground check circuit and 125 VAC outlets

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02090 DBT-1500D Dual 480/575/60hz 1500 Yes approx. 84” approx. 53” approx. 20.5”

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02091 DBT-1375D Dual 480/575/60hz 1320 - 1375 Yes approx. 84” approx. 53” approx. 20.5”

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02092 DBT-1200D Dual 480/575/60hz 1200 - 1210 Yes approx. 84” approx. 53” approx. 20.5”

Model DBT Super Service Battery Charger

Components of the battery charger

A6474X233

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02094 DBT-1000D Dual 480/575/60hz 1000 - 1020 Yes approx. 84” approx. 53” approx. 20.5”

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02095 DBT-850D Dual 480/575/60hz 750 - 850 Yes approx. 84” approx. 53” approx. 20.5”

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02096 DBT-650D Dual 480/575/60hz 585 - 650 Yes approx. 84” approx. 53” approx. 20.5”

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02097 DBT-550D Dual 480/575/60hz 495 - 550 Yes approx. 84” approx. 53” approx. 20.5”

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6.11

Components of the battery charger

6.12

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02098 DBT-1500S Single 480/575/60hz 1500 Yes approx. 84” approx. 35” approx. 20.5”

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02099 DBT-1375S Single 480/575/60hz 1320 - 1375 Yes approx. 84” approx. 35” approx. 20.5”

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02100 DBT-1200S Single 480/575/60hz 1200 - 1210 Yes approx. 84” approx. 35” approx. 20.5”

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02101 DBT-1000S Single 480/575/60hz 1000 - 1020 Yes approx. 84” approx. 35” approx. 20.5”

Model DBT Super Service Battery Charger

Components of the battery charger

A6474X233

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02102 DBT-850S Single 480/575/60hz 750 - 850 Yes approx. 84” approx. 35” approx. 20.5”

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02103 DBT-650S Single 480/575/60hz 585 - 650 Yes approx. 84” approx. 35” approx. 20.5”

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height:

LUP02104 DBT-550S Single 480/575/60hz 495 - 550 Yes approx. 84” approx. 35” approx. 20.5”

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02105 DBT-1500D Dual 480/575/60hz 1500 Yes approx. 84” approx. 53” approx. 20.5” With ground check circuit and 125 VAC outlets

SSVP/01

6.13

Components of the battery charger

6.14

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02106 DBT-1375D Dual 480/575/60hz 1320 - 1375 Yes approx. 84” approx. 53” approx. 20.5” With ground check circuit and 125 VAC outlets

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02107 DBT-1200D Dual 480/575/60hz 1200 - 1210 Yes approx. 84” approx. 53” approx. 20.5” With ground check circuit and 125 VAC outlets

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02108 DBT-1000D Dual 480/575/60hz 1000 - 1020 Yes approx. 84” approx. 53” approx. 20.5” With ground check circuit and 125 VAC outlets

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02109 DBT-850D Dual 480/575/60hz 750 - 850 Yes approx. 84” approx. 53” approx. 20.5” With ground check circuit and 125 VAC outlets

Model DBT Super Service Battery Charger

Components of the battery charger

A6474X233

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02110 DBT-650D Dual 480/575/60hz 585 - 650 Yes approx. 84” approx. 53” approx. 20.5” With ground check circuit and 125 VAC outlets

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02111 DBT-550D Dual 480/575/60hz 495 - 550 Yes approx. 84” approx. 53” approx. 20.5” With ground check circuit and 125 VAC outlets

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02112 DBT-1500S Single 480/575/60hz 1500 Yes approx. 84” approx. 35” approx. 20.5” With ground check circuit and 125 VAC outlets

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02113 DBT-1375S Single 480/575/60hz 1320 - 1375 Yes approx. 84” approx. 35” approx. 20.5” With ground check circuit and 125 VAC outlets

SSVP/01

6.15

Components of the battery charger

6.16

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02114 DBT-1200S Single 480/575/60hz 1200 - 1210 Yes approx. 84” approx. 35” approx. 20.5” With ground check circuit and 125 VAC outlets

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02126 DBT-1000S Single 480/575/60hz 1000 - 1020 Yes approx. 84” approx. 35” approx. 20.5” With ground check circuit and 125 VAC outlets

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02127 DBT-850S Single 480/575/60hz 750 - 850 Yes approx. 84” approx. 35” approx. 20.5” With ground check circuit and 125 VAC outlets

Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

LUP02128 DBT-650S Single 480/575/60hz 585 - 650 Yes approx. 84” approx. 35” approx. 20.5” With ground check circuit and 125 VAC outlets

Model DBT Super Service Battery Charger

Components of the battery charger Part number: Model number: Output: Voltage/hz: Battery size: PA kit: Overall length: Overall width: Overall height: Special:

A6474X233

SSVP/01

LUP02129 DBT-550S Single 480/575/60hz 495 - 550 Yes approx. 84” approx. 35” approx. 20.5” With ground check circuit and 125 VAC outlets

6.17

Components of the battery charger

6.18

Model DBT Super Service Battery Charger

Tightening torques Tightening torques IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled.

The tightening torques stated in the spare parts lists have to be observed, as well, for installation and maintenance.

Table 7 : Set screws (Socket long-lok) Nominal diameter #6 #8 #10 ¼” 5/16” 3/8” 7/16” ½”

Recommended torque setting 6 in-lbs 9 in-lbs 13 in-lbs 30 in-lbs 5 ft-lbs 8 ft-lbs 11 ft-lbs 16.7 ft-lbs

Table 8 : Set screws (Socket standard steel) Nominal diameter #6 #8 #10 ¼” 5/16” 3/8” 7/16” ½” 5/8” ¾” 7/8” 1”

A6474X233

SSVP/01

Recommended torque setting 9 in-lbs 16 in-lbs 30 in-lbs 6 ft-lbs 12 ft-lbs 18 ft-lbs 29 ft-lbs 43 ft-lbs 100 ft-lbs 146 ft-lbs 199 ft-lbs 262 ft-lbs

6.19

Tightening torques Table 9 : FSR hex bolts (SAE 5 and 325 steel) Nominal diameter ¼” 5/16” 3/8” 7/16” ½” 9/16” 5/8” ¾” 7/8” 1” 1 1/8” 1 ¼” 1 3/8” 1 ½” 1 ¾” 2” 2 ¼” 2 ½” 2 ¾” 3”

Recommended torque setting 9 ft-lbs 18 ft-lbs 31 ft-lbs 50 ft-lbs 75 ft-lbs 110 ft-lbs 150 ft-lbs 250 ft-lbs 378 ft-lbs 583 ft-lbs 782 ft-lbs 1,097 ft-lbs 1,461 ft-lbs 1,748 ft-lbs 3,114 ft-lbs 4,504 ft-lbs 6,497 ft-lbs 7,144 ft-lbs 12,092 ft-lbs 15,744 ft-lbs

Table 10 : Socket, flat and button head cap screws (Steel only) Nominal diameter #6 #8 #10 ¼” 5/16” 3/8” 7/16” ½” 5/8” ¾” 7/8” 1” 1 1/8” 1 ¼” 1 3/8” 1 ½”

6.20

Recommended torque setting 26 in-lbs 52 in-lbs 6 ft-lbs 14 ft-lbs 30 ft-lbs 50 ft-lbs 81 ft-lbs 121 ft-lbs 240 ft-lbs 395 ft-lbs 629 ft-lbs 964 ft-lbs 1,523 ft-lbs 2,121 ft-lbs 2,843 ft-lbs 3,402 ft-lbs

Model DBT Super Service Battery Charger

Tightening torques Table 11 : Untreated screw, black finish (Coarse thread) Property class 5.6 8.8

Torque Ma Nm Ft-lbs Nm Ft-lbs

10.9

Nm Ft-lbs

12.9

Nm Ft-lbs

Recommended torque setting M3 M4 M5 0.60 1.37 2.70 0.44 1.01 1.99 1.37 3.10 6.15 1.01 2.29 4.54 1.92 4.40 8.55 1.42 3.25 6.38 2.30 5.25 10.4 1.70 3.87 7.6

Nominal diameter M6 4.5 3.3 10.5 7.7 15 11 18 13

M7 7.8 5.6 17.5 12.9 25 18.4 29 21.3

M8 11 8.1 26 19 36 26 43 31

M10 22 16 61 37 72 53 87 64

Table 12 : Untreated screw, black finish (Coarse thread, continued) Property class 5.6 8.8

Torque Ma Nm Ft-lbs Nm Ft-lbs

10.9

Nm Ft-lbs

12.9

Nm Ft-lbs

Recommended torque setting M12 M14 M16 39 62 85 28 45 70 89 141 215 65 103 158 125 198 305 92 146 224 150 240 365 110 177 269

Nominal diameter M18 130 95 295 217 420 309 500 368

M20 184 135 420 308 690 435 710 523

M22 250 184 570 420 800 590 960 708

M24 315 232 725 634 1020 752 1220 899

Table 13 : Untreated screw, black finish (Coarse thread, continued) Property class 5.6 8.8

Torque Ma Nm Ft-lbs Nm Ft-lbs

10.9

Nm Ft-lbs

12.9

Nm Ft-lbs

A6474X233

SSVP/01

Recommended torque setting M27 M30 470 635 346 468 1070 1450 789 1069 1510 2050 1113 1511 1810 2450 1334 1606

Nominal diameter M33 865 637 1970 1452 2770 2042 3330 2455

M36 1111 819 2630 1885 3560 2625 4280 3156

M39 1440 1062 3290 2428 4620 3407 5550 4093

6.21

Tightening torques Table 14 : Untreated screw, black finish (Fine thread) Property class 8.8 10.9

Torque Ma Nm Ft-lbs Nm Ft-lbs

12.9

Nm Ft-lbs

Recommended Nominal diameter torque setting M8 X 1 M10 X 1.25 M12 X 1.25 27 52 95 19 38 70 38 73 135 28 53 99 45 88 160 33 64 118

Table 15 : Untreated screw, black finish (Fine thread, continued) Property class 8.8 10.9

Torque Ma Nm Ft-lbs Nm Ft-lbs

12.9

Nm Ft-lbs

Recommended Nominal diameter torque setting M14 X 1.5 M16 X 1.5 M18 X 1.5 150 225 325 110 165 239 210 315 460 154 232 339 260 380 550 184 280 405

Table 16 : Untreated screw, black finish (Fine thread, continued) Property class 8.8 10.9

Torque Ma Nm Ft-lbs Nm Ft-lbs

12.9

Nm Ft-lbs

6.22

Recommended Nominal diameter torque setting M20 X 1.5 M22 X 1.5 M24 X 2 399 610 780 449 575 640 860 1100 472 634 811 770 1050 1300 567 774 958

Model DBT Super Service Battery Charger

Tightening torques Table 17 ; Electrically zinc plated (Coarse thread) Property class 5.6 8.8

Torque Ma Nm Ft-lbs Nm Ft-lbs

10.9

Nm Ft-lbs

12.9

Nm Ft-lbs

Recommended torque setting M33 M4 M5 0.56 1.28 2.50 0.41 0.94 1.84 1.28 2.90 5.75 0.94 2.14 4.24 1.80 4.10 8.10 1.33 3.02 5.97 2.15 4.95 9.70 1.59 3.65 7.15

Nominal diameter M6 4.3 3.1 9.9 7.3 14 10.3 16.5 12.1

M7 7.1 5.2 16.5 12.1 23 16.9 27 19.9

M8 10.5 7.7 24 17.7 34 25 40 29

M10 21 15 48 35 67 49 81 59

Table 18 : Electrically zinc plated (Coarse thread, continued) Property class 5.6 8.8

Torque Ma Nm Ft-lbs Nm Ft-lbs

10.9

Nm Ft-lbs

12.9

Nm Ft-lbs

Recommended Nominal diameter torque setting M12 M14 M16 M18 M20 M22 36 58 88 121 171 230 26 42 54 89 126 169 83 132 200 275 390 530 61 97 147 202 287 390 117 185 285 390 550 745 86.2 136 210 287 405 549 140 220 340 470 660 890 103 162 250 346 486 656

Table 19 : Electrically zinc plated (Coarse thread, continued) Property class 5.6 8.8

Torque Ma Nm Ft-lbs Nm Ft-lbs

10.9

Nm Ft-lbs

12.9

Nm Ft-lbs

A6474X233

SSVP/01

Recommended Nominal diameter torque setting M24 M27 M30 295 435 590 800 1030 1340 217 320 435 590 759 988 675 995 1350 1830 2360 3050 497 733 995 1349 1740 2249 960 1400 1900 2680 3310 4290 708 1032 1401 1902 2441 3163 1140 1680 2280 3090 3980 5150 840 1239 1661 2278 2935 3798

6.23

Tightening torques Table 20 : Electrically zinc plated (Fine thread) Property class 8.8 10.9

Torque Ma Nm Ft-lbs Nm Ft-lbs

12.9

Nm Ft-lbs

Recommended Nominal diameter torque setting M8 X 1 M10 X 1.25 M12 X 1.25 25 49 88 18 36 84 35 68 125 25 50 92 42 82 150 30 60 110

Table 21 : Electrically zinc plated (Fine thread, continued) Property class 8.8 10.9

Torque Ma Nm Ft-lbs Nm Ft-lbs

12.9

Nm Ft-lbs

Recommended Nominal diameter torque setting M14 X 1.5 M16 X 1.5 M18 X 1.5 140 210 305 103 154 224 195 295 425 143 217 313 235 350 510 173 258 376

Table 22 : Electrically zinc plated (Fine thread, continued) Property class 8.8 10.9

Torque Ma Nm Ft-lbs Nm Ft-lbs

12.9

Nm Ft-lbs

6.24

Recommended Nominal diameter torque setting M20 X 1.5 M22 X 1.5 M24 X 2 425 570 720 313 420 531 600 800 1000 442 590 737 720 960 1200 531 708 885

Model DBT Super Service Battery Charger

7

For your information

Our Service

For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct.

Service address Beckley, WV 200 George Street, Suite 4 Beckley, WV 25801 Phone: (304) 256-5927 Fax: (304) 256-5928

Craig, CO 400 Mack Lane Craig, CO 81625 Phone: (970) 824-3249 Fax: (970) 824-8851

Duffield, VA P.O. Box 847 6808 Fraley Avenue Duffield, VA 24244 Phone: (276) 431-7000 Fax: (276) 431-2464

Houston, PA (Corporate Headquarters) 2045 West pike Street Houston, PA 15342 Phone: (724) 743-1200 Fax: (724) 743-1201

Marion, IL 3206 west DeYoung Street Marion, IL 62959 Phone: (618) 997-4335 Fax: (618) 993-5618

Oak Hill, WV P.O. Box 60 Oak Hill, WV 25901

Paonia, CO P.O. Box 566 Paonia, CO 81428

Price, UT 1814 North 1500 West P.O. Box 1016 Price, UT 84501 Phone: (435) 637-3930 Fax: (435) 637-9754

719 Second Street Paonia, CO 81428 Phone: (970) 527-3151 Fax: (970) 527-6846 Pulaski, VA 4041 Wurno Road Pulaski, VA 24301 Phone: 540-980-4530 Fax: 540-980-6211

A6474X233

SSVP/01

843 Lochgelly Road Oak Hill, WV 25901 Phone: (304) 469-3302 Fax: (304) 465-0450

Washington, PA 255 Berry Road Washington, PA 15301 Phone: (724) 743-1200 Fax: (724) 228-2177

7.3

Our service

Rebuild facility address Huntington, UT P.O. Box 1190 Route 10, 1Mile North Huntington, UT 84528 Phone: (435) 687-9831 Fax: (435) 687-2522

Norris City, IL 635 Illinois Highway 1 Norris City, IL 62869 Phone: (618) 378-3441 Fax: (618) 378-3106

Pearisburg, VA P.O. Box 463 222 Industrial Park Drive Pearisburg, VA 24134 Phone: (540) 921-2111 Fax: (540) 921-2711

7.4

Model DBT Super Service Battery Charger

OPERATION AND TROUBLESHOOTING GUIDE MODEL LA 2000 DUAL AND SINGLE MOTOR SOLID STATE CONTROLLERS

THIS GUIDE CONTAINS IMPORTANT OPERATION AND SAFETY INFORMATION AND SHOULD BE KEPT AVAILABLE TO THOSE PERSONNEL INSTALLING AND OPERATING THIS EQUIPMENT. P/N A6474X226 Revision 0, January / 03  DBT AMERICA 2003 ALL RIGHTS RESERVED

DBT America _______________________________________________________________________ 4041 Wurno Road Telephone: 540-980-4530 Pulaski, VA 24301 Fax: 540-994-3763 Internet: www.dbtamerica.com

DBT America

TABLE OF CONTENTS DESCRIPTION

PAGE #

PREFACE ..............................................................................................................................................2 SYMBOLS AND SPECIAL NOTATIONS ..............................................................................................3 MAJOR HAZARDS................................................................................................................................5 SAFETY PRECAUTIONS AND GUIDELINES ......................................................................................6 OVERVIEW ........................................................................................................................................6 MAINTENANCE .................................................................................................................................6 INTRODUCTION....................................................................................................................................7 LA 2000: INNOVATIVE SPEED CONTROL BY DBT AMERICA .......................................................7 GENERAL SPECIFICATIONS.............................................................................................................12 FAIL-SAFE OPERATION WILL INCLUDE THE FOLLOWING:......................................................12 DESCRIPTION OF FEATURES ..........................................................................................................13 LA 2000 MOTOR CONTROLLER CONSIST OF:............................................................................13 LA 2000 MOTOR IGBT PANEL (POWER CONNECTIONS) ..........................................................13 MICROPROCESSOR BASED LOGIC CARD (CONTROL INPUTS) ..............................................13 CONFIGURATION JUMPER TABLE...............................................................................................15 OPTIONAL DASHBOARD DISPLAY FEATURES (SEE FIGURE 9)...............................................15 FAULT MESSAGE CHART..............................................................................................................16 OPTIONAL HAND HELD DIAGNOSTICS/CALIBRATOR UNIT......................................................18 PERSONALITY ADJUSTMENT PROCEDURE ...............................................................................19 TRACTION PERSONALITIES (CONTROLLER ADJUSTMENTS) .................................................19 TRACTION STATUS DISPLAY .......................................................................................................21 TRACTION TEST DISPLAY.............................................................................................................23 TRACTION BDI DISPLAY................................................................................................................24 ERROR CODE LEGEND (STATUS DISPLAY)................................................................................25 TROUBLESHOOTING.........................................................................................................................26 IGBT MEASUREMENTS..................................................................................................................27 INDIVIDUAL IGBT MEASUREMENTS ............................................................................................28 DIODE MEASUREMENTS...............................................................................................................29 DIODE MEASUREMENTS...............................................................................................................30 PANEL MEASUREMENTS ..............................................................................................................31 DRIVER MEASUREMENTS.............................................................................................................32 IGBT DUAL MOTOR PANEL, FIGURE 16 .......................................................................................34 IGBT SINGLE MOTOR PANEL,FIGURE 17 ....................................................................................35 IGBT HEAT SINK ASSEMBLY, FIGURE 18 ....................................................................................36 SINGLE MOTOR PANEL HARNESS ASSEMBLY, FIGURE 19......................................................37 DUAL MOTOR PANEL HARNESS ASSEMBLY, FIGURE 20 .........................................................38 DASHBOARD DISPLAY, FIGURE 21..............................................................................................39 DUAL "Y" HARNESS, FIGURE 22 ..................................................................................................40 HARNESS FOR DASHBOARD DISPLAY, FIGURE 23 ...................................................................41 CALIBRATOR UNIT, FIGURE 24 ....................................................................................................42 LA 2000 PUMP MOTOR SHUNT, FIGURE 25 .................................................................................42 LA 2000 PANEL WIRING HARNESS, FIGURE 26 ..........................................................................43

1

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MODEL LA 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

DBT America

PREFACE This manual is intended to provide GENERAL operating and service procedures for the DBT America (DBT) LA 2000 motor vehicle solid-state controller. The illustrations, descriptions and procedures contained in this publication apply only to DBT LA 2000 motor vehicle solid-state controllers. DBT reserves the right to revise models and designs without prior notice.

This DBT LA 2000 motor vehicles solid-state controller was manufactured under the guidelines, procedures and requirements of the U. S. Federal Coal Mine Health and Safety Act, Code of Federal Regulations, Title 30, Chapter 1, Subpart 0, Part 75 for underground coal mines, and other applicable non-U. S. regulatory agency standards.

At the completion of the manufacturing process, the DBT LA 2000 motor vehicles solid-state controller was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of the controller, without the consent of DBT and these regulatory agencies, or any repair or replacement of parts contrary to DBT’s instructions, may invalidate these approvals and render the controller unsafe to operate.

Strict compliance with all Federal and State Mining laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this controller.

While this manual attempts to anticipate the most important operations and maintenance needs for this controller, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your DBT America Service Representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is nontransferable. Distribution and access is limited only to authorized personnel.

Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

 DBT America 2003 All rights reserved.

2

Revised 01 – 03

MODEL LA 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

DBT America

SYMBOLS AND SPECIAL NOTATIONS Throughout this manual there are specific notations that are either UPPERCASE BOLD, UNDERLINED or ITALICIZED for the primary purpose of emphasis. Please pay special attention to such statements as they regard safety or critical maintenance installation information.

You will also see the following:

NOTICE: THIS NOTATION DENOTES A REFERENCE TO PREVIOUSLY STATED INSTRUCTIONS.

IMPORTANT: THIS SYMBOL DENOTES THAT SPECIAL ATTENTION MUST BE ADHERED TO IN THE ATTACHED STATEMENT.

CAUTION: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A CUT, BRUISE OR ABRASION.

WARNING: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A LOST TIME ACCIDENT.

DANGER: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE POINTS IN THE TEXT MARKED WITH THIS SYMBOL DRAW YOUR ATTENTION TO IMMEDIATELY IMPENDING DANGER INCLUDING ELECTRICAL DANGERS. POSSIBLE CONSEQUENCES ARE: VERY SERIOUS INJURY, DEATH OR DEATH BY ELECTROCUTION.

3

Revised 01 – 03

MODEL LA 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

DBT America

DANGER ONLY TRAINED AND/OR AUTHORIZED PERSONNEL SHOULD PERFORM MAINTENANCE ON THE CONTROLLER. FAILURE TO ADHERE TO DANGERS, WARNINGS AND CAUTIONS, NOTED IN THIS MANUAL, COULD RESULT IN SERIOUS INJURY OR DEATH. FAILURE TO MAINTAIN THIS CONTROLLER IN STRICT ADHERENCE TO THESE INSTRUCTIONS AND WARNINGS IN THIS MANUAL COULD VOID THE WARRANTY.

4

Revised 01 – 03

MODEL LA 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

DBT America

MAJOR HAZARDS AREA WHERE HAZARD CAN OCCUR

HAZARD WHAT CAN HAPPEN IF PRECAUTIONS AND SAFEGUARDS ARE NOT OBEYED

SAFEGUARDS HOW TO AVOID THE HAZARD

MOTORS AND CONTROLLER

Electrical shock could cause irreparable injury or death.

All electrical systems should be maintained by certified electricians.

The battery should be disconnected before servicing the motors or controller. When the controller cover is removed, wait for one minute for the capacitors to discharge.

BATTERY

The battery produces lethal amounts of power whether connected to the machine or charger, or not.

The battery should be maintained by qualified personnel. (Refer to DBT America "INSTALLATION, USE, MAINTENANCE, AND REPAIR OF MINE POWER STORAGE BATTERIES,” PART NUMBER A6474X26, for complete instructions).

Battery covers could fall crushing hands or arms.

Be sure cover supports are in place when working on battery.

Battery hold-down clamps could crush fingers or hands.

Keep fingers and hands away from hold-down clamps.

Batteries produce explosive gases that could be ignited causing burns or explosions.

Batteries should be well vented before servicing particularly if welding or burning on the battery.

Batteries should be maintained by qualified personnel.

Batteries contain strong acid that could cause severe burns if spilled or splashed on body parts or in the eyes.

Protective clothing, gloves, and eyewear must be worn when working on batteries. Batteries should be maintained by qualified personnel.

5

Revised 01 – 03

MODEL LA 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

DBT America

SAFETY PRECAUTIONS AND GUIDELINES Overview Before you test, troubleshoot, service or in any other way, use this unit READ and STUDY this guide. KNOW what you must do for safe maintenance.

ALWAYS wear or use the proper safety items required for your personal protection.

If you have ANY QUESTIONS about the safe use or maintenance of this unit: ASK YOUR SUPERVISOR - NEVER GUESS - ALWAYS CHECK Maintenance AVOID, whenever possible, servicing, cleaning or examining the unit in congested areas.

AVOID, whenever possible, servicing or providing maintenance to the unit unless the wheels are adequately choked. If the drive motor (s) is to be run, the unit must be jacked clear of the ground and all four (4) wheels must be free to turn.

DO NOT alter the electrical settings from that indicated in this guide or as set at the factory.

ALWAYS replace damaged or lost decals or metal instruction plates. Refer to the Parts Manual for the proper location and part number of decals and plates.

DISCONNECT the battery when working with electrical systems, or when welding on the unit to prevent electrical shock.

It is important that any procedure not specifically recommended in this guide be thoroughly evaluated from the standpoint of safety before it is implemented.

Some photographs and illustrations in this guide may show guards or covers removed for purposes of clarity. Never operate unit without all guards and covers in place.

SOME PHOTOGRAPHS OR ILLUSTRATIONS IN THIS GUIDE MAY SHOW PROTOTYPE UNITS OR UNITS WITH OPTIONAL EQUIPMENT INSTALLED THAT MAY OR MAY NOT BE ON YOUR PARTICULAR MACHINE. PRODUCTION MODELS MAY VARY IN SOME DETAIL. OPTIONAL EQUIPMENT MAY BE PURCHASED FROM YOUR DBT DEALER. CONTINUING IMPROVEMENT AND ADVANCEMENT OF PRODUCT DESIGN MAY CAUSE CHANGES TO YOUR MACHINE WHICH MAY NOT BE INCLUDED IN THIS PUBLICATION. EACH PUBLICATION IS REVIEWED AND REVISED, AS REQUIRED, TO UPDATE AND INCLUDE THE CHANGES IN LATER ADDITIONS. DBT RESERVES THE RIGHT TO MODIFY OR MAKE CHANGES WITHIN A SPECIFIC MODEL GROUP WITHOUT NOTICE AND WITHOUT INCURRING ANY LIABILITY TO RETROFIT UNITS PREVIOUSLY SHIPPED FROM THE FACTORY. CONTACT YOUR DBT DEALER FOR MAINTENANCE THAT IS NOT COVERED IN THIS PUBLICATION. 6

Revised 01 – 03

MODEL LA 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

DBT America

INTRODUCTION LA 2000: Innovative Speed Control by DBT America FIGURE 1 – SIMPLIFIED LA 2000 CIRCUIT

In the early 1970's, S&S Corporation lead the way in mining innovation with the introduction of Solid State speed controls for battery-powered underground mining equipment. Solid State controls increased the range and reliability of the battery powered vehicles along with providing smooth, stepless acceleration. Even with solid state speed control, direction change was achieved with the use of electromechanical contactors. These contactors provided an endless source of maintenance problems and consumed excessive amounts of valuable controller-box space. Also, most solid state controllers of the past utilize an electromechanical "bypass" contactor to connect the motor directly to the batteries which caused more contactor problems.

In the 1980’s DBT America, in conjunction with Sevcon, developed a contactorless motor controller (X90) to be used exclusively on DBT equipment. The X90 system used a dual-field motor in combination with SCR's (Silicone Controlled Rectifier) to achieve solid state direction change.

Now DBT America, in conjunction with Sevcon, has developed the LA 2000 motor controller. The LA 2000 system uses IGBT’s (Insulated Gate Bipolar Transistors) to achieve motor control and direction change. Unlike an SCR, an IGBT is turned ON and OFF via a gating electronic signal.

This eliminated commutating capacitor banks and coils. The microprocessor based LA 2000 Logic Card provides complete motor control, and drives both a Diagnostic Dashboard Display along with a hand held Calibrator/Diagnostic Unit.

The IGBT switch operates so fast that it can connect and disconnect the motor in less than 1/1700 second. This is such a short time period that the dual-field motor does not have time to move. Each time the IGBT switch closes and reopens the full battery voltage is applied to the motor terminals for about 1/1700 second. This is commonly referred to as a "pulse."

The IGBT speed control works by feeding to the motor a rapid series of pulses. The number of pulses per second determines the average voltage at the motor terminals 7

Revised 01 – 03

MODEL LA 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

DBT America

Since the windings of the motor are inductive, the current in the motor cannot change quickly.

When the IGBT switch is closed, the current builds up slowly and when the switch opens, the inductance wants to keep the current flowing. For this reason, the "flywheel" diode is provided.

Figures 3 and 4 illustrate the current paths with the switch closed in both forward (Figure 3) and reverse (Figure 4) modes.

FIGURE 2

FIGURE 3

8

Revised 01 – 03

MODEL LA 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

DBT America

FIGURE 4

As seen in Figure 5, the direction of the current through the motor does not change. More important, when the switch opens, although the battery current stops, the motor current continues to flow via the "flywheel" diode. The motor current is therefore made up of two components: 1. The battery current when the IGBT switch is closed.

2. The "flywheel" current when the IGBT switch is open.

FIGURE 5

9

Revised 01 – 03

MODEL LA 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

DBT America

The amount of the motor current supplied from the battery varies with the pulse frequency.

Figure 6 illustrates a typical situation at low speed. It can be seen from the illustration that the "flywheel" current, because it is flowing for a longer period, forms a larger part of the motor current than does the battery current. However, at high speeds (Figure 7), the motor current is made up of almost all battery current.

FIGURE 6

To summarize, the motor current is made up of a combination of battery current and "flywheel" current so that under all conditions the average motor current is always greater than the average battery current.

At low speeds the motor current can be several times greater than the battery current.

At high speeds, when the IGBT switch is open only for short periods before closing, the motor current is made up almost entirely of battery current.

10

Revised 01 – 03

MODEL LA 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

DBT America

FIGURE 7

11

Revised 01 – 03

MODEL LA 2000 SINGLE AND DUAL MOTOR SSTS GUIDE

DBT America

GENERAL SPECIFICATIONS The DBT LA 2000 Motor Controller is designed to operate at 128 volts DC, 1200 Amps maximum current limit per motor and controls one or two dual-field electric motors. ¾

The maximum current default settings are: 800A, 1100A and 1200A

¾

Traction functions operate at a speed that is directly proportional to the accelerator (FS1) demand. (See Figure 8)

¾

Traction motor current will be continuously monitored in the motor. Current limit is preset and is adjustable via the optional hand held diagnostics/calibrator unit and is password protected.

FIGURE 8 – ACCELERATOR VOLTAGE

Fail-safe operation will include the following: ¾

In the event of a shorted IGBT, the circuit breaker will be opened, disconnecting power from the traction motors.

¾

Operation of the circuit breaker will always be sensed, and if faulty, drive will be inhibited.

¾

Whenever the vehicle is power-cycled, power-up diagnostics will be executed to test the tram drive circuitry. If faulty, drive will be inhibited.

The temperature of the LA 2000 Motor Controller will be continuously monitored and if it rises above 95°C the motor current will be limited to a maximum of 300 amps of motor current will be allowed.

The LA 2000 Motor Controller features a data logging capability that stores critical data into nonvolatile data RAM. The stored data is displayed in the traction status display of the optional hand held diagnostics/calibrator unit.

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DESCRIPTION OF FEATURES The LA 2000 Solid State Controller incorporates a variety of independent protection systems.

These improve reliability, shield the motors and controller from overload, protect the machine from inadvertent abuse by the operator, and help to protect workers from potential harm from malfunctioning equipment.

LA 2000 Motor Controller Consist of: ¾

Dual Motor IGBT Panel or single motor IGBT Panel or 2-single motor IGBT panels

¾

Microprocessor Based Logic Card

¾

Optional Dashboard Display

¾

Optional Hand held Diagnostics/Calibrator Unit

¾

“Y” connecting harness (used only with 2-single motor panel systems)

LA 2000 Motor IGBT Panel (Power Connections) ¾ ¾ ¾

Battery positive Battery negative 4 motor connections for each motor (S1, S2, A1 and A2)

(For Power Circuit Layout see Machine Wiring diagram and schematic)

Microprocessor Based Logic Card (Control Inputs) ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾

Input applies battery voltage to logic card (Pin 16) Proportional control accelerator, 5000 OHMS (Pins 1 and 2) Tram direction select (Pin 7) Tram direction select (Pin 8) Park brake condition (set / release) (Pin 14) Circuit breaker driver (Pin 6) Circuit breaker condition (Pin 11) Current limit default setting (Pin 12) Accelerator (FS1) input switch (Pin 4) CAN Communication Input Port for optional hand held diagnostics/calibrator unit CAN Communication Input Port for optional dashboard display Analog Input for connection to pump motor shunt to allow pump motor current measurement

The LA 2000 Microprocessor-Based Logic Card will control dual two-quadrant IGBT devices, controlled by PWM (PULSE WIDTH MODULATED) switching, providing forward and reverse direction control.

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There is an LED on the logic card which serves as an indicator of the status of the controller. The following diagnostics shall apply: ¾ ¾ ¾

LED on LED off 1 Flash

¾

2 Flash

¾

3 Flash

¾

4 Flash

¾

5 Flash

¾

6 Flash

¾

7 Flash

¾

8 Flash

Controller operational Power-up fault – check display or calibrator. If all is blank, then replace logic.

Personality CRC EEPROM Error.

Using the hand-held calibrator, change a password to any number then recycle power – should clear, otherwise replace logic.

Procedure FAULT FS1 closed before power on ,2 Directional Fault or Current imbalance fault.

Recycle through NEUTRAL to clear.

IGBT permanently low (IGBT Short Circuit FAULT).

This includes IGBT short circuit or IGBT open circuit. This fault shuts down all modes. Recycle through NEUTRAL to clear.

Motor neither low nor high (Breaker Open FAULT).

This includes breaker open circuit or IGBT open circuit. This fault shuts down all modes. Recycle through NEUTRAL to clear.

Motor permanently high.

This includes breaker welded. This fault shuts down all modes. Recycle “KEY” to clear.

Faulty TRACTION accelerator.

This includes the accelerator greater than 15% at power on and wire-off. If wireoff occurs during active function then the motor speed will set to zero. This fault auto-clears.

Battery voltage FAULT. This includes battery below a predetermined value. Recycle through NEUTRAL to clear.

Thermal cut-back (Over-Temperature FAULT).

This includes Heatsink temperature above 95° centigrade.

AS TEMPERATURE RISES CONTROLLER WILL LIMIT REGARDLESS OF DEMAND. ¾

9 Flash

¾

10 Flash

¾

15 Flash

ABOVE 95° CENTIGRADE, THE THE CURRENT TO 300 AMPS

UVR coil over-current FAULT (Coil short circuit FAULT).

Cleared with “KEY” recycled.

Brake on FAULT Will trip Directional and FS1 are energized without releasing brake. Recycle through NEUTRAL to clear.

Current Transducer FAULT. Occurs when current output is read during power-up or if no current is read during drive above 50% demand. “KEY” recycle to clear.

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Configuration Jumper Table MAX. CURRENT CONFIG. LOGIC PIN 12 OPEN GROUND (CLOSED) OPEN

VEHICLE TYPE SINGLE MOTOR – 1200 AMP SINGLE MOTOR – 1100 AMP DUAL MOTORS 1100 AMP PER MOTOR – ADJUSTABLE TO 1200 AMP DUAL MOTORS 800 AMP PER MOTOR

GROUND (CLOSED)

OPTIONAL DASHBOARD DISPLAY FEATURES (See Figure 9) ¾ ¾ ¾ ¾

A battery discharge indicator An hour meter displaying tram-on hours An hour meter displaying pump-on hours A rotating display showing: 1. Battery voltage 2. Pump motor current 3. Diagnostic fault status, when applicable. Rotating display will lock on one of the following fault messages: (See Fault Message Chart, page 19)

FIGURE 9 – OPTIONAL DASHBOARD DISPLAY

BATTERY DISCHARGE FUNCTION

ROTATING DISPLAY

TRAM – ON PUMP – ON HOURS

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Fault Message Chart DASHBOARD DISPLAY “Rotating Disp.”

“Testing”

CALIBRATOR DISPLAY “OK” “Testing”

“System OK”

“System Okay”

“Over Temp.”

“Brkr Open”

“Thermal Cutback” “Breaker Open”

“Brkr Weld”

“Breaker Weld”

“UVR Coil” “Cap Fault” “Accel Flt.”

“UVR Coil” “Capacitor Fault” “Accel Flt.”

“Seq. Fault”

“Sequence Fault”

“2 Dir Fault” “Tram Fault” “Bat Low” “CRC Error”

“2 Dir Fault” “Tram Fault” “Bat Low” “CRC Error”

“IGBT s/c” “IGBT s/c” “Brake on”

“IGBT s/c” “IGBT s/c” “Brake on”

“Cur Xducer”

“Cur Xducer Flt”

“Bad Logic”

“Bad Logic”

“Bad Logic”

“Bad Logic”

“Cap Fault” “PTA Short”

“Cap Fault” “P. Up PTA Short”

“RPTA Short”

“P. Up R. PTA Short”

DESCRIPTION No fault Only visible when power-up diagnostics is running. Check connections if not clearing.

Power-up check completed, waiting to closure of Circuit Breaker Controller in thermal cut-back.

Circuit breaker failed to close. Faulty Circuit breaker, UVR, CB Auxiliary or faulty logic board.

Circuit breaker welded close. Faulty CB auxiliary switch or faulty logic will give this fault also.

UVR coil driver over-current sensed.

Caps failed to charge after power-up.

Accelerator fault sensed. Faulty accelerator (accelerator voltage 4.0v; accelerator voltage below 1.2v in NEUTRAL).

Faulty FS1 or logic board.

FS1 closed at power-up. Possible circuit breaker auxiliary switch not closing Both directional switches active.

Motor current imbalance sensed.

Battery fell below personality level.

During power-up a personality CRC error occurred. Try adjusting one of the passwords (1 or 2) then power recycle.

If not cleared replace logic board.

An IGBT short has been detected – SM. A left or right IGBT short has been detected – DM. The vehicle BRAKES are on while there is a direction and demand selected.

The controller reads current when it is first powered-up or does not read any current when demand for drive over 50%.

An internal errors has occurred in the software state machine. Faulty logic board.

Invalid status state encountered (internal error). Faulty logic board. * * * * POWER UP TEST STATUS * * * * Caps failed to change after power-up.

Single motor Block 0 point “A” short Motor short to ground or IGBT shorted Other electrical component (coil/etc.) shorted or grounded not allowing voltage to come up to or above 64VDC on IGBT panel.

Dual motor Block 0 point “A” short Motor shorted to ground or RIGHT IGBT shorted Other electrical component (coil/etc.) shorted or grounded not allowing voltage to come up to or above 64VDC on IGBT panel.

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Fault Message Chart (Continued) “LPTA Short”

“P. Up L. PTA Short”

“I. D. Fault” “Bad Logic”

“Vehicle ID Flt” “Bad Logic”

“R FWD ON”

“Tract R. FWD on”

“FWD ON”

“Tract FWD on”

“R REV ON”

“Tract R. REV on”

“REV ON”

“Tract REV on

“L FWD ON”

“Tract L. FWD on”

“L REV ON”

“Tract L. REV on”

“Drive off”

Drive 0 off Flt”:

“R FWD OFF”

“Tract R. FWD off”

“FWD OFF”

“Tract FWD off”

“R REV OFF”

“Tract R. REV off”

“REV OFF”

“Tract REV off”

“L FWD OFF”

“Tract L. FWD off”

“L REV OFF”

“Tract L. Rev off”

“BAD LOGIC”

“BAD LOGIC”

Dual motor Block 1 point “A” short Motor shorted to ground or LEFT IGBT shorted Other electrical component (coil/etc.) shorted or grounded not allowing voltage to come up to or above 64VDC on IGBT panel.

Vehicle Configuration ID invalid Diagnostic point “A” trip failed to disable UVR coil. Faulty logic board.

Diagnostic RIGHT FWD point “A” trip failed to be disabled. .

Faulty logic board, shorted motor to ground or shorted IGBT. Single motor Point “A” trip failed to disable FWD IGBT. Faulty logic board, shorted motor to ground or shorted IGBT. Diagnostic RIGHT REV point “A” trip failed to be disabled.

Faulty logic board, shorted motor to ground or shorted IGBT. Single motor Diagnostic REV point “A” trip failed to be disabled. Faulty logic board, shorted motor to ground or shorted IGBT. Diagnostic LEFT FWD point “A” trip failed to be disabled.

Faulty logic board, shorted motor to ground or shorted IGBT. Diagnostic LEFT REV point “A” trip failed to be disabled.

Faulty logic board, shorted motor to ground or shorted IGBT. Diagnostic test to enable UVR coil driver failed. Faulty logic board.

Diagnostic RIGHT FWD point “A” trip failed to disable PWMO. Faulty logic board.

Single motor Diagnostic FWD point “A” trip failed to disable PWMO. Faulty logic board.

Diagnostic RIGHT REV point “A” trip failed to disable PWMO. Faulty logic board.

Single motor Diagnostic REV point “A” trip failed to disable PWMO. Faulty logic board.

Diagnostic LEFT FWD point “A” trip failed to disable PWM1.

Faulty logic board.

Diagnostic LEFT REV point “A” trip failed to disable PWM1.

Faulty logic board.

Internal error (Software Only) Faulty logic board.

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Optional Hand Held Diagnostics/Calibrator Unit Security Levels: 1.

2.

3.

4.

Customer level Service Level Advanced Level Engineering Level

SECURITY LEVELS 2-4 ARE ONLY ACCESSIBLE BY ENTERING THE APPROPRIATE PASSWORDS.

FIGURE 10 – OPTIONAL HAND HELD DIAGNOSTICS/CALIBRATOR UNIT RIGHT BUTTON

LEFT BUTTON

DOWN BUTTON

UP BUTTON

Connecting for Operation: 1. Turn the machine “OFF”.

2. Turn the main circuit breaker to the “OFF” position to de-energize power on machine.

3. Remove the main controller cover.

4. Connect the hand held diagnostics/calibrator unit to the CAN Communication Input Port of the logic card.

5. Turn the main circuit breaker to the “ON” position.

6. Leave the “Park Brake Set”.

The hand held diagnostics/calibrator unit is now operational.

Operation: Upon power-up of the hand held diagnostics/calibrator unit, before pressing any buttons, a top level display is visible to provide diagnostic information as follows: See list on page # 19 and 20 18

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Personality Adjustment Procedure 1. Power-up calibrator.

2. If the top level display indicates “OK”, go to step (4). If not “OK”, go to step (3).

3. Consult above diagnostic information table to determine cause of fault.

4. Press the “DOWN” button two times to access the personalities table.

5. Use the “LEFT” or “RIGHT” buttons to locate the desired personality.

6. After locating the personality, use the “+” or “-” buttons to adjust the values accordingly.

7. To go back to the top level display, press the “UP” button two times.

The following features shall be customer adjustable personalities, accessible using the Calibrator

Traction Personalities (Controller Adjustments) DISPLAY NAME

MAX CONTROLLER CURRENT

RANGE / NOTES

SECURITY LEVELS DISPLAYED

50 amps to maximum controller capacity.

ALL

ACCELERATOR DELAY

0.5 seconds to 5.0 seconds

DECELERATION DELAY

(1.0 seconds ALL VEHICLES) 1.0 seconds to 5.0 seconds

CREEP SPEED

(1.0 seconds ALL VEHICLES) 0% to 25%

MAXIMUM SPEED

(5%) 0% to 100%

PASSWORD ONE PASSWORD 2 PWM FREQUENCY ADJUST PLUG CONFIGURATION NOTE: REQUIRES POWER RECYCLE

BATTERY PROTECTION CUTOUT BATTERY PROTECTION DELAY MOTOR CURRENT LOG LEVEL

(100%) 0 – 255 characters 0 – 255 characters 0 – 255 characters (17) 0 – 1 (Internal factor) 0. RFU 1. Auto plug breaking 2. Selective plug breaking (Normal plug) (2) 50 v – 255 v

SERVICE ADVANCED ENGINEERING SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING SERVICE ADVANCED ENGINEERING ENGINEERING SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING ALL ALL ALL ALL ENGINEERING ENGINEERING SERVICE ADVANCED ENGINEERING ENGINEERING

ALL

(50v) 0.1 – 5.0 seconds

ALL

(5.0 seconds) 50 – 1200 Amps

ALL

19

SECURITY LEVELS ADJUSTABLE

SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING

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Traction Personalities (Controller Adjustments) (Continued) PLUG CURRENT LOG LEVEL TEMPERATURE ADJUSTMENT

CLEAR DATA LOG

CLOSE CB DELAY ALLOWED

50 – 1200 Amps Compensates temperature look-up tables.

0-20 = Positive additives 21 – 40 = Negative additives 95° default (ALL VEHICLES) OFF – ON NOTE: THIS PERSONALITY CLEARS ALL OF THE DATALOG LOCATIONS IN NON-VOLATILE MEMORY. TO ENABLE THIS PERSONALITY PRESS THE “-” BUTTON. IT DISABLES ITSELF ONCE IT COMPLETES THE CLEARING TASK. FS1 MUST BE OPEN. 0 seconds (disables) to 90 seconds 45 seconds (ALL VEHICLES)

NO ACTIVITY DELAY TIMER

0 seconds (disables) to 40 minutes 0 minutes (ALL VEHICLES)

CURRENT IMBALANCE TIMER

0 seconds (disables) to 90 seconds

20

ALL

SERVICE ADVANCED ENGINEERING ENGINEERING SERVICE ADVANCED ENGINEERING ALL

SERVICE ADVANCED ENGINEERING

SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING SERVICE SERVICE ADVANCED ADVANCED ENGINEERING ENGINEERING

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Traction Status Display DISPLAY NAME

RANGE / NOTES

Battery Voltage Motor Voltage (S. M.) Right Motor Voltage Left Motor Voltage Motor Current (S. M.) Right Motor Current Left Motor Current S. M. Rev. IGBT Block Temp.

S. M. Fwd IGBT Block Temp.

DM Right IGBT Block Temp.

DM Left IGBT Block Temp.

IGBT Voltage (S. M.) Right IGBT Voltage Left IGBT Voltage Error Code (see error code sec.)

Number of “Key On” Hours Number of “Driving” Hours Current Calibration Factor (S. M.) Right Channel Zero Current Calibration Factor Left Channel Zero Current Calibration Factor Peak Motor Current (S. M.) Right Channel Peak Motor Current Motor Current Stored Duration High Bytes (S. M.) Right Channel Motor Current Stored Duration High Bytes (S. M.) Motor Current Stored Duration Mid Bytes (S. M.) Right Channel Motor Current Stored Duration Mid Bytes (S. M.) Motor Current Stored Duration Low Bytes (S. M.) Right Channel Motor Current Stored Duration Low Bytes (S. M.) Motor Current Stored Duration Low Bytes (S. M.) Right Channel Motor Current Stored Duration Low Bytes (S. M.)

21

SECURITY LEVELS DISPLAYED ALL ALL

SECURITY LEVELS ADJUSTABLE N/A N/A

ALL ALL

N/A N/A

ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

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Traction Status Display (Continued) Peak Plugging Current (S. M.) Right Channel Peak Plugging Current Selected Plugging Current Recording Level

NOTE: CONVERT AS FOLLOWS 1. CONVERT EACH BYTE TO ITS HEX EQUIVALENT. 2. CONVERT THE (3) BTYE FIELD TO A DECIMAL AND MULTIPLY BY 3.0 MSECONDS TO OBTAIN REAL TIME.

Plugging Current Stored Duration High Bytes (S. M.) Right Channel Plugging Current Stored Duration High Bytes (S. M.) Plugging Current Stored Duration Mid Bytes (S. M.) Right Channel Plugging Current Stored Duration Mid Bytes (S. M.) Plugging Current Stored Duration Low Bytes (S. M.) Right Channel Plugging Current Stored Duration Low Bytes (S. M.) Peak Motor Current (S. M.) Left / Right Motor Peak Plugging Current Stored Duration High Bytes (S. M.) Left Channel Plugging Current Stored Duration High Bytes (S. M.) Plugging Current Stored Duration Mid Bytes (S. M.) Left Channel Plugging Current Stored Duration Mid Bytes (S. M.) Plugging Current Stored Duration Low Bytes (S. M.) Left Channel Plugging Current Stored Duration Low Bytes (S. M.) Peak Plugging Current (S. M.) Left Channel Peak Plugging Current Plugging Current Stored Duration High Bytes (S. M.) Left Channel Plugging Current Stored Duration High Bytes (S. M.) 22

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

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Traction Status Display (Continued) Plugging Current Stored Duration Mid Bytes (S. M.) Left Channel Plugging Current Stored Duration Mid Bytes (S. M.) Plugging Current Stored Duration Low Bytes (S. M.) Left Channel Plugging Current Stored Duration Low Bytes (S. M.) SM FWD IGBT High Temperature SM REV IGBT High Temperature DM RIGHT IGBT High Temp.

DM LEFT IGBT High Temp.

SM FWD IGBT Low Temperature SM REV IGBT Low Temperature DM RIGHT IGBT Low Temp.

DM LEFT IGBT Low Temp.

Battery Voltage High Battery Voltage Low

ALL

N/A

ALL

N/A

ALL

N/A

ALL

N/A

ALL ALL ALL

N/A N/A N/A

ALL ALL ALL ALL ALL

N/A N/A N/A N/A N/A

Security Level Displayed

Security Level Adjustable

ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

Traction Test Display Display Name Accel. Voltage Accel. Percent Demand Forward Switch Reverse Switch FS1 Switch Configuration Jumper 1 Configuration Jumper 2 Brake Input Circuit Breaker Input Oil Temperature Oil Level Software Version

Range / Notes 0.0 V - 5.0 V 0 - 100% OPEN / CLOSED OPEN / CLOSED OPEN / CLOSED OPEN / CLOSED OPEN / CLOSED OPEN / CLOSED OPEN / CLOSED OK / HOT OK / LOW VX.XXX

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Traction BDI Display Display Name % CHANGE LEFT BDI CELLS

Range / Notes

RESET CELL LEVEL

0 - 100% 35 - 80 (64) 1.85V - 2.50V

EMPTY CELL LEVEL

(2.04V) 1.00V - 1.99V

WARNING LEVEL

(1.70V) 0% - 90%

CUTOUT LEVEL

(20%) 0% - 90%

BATTERY CALLIBRATION VOLTAGE BDI SAMPLE TIMER DISPLAY WORKING DISPLAY STATUS SELECT DASHBOARD DISPLAY STATUS

DISPLAY CONTRAST

(0%) 1.00V – 10.0V (5-VOLTS) 1.0 - 255 SECONDS 2.0 (20 SECONDS) OK LOCK / ROTATE (ROTATE) 0 - 4 (BATTERY VOLTAGE, PUMP CURRENT AND MOTOR CURRENT) BATTERY VOLTAGE (1) 0 - 127 1 (33)

24

Security Level Displayed ENGINEERING ENGINEERING

Security Level Adjustable ENGINEERING ENGINEERING

SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING ENGINEERING

SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING SERVICE ADVANCED ENGINEERING ENGINEERING

ENGINEERING

ENGINEERING

ENGINEERING

ENGINEERING

ADVANCED ENGINEERING ALL

ADVANCED ENGINEERING ALL

ALL

ALL

ALL

ALL

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Error Code Legend (Status Display) ERROR CODE 0 1 2

3

4

5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20 21

DESCRIPTION No Fault Caps failed to change after power-up Check for shorted cap Single Motor Block “0” Point “A” short Shorted IGBT or short between motor and ground Dual Motor Block “0” Point “A” short Shorted Right IGBT or short between motor and ground Dual Motor Block “0” Point “A” short Shorted Left IGBT or short between motor and ground Vehicle configuration ID invalid Diagnostic Point “A” trip failed to disable UVR Coil Replace logic assembly Diagnostic Right FWD Point “A” trip failed to disable Replace logic assembly Single Motor Point “A” trip failed to disable FWD IGBT Replace logic assembly Diagnostic Right REV Point “A” trip failed to disable Replace logic assembly Single Motor Diagnostic REV Point “A” trip failed to disable Replace logic assembly Diagnostic Left FWD Point “A” trip failed to disable Replace logic assembly Diagnostic Left REV Point “A” trip failed to disable Replace logic assembly Diagnostic test to enable UVR Coil driver failed Fault in logic assembly or faulty UVR Coil Diagnostic Right FWD Point “A” trip failed Replace logic assembly Single motor diagnostic FWD Point “A” trip failed Replace logic assembly Diagnostic Right REV Point “A” trip failed Replace logic assembly Single motor diagnostic FWD Point “A” trip failed Replace logic assembly Diagnostic Left FWD Point “A” trip failed Replace logic assembly Diagnostic Left REV Point “A” trip failed Replace logic assembly Breaker welded fault Internal error (Software Only) Replace logic assembly

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TROUBLESHOOTING This section provides troubleshooting information. This guide assumes you have a working knowledge of IGBT controller servicing and that you have the following equipment.

1. Volt/Ohm Meter with Leads 2. Insulated Basic Hand Tools

WHEN WORKING INSIDE THE CONTROLLER, USE INSULATED GLOVES AND TOOLS WHERE POSSIBLE. ALL CONNECTIONS MUST BE TIGHT AND CARE MUST BE TAKEN TO PREVENT BOLTS, NUTS, WASHERS AND OTHER SMALL METAL FASTENERS FROM BEING DROPPED OR LOST INSIDE THE CONTROLLER. BEFORE STARTING ANY POWER-RELATED PERFORMANCE TESTS, THE MACHINE MUST BE JACKED AND SECURELY BLOCKED CLEAR OF THE GROUND WITH ALL FOUR (4) WHEELS FREE TO TURN.

REFER TO THE PARTS MANUAL FOR YOUR PARTICULAR MACHINE WIRING DIAGRAMS AND SCHEMATICS.

THE LOGIC UNIT CONTAINS NO USER-SERVICEABLE PARTS. OPENING THIS SEALED DEVICE WILL VOID THE WARRANTY.

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IGBT and Diode Measurements Before taking readings, the following system conditions must be met: 1. Master switch or control handle in the “OFF” position.

2. Panel disconnected from and isolated from the battery (via main circuit breaker) and battery plugs being disconnected.

3. Motor leads disconnected from panel 4. After power is removed, wait for one (1) minute before making measurements to allow voltage to bleed down

IGBT Measurements (See Figure 11) If reading is 0, IGBT is shorted.

There are two IGBT’s wired in parallel; therefore, if one IGBT indicates short, it may be one or both.

FIGURE 11

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Individual IGBT Measurements FIGURE 12

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Diode Measurements FIGURE 13

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Diode Measurements FIGURE 14

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Before taking readings, the following system conditions must be met: 1. Panel mounted in vehicle 2. Main circuit breaker in the “OFF” position 3. Power “OFF” at master switch or control handle (must be off at least one minute before taking measurement)

Panel Measurements FIGURE 15

Panel Measurements Before taking readings, the following system conditions must be met: 1.

2.

3.

4.

5.

All connections attached, and power applied Main circuit breaker on Master switch or control handle in the “PARK” or “PARK BRAKE APPLIED” position Accelerator NOT depressed (FS1 open) Main line contactor open • • •

B+ to B-: Battery Voltage B- to AA: ≈50V B- to S1L, S4L, S1R, & S4R: ≈50V

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Driver Measurements The measurement of the driver on the DBT America Inc. LA 2000 Motor Controller cannot be done with a volt-ohm-meter. In order to determine whether the driver is faulty, a process of elimination is required. The LED indicates if there is “look ahead” voltage on the IGBT’s and as such does not fully indicate whether the driver is working properly or not.

The steps to follow to determine if the driver is faulty are as follows: 1. Determine if any of the IGBT’s or diodes are faulty by performing the previously illustrated tests.

2. With power applied, the master switch or control handle to the “PARK” PARK BRAKE APPLIED” position, and all motor leads connected, measure the voltage with a volt-ohm meter from “B-” to the motor connection leads, each in turn (“S1” to “B-”, “S4” to “B-”, and so on). The main line contactor must be open.

3. The reading should be less than the battery voltage, but higher than “B-” (in the range of approximately 70 volts). This voltage may vary panel to panel as there is leakage voltage through the IGBT’s and diodes.

4. If the voltage is at the same potential as “B+”, then most likely a diode is shorted.

5. If the voltage is at “B-”, then most likely an IGBT is shorted.

6. The calibrator should indicate which channel is faulty.

7. If the calibrator does not indicate which channel is faulty, the faulty component can be determined in the following manner: • Remove power from the panel, remove the motor connection leads from the panel and follow the measurements as indicated in the previous sections, or determine which channel is faulty.

8. If all the IGBT’s and diodes measure okay, the problem may be with the driver or the logic board.

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IGBT PANELS

FOR REPLACEMENT PARTS AND MACHINE WIRING DIAGRAMS, PLEASE REFER TO YOUR SPARE PARTS MANUAL.

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IGBT Dual Motor Panel FIGURE 16 RESISTOR ASSEMBLY BUSS BAR, B -

THERMAL STRIP AND THERMISTOR

WIRING HARNESS

BUSS BAR, B +

BUSS BAR AND CURRENT TRANSDUCER

RESISTOR ASSEMBLY HEAT SINK ASSEMBLY

BUSS BAR SHUNT ASSEMBLY

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IGBT Single Motor Panel FIGURE 17 BUSS BAR CURRENT TRANSDUCER DIODE KIT

HARNESS ASSEMBLY

RESISTOR ASSEMBLY

BUSS BAR ASSEMBLY

BUSS BAR ASSEMBLY

THERMAL STRIP

DRIVER BOARD ASSEMBLY

CAPACITOR ASSEMBLY

INSULATOR PLATE

HARNESS ASSEMBLY

COLLECTOR PLATE ASSEMBLY

DIODE KIT IGBT KIT

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IGBT Heat Sink Assembly FIGURE 18

CAPACITOR ASSEMBLY

INSULATOR PLATE

IGBT KIT

COLLECTOR PLATE ASSEMBLY

COPPER SPACER DRIVER BOARD

DIODE KIT HEAT SINK

WIRING HARNESS

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Single Motor Panel Harness Assembly FIGURE 19

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Dual Motor Panel Harness Assembly FIGURE 20

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Dashboard Display FIGURE 21

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Dual “Y” Harness FIGURE 22

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Harness for Dashboard Display FIGURE 23

RJ11 PLUG CABLE

RJ11 PLUG CABLE

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Calibrator Unit FIGURE 24

LA 2000 Pump Motor Shunt FIGURE 25

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LA 2000 Panel Wiring Harness FIGURE 26

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PRELIMINARY PREVENTIVE MAINTENANCE AND SERVICE GUIDE MODELS CH816, CH816L, AND CH818

 DBT AMERICA 2003 ALL RIGHTS RESERVED

DBT America _______________________________________________________________________ 4041 Wurno Road Telephone: 540-980-4530 Pulaski, VA 24301 Fax: 540-994-3763 Internet: www.dbtamerica.com

GENERAL MAINTENANCE INSTRUCTIONS Long reliable service and the safety of those working with this Un-A-Hauler® can only be ensured by conscientious periodic maintenance of the machine.

Anyone performing maintenance on this machine should be trained to operate it and must be familiar with this DBT AMERICA Guide.

All electrical work must be supervised and inspected by a MSHA certified electrician.

BEFORE MAINTENANCE OR SERVICING: A. Shutdown the Un-A-Hauler® on level ground.

B. Disconnect the power. Either the battery circuit breaker or the machine circuit breaker must be in the "OFF" position. If work is to be done inside the electrical controller, the battery should be disconnected. Also make sure the capacitor discharge module indicates that the capacitors are discharged before working inside the controller.

C. Test the controls to be sure that the Un-A-Hauler® will not operate.

D. Chock all four (4) wheels in both directions.

E. Connect the steering lockout device.

During maintenance or servicing, if the drive motors are to be run, the Un-A-Hauler® must be jacked clear of the ground and securely blocked. All four wheels must be free to rotate. The center section should also be blocked. The machine should be blocked at the points shown below.

BLOCKING POINTS

DO NOT perform maintenance in a congested area. This could endanger the maintenance person or others in the vicinity. The maintenance area should be as clean as possible.

Whenever a potential problem is uncovered during a periodic maintenance check, it is imperative that it be corrected immediately by a qualified service person.

CLEANLINESS cannot be overemphasized as the essential ingredient of a good maintenance program. Machines should be kept as free as possible of dirt and debris which could impede performance or infiltrate systems and cause premature wear or failure.

DBT America

DO NOT MOVE ANY HYDRAULIC CONTROL LEVER UNLESS YOU ARE CERTAIN THAT NO ONE COULD BE HURT BY THE MACHINE'S MOVEMENT. DO NOT DISCONNECT A HYDRAULIC CIRCUIT FROM A CYLINDER WHILE THERE IS A LOAD ON THE CYLINDER. DO NOT DISCONNECT ANY HOSES FROM THE BRAKE SYSTEM WHILE THERE IS PRESSURE PRESENT IN THE BRAKE SYSTEM ACCUMULATOR. THE PRESSURE MUST BE RELIEVED BY SHUTTING DOWN THE MACHINE AND PRESSING THE "BRAKE RELEASE" BUTTON. DISCONNECT THE BATTERY BEFORE WORKING ON ANY PART OF THE ELECTRICAL SYSTEM.

CRITICAL TORQUE VALUES Torque values are expressed in lubricated and dry thread values. Lubricated thread torque values should be used any time the bolt threads are covered with oil, grease, anti-seize or thread-locking compounds.

Dry thread torque values should be used when threads are completely clean and dry.

CRITICAL BOLT TORQUE VALUES (ft-lb) LOCATION Steering Cylinder Pins Tire-Wheel Mounting Bolts (Front) Tire-Wheel Mounting Bolts (Rear) Planetary Wheel End-toFrame Mounting Bolts Gear Case-to-Frame Mounting Bolts Drive Motor-to-Gear Case Mounting Bolts

BOLT SIZE

GRADE Grade 8

DRY 400 420

LUBRICATED 240 250

3/4-16UNF X2-1/2 3/4-16UNF X2 3/4-NC 3-1/4 3/4-NC 2-1/4 3/4-NC 2-3/4

Grade 8

420

250

Grade 8

380

230

Grade 8

380

230

Grade 5

380

230

LUBRICANTS, FLUIDS AND CAPACITIES LOCATION

TYPE OF LUBRICANT

Hydraulic Oil Drive Sump (Gear Case) Multi-Purpose Grease

Texaco Rando HD68 Phillips 66 MM SAE 40 Oil Texaco Multifak EP-1

APPROXIMATE CAPACITY 77 Gallons 4 Gallons Each As Required

NOTES 1 2, 3 4

Notes: 1. With false bottom/ejector blade completely retracted.

2. 4 gallons of oil to completely fill dry system. Actual level should be checked after running unit to fill cooling system. Use dipsticks (one in each drive gear case) to check oil level.

3. Drain gear case and wheel end separately. Fill gear case only to proper level on dipstick.

4. Pump grease into fitting until old grease can be observed coming out of component.

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MAINTENANCE CHECK LIST ITEM OR LOCATION

INSPECT

ADJUST

CHANGE

LUBRICATE

EVERY THIRD SHIFT Grease Points Electrical Cables and Conduits; Hydraulic Hoses and Fittings; Reflectors Tires and Headlights; Warning Tags Hydraulic Oil Level Tape Switches

• • • •

A/R

ONCE PER WEEK Grease Points Center Section Pins and Nuts Fire Suppression System Hydraulic System Oil Filter Gear Cases and Planetary Wheel Ends Oil (First Week of Service) Battery Hold-down Latches Steering Cylinder pins and Nuts Contactor Tips Wheel Mounting Bolts (First Week of Service) Brake Cooling Fluid Filters Wheel End and Spindle Bolts (First Week of Service)

• • • •

A/R

• • • • • •

• •

ONCE PER MONTH Drive Motors Pump Motor Gear Case and Planetary Wheel End Oil Wheel Bolts

• • • •

EVERY THREE MONTHS Hydraulic System Pressure Steering Relief Pressure Battery Hold-down Relief Pressure Brake Cooling Relief Pressure Ejector/False Bottom Sequence Valve Hydraulic Oil Suction Filter Rear Wheel Bearings **

• • • • • • •

• • • • • • •

** For units not equipped with optional rear tractive assist.

A/R - Perform service as required.

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LUBRICATION CHART The following lubricants are recommended for use in the Un-A-Hauler®. Other lubricants with equivalent specifications may be used.

Hydraulic oil Heavy-duty, Multi-purpose Grease Drive Unit (Brake Cooling Circuit)

Texaco Rando HD68 Texaco Multifak EP 1 SAE 40 Oil (Texaco Regal Oil R & O 150)

NOTICE CLEAN ALL EXCESS OIL AND GREASE FROM THE UN-A-HAULER® AFTER COMPLETING MAINTENANCE PROCEDURES. The following points should be lubricated at the grease fittings with heavy-duty, multi-purpose grease.

EVERY THIRD SHIFT SYMBOL

• • • • • • • • • • • • •

LOCATION 1- Center section pivots 2- Steering cylinders (rod end) left and right 3- Steering cylinders (base end)left and right 4- Ball bearing center section 5- Foot pedal pivot bearings 6- Control handles & steering linkage 7- Ejector hose carrier 8- Battery change assembly 9- Articulation cylinders 10- Articulation pivot 11- Tail gate cylinders 12- Brake pedal 13- Battery change cylinders

NUMBER OF GREASE POINTS 4 2 2 9 2 13 2 8 4 2 4 1 4

ONCE PER MONTH SYMBOL

LOCATION 14. Battery hold-down latches (Optional) 15. Rear (payload) section hubs

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LUBRICATION CHART 14 14

•8 •8 • 13

Drive Motors Drive Gear Case

• 5-12

• 13 Planetary Wheel End

•6 •4 •1 Center Section

• 2-3 • 2-3 • 9-10 • 9-10

Hydraulic Oil Tank

Pump Motor

•7 15 15

• 11 • 11

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Revised 10 – 03 MODEL 800 SERIES UN-A-HAULER®

INSTALLATION, USE MAINTENANCE, AND REPAIR OF MINE POWER STORAGE BATTERIES

THIS GUIDE CONTAINS IMPORTANT OPERATION AND SAFETY INFORMATION AND SHOULD BE KEPT AVAILABLE TO THOSE PERSONNEL INSTALLING AND OPERATING THIS EQUIPMENT. P/N A6474X26 Revision 8, November / 03  DBT AMERICA INC. 2002 ALL RIGHTS RESERVED

DBT America Inc.

TABLE OF CONTENTS Page PREFACE ..................................................................................................................................................... 1 SYMBOLS AND SPECIAL NOTATIONS..................................................................................................... 3 MAJOR HAZARDS....................................................................................................................................... 5 SAFETY PRECAUTIONS AND GUIDELINES............................................................................................. 7 OVERVIEW ............................................................................................................................................... 7 MAINTENANCE ........................................................................................................................................ 7 CHAPTER 1 - INTRODUCTION ................................................................................................................... 8 SECTION I. GENERAL ................................................................................................................................... 8 SECTION II. DEFINITIONS ............................................................................................................................. 9 SECTION III. DESCRIPTION AND CONSTRUCTION ........................................................................................... 9 SECTION IV. PRINCIPLES OF OPERATION.................................................................................................... 12 CHAPTER 2 – INSTALLATION, USE, AND MAINTENANCE .................................................................. 15 SECTION I. PREPARATION FOR USE ............................................................................................................ 15 SECTION II. ROUTINE MAINTENANCE ........................................................................................................... 19 CHAPTER 3 – FIELD SERVICING AND REPAIR ..................................................................................... 23 SECTION I. TROUBLESHOOTING .................................................................................................................. 23 SECTION II. REPAIRING BATTERIES ............................................................................................................ 24 CHAPTER 4 – HEALTH AND SAFETY ..................................................................................................... 33 SECTION I. BATTERY HAZARDS ................................................................................................................... 33 SECTION II. SAFETY PROCEDURES ............................................................................................................. 33 CHAPTER 5 – STORAGE AND SHIPMEMT ............................................................................................. 37

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PREFACE This manual is intended to provide GENERAL product information for DBT mine power storage batteries.

The illustrations, descriptions and procedures contained in this publication apply only to DBT mine power storage batteries.

DBT America Inc. reserves the right to revise models and designs without prior notice.

This DBT mine power storage battery was manufactured under the guidelines, procedures and requirements of the U. S. Federal Coal Mine Health and Safety Act, Code of Federal Regulations, Title 30, Chapter 1, Subpart 0, Part 75 for underground coal mines, and other applicable non-U. S. regulatory agency standards.

At the completion of the manufacturing process, the battery was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of the battery, without the consent of DBT America Inc., and these regulatory agencies, or any repair or replacement of parts contrary to DBT America's instructions, may invalidate these approvals and render the battery unsafe to operate.

Strict compliance with all Federal and State Mining laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this battery.

While this manual attempts to anticipate the most important operations and maintenance needs for this battery, unforeseen circumstances may arise that have not been

addressed in this manual. If any concerns or questions arise, please contact your DBT America Service Representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is nontransferable. Distribution and access is limited only to authorized personnel.

Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

 DBT America Inc. 2001 All rights reserved.

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SYMBOLS AND SPECIAL NOTATIONS Throughout this manual there are specific notations that are either UPPERCASE BOLD, UNDERLINED or ITALICIZED for the primary purpose of emphasis. Please pay special attention to such statements as they regard safety or critical maintenance installation information.

You will also see the following:

NOTICE: THIS NOTATION DENOTES A REFERENCE TO PREVIOUSLY STATED INSTRUCTIONS.

IMPORTANT: THIS SYMBOL DENOTES THAT SPECIAL ATTENTION MUST BE ADHERED TO IN THE ATTACHED STATEMENT.

CAUTION: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A CUT, BRUISE OR ABRASION.

WARNING: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A LOST TIME ACCIDENT.

DANGER: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A SERIOUS INJURY OR FATALITY.

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DANGER ONLY TRAINED AUTHORIZED PERSONNEL SHOULD OPERATE OR PERFORM MAINTENANCE ON THE BATTERY. FAILURE TO ADHERE TO DANGERS, WARNINGS AND CAUTIONS, NOTED IN THIS MANUAL, COULD RESULT IN SERIOUS INJURY OR DEATH. FAILURE TO OPERATE OR MAINTAIN THIS BATTERY IN STRICT ADHERENCE TO THESE INSTRUCTIONS AND WARNINGS IN THIS MANUAL COULD VOID THE WARRANTY.

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MAJOR HAZARDS AREA WHERE HAZARD CAN OCCUR

HAZARD WHAT CAN HAPPEN IF PRECAUTIONS AND SAFEGUARDS ARE NOT OBEYED

SAFEGUARDS HOW TO AVOID THE HAZARD

ENTIRE BATTERY

Mine service batteries can weigh several thousand pounds and could cause severe injury or death should the battery fall on persons or body parts

Batteries must be resting securely in a machine, on battery tables, or platforms capable of supporting the weight while performing maintenance or service on battery.

ELECTRICAL

Electrical shock could cause death or serious injury. The battery produces lethal amounts of current whether connected to a machine or not.

Batteries should be maintained and serviced by qualified personnel.

The battery should be disconnected before servicing.

EXPLOSIVE GASES

Batteries produce explosive gases that could be ignited causing burns or explosions.

Batteries should be well vented before servicing, particularly if welding or burning on the battery.

Batteries should be maintained by qualified personnel.

CORROSIVE ACIDS

Batteries contain strong acid that could cause severe burns if spilled or splashed on body parts or in the eyes.

Protective clothing, gloves, and eyewear must be worn when working on batteries. Batteries should be maintained by qualified personnel.

COVERS

Battery covers could fall, crushing hands, arms, or fingers.

Battery covers must be secured with the cover supported when working under the covers.

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SAFETY PRECAUTIONS AND GUIDELINES OVERVIEW Before you install, maintain or repair a mine service battery READ and STUDY this guide. KNOW how to safely use the battery and what you must do for safe maintenance.

ALWAYS wear or use the proper safety items required for your personal protection.

If you have ANY QUESTIONS about the safe use or maintenance of this unit: ASK YOUR SUPERVISOR - NEVER GUESS - ALWAYS CHECK

MAINTENANCE AVOID, whenever possible, servicing, cleaning or examining the battery in congested areas.

ALWAYS replace damaged or lost decals or metal instruction plates. Refer to the Parts Manual for the proper location and part number of decals and plates.

DISCONNECT the battery when servicing or when welding on the battery.

BE SURE the battery area is well ventilated (clear of fumes) when it is necessary to connect battery charger. Fumes from the battery could ignite by a spark and explode.

It is important that any procedure not specifically recommended in this guide be thoroughly evaluated from the standpoint of safety before it is implemented.

Chapter 4 of this guide is dedicated to safety procedures that MUST be followed when using or servicing lead-acid batteries. It is important that you read and understand the procedures outlined in this guide, particularly those in Chapter 4.

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CHAPTER 1 - INTRODUCTION Section I. General 1-1. Scope This guide contains information concerning the theory, construction, installation, use, maintenance, repair, and hazards of lead-acid storage batteries used to power mine tractors, scoops, locomotives, and coal haulers.

1-2. Forms, Records and Reports The following form will be used by personnel responsible for the receipt, storage, operation, charging, and maintenance of lead-acid storage batteries. a. Monthly Storage Battery Record - The Monthly Storage Battery Record is to be used to record the services performed on motive power batteries. This record should be prepared and maintained by the using operator and should accompany the battery at all times. (See Figure 1 for a typical "Monthly Storage Battery Report" form.)

FIGURE 1 – MONTHLY STORAGE BATTERY RECORD

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Section II. Definitions 1-3. Standards Those definitions referenced throughout this manual generally agree with accepted industry standards.

For a more complete listing of "Definitions for Lead-Acid Industrial Storage Batteries" see NEMA Standards publication No. 1B 1-1971.

Copies of NEMA standards may be obtained at nominal cost by writing to: National Electrical Manufacturers Association, Department of Engineering and Safety Regulations, 2101 L Street, N.W. Washington, D.C. 20037.

Section III. Description and Construction 1-4. Battery Mine power lead-acid batteries for electric vehicles typically consist of of: (1) a steel tray into which the cells are assembled; (2) a battery terminal connector; and (3) other components necessary to secure and protect the cells and provide the necessary electrical interconnections. a. Battery Identification and Data - The essential information necessary for proper care of an industrial motive power battery appears on the battery, either stamped into one of the intercell connectors or on a name plate affixed to the tray. This information usually includes the manufacturer's name and model, number of plates per cell, battery capacity, battery voltage, serial number, suggested charging rate, and fully charged specific gravity of electrolyte.

If vital information is missing, or is no longer legible, such information can be obtained by contacting your nearest DBT AMERICA INC. representative.

Some manufacturers list, as a part of the model or type designation, the rated ampere-hour capacity of a single positive plate, such as "SS75". As an alternate means of determining rated battery capacity, this number should be multiplied by the total number of positive plates in one cell. To find the number of positive plates in a cell, subtract one from the total number of plates and divide by two. To find the capacity of a battery designated "SS75-19," therefore: 19 - 1 = 18; 18 divided by 2 = 9; 9 x 75 = 675 Ah battery capacity. b. Cell Arrangement - The individual cells, which contain the energy generating components of the battery, may be arranged slightly differently for various types of equipment. The cells of all motive power batteries are, however, always connected in series to produce the required voltage. Cell and battery capacity, which is the available ampere-hours or watt-hours, is a function of the total number and size of plates within each cell. Voltage, though, is the same for all cells regardless of size. Each lead-acid cell yields a nominal 2 volts. c. Connector Arrangement - Connections between cells are made by intercell connectors which may be lead-coated copper straps or be cast of solid lead. These connections are always welded, in proper sequence, by the application of heat to the terminals of the cells. Energy from the battery is drawn off by terminal cables which extend beyond the steel tray wall and are in turn permanently joined to the battery terminal connector.

1-5. Cell This is the basic unit of any battery. It is a galvanic cell which produces electrical energy when connected to an electrical load and, after being discharged, may be restored to its original fully charged condition. It has a nominal voltage of 2 volts and consists of an element, from which the energy is 9

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derived, and the electrolyte; both are contained by an impact resistant, molded plastic jar. The element is prevented from contacting the bottom of the jar by means of a high impact bridge, which consists of a series of support ribs. These ribs provide sediment space below the bottom of the element to accommodate particles of active material, shed by the positive plates during normal operation of the battery. (See Figure 2.)

FIGURE 2 – TYPICAL DBT AMERICA INC. CELL

Cover - With lead insert bushing prevents leakage and voltage to ground.

Vent Cap – Quarter turn bayonet type simplifies watering and inspection.

Post - Special alloy for increased strength and conductivity.

Separator Guard – White in color to increase visibility for fast electrolyte check.

Post Plate Strap - Extra heavy to insure a permanent connection between post and plates.

Negative Plate – Designed to compliment positive plate performance.

Positive Grid - A non-porous lead alloy casting, designed for maximum current carrying capacity, capable of many years of service.

Vertical Mat - Laminated construction compromised of uniformly spaced fine glass tape that imbed into the active material and an interwoven glass fiber mat wrapped vertically around the positive plate insuring optimum active material retention.

Horizontal Mat - Made of glass fibers with an insoluble binder.

Breaks up gas bubbles and increases positive plate insulation.

Active Material - Specially formulated and uniformly applied under rigid laboratory control to insure maximum efficiency throughout long battery life.

Retainer and Bottom Shield - A high porosity perforated envelop that encases positive plate and glass mats to prevent shorts and insure maximum performance and life.

Jar - Molded of high-impact material to remain leak free under rough treatment.

Separator - Deep channeled, microporous, impervious to heat, acid and corrosion: provides insulation between positive and negative plates while allowing the free flow of electrolyte throughout the cell.

Bridge - Provides firm element support and ample sediment space.

DBT America Inc. mine batteries incorporate every feature required by today’s mines. They are designed by engineering technology and built by master battery craftsmen according to strict quality control guidelines. DBT America Inc. batteries are the finest available to meet today’s mining requirements, and our precision construction provides new equipment performance throughout a long life.

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The top of each cell is fitted with a molded rubber plastic cover sealed to the jar at the edges. A vent or filler cap is located in the center of the cover. This vent permits the escape of hydrogen and oxygen while the cells are gassing and, when removed, provides an opening through which water may be added to the cell. The positive and negative terminal posts, which are part of the element, fit through openings in the cover. Prior to being connected together, cells are placed so that the positive terminal of one cell is adjacent to the negative terminal of the next. This arrangement permits a conveniently made series connection. a. Element - The element of the cell consists of one group each of positive and negative plates meshed together. The plates are insulated from each other by separators which are inserted between all plates. A plastic element protector is positioned on top of the separators. This prevents mechanical damage to the element and aids in preventing electrical shorts which occur when particles of active material bridge the space between plates. Terminal posts are welded to each group and are used to electrically connect one cell to another. b. Group - This is an assembly of plates of like polarity connected in parallel by welding to a common strap or busbar. A cell must contain one positive and one negative group. The negative group always has one more plate than the positive group. One or more terminal posts are welded to each. c. Plates - The plates (also called "electrodes") are either positive or negative and consist of a cast lead alloy grid and active material. The grid provides support to the active material and becomes the primary electrical conductor. The active materials result from the addition of chemicals to lead oxides which are converted, by electrochemical processing, to lead dioxide in the positive and to sponge lead in the negative.

(1) Pasted type - The grid of the pasted plate consists of horizontal and vertical or diagonal cast lead conducting members within a rectangular cast frame. A slurry of active material is pasted or squeezed into the voids, and the surfaces are then covered by porous glass and plastic retainers to prevent the loss of active material. d. Electrolyte - The element within the jar is immersed in an electrolyte, which is a solution of sulfuric acid and "pure" water. This permits the necessary chemical reaction to occur and provides a conducting medium in which the flow of electric current takes place. The electrolyte in a fully charged cell normally has a specific gravity of between 1.275 and 1.285 at 77 degrees F. As a cell discharges, the specific gravity decreases. Measurement of this specific gravity, by means of a hydrometer, indicates the state of charge of a cell. To save time in determining- this state of charge for the battery, a pilot cell or cells may be chosen; a pilot cell is a selected cell(s) whose condition is assumed to be representative of the condition of the entire battery. e. Separators - Separators are made from microporous plastic, which is resistant to heat and acid.

Separators provide mechanical and electrical insulation between positive and negative plates, but are porous enough to permit passage of electrolyte. The grooved or ribbed side of the separator is placed toward the positive plate to allow a free flow of electrolyte to the active material. The flat side faces the negative plate to contain the sponge lead. f. Positive Plate Retainers - Pasted type plate retainers are added, after pasting, typically by wrapping the plate first with fibrous-type glass tape or mats and then by a perforated plastic envelope complete with bottom boot or by other suitable filtering systems. All types of retainers act to prevent the escape of positive active material during normal use. Retainers are not needed on negative plates.

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Section IV. Principles of Operation 1-6. Fundamentals of Cycling A cycle is a discharge followed by a charge. During the charge, the electrical energy supplied by the charger causes an electromechanical reaction within the battery. This restores the active materials to a fully charged condition. a. The Fully Charged Cell or Battery - The positive and negative plates (electrodes) are separated from each other and immersed in electrolyte. In the fully charged condition, the active material of the positive plate is lead dioxide and that of the negative plate is sponge lead. The electrolyte is a solution of sulfuric acid and water that normally varies in a specific gravity from 1.275 to 1.285. The combination produces a voltage of approximately 2 volts on open circuit. This voltage potential results from the fundamental characteristic of a storage battery which dictates that when two electrodes of dissimilar metals are immersed in suitable electrolyte, and a circuit is closed between the two, electrons begin to flow. A fully charged cell should normally have an on-charge voltage of from 2.45 to 2.70 volts when charging at the finish rate. b. The Discharging Cell or Battery - While a battery is being discharged or used, lead dioxide and sponge lead combine with sulfuric acid to form lead sulfate within both plates. This action causes the specific gravity of the electrolyte to decrease. As the discharge progresses, individual cell and battery voltages decline, generally in direct proportion to the rate of discharge. c. The Discharged Cell or Battery - As the depth of discharge increases, more sulphuric acid is removed from the electrolyte so the specific gravity decreases and may drop below 1.100 as it approaches the specific gravity of water. Almost all of the active material of both positive and negative plates is converted to lead sulfate, and an effective electromechanical reaction is no longer possible.

At this point the battery has reached its discharge limit. d. The Charging Cell or Battery - The charging action begins when the terminals of the battery are connected to an external source of direct current. The electromechanical reaction is reversed and the positive plates, negative plates, and electrolyte start returning to their original charged condition.

Charging causes the battery voltage to rise as active materials are restored. A cell being charged may have a voltage of from 2.12 to 2.70 volts depending upon charging rate and time. e. General - Storage batteries do not actually store electrical energy; instead, they accept the electrical energy delivered to them during charging and convert it into chemical energy. During discharging, this chemical energy is reconverted into electrical energy to be used as needed.

To obtain the best performance and life from a mine power storage battery, it should usually be charged after each shift of use or whenever the specific gravity of the electrolyte falls below 1.240. It is very important that proper ventilation be provided during charging to make certain that (1) the hydrogen gas, given off toward the end of the charging process is dissipated (see Chapter 4), and (2) that individual cell electrolyte temperatures, during normal operations, do not exceed 110 degrees F. 1-7. Ampere-Hour Capacity The electrical capability of a storage battery is usually expressed in ampere-hours. The ampere-hour capacity is the number of ampere-hours which can be delivered under specified conditions of temperature, rate of discharge, and final voltage. Basically, ampere-hours are determined by multiplying the number of amperes which the battery will deliver by the number of hours during which the current is flowing. Total cell or battery capacity then is determined by the size and number of plates which make up the element. Due to the variety of job requirements, batteries are produced with many different sizes of cells.

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1-8. Voltage With reference specifically to storage batteries, many "voltage" conditions have been recognized. The most important of these are: a. Open Circuit Voltage - This is the voltage of a cell or battery at the terminals, when no current is flowing. The nominal open circuit voltage of an individual fully charged cell is 2 volts. This is true regardless of cell size. The voltage of a 64 cell lead-acid battery is stated, therefore, as 128 volts. b. Initial Voltage - The initial voltage of a cell or battery is the closed circuit voltage at the beginning of a discharge. It is usually taken after current has been flowing for a sufficient period of time for the rate of change of the voltage to become practically constant, usually a matter of minutes. c. Average Voltage - The average voltage of the cell or battery is the average value of the voltage during the period of charge or discharge. d. Final Voltage - The final or cut-off voltage of a cell or battery is the prescribed voltage at which the discharge is considered complete. It is usually chosen so that the useful capacity of the battery is realized without subjecting it to harmful overdischarging. Final voltage will vary with the rate of discharge, cell temperature, and the type of service, but for mine power applications it is considered to be 1.70 volts per cell.

Inital voltage, average voltage, and final voltage are monitored when conducting test discharges.

1-9. Rated Capacity The rated capacity of a storage battery is the number of ampere-hours or watt-hours which it is capable of delivering when fully charged and under specified conditions of temperature, rate of discharge, final voltage, and specific gravity. United States industry standards for mine power batteries always specify this to be at the 6 hour rate of discharge. The total capacity available from a battery is greatest at low rates of discharge over a long period of time. Discharging at high current rates reduces the total ampere-hours available.

1-10. Sulfation Sulfation occurs when conditions within the cell cause sufficient accumulation of abnormal lead sulfate at both the positive and negative plates, permanently affecting the normal chemical reactions. Habitual overdischarging below final voltage, prolonged operation in an undercharged condition, and extended stand periods while in a discharged state are major causes of sulfation. A servicing schedule should be followed to provide frequent monitoring and adequate charging. See Chapter 3, Section 1, for methods of restoring a sulfated battery.

1-11. Operating Cycle An operating cycle of a storage battery is the discharge during use and subsequent charge to restore its initial condition.

1-12. Service Life The service life of a storage battery is the period during which it provides useful power while being discharged. It is usually expressed as the time period, or number of cycles, which elapses before the ampere-hour capacity falls below 80% of its rated value. To obtain maximum service life, it is recommended that a battery be restricted to one full cycle per 24 hour day or fewer than 300 cycles per year. Other factors which most often adversely influence service life are: 1. Abnormally high or low electrolyte temperatures.

2. Frequent overdischarging.

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3. Failure to add water regularly.

4. Frequent overcharging.

5. Poor, or high, resistance, connections or contacts.

6. Adding too much water.

1-13. Effect of Temperature The normal operating characteristics of a storage battery are modified by unusually low or high cell temperatures. a. Low Temperature - Available battery power is reduced by low temperature because electrolyte viscosity and resistance is increased and diffusion throughout the pores of the active material is retarded. For example, a fully charged battery (1.275 to 1.285 specific gravity at 77 degrees F.), when its electrolyte temperature is about 32 degrees F., will deliver only 75% of the capacity which would be available at normal room temperature. This drops to 40% at 0 degrees F. The electrolyte could freeze if a discharged battery were exposed to very cold temperatures for several hours. (See Table 1 for freezing points of various electrolyte concentrations.)

In addition to the discharge-related problems, the charge acceptance of a lead-acid battery is impaired when electrolyte temperatures drop below 60 degrees F. As a result, batteries should always be kept fully charged, especially in cold weather. They should be heated, even during operation or storage, if exposure is severe enough to cause the temperature of the electrolyte to approach 32 degrees F. b. High Temperatures - Although high temperatures (up to 110 degrees F.) do not cause a reduction in available capacity, battery operation is adversely affected. Because most chemical reactions are accelerated at high temperatures, the rate of corrosion of the positive grid is increased and the active material is shed more rapidly. Even electrolyte temperatures above 90 degrees F. will cause some reduction in service life and should be avoided whenever possible. Cell temperatures should never be allowed to exceed 110 degrees F.

TABLE 1 FREEZING POINTS OF VARIOUS ELECTROLYTE CONCENTRATIONS State of Charge-Approximate (Percent)

Specific Gravity

Freezing Point (Degrees Fahrenheit)

100 75 50 25 10

1.280 1.250 1.220 1.160 1.130

-95 -62 -31 +1 +10

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CHAPTER 2 – INSTALLATION, USE, AND MAINTENANCE Section I. Preparation for Use 2-1. Establishing Requirements The number of batteries required for service depends primarily upon the number of 8-hour shifts in effect. Normally, for operation on a single-shift basis, the minimum number of batteries required will be the same as the number of items of operating equipment and the batteries need not be removed from the unit for charging. For operation on a 2- or 3-shift basis, the minimum number of batteries required will be twice the number of items of operating equipment and it will, therefore, be necessary to exchange discharged batteries for charged batteries at the end of each work shift. Whenever possible, it is recommended that more than the minimum number of batteries be available for multiple-shift operation, providing at least an 8-hour cooling period after charging. In an emergency, any one battery can be used for two 8-hour shifts during a 24-hour period, but this procedure, repeated regularly, will probably cause high electrolyte temperatures and could seriously affect service life. Therefore, where 3-shift operation is normal, 3 batteries will be required per item of equipment.

2-2. Unpacking Upon Receipt 1. It is important first to examine the exterior of the packing for wet spots on bottom or sides which may indicate leaking jars. Inspect also for physical damage to battery package because the battery could be affected as well. Report any damage to your supervisor.

2. Make certain that the package is right side up, with skid mounts resting firmly on floor.

3. Use a forklift truck or crane of sufficient capacity to remove the packaged battery from the truck or freight car. If a crane is employed, be sure the sling is secured against the bottom of the skid and not around the skid mounts.

LIFTING DEVICES USED TO MOVE BATTERIES MUST BE CAPABLE OF CARRYING THE WEIGHT STAMPED ON THE BATTERY CASE. KEEP ALL PERSONS AND BODY PARTS FROM UNDER THE BATTERIES WHEN THEY ARE LIFTED. 4. Move the crated battery to the uncrating area and remove packaging, including any wrapping or other protection provided to the battery terminal cable connectors.

5. Inspect battery and report any damage to your supervisor.

6. Use a properly insulated lifting beam of adequate capacity to lift the battery, by means of an overhead hoist, from the battery skid.

2-3. Handling Batteries When lifting batteries, always use a device which exerts a vertical pull on the lifting eye or tab. If a chain must be used, it should be in combination with a lifting beam with provision for adjusting lifting hook centers to the exact length of the tray. Any method of lifting which tends to "squeeze" or "stretch" the battery tray may distort it and could damage jars or disturb cell seals. A piece of rubber sheet or other insulating material, temporarily laid on the battery while lifting, will prevent any possible short circuits from chains or hooks. As an additional precaution against accidental shorting, the lifting beam hooks should be electrically insulated from each other.

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2-4. Preparing Batteries for Use a. See Table 2 for proportions of sulfuric acid and water to make electrolyte.

TABLE 2 Note: Sulfuric Acid of 1.400 Specific Gravity Specific Gravity Required

Parts Water Required

1.375 1.365 1.355 1.350 1.340 1.330 1.325 1.315 1.310 1.300 1.290 1.285 1.280 1.275 1.270 1.260 1.255 1.250 1.245 1.240 1.230 1.225 1.220 1.215 1.210 1.205 1.200

.075 .11 .14 .16 .20 .24 .27 .31 .33 .38 .43 .46 .49 .53 .56 .63 .67 .70 .74 .78 .85 .905 .96 1.00 1.05 1.11 1.16

Parts Acid Required 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

b. Charged and Wet Batteries - Charged and wet batteries are shipped with cells filled and fully charged. Prepare these batteries for use as follows:

PROPER EYE AND BODY PROTECTION MUST BE WORN AT ALL TIMES WHEN SERVICING THE BATTERIES TO PREVENT ELECTRICAL SHOCK AND CONTACT WITH THE BATTERY ACID. CLEAN AND NEUTRALIZE ANY ACID SPILLS IMMEDIATELY. 1. Examine battery to see if electrolyte has been accidentally spilled. If so, clean and neutralize any spillage with a cloth that has been dipped in a soda solution. Rinse area with clear water.

2. Remove vent caps and check the electrolyte level in each cell. Take and record the specific gravity reading, electrolyte temperature, and individual open circuit voltage of each cell. Note any irregularities.

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3. Check to make sure that all cells are properly connected and that terminal connections are tight. If there are irregularities in the electrolyte levels or specific gravity readings, or if the battery has been in storage for more than 30 days, it should be given a freshening charge (see Paragraph 2-10d).

4. Recheck electrolyte levels after charging and after gassing has stopped. Again take and record specific gravity readings and electrolyte temperatures. If irregularities in electrolyte specific gravity readings still exist, they should be adjusted as described in Paragraph 3-12.

2-5. General Economical and dependable performance from a storage battery depends, to a great extent, upon proper charging. Faulty charging causes a decrease in battery service life and dissatisfaction with its performance. The selection of suitable charging equipment and methods is as important as the application of the correct battery. A mine battery installation is completely satisfactory only when the unit, battery, and charger operate as a smoothly functioning team. This text on chargers is for general information and guidance only. If specific data is required on a particular type of charger, contact the nearest sales representative.

When preparing a battery to be charged, make certain that all points of contact between the charger and the battery are clean to assure good conductivity. Also make certain that the positive terminal of the battery is connected to the positive terminal of the charger and, correspondingly, negative of battery to negative of charger.

PERMANENT DAMAGE TO THE BATTERY OR CHARGER MAY RESULT IF THE BATTERY IS CONNECTED INCORRECTLY. 2-6. Charging Principles Charging, as applied to a storage battery, is the conversion of electrical energy into chemical energy within the cell or battery. This restores the active materials and is accomplished by maintaining a unidirectional current to the battery in the opposite direction to that during discharge. When a cell or battery is said to be charged it is understood to mean fully charged. The type of battery, service condition, time available for charging, and the variation in battery voltages will strongly influence which charging method is best for a particular situation. Normally lead-acid batteries are recharged in 8 hours following a full discharge. However, they can be recharged within other time periods when desirable. A deeply discharged battery will absorb high current rates when the voltage is low. As the charge progresses, the voltage steadily increases until it reaches gassing voltage, approximately 2.37 volts per cell at 77 degrees F. At this point, battery chargers normally reduce charging rates automatically and taper to finishing rates which are used to complete the charge. The battery is fully charged when nearly all of the active material has been converted and when the specific gravity of the electrolyte and cell voltage have reached their maximum or constant values (corrected for temperature), as indicated by similar readings over a two or three hour period.

Batteries used in mine power applications are cycled - they are either being charged or discharged. In most circumstances, batteries are charged after each shift of use, so they are cycled many times during their lifetime. Incorrect charging for only a few cycles will do little harm, but if repeated day after day, the battery's service life will be seriously shortened.

2-7. Charging Rates Proper charging means charging the battery sufficiently without overcharging, overheating, or excessive gassing. The charge is usually started at high amperage which is known as the starting rate.

Later during the charge, this rate of current flow is reduced to what is called the finishing rate. It is 17

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suggested that this finishing rate should not exceed 5 amperes per 100 ampere-hours of rated battery capacity. The starting rate may be as much as four to five times higher than the finishing rate.

Lead-acid batteries should be charged for a sufficient length of time and at a rate which will put back into the battery the same number of ampere-hours removed on discharge, plus approximately 10% additional which is an acceptable, and in fact desirable, overcharge. The specific amount of overcharge depends upon the temperature, age, and history of the battery. In general, it is more harmful to excessively overcharge an older battery, or one which is operating at high temperature, than a new battery or one operating consistently at room temperature. Any charge rate is permissible which does not produce excessive gassing or cell temperatures greater than 110 degrees F. 2-8. Control of Gassing Gassing is the evolution of gases from one or more of the electrodes during electrolysis. It is a natural phenomenon which takes place when a battery on charge can no longer accept all of the current being applied to it. Gassing is evidenced by bubbling of the electrolyte. The gases liberated are oxygen (evolved at the positive plates) and hydrogen (evolved at the negatives).

The point at which significant gassing begins is determined by voltage, but the amount of gas depends upon the portion of the charging current that is not being absorbed by the battery. Normally, noticeable gassing will begin when the voltage exceeds 2.30 volts per cell. At 2.40 volts per cell, gassing will be normal; at 2.50, it will be rapid. The amperage at which gassing becomes excessive depends primarily upon the state of charge and electrolyte temperatures. As the battery approaches full charge, it is necessary to reduce the charging rate to a point at which excessive gassing is prevented. This safe rate is the finishing rate or below. When proper charging equipment is used, the tapering of the charging current to the finishing rate is achieved automatically.

2-9. Charging Methods and Equipment The modern storage battery, used with a properly designed, modern, automatic charger, needs only normal water additions, occasional cleaning, and regular checking of both charger adjustment and battery condition to provide long, dependable service.

There are two recommended methods for the normal charging of motive power batteries: a. Modified Constant Voltage (potential) Method - The modified constant voltage method, in which the tapering of the charging rate is accomplished gradually, requires a source of direct current with a constant bus voltage of approximately 2.63 volts for each cell. This is for an 8-hour charge. Proper series resistance in the output circuit inherently provides the correct starting rate and assures that the rate will automatically be reduced, as the charge progresses, to the recommended finish rate. The constant voltage source may be either a motor-driven generator or rectifier. b. Taper Method - The taper method can be used with either generator or rectifier type equipment. The charger is designed to provide the correct charge rate during a constantly tapering charge. This is accomplished by coordinating the rising battery voltage with the design characteristics of the charger.

The shape of the current-taper curve will vary with different types of equipment, but the result is essentially the same. Solid state chargers are available which deliver as much current as the battery can accept, up to maximum charger output, and then taper the input sharply, when cells begin to gas, to keep finish rates low. These chargers do not require adjustment.

2-10. Types of Charge a. Normal Charge - The two generally recommended types of normal or routine charges, following a deep discharge, are: (1) modified constant voltage charge, and (2) taper charge.

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b. Boost Charge (Quick Charge) - A boost charge of a storage battery is a partial charge, usuallly at a high rate for a short period. Such a charge is given in an emergency when it is believed that the amperehour capacity of the battery may be less than normal and insufficient to complete a planned period of work. A boost charge may also be used when it is not possible to give a battery one of the recommended types of normal charge. c. Equalizing Charge - An equalizing charge of a storage battery is a prolonged charge, usually at the finishing rate or less, to correct any inequalities of voltage or specific gravity which may have developed between cells during service. It consists of following a normal charge with an extended charge of 4 hours at a rate no higher than the finishing rate. In mine power applications, a battery should receive an equalizing charge weekly. d. Freshening Charge - A freshening charge of a storage battery is a charge given to batteries in storage or during inactive periods to replace losses due to self-discharge and to assure that every cell is periodically brought to a fully charged state.

2-11. Charging Precautions 1. When connecting the battery to the charger always connect positive (+) to positive and negative (-) to negative terminals.

2. Always recharge the battery as soon as possible after discharging.

3. Keep vent caps tightly in place while the battery is being charged, except when servicing the cell or when taking specific gravity or temperature readings.

4. Make sure that battery and charger voltages and ampere-hour ratings match when preparing to charge batteries.

5. Make certain that charging area is well ventilated.

6. Prohibit smoking and open flames in charging area.

7. Do not allow tools or other metal objects to contact intercell connectors.

8. Observe safety and health practices defined in Chapter 4, Section 11. It is especially important, while preparing for charging, to take the following precautions: (1) Wear protective gear provided and know the location of fresh water for emergency purposes.

(2) Use proper mechanical equipment to move or lift batteries.

(3) Provide acceptable fire extinguishing equipment.

Section II. Routine Maintenance 2-12. General The modern industrial battery is designed and built to give an average of 1500 cycles of charge and discharge during its life, depending upon the application and the operating environment. The exact length of the service life will depend, to a great extent, upon the care the battery receives. The following maintenance procedures, carried out at the proper time, will do much to prolong the life of the battery and provide efficient, satisfactory service.

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PROPER PROTECTIVE CLOTHING AND EQUIPMENT MUST BE USED WHEN SERVICING BATTERIES TO PROTECT AGAINST ELECTRICAL SHOCK AND BATTERY ACID. BATTERIES, CHARGERS AND RELATED ELECTRICAL EQUIPMENT SHOULD ONLY BE SERVICED BY QUALIFIED, PROPERLY TRAINED PERSONNEL. 2-13. Charger Adjustment Make sure that the charger adjustment, for control of charging rates and cut-off, are correct. This will ensure that the batteries are properly charged with no excessive overcharge. Batteries that are overcharged regularly will need water more often, and cell temperatures usually will be higher than normal. If either condition is evident, adjust the charge rate downward, in those chargers which have provision for adjustment, so it is between a normal finish rate and one-half normal finish rate.

2-14. Cleaning a Battery Inspect the battery at least once each month to make certain the terminal connections are tight.

Remove dirt or electrolyte accumulation from the tops of the cells. Wash weekly with clean water. Using a solution of baking soda and water (one pound of baking soda to one gallon of water), neutralize any acid which may be collected at cell or battery terminals to keep them free from corrosion.

Use the solution until all fizzing stops. Work the solution under the connectors. To remove all traces of soda solution and loose dirt, rinse the battery down with clear water from a low pressure hose.

Whenever the battery top is being cleaned or rinsed, vent caps must be tightly in place.

2-15. Adding Water A certain amount of water loss in cells is normal and it should be replaced with "pure" tap water or distilled water. In some geographical areas, tap water may contain chemicals or other impurities harmful to batteries. The NEMA recommendation for battery replacement water lists the following maximum allowable impurities (parts per million): Total Solids Chlorides as CI Nitrates as NO 3 Iron as Fe

350 PPM 25 PPM 10 PPM 4 PPM

DBT AMERICA INC. PROVIDES WATER ANALYSIS SERVICE. A MINIMUM OF ONE QUART IS REQUIRED. CONSULT YOUR SALES REPRESENTATIVE. Check the height of the electrolyte at least weekly and if water is needed, add just enough to bring the electrolyte to proper level. Do not overfill. Batteries should be watered only when discharged and only cover plastic plate with holes - never any higher.

Add water often enough to prevent the electrolyte level from dropping below the perforated separator protector. Ideally, a watering schedule should be established. This schedule should assure adequate watering while taking into consideration those factors which control water consumption, such as (1) frequency of charging, (2) water storage capacity of the specific cell type, and (3) age and condition of the battery.

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2-16. Taking Hydrometer Readings 1. With the tip of the hydrometer immersed in the electrolyte, squeeze the syringe bulb and then slowly release it, drawing into the cylinder or barrel just enough electrolyte to permit the hydrometer float to ride free. The float stem must not touch the side of the cylinder nor the top of the syringe. If the float stem touches the upper area of the syringe, too much electrolyte has been drawn up; if the float still rests on the bottom, too little electrolyte has been drawn up. (See Figure 3.)

2. Read the hydrometer float scale with your eye at the same level as the electrolyte. The reading should be taken at the surface of the liquid, disregarding any slight curvature. This reading will be the specific gravity uncorrected for temperature. (See Table 3 for correction factors.)

3. Return all electrolyte to cell.

2-17. Record Keeping Facilities with more than just a few batteries will find that records of battery cycles, maintenance, and repair are indispensable for an effective battery maintenance program. In addition to those monthly records which require the posting of data each time a battery is charged, the following procedure will be helpful: 1. Establish a battery identification system giving each battery a code number. A multiple-digit system is suggested.

2. Record specific gravity of the pilot cell or cells before and after each charge. Pilot cells should be selected from those nearest the center of the battery and identified by differently colored vent caps.

They should be representative of the balance of the cells in the battery.

3. Record the number of cycles on a cumulative basis plus maintenance and repair information. Note any irregularities. The use of a "Battery Cycle and Maintenance Record" form is recommended. If variations in specific gravity readings exceed 20 points (.020) and on-charge voltage, after an equalizing charge, varies by more than .15 volts, contact your DBT AMERICA INC. service representative.

4. When the battery is new, and on at least an annual basis thereafter, read and record the specific gravity and open circuit voltage for all cells of the battery.

FIGURE 3 – TAKING HYDROMETER READINGS

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TABLE 3 SPECIFIC GRAVITY TEMPERATURE CORRECTION CHART Electrolyte Temperature (Degrees Centigrade)

Electrolyte Temperature (Degrees Fahrenheit)

Point Correction

110 107 104 101 98 95 92 89 86 83 80 77 74 71 68 65 62 59 56 53 50 47 44 41 38 35 32

230 221 218 212 209 203 198 194 185 180 176 171 167 158 152 149 140 135 131 128 122 118 113 104 99 95 86

+11 +10 +9 +8 +7 +6 +5 +4 +3 +2 +1 No Correction -1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15

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CHAPTER 3 – FIELD SERVICING AND REPAIR Section I. Troubleshooting 3-1. General In addition to the required routine maintenance described in Chapter 2, Section III, storage batteries may, at some time during their service life, require more extensive or unusual care. Such care should be given as soon as it has been determined that a problem exists or that trouble may be developing. This section deals with the means of identifying existing or impending problems and offers possible solutions.

The Troubleshooting Chart, Table 4, defines the most common problems which could occur during a battery's lifetime. If the suggested operational remedies are ineffective, it may be assumed that there is an internal problem and it will be necessary to disassemble the cell or cells to inspect the elements and sediment well. If the cause of the problem can only be corrected by completely replacing cells or the battery, this information should be reported to the person in authority.

3-2. Restoring a Sulfated Battery Continued undercharging a battery, even to a small degree, leads to excessive "sulfation." The same is true of batteries which have been left standing in an uncharged state for an extended period. High temperatures rapidly accelerate sulfation when batteries are left standing in a partially charged condition.

The cells of a sulfated battery will give low specific gravity and voltage readings. The battery will not become fully charged after a single normal charging when sulfation has taken place over a prolonged period.

If the sulfation has not progressed too far, it may be possible to restore the battery to a serviceable condition by using the following special procedures: 1. Thoroughly clean the battery. (See Paragraph 2-14.)

2. Bring the electrolyte level up to a point which is just visible over the separator-protector by adding approved water.

3. Put the battery on charge at the prescribed finishing rate until the rated ampere-hour capacity has been returned to the battery. Record the voltage and specific gravity readings. Correct the specific gravity readings for temperature by using Table 3. If the temperature at any time during these procedures exceeds 110 degrees F., stop the charge and allow the battery to cool to 90 degrees F. or below before continuing. Charge the battery until the specific gravity shows no change during a 4 hour period while taking hourly readings. With automatic charging equipment, the battery may have to be placed on equalizing charge two or three times. If a battery is badly sulfated, the specific gravity may rise only 30 to 40 points (.030 to .040) during the first charge.

4. Place the battery into service and discharge it to a fully discharged condition.

5. Charge the battery again until the specific gravity shows no change during a 4 hour period.

6. Repeat the cycling process until the specific gravity rises to within 30 points of a normal fully charged battery, then place the battery back in routine service. Even though specific gravities may be lower than normal, they should not vary much from cell to cell. If they do, problems other than sulfation may be present. If the spread between the highest and the lowest gravity reading is 50 points or more, refer to the Troubleshooting Chart for help in identifying the problem. If the battery still has not responded to treatment, it should be replaced.

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3-3. Correcting Excessive Self-Discharge While a storage battery is in a charged state, a local electrochemical reaction takes place within the cells, which causes very gradual discharging. This reaction is known as self-discharge. A small amount is quite normal in mine power batteries where grids are made from antimonial lead. The rate of selfdischarge is temperature-related and increases significantly as temperatures rise. Table 4 shows the relationship between temperature and loss of specific gravity. The normal rate at 77 degrees F. to 80 degrees F. is a loss in specific gravity of about one point (.001) per day. This becomes of concern only when a wet battery is to be stored for weeks at a time. It can be ignored as a factor in normal battery operation.

It is possible, however, particularly during the latter stages of a battery's life, for the rate of discharge to become much greater and even limit the battery's duty cycle. Excessive self-discharge may be caused by defective separators or plates which have become shorted at the edges. Edge shorting is usually caused by loss of positive active material which can fill the sediment well or build up on the top or sides of the plates and eventually bridge the space between the positives and negatives. If a shorted condition seems likely, the element should be pulled for examination and the defective separator replaced, shorts cleared, or cells replaced. Usually, if the sediment well is full, salvage is impractical.

3-4. Test Discharge A capacity test is sometimes desirable to determine a battery's actual discharge capability as compared to its 6-hour rated capacity.

This can be a significant diagnostic tool when equipment does not operate as expected and it can help determine when the battery should be replaced. When a battery consistently delivers less than 80% of its rated ampere-hour capacity, either some cells are substandard or the battery has reached the end of its useful life and should be replaced.

A test discharge is performed by discharging a fully charged battery at a fixed rate under carefully controlled test conditions.

Section II. Repairing Batteries 3-5. General Storage batteries which have been damaged or which contain defective cells may, if the rebuilding cost and time are justified, be restored to a serviceable condition.

It is important to check a battery thoroughly if it has been involved in an accident or if it is believed to be defective. A neglected battery will continue to deteriorate even when not in use. Usually rebuilding is justified if the majority of the cells are in good condition.

This section explains how to remove cells from a battery and how to repair them if they are to be salvaged. Some special tools and parts will be required, depending upon the work to be done.

Reference will be made to the use of such special devices but they will not be further identified in this manual. Each manufacturer identifies all tools, accessories, and replacement parts by an appropriate part number. Use this number when making reference to them.

3-6. Purging of Gas Before starting any repairs, remove all vent caps from cells to be repaired as well as from all surrounding cells. The space above the electrolyte must be cleared of hydrogen gas before proceeding with repairs. Introduce a low volume air stream (volume and force equal to that produced by fanning 24

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each cell with a stiff piece of cardboard or other suitable nonconducting material) into each cell for at least 30 seconds. Be very careful when using air so that the electrolyte is not splashed out of the cell. Do not blow breath into cells. Wear protective face shield or goggles, rubber gloves, and apron. After cells have been purged, cover all vent openings with several layers of water-dampened cloth before starting repairs.

3-7. Removing lntercell Connectors Special intercell connector drills are designed to cut the bond between the cell post and the connector while permitting the post to remain for later rebuilding. The drills come in different sizes. When using them, be careful to cut only as deep as necessary, usually 1/4" to 3/8". Make certain vent plugs are in place. During drilling, try to center on the cover bushing and make sure any lead curl produced does not short across other connectors. After drilling, the intercell connectors can be lifted off with a pair of pliers.

3-8. Removing a Complete Cell After removing connectors as described in Paragraph 3-7, isolate the cell from adjacent cells. This may require cutting of compound or removal of spacers. Use a long spatula or similar tool to free the cell from top to bottom. When the jar walls are free, the cell can be lifted from the battery tray. All cells are heavy so a suitable lifting device, such as an electric hoist, is recommended. Threaded post clamps or cell pullers are available which can be burned or clamped to the posts, and used to pull the cell. Use a non-conducting bar between the loops of the post clamps and hook the hoist to this bar.

After removing the cell, neutralize any acid in the tray with a soda solution and clean up the residue.

When a cell or element is being pulled, it is advisable to have on hand both a replacement jar and a cover in the event that either of the original parts are damaged in the process.

If a wet and charged cell has been pulled and allowed to stand unsupported, the jar walls may bulge and permit the electrolyte level to drop. Do not attempt to adjust electrolyte levels until cells have been reinstalled in the battery.

TABLE 4 TEMPERATURE EFFECT ON BATTERY SELF-DISCHARGE Temperature (Degrees Fahrenheit)

Loss of Specific Gravity Per Day

120 100 80 50

.004 .003 .001 .0005

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TABLE 5 STORAGE BATTERY TROUBLESHOOTING CHART SYMPTOMS

PROBABLE CAUSE

POSSIBLE REMEDY

BATTERY OVERHEATS DURING CHARGE

1. Malfunctioning charging equipment.

1. Replace or repair defective charger parts (timer, voltage sensitive relay, control board, etc.)

2. Charging equipment out of adjustment.

2. Adjust start or finish charging rates.

3. Defective or weak cell(s).

3. Replace or repair problem cell(s).

4. Battery worn out and beyond economical repair.

4. Replace battery.

5. High resistance connection within battery.

5. Check for hot wires, cells, intercell connectors, charging plugs, etc. Repair or replace defective component(s).

6. Low electrolyte level.

6. Add water; Just cover separator protector when discharged.

7.Battery charged in the vehicle with battery compartment closed or the tray cover closed.

7. Open the compartment during charge or charge the battery out of the unit with the tray cover opened.

8. Battery over 100 degrees F. when placed on charge.

8. Allow battery to cool below 90 degrees F. before charging.

1. See causes 3 through 8 above.

1. See remedies 3 through 8 above.

2. Worn out bearings, brakes dragging, or other vehicle problem causing high current draw.

2. Repair or replace defective unit problems.

3. Over discharge of battery.

3. a. Require drivers to return battery for recharge when vehicle begins to slow down.

BATTERY OVERHEATS DURING DISCHARGE

b. Put more batteries into service.

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TABLE 5 (Continued) STORAGE BATTERY TROUBLESHOOTING CHART SYMPTOMS

PROBABLE CAUSE

POSSIBLE REMEDY

BATTERY NOT COMPLETING FULL WORK SHIFT

1. Battery not fully charged before placed into operation.

1. See that battery has reached full charge specific gravity before placing into operation.

2. Weak, leaking, or defective cell(s) in battery.

2. Repair or replace cell(s) or battery.

3. Grounds or shorts in the battery.

3. Remove grounds or shorts.

4. Battery worn out and beyond economical repair.

4. Replace battery with equal or higher capacity battery.

5. Battery too small for job.

5. a. Replace battery with one having higher capacity. b. Purchase extra batteries (with higher capacity if possible) and change them more frequently.

LOW ELECTROLYTE

6. Electrical or mechanical problem.

6. Troubleshoot vehicle and repair.

1. Cracked or broken jar(s).

1. Replace jar(s) and adjust gravity.

2. Cell missed when watered.

2. More careful attention when watering.

3. Defective or weak cell(s).

3. Repair or replace cell(s)

4. Frequent overcharge.

4. See items 1 and 2 in “Battery Overheats During Charge.”

5. Battery not regularly watered.

5. Water battery regularly.

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TABLE 5 (Continued) STORAGE BATTERY TROUBLESHOOTING CHART SYMPTOMS

PROBABLE CAUSE

POSSIBLE REMEDY

UNEQUAL CELL VOLTAGES

1. Grounds in battery.

1. Clean battery.

2. There is a “tap” off the battery for auxiliary equipment (radio, light, etc.)

2. a. Use dropping resistor instead of tap. b. Equalize battery regularly.

3. Battery sluggish due to lack of work.

3. Give battery a deep discharge and equalizing charge.

4. Leaking cell or cover.

4. Replace jar or cover and adjust gravity.

5. Defective or weak cell(s).

5. Repair or replace defective cell(s)

6. Battery worn out beyond economical repair.

6. Replace the battery.

7. Acid loss in few cells by tipping battery over.

7. Adjust specific gravity.

3-9. Removing an Element If the jar is known to be serviceable, it may not be necessary to remove the complete cell. Usually only the element, complete with cover, has to be pulled. This can only be done, however, on those batteries containing a compound type cover-to-jar seal. On these, after removing connectors, draw a warm putty knife through the sealing compound close to the inside jar wall. Use a threaded post clamp or cell puller and hoist to raise the element, with cover in place, first to drain position, and then up and out of the jar.

When pulling an element from a cell which has been removed from a battery, use jar hold-down clamps.

Some batteries are furnished with permanent seals between the cover and jar. With these, if a defect occurs, the complete cell must be pulled and cover-to-jar seal cut or sawed to permit removal of the element. In doing so, both jar and cover must be replaced and resealed in accordance with the correct instructions.

When removing an element, lift it halfway out of the jar and hold it at this position until most of the electrolyte has drained off. Then raise the element to clear the top of the jar. Do not, unless absolutely necessary, expose an element to air longer than five minutes. Oxygen in the air combines with the active material in the negative plates, causing them to oxidize and heat. If the exposure persists, negatives will discharge. While the element is out of the jar, check the sediment well in the bottom of the jar. If it is full of shed material, the cell probably will have to be replaced.

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Plate and separator edges may be inspected while the element is suspended above the jar. A more thorough inspection of separators, plate insulation, grids, and active materials may be indicated. If so, lay the element on its side on a clean non-metallic surface. The plates should be at right angles to the table surface so the element can be fanned slightly to permit the removal of separators. Always on negative side.

When reinstalling separators, make certain that the flat side of the separator is against the negative plate and the ribbed side is facing the positive. They should be pushed up until they are flush with the bottom of the element and they should project equally on each side of the plates.

Before installing an element in a previously used jar, wash out any sediment which may have accumulated in the bottom of the jar and clean all compound from around the inside of the top edge.

Clamp the element, if necessary, when reinstalling it in the jar. Make certain that the element is entering the jar properly and that the plates are at right angles to the plate support ribs in the bottom.

When installing an element with a cell cover attached, use a putty knife to guide the lip of the cover past the top edges of the jar.

3-10. Replacing Cell in Battery Cells from which the elements were pulled, or which had damaged jars replaced, should be given an equalizing charge and acid should be adjusted immediately followinging repair before they are returned to service. (See Paragraphs 2-10c and 3-12.)

Before lowering a cell into a battery tray, be sure that it is correctly positioned relative to adjoining cells to which it is to be connected. Cells must be connected in series with the positive side of one cell connected to the negative side of the adjacent cell.

When the problem has been corrected and the cell is returned to the battery tray, the cover must be resealed to the jar. With the exception of those cells which contain a permanent jar-to-cover seal, a special asphalt type sealing compound is used for this purpose. Heat the compound until it melts, but do not let the temperature get above 400°F. Pack any large openings between cover lip and jar wall with cold compound and then pour the hot compound into the sealing groove in two steps. First pour the groove full and soft flame with a torch to improve the adhesion; then fill and flame again. Allow compound to cool and trim excess.

After sealing, pressure test cells for 10 seconds at a maximum of 1.5 psi and reinstall intercell connectors by welding or "burning" them to the terminal posts. A small hot flame is recommended such as is available from a standard commercial burning torch using natural gas and oxygen or propane and oxygen. Carbon burning outfits are also acceptable.

ALWAYS BE SURE THE CELLS ARE PURGED OF GAS, AS EXPLAINED IN PARAGRAPH 3-6, BEFORE USING AN OPEN FLAME OR BURNING ARC ON TOP OF THE BATTERY. 3-11. Replacing a Cell Cover The specific methods used to seal cell covers to both the jar and the terminal posts are as follows: a. Sealing Compound and Lead Bushing Design - Probably the most commonly used system, an asphalt type compound is applied to seal the cover to both rubber and plastic jars. Lead bushings, molded into the cover as inserts, are welded or "burned" to the terminal posts to prevent electrolyte 29

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leakage around the posts. When replacing a cover of this type, first cut the compound with a warm putty knife. Cut the full depth of the cover adjacent to the jar wall from corner to corner on each of the four sides. Since reuse of covers which have been removed from the element is not recommended, use a post trimmer to cut off the post extensions above the cover. Break the lead bond between post and lead insert by driving the cover down approximately 1/32". The lead insert mold placed over the post and tapped with a hammer serves this purpose. Insert a hook through the vent opening and lift the cover off. Remove all sealing compound adhering to jar wall and neutralize these surfaces and upper portion of all terminal posts, using a cloth moistened with a soda solution. Thoroughly dry all of the neutralized surfaces. Install the new cover, complete cover-to-jar seal, and reburn cell connectors as described in Paragraph 3-10. b. Epoxy Seal and Seal Nut Design - This is one of the newer systems which employs an epoxy or permanent, hard seal between cover and jar. To disassemble a cell of this design requires that the jar be cut and that both jar and cover be replaced. When reassembling with a new jar and cover, it is very important to adhere to the following procedure to obtain an effective seal: 1. Epoxy can be used only on rubber jars and covers.

2. Thoroughly clean cover and jar sealing areas first with xylol (xylene), then with isopropyl alcohol; use a separate cleaning cloth for each.

3. Caulk bottom of seal groove with glass cord. Tamp corners in. Make overlap small. Do not use warm compound with epoxy.

4. Use special epoxy sealant as recommended by the battery manufacturer. Follow instructions provided.

5. Apply epoxy in two pours. Make second pour within two hours after first pour. Fill to top of jar. Do not overfill.

6. Pressure test seal after three hours or more from time of final pouring. Pressure test to 1.5 psi for 10 seconds. d. Heat Bonded Plastic Cover-to-Jar Seal and Lead Bushing Design - This is the newest of the sealing systems used with motive power batteries. To disassemble a cell of this design also requires that the jar be cut and both jar and cover be replaced. The seal between jar and cover is, in effect, a plastic weld. It can only be used with jars and covers made from identical plastic molding material.

Since special techniques must be used when resealing these covers, the battery manufacturer recommends that these cover-to-jar seals not be repaired in the field. Manufacturers' instructions request that such repairs be made in their service stations only.

3-12. Adjusting Specific Gravity of Electrolyte Fully charged cells usually operate at a specific gravity between 1.275 and 1.295. Normally it should never be necessary to adjust the gravity, but upsets, jar breakage, additions of too much water, and careless use of hydrometer can result in electrolyte loss and possible reductions of battery capacity. Lost electrolyte must be replaced but only after it has been determined that charging will not restore the gravity to normal when at the recommended level.

Therefore a cell or battery should first be given an equalizing charge as described in Paragraph 2-10c.

Never make a gravity adjustment on a cell which does not gas vigorously while on charge.

If, after the equalizing charge, the specific gravity of any cell, corrected for temperature, is lower than normal, it should be adjusted in the following manner: 30

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1. Put battery back on charge at the finish rate until cells are actively gassing to provide proper mixing.

2. Remove electrolyte from the low reading cells until level reaches separator protector.

3. Slowly add 1.400 specific gravity sulfuric acid to the cell while it is still gassing.

4. Wait 15 to 20 minutes for the added acid to become thoroughly mixed, then read the specific gravity. If it is still low, repeat the process until gravity is normal. As a guide, every 1/4" of electrolyte that has been removed and replaced by 1.400 acid will cause the specific gravity to rise 4 to 5 points (.004 to .005).

If the corrected specific gravity of any cell is higher than normal, proceed as follows: 1. While the battery is gassing on charge, withdraw from the cell a small amount of electrolyte and replace with approved water.

2. Repeat, if necessary, at 20 to 30 minute intervals until the desired reading is obtained. Every 1/4" of electrolyte which is replaced with water will cause the specific gravity of the cell electrolyte to drop 4 to 5 points (.004 to .005).

NEVER ADD ACID WITH A SPECIFIC GRAVITY HIGHER THAN 1.400.

STRONGER ACID COULD PERMANENTLY DAMAGE THE CELL. WHEN MIXING OR CUTTING ACID, ALWAYS ADD THE ACID TO THE WATER. NEVER POUR WATER INTO ACID. A VIOLENT REACTION COULD RESULT WHICH MIGHT CAUSE PERSONAL INJURY. WHEN WORKING WITH ACID, ALWAYS USE A FACE SHIELD OR GOGGLES, RUBBER GLOVES, AND AN ACID RESISTANT APRON.

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CHAPTER 4 – HEALTH AND SAFETY Section I. Battery Hazards 4-1. General A lead-acid battery can be very useful, safe source of electrical power. While installing, using, maintaining, or repairing a motive power battery, opportunities exist, however, for exposure to potentially dangerous situations. This section identifies those hazards which could result from improper handling or use.

4-2. Hazards a. A sulfuric acid solution is used as the electrolyte in lead-acid batteries and has a concentration of approximately 37% by weight of sulfuric acid in water. In this diluted state, it is not as hazardous as strong or concentrated sulfuric acid, but it acts as an oxidizing agent and can burn the skin or eyes and destroy clothing made of many common materials such as cotton or rayon. b. An explosive mixture of hydrogen and oxygen is produced in a lead-acid battery while it is being charged. The gases can combine explosively if a spark or flame is present to ignite them. Because hydrogen is so light, it normally rises and diffuses into the air before it can concentrate in any explosive mixture. If it accumulates into gas pockets, as can occur within a cell, it might explode if ignited. c. Electricity is produced by the batteries on discharge and, while most persons cannot "feel" voltages below 35 to 40 volts, all mine power batteries should be regarded as potentially dangerous. A lead-acid battery is capable of discharging at extremely high rates and, under conditions of direct shorting, can cause damage and serious injury. d. The weight of these heavy batteries can easily cause painful strains or crushed hands or feet if improperly lifted or handled. Batteries can be damaged if dropped. The average mine power battery weighs more than one ton, so proper equipment must be provided when changing or handling batteries. e. Burns can result from contact with molten lead or hot compound while repairing a battery. Lead can splash when intercell connectors are being reburned and hot compound can be spilled when resealing covers to jars. The protective gear provided, if worn, will prevent such burns.

Section II. Safety Procedures 4-3. Federal Standards In 1970, Congress passed the Occupational Safety and Health Act (OSHA). This act established the minimal acceptable standards for safe and healthful working conditions. The safety procedures suggested in this manual have been compiled from standards developed over the years by professional and technical organizations and by battery manufacturers and users. Experience has shown them to be the most effective safety standards. In all cases, they exceed the minimum standards of OSHA for personal safety and include procedures for safeguarding equipment as well.

The safety procedures have been grouped by functional area of most logical application or need.

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4-4. Safety Procedures While Handling Batteries 1. Lift batteries with mechanical equipment, such as an overhead hoist, crane or lift truck. A properly insulated lifting beam, of adequate capacity, should always be used with overhead lifting equipment. Do not use chains attached to a hoist at a single central point forming a triangle. This procedure is unsafe and could damage the steel tray.

2. Always wear safety shoes and safety glasses.

3. Tools, chains, and other metallic objects should be kept away from the top of uncovered batteries to prevent possible short circuits.

4. Battery operated equipment should be properly positioned with switch off, brake set, and battery unplugged when changing batteries or charging them while in the equipment.

5 Personnel who work around batteries should not wear jewelry made from a conductive material.

Metal items can short circuit a battery and could cause severe burns.

6. Only trained and authorized personnel should be permitted to change or charge batteries.

7. Reinstalled batteries should be properly positioned and secured in the unit. Before installing a new or different battery, check both the unit nameplate and battery service weight to make sure that the proper weight battery is being used. A battery of the wrong weight could change the center of gravity and cause equipment to upset.

4-5. Safety Procedures While Charging Batteries 1. Specific areas should be designated for charging batteries.

2. Charging areas should be adequately ventilated. The actual amount of ventilation will depend upon such factors as number and size of batteries being charged at the same time, room size, ceiling height and air-tightness of the building. Hydrogen concentrations above 4% can be explosive.

3. Smoking, open flames, and sparks should all be prohibited in the charging area. Post placards "Hydrogen," "Flammable Gas,” “ No Smoking," and "No Open Flames."

4. Facilities should be provided for flushing and neutralizing spilled electrolyte, for fire protection (including hand-operated fire extinguishers), and for protecting charging equipment from damage by units.

5. Fresh water should always be available in case electrolyte is splashed on skin, clothing, or into eyes. The kinds of equipment available for eye-wash and acid neutralization vary widely. A squeeze bottle containing a buffering solution for relief of acid burns should be located in the immediate work area. These should be clearly identified and readily accessible.

6. Before connecting a battery to, or disconnecting it from, a charger, the charger should be turned off.

Live leads can cause arcing and pitting of battery connector contact surfaces.

7. Make sure that all electrical connections are tight and mechanically sound to prevent any arcing or loss of power.

8. Wear a face shield or goggles, rubber gloves, apron, and boots when checking, filling, charging, or repairing batteries during periods of possible exposure to acid or electrolyte.

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9. When charging an enclosed or covered battery, always keep the battery tray cover, or compartment cover, open during the charging period. This will help to keep the battery cool and disperse the gases.

10. Keep vent caps in place at all times except while servicing or repairing cells. This minimizes the loss of electrolyte and prevents foreign matter from entering the cells.

11. Shut off and disconnect both input and output connections to the charger before charging equipment.

4-6. Safety Procedures While Handling Acids 1. The splashing of acid Into the eyes Is the most dangerous condition which can be encountered while handling sulfuric acid or electrolyte. If this should happen, the eyes should immediately be gently flooded with clean, fresh, running water for at least 15 minutes, followed as quickly as possible with a physician's examination. If the person is wearing contact lenses, they should be removed before rinsing the eyes.

DO NOT USE A BUFFERING OR NEUTRALIZING AGENT IN THE EYES WITHOUT MEDICAL APPROVAL. 2. Acid or electrolyte splashed onto the skin should be washed off under running water. Battery electrolyte will usually only cause irritation of the skin; if a burn develops, it should be treated medically.

3. When electrolyte is splashed on clothing, use a weak solution of bicarbonate of soda, as soon as possible, to neutralize the acid.

4. A carboy tilter or safety siphon should be provided for handling acid from a carboy container. Use the protective box when moving a carboy. Store acid in a cool place out of the direct rays of the sun. Use only glass, rubber containers, lead, or acid-resistant plastic containers when storing acid or electrolyte.

5. When mixing acid to prepare electrolyte, always pour the acid slowly into the water and stir constantly to mix well. Never pour water Into acid. Never use sulfuric acid solutions which are over 1.400 specific gravity.

6. Apply a neutralizing solution, such as bicarbonate of soda and water, when acid is spilled on floor.

Clean up affected area promptly. A mixture of one pound of soda to one gallon of water is recommended.

4-7. Safety Procedures While Servicing or Repairing Batteries.

1. Disconnect the battery from the unit when servicing or repairing either the battery or the equipment.

Also make certain the battery is disconnected from the charger before handling or repairing the battery.

2. Before repairing a battery, remove all of the vent caps and blow out each cell with a low pressure air hose to remove any residual gas. Use only a gentle stream of air to avoid splashing electrolyte.

Do not blow breath Into cells.

3. Open or "break" the circuit before repairing damaged or dirty terminal plugs or receptacles connected to a battery by removing and insulating one terminal lead at a time.

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4. When melting sealing compound in preparation for resealing cells, be careful not to puncture the top section of unmelted compound with a screw driver or other pointed object. A build-up of pressure from the melted compound in the bottom could cause liquid compound to squirt and inflict a severe burn. Do not allow compound to ignite by overheating. Compound becomes workable at 400 to 425 degrees F. 5. Check batteries frequently for acid leakage or signs of corrosion.

6. Use insulated tools whenever possible when working on batteries. If possible, also cover the terminals and connectors of a battery with a sheet of plywood or other insulating material to prevent short circuits.

7. When taking specific gravity readings, use a face shield or goggles and read the hydrometer with your eye at about the same level as the electrolyte. Return all electrolyte to the cell.

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CHAPTER 5 – STORAGE AND SHIPMEMT 5-1. General Follow these guidelines for those occasions when batteries must be stored, in either a wet or dry state, and for possible reshipment to other areas.

5-2. Storage Methods a. Charged and Wet Batteries - Lead acid batteries may be stored in a charged and wet (filled with electrolyte) condition when necessary for periods of up to several months. During such periods they should be stored in a clean, cool, dry, and well ventilated location away from radiators, hot air ducts, or other sources of heat, and protected from exposure to direct sunlight. Before being stored, the battery should be fully charged and the electrolyte brought to the proper level. Any leads should be disconnected or insulated to prevent accidental discharge. The top of the battery should be protected from dust, foreign matter, and moisture. Do not attempt to dismantle the battery.

If the average storage temperature is 80 degrees F. or higher, the specific gravity of the electrolyte should be checked at least monthly. If below 80 degrees F., check gravities at least every two months.

Whenever the specific gravity, corrected to 80 degrees F., falls to 1.240 or below, the battery should be given a freshening charge as described in Paragraph 2-10d. A freshening charge is also recommended just before returning a battery to service. b. Charged and Dry Batteries - New batteries are often supplied charged and dry (without electrolyte).

Batteries in this condition can remain in storage, unattended, for a period of at least two years. They should be stored in a cool, dry place with vent caps tightly closed. Average temperatures should not exceed 80 degrees F. Batteries should not be stored near radiators, hot air ducts, or other sources of heat, and should be protected from exposure to direct sunlight. The top of the battery should be protected from dust, foreign matter, and moisture. Charged and dry batteries when removed from storage should be activated as described in Paragraph 2-4a.

5-3. Shipment a. Charged and Wet Batteries - Depots or using organizations may make shipments of motive power batteries in a charged and wet condition if intended for use within a period of 90 days. The battery service weight is usually stamped into the steel tray near one of the lifting holes.

Before crating a wet battery for shipment, it should be given a freshening charge as described in Paragraph 2-10d. A tag should be attached to both the battery and the crate showing the date of the last charge and the specific gravity of the electrolyte at the completion of the charge. Make certain that the battery is properly protected when crated. The receiving organization should be alerted also to the need for a freshening charge before the battery is put into service. b. Charged and Dry Batteries - Depots will normally make domestic and export shipments of new batteries which usually will be in a charged and dry condition. Batteries, and the accompanying electrolyte in separate carboys, which are intended for export shipment must be packaged in accordance with approved methods.

WHENEVER BATTERIES ARE REGULATIONS WILL APPLY.

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SHIPPED

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CARRIER,

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BATTERY CHARGING AND MAINTENANCE INSTRUCTIONS ALWAYS WEAR SAFETY GLASSES AND PROTECTIVE CLOTHING WHEN SERVICING BATTERIES. NEUTRALIZE ANY ACID SPILLS IMMEDATELY. IF ACID CONTACTS ANY PART OF THE BODY, FLUSH IMMEDATELY WITH RUNNING WATER AND SEEK MEDICAL ATTENTION. CARE SHOULD BE TAKEN AT ALL TIMES TO AVOID ELECTRICAL SHOCK FROM THE BATTERY OR CHARGER. THE CHARGER MUST BE TURNED OFF BEFORE CONNECTING OR DISCONNECTING THE LEAD(S) TO THE BATTERY. I.

CHARGING A.

Tray covers should be open during charge.

B.

Be sure charger switch is in “OFF” position.

C.

Check plugs and receptacles to be sure they are clean and in good condition. Connect the charger to the battery.

NEVER CONNECT OR DISCONNECT THE BATTERY AND CHARGER UNLESS THE CHARGER IS TURNED OFF. DAMAGE TO THE PLUGS AND RECEPTACLES WILL OCCUR. ALSO AN ARC WILL BE DRAWN THAT COULD BE A SAFETY HAZARD. D.

Turn switch “ON”, and press “START” to start daily charge. Check ammeter to be sure battery is charging and charger is operating correctly.

E.

Charger is fully automatic and will stop charging when it recognizes a fully charged battery in approximately 8 hours.

F.

Full charge specific gravity reading should be 1.275 to 1.280. Higher readings will result due to low water levels. Do not over water battery as lost acid will result in less work per charge and shorten battery life.

ALL SPECIFIC GRAVITY READINGS ARE BASED ON BATTERY TEMPERATURE OF 25 DEGREES C.

II.

III.

IV.

EQUALIZING CHARGE A.

After the daily 8-hour charge is complete, turn switch “ON” and press “START” (If equipped) for an equalizing charge once per week.

B.

When equalizing charge is completed and automatic electronic timer has turned charger off, read specific gravity of each cell and record. If variations of 10 or 20 points of specific gravity are recorded, call a DBT America Technician. If cells show variations of 0.1 or more, call a DBT America Technician.

OPERATING INSTRUCTIONS A.

Do not charge or operate in service if temperature of battery reaches 46 degrees C. High temperatures are a result of improper charger adjustments, high discharge rates, over discharging, short cycling, and low water levels.

B.

Keep plugs and receptacles clean and adjusted for tension. If plug is hot, it is not making good contact. Remember the battery has current at all times. Be careful when working on plugs and receptacles.

C.

Vent caps should only be removed to check water level, temperature, and specific gravity, or to add water. Be sure they are in place and tight at all times.

D.

Do not weld, grind or allow sparks or allow flame near battery. Do not allow tools or any other metal to be laid on connector of battery.

E.

Never add anything to the battery except approved water.

F.

Never add acid to battery.

WATERING A.

Add approved water to 1/4” (6.35 mm) below vent well only at the end of charge.

Filling to this level before charging will cause acid overflow. Acid attacks external battery parts. Any acid loss from the battery will result in power loss and shortened life.

B.

Replace vent caps securely.

6.35 mm .63 mm

V.

CLEANING A.

Wash battery at least weekly using soda and water, then rinse with plain water 1 lb. (0.45 kg) soda to 1 gal. (3.78 l) water mixture). Vent caps should be in place when washing battery.

B.

Dirty batteries create grounds, reduce work time, increase battery cost, and shorten life. Correctly charged, watered, and cleaned batteries give longer work time per shift per charge, reduced cost, and longer life.

DBT AMERICA HAS COMPLETE SERVICE FOR BATTERIES AND CHARGERS AT YOUR MINE SITE. WE ALSO HAVE COMPLETE BATTERY REBUILD CENTERS FOR QUICK TURNARROUND ON BATTERY AND CHARGER REBUILDS.

P/N A6474X61 Revised 03 – 03 BATTERY CHARGING AND MAINTENANCE INSTRUCTIONS