S C 661-500 Three-Phase Battery Charger Instructions

: June 9, 2024
: S C

Table of Contents

Introduction
Safety Information
Safety Precautions
Ratings and Standards
Components
Operation
Appendix A
Appendix B
Appendix C
Appendix D
References
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Three-Phase Battery Charger
For 24-Volt Batteries
Instructions Manual

Introduction

Qualified Persons
WARNING
Only qualified persons who are knowledgeable in the installation, operation, and maintenance of overhead and underground electric distribution equipment, along with all associated hazards, may install, operate, and maintain the equipment covered by this publication . A qualified person is someone who is trained and competent in:

The skills and techniques necessary to distinguish exposed live parts from nonlive parts of electrical equipment
The skills and techniques necessary to determine the proper approach distances corresponding to the voltages to which the qualified person will be exposed
The proper use of special precautionary techniques, personal protective equipment, insulated and shielding materials, and insulated tools for working on or near exposed energized parts of electrical equipment

These instructions are intended ONLY for such qualified persons . They are not intended to be a substitute for adequate training and experience in safety procedures for this type of equipment .

Read this Instruction Sheet
NOTICE
Thoroughly and carefully read this instruction sheet and all materials included in the product’s instruction handbook before installing or operating your Three-Phase Battery Charger . Familiarize yourself with the Safety Information and Safety Precautions on pages 3 through 5 . The latest version of this publication is available online in PDF format at sandc.com/en/support/product-literature/ .

Retain this Instruction Sheet
This instruction sheet is a permanent part of your Three-Phase Battery Charger. Designate a location where you can easily retrieve and refer to this publication.

Proper Application
WARNING
The equipment in this publication is only intended for a specific application . The application must be within the ratings furnished for the equipment .

Warranty
The warranty and/or obligations described in S&C’s Price Sheet 150, “Standard Conditions of Sale–Immediate Purchasers in the United States,” (or Price Sheet 153, “Standard Conditions of Sale–Immediate Purchasers Outside the United States,”) plus any special warranty provisions, as set forth in the applicable product-line specification bulletin, are exclusive. The remedies provided in the former for breach of these warranties shall constitute the immediate purchaser’s or end user’s exclusive remedy and a fulfillment of the seller’s entire liability. In no event shall the seller’s liability to the immediate purchaser or end user exceed the price of the specific product that gives rise to the immediate purchaser’s or end user’s claim. All other warranties, whether express or implied or arising by operation of law, course of dealing, usage of trade or otherwise, are excluded.
The only warranties are those stated in Price Sheet 150 (or Price Sheet 153), and THERE ARE NO EXPRESS OR IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. ANY EXPRESS WARRANTY OR OTHER OBLIGATION PROVIDED IN PRICE SHEET 150 (OR PRICE SHEET 153) IS GRANTED ONLY TO THE IMMEDIATE PURCHASER AND END USER, AS DEFINED THEREIN. OTHER THAN AN END USER, NO REMOTE PURCHASER MAY RELY ON ANY AFFIRMATION OF FACT OR PROMISE THAT RELATES TO THE GOODS DESCRIBED HEREIN, ANY DESCRIPTION THAT RELATES TO THE GOODS, OR ANY REMEDIAL PROMISE INCLUDED IN PRICE SHEET 150 (or PRICE SHEET 153).

Safety Information

Understanding Safety-Alert Messages
Several types of safety-alert messages may appear throughout this instruction sheet and on labels and tags attached to your Three-Phase Battery Charger. Familiarize yourself with these types of messages and the importance of these various signal words:

DANGER
“DANGER” identifies the most serious and immediate hazards that will likely result in serious personal injury or death if instructions, including recommended precautions, are not followed .
WARNING
“WARNING” identifies hazards or unsafe practices that can result in serious personal injury or death if instructions, including recommended precautions, are not followed .
CAUTION
“CAUTION” identifies hazards or unsafe practices that can result in minor personal injury if instructions, including recommended precautions, are not followed .
NOTICE
“NOTICE” identifies important procedures or requirements that can result in product or property damage if instructions are not followed .

Following Safety Instructions
If you do not understand any portion of this instruction sheet and need assistance, contact your nearest S&C Sales Office or S&C Authorized Distributor. Their telephone numbers are listed on S&C’s website sandc.com, or call the S&C Global Support and Monitoring Center at 1-888-762-1100.
NOTICE
**** Read this instruction sheet thoroughly and carefully before installing your Three-Phase Battery Charger .

Replacement Instructions and Labels
If additional copies of this instruction sheet are needed, contact your nearest S&C Sales Office, S&C Authorized Distributor, S&C Headquarters, or S&C Electric Canada Ltd.
It is important that any missing, damaged, or faded labels on the equipment be replaced immediately. Replacement labels are available by contacting your nearest S&C Sales Office, S&C Authorized Distributor, S&C Headquarters, or S&C Electric Canada Ltd.

Safety Precautions

DANGER
S&C switchgear contains high voltage. Failure to observe the precautions below will result in serious personal injury or death.
Some of these precautions may differ from company operating procedures and rules . Where a discrepancy exists, users should follow their company’s operating procedures and rules .

QUALIFIED PERSONS. Access to S&C switchgear must be restricted only to qualified persons . See the “Qualified Persons” section on page 2 .
SAFETY PROCEDURES. Always follow safe operating procedures and rules .
PERSONAL PROTECTIVE EQUIPMENT. Always use suitable protective equipment, such as rubber gloves, rubber mats, hard hats, safety glasses, and flash clothing, in accordance with safe operating procedures and rules .
SAFETY LABELS. Do not remove or obscure and of the “CAUTION,” “WARNING,” or “DANGER” labels .
OPENING DOORS. Do not force doors open . Forcing a door open can damage the latching mechanism . If optional key interlocks are provided, correctly position the interlocks so the doors can be opened .
CLOSING AND LOCKING DOORS.
• Doors must be securely closed and latched, with padlocks in place at all times unless work is being performed inside the enclosure .
• For pad-mounted gear, Mini-Rupter® Switches have switch-operating shaft access covers located on the sides of the pad-mounted gear enclosure . They must be closed and padlocked at all times unless the switches are being operated .
• For PME pad-mounted gear, do not close a door on a TransFuser™ Mounting in the Open position with a fuse in the mounting . The door will strike the fuse pull-ring, which will interfere with door-closing . The door may be closed if the fuse is removed from the mounting .
• For PMH pad-mounted gear, do not close a door on a fuse in the Open position . The door will strike the fuse pull-ring, which will interfere with door- closing . The door may be closed if the fuse is removed from the mounting .
OPERATING MECHANISM AND BASE.
Scada-Mate SD Switching Systems contain fastmoving parts that can severely injure fingers. Do not remove or disassemble operating mechanisms or remove access panels on the Scada-Mate SD switch base unless directed by S&C Electric Company.
ENERGIZED COMPONENTS.
• Always assume both sets of power terminals on any Mini-Rupter Switch or fuse in pad-mounted gear are energized unless proved otherwise by test, by visual evidence of open-circuit conditions on both sets of terminals, or by observing both sets of terminals are grounded .
• For Scada-Mate SD Switching Systems, always consider all parts live until de-energized, tested, and grounded.
• The Three-Phase Battery Charger contains the following energized components:
— 300 Volts in pins 1 through 10 in the J3 connector.
— 30 Volts for the other wire connection terminals (pins 11 through 20 in the J3 connector, J2 connector, and J4 connector).
BACKFEED. Mini-Rupter Switches and fuses in pad-mounted gear may be energized by backfeed.
GROUNDING .
• For pad-mounted gear, make sure enclosure is properly grounded to the station or facility ground.
• After the pad-mounted gear has been completely disconnected from all sources of power and tested for voltage, install suitable grounding cables in all compartments before touching any device to be inspected, replaced, serviced, or repaired in the high-voltage compartments.
• For Scada-Mate SD Switching Systems, before energization and at all times when energized, the switch base and control unit enclosure must be connected to suitable earth ground at the base of the pole in accordance with the S&C instruction sheet furnished with the device.
SWITCH POSITION.
For pad-mounted gear:
• Always confirm the Open/Close position of MiniRupter Switches by visually observing the position of the switch blades.
• Switches may be energized by backfeed .
• Switches may be energized in any position .
For Scada-Mate SD Switching Systems:
• Always confirm the Open/Close position of loadinterrupter switches by visually observing the indicator.
• Interrupters, terminal pads, and disconnect blades on disconnect-style models may be energized from either side of the Scada-Mate SD switch.
MAINTAINING PROPER CLEARANCE. Always maintain proper clearance from energized components.

Ratings and Standards

Input Power Requirement
Table 1. Input Power Ratings

Input parameter	Rating
Three-phase current source (from S&C voltage sensor)	140 – 195 mA at 20 VA
Auxiliary voltage	120 Vac
Frequency	50 or 60 Hz

Output Power Requirement
Table 2. Output Power Ratings

Output parameter	Rating
Total output power (all three phases)	30 W
Radio output power	12 W (average), 27 W (maximum) during .25 second transmit

every 5 seconds.
To relays and motor load| 24 Vdc
Voltage to charge the 24-V battery| 26.5 – 33 Vdc

Environmental Requirements
Table 3. Environmental Ratings

Environmental parameter	Rating
Operating temperature	-40°C to +70°C (-40°F to +158°F)
Storage temperature	-40°C to +85°C (-40°F to +185°F)
Relative humidity	5% to 95% at 60°C (140°F), non-condensing

Regulatory Compliance
The Three-Phase Battery Charger complies to the following standards:
Emissions Testing

IEC 60255-26:2013 – Radiated RF emission
Immunity Testing
IEC 60255-26:2013 – Radiated RF immunity 80 – 2700 MHz
IEEE C37.90.2 – Radiated Susceptibility
IEC 60255-26:2013 – Electrical fast transient/burst immunity
IEEE C37.90.1:2002 – Fast transient SWC
IEC 60255-26:2013 – Conducted RF immunity
IEEE C37.90.1 – Oscillatory transient SWC
IEC 60255-26:2013 – Damped Oscillatory Burst
IEC 60255-26:2013 – Surge immunity
IEC 61000-4-8 – Magnetic Field
IEEE C37.90.3 – Electrostatic discharge: air and direct
IEC 60255-26 – Electrostatic Discharge: Air/direct Environmental and Safety Testing
IEC 60255-27:2013 – Dielectric Strength
IEC 60255-27:2013 – Insulation Resistance
Mil-Std 810, 20 cycles -40°C to +70°C (-40°F to +158°F) – Temperature cycling

Components

Overview
The purpose of this document is to instruct users how to operate the Three- Phase Battery Charger to supply power to gear radios, relays, and motor loads in the event source
power is lost. This document also instructs users on how to identify the status of the battery and to be familiar with the use the graphical user interface (GUI) computer application software to monitor the gear. Table 4 on page 8 provides the description of the components.

S C 661 500 Three Phase Battery Charger - FIGURE 1

Table 4. Component Descriptions

Component or Label	Type	Description
CHARGER POWER	Switch	The charger will be powered from any of the three

sources (three-phase, 120 Vac, or battery) when this switch is turned on. Charging power is exported from the charger only when the battery is connected.
THREE-PHASE VOLTAGE SENSORS| Switch| Turns on/off the three-phase voltage sensors to the charger
SINGLE-PHASE 120 VAC| Switch| Turns on/off the 120-V single-phase ac source to the charger
DB9 PORT| DB9 connection port| Using a USB-to-DB9 serial cable, this port is used to connect a computer to the charger in order to use the GUI application software
Upper-right green connector ①| Wire connection terminals| This is the J2 connector. Used to connect output wires
Lower-right green connector ①| Wire connection terminals| This is the J3 connector. Used to connect power wires
Upper-left green connector ①| Wire connection terminals| This is the J4 connector. Used to connect control wires
J2 connector pinout label| Drawing label| Shows the pin locations to connect the output wires
J3 connector pinout label| Drawing label| Shows the pin locations to connect the power wires
J4 connector pinout label| Drawing label| Shows the pin locations to connect the control wires
UP ②| Pushbutton| Used to increment digits on the LCD screen. The digit displayed after the maximum will roll back to the minimum digit
DOWN ②| Pushbutton| Push and hold: Used to change programming modes on the LCD screen
Push: Used to shift to the next digit(s) on the LCD screen
RESET ②| Pushbutton| Used to reset the charger when any of these occurs: The battery is bad The battery has open cells The battery has been removed
BATTERY TEST ②| Pushbutton| Used to test the battery
BATTERY TESTING| LED| Indicator turns on during battery testing
UNDER VOLTAGE| LED| Turns on when the battery voltage is lower than 21 Volts
OVER VOLTAGE| LED| Turns on when the battery voltage is higher than 34 Volts
AC NOT PRESENT| LED| Turns on when the charger is powered by the battery only
Screen| LCD screen| Used to show menus and status of the battery charger

① Refer to Appendix B on page 28 for wire connector pin location details .
② S&C recommends using the GUI application software to operate and configure the charger . See pages 11 to 16 . For manual operation, refer to Appendix A on page 24 .

Wiring Interface
The charger has three wiring connector interfaces (J2, J3, and J4), each with two removable 10-terminal Phoenix interface connectors. See Figure 1 on page 7. Pins 1 through
10 are located in the upper row (inside) and pins 11 through 20 are on the lower row (outside). See Figure 2. Complete the following steps to install a wire in a connector pin:
STEP 1. Using a small flathead screwdriver, unscrew the pin location needed to wire. See Figure 3.
STEP 2. When the pin screw is loosened, place the bare part of the wire in the square slot under the loosened screw and tighten the screw. Tighten the screw until tight. Pull the wire to ensure it is installed properly and does not come out. The wire is now installed. See Figure 4.

S C 661 500 Three Phase Battery Charger - FIGURE 2

NOTICE
For functional descriptions of the J2, J3, and J4 connector pin locations, please refer to Appendix B on page 28 .

LCD Screen
When the charger is on, the LCD screen will display the charger status. Information displayed on the LCD screen depends on either of the following:

If the charger is powered from the battery only
If the charger is powered from either the 120-Vac singlephase or three-phase power source with the battery connected

Display on the screen when the charger is powered from battery only: If the charger is powered from battery only, the following information will be displayed on the LCD screen:
Battery status:

BAT OK–Battery is good
BAT LOW–Battery is low
BAT BAD–Bad battery

Internal temperature (°F)
Time (24-hour format)
Date (MM/DD/YYYY format)
BV – Battery voltage
Battery test history

NOTICE
The battery test results on the LCD screen will be overwritten by the results of subsequent battery tests . The battery test results on the LCD screen are also cleared if the charger is turned off and then turned back on .
This information will automatically scroll on the LCD screen every three seconds.
Display on the screen when the charger is powered from either ac source with the battery connected:
If the charger is powered from an ac source (either 120-Vac single-phase or three-phase voltage sensors) with the battery connected, the following information will be displayed on the LCD screen:
Battery Status:

BAT OK–Battery is good
BAT LOW–Battery is low
BAT BAD–Bad battery

Charger Status:

CHR OK–Charger is good
CHR UV–Charger undervoltage
CHR OV–Charger overvoltage

Internal temperature (°F)
Time (24-hour format)
Date (MM/DD/YYYY format)
CV–Charger Voltage
BC–Battery Charge Current
Battery test history

NOTICE
The battery test results on the LCD screen will be overwritten by the results of subsequent battery tests.
The battery test results on the LCD screen are also cleared if the charger is turned off and then turned back on .
This information will automatically scroll on the LCD screen every three seconds.

Operation

Accessing the GUI Application Software
The GUI application software is used to operate and configure the charger. S&C recommends using this application instead of manually operating and configuring the charger through the pushbuttons on the charger. To use the pushbuttons, please refer to Appendix A on page 24 of this instruction sheet.
Complete the following steps to log in to the GUI application:

STEP 1.
Obtain the USB-to-DB9 serial cable and connect the DB9 end to the DB9 PORT on the charger and the USB end to the user’s computer.
NOTICE
The GUI application software BatteryCharger .exe file can be downloaded by logging in to S&C’s customer portal at sandc.com/en/support/sc-customer- portal .
STEP 2.
Run the BatteryCharger.exe file from the computer to launch the GUI application.
STEP 3.
When the GUI application Login screen opens, enter the User Name and Password as shown in Figure 5 to log in:
NOTICE
To obtain the User Name and Password to log in to the GUI application, please contact S&C Electric Company .
STEP 4.
Click on the Login button to access the GUI application. The user can also click on the Cancel button to clear the User Name and Password text boxes.

S C 661 500 Three Phase Battery Charger - FIGURE 3

Navigating the GUI Application Software
When logged in to the GUI application software, the user will see five tabs across the top of the screen from left to right:

Firmware Upload
Battery Status
Settings
Battery Test
Battery Test History

To the left side of each tab screen is a side window that shows the available communication ports, the connected port, and the status of the connection. See Figure 6. At the bottom of the side window is a reference to the version of the GUI application software.

S C 661 500 Three Phase Battery Charger - FIGURE 4

Firmware Upload Tab
The Firmware Upload tab is the default screen when the user logs in and is used for updating the charger firmware.
See Figure 7. Table 5 defines the fields and buttons in the Firmware Upload screen.
Table 5. Firmware Upload Field and Button Descriptions

Field or Button	Description
Firmware Path	This field allows the user to enter the location of the

firmware file using the Browse button.
Browse| This button allows the user to select the firmware file from the computer.
Clear| This button is used to clear the Firmware Path field.
Install| This button is used to start the firmware upload. While updating, the user is restricted from accessing other tabs.
Firmware Upload| This status bar shows the % completion of the firmware upload.

Complete the following steps to download the latest firmware to the charger:
STEP 1.
Obtain the USB-to-DB9 serial cable. Connect the DB9 end to the DB9 PORT of the charger and the USB end to the computer.
STEP 2.
Log in to the S&C customer portal at sandc.com/en/support/sc-customer- portal to download the latest version of the firmware to the computer.
STEP 3.
Log in to the GUI application software. In the Firmware Upload tab (See Figure 7 on page 12), select the file from the computer and download the firmware to the charger by clicking on the Install button.

S C 661 500 Three Phase Battery Charger - FIGURE 5

Battery Status Tab
The Battery Status screen is used to view the status of the charger. See Figure 8.
NOTICE
The Battery Status screen may need to be refreshed to capture present data . Click on the Battery Status tab to refresh.
The two buttons on this screen are:
Convert to °C – This button enables the user to convert the temperature seen on the screen to degrees centigrade.
The button can also revert the temperature shown on the screen from degrees centigrade to degrees Fahrenheit.
Alarm Reset – This button enables the user to reset external alarms with these conditions:

Battery Bad
Battery Under Voltage
Battery Over Voltage
Battery Removed
Battery with Open Cells

For Battery Removed or Battery with Open Cell alarms: To replace a battery or to clear the battery records:
STEP 1.
Disconnect the two-pin connector separating the battery from the charger. See Figure 18 on page 18.
STEP 2.
Run a battery test by clicking on the Battery Test button in the Battery Test tab. See Figure 11 on page 14.
STEP 3.
Confirm the “No Battery” message appears on the Battery Status screen. See Figure 9.
STEP 4.
Connect the desired battery. Click on the Alarm Reset button to enable the battery to reconnect to the charger. When the button is clicked, a message will pop up, “Do you want to override the BAT Records?” See Figure 10.
STEP 5.
Click on the Yes button if battery test results must be overwritten. This is recommended if the battery was replaced so records from the old battery are not displayed for a newly installed battery.
STEP 6.
Click on the No button if battery test results must be stored. This is recommended if the battery was just unplugged for maintenance.

Settings Tab
In the Settings tab, the user can configure the charger with the fields shown in Figure 11. Each setting must have the box to the left of the setting checked in order to be saved. Table 6 shows the descriptions of the fields shown on the Settings screen.

S C 661 500 Three Phase Battery Charger - FIGURE 6

Table 6. Field Descriptions for the Settings Tab

Field	Description
Battery Charger Current	The user can set the battery charger current. The

current range is from 0.000 to .500 amperes. A read-back of this value is displayed on the Battery Status screen under the User Set Max Current field.
Date/Time| The user can configure the date and time. By placing the cursor on the exact parameter, the user can click on the up and down arrows to increment or decrement the values respectively.
The date and time can also be entered by means of the keyboard numbers and traversing left and right by using the keyboard arrows.
Date is in the form of MM/DD/YYYY and time is in the form of HH:MM:SS (24-hour format).
Get PC Time button| This button allows the user to set the Date/Time field to the present date/time of the connected computer. To apply the time, the Date/Time box must be checked and the Save button must be clicked on.
Remove battery from charger under BAD condition or less than 17.5 V ①| The charger will disconnect the battery from the charger under the Battery Bad condition or if battery voltage is less than 17.5 V.
Select the Yes option if the battery should be disconnected.
Select the No option if the battery should not be disconnected.
A read-back of this selection is displayed on the Battery Status screen under the Bad Battery or Under 17.5V Action field.
Save button| This button allows the user to save the changes made to the checked/selected configurable fields.
Update Setting| This status bar shows the % completion of the saving process when the Save button is used.

① Default answer is the Yes option (recommended) .
Battery Test Tab
The Battery Test screen can be accessed by clicking on the Battery Test tab. This screen is used to conduct a battery test. See Figure 12.
To conduct a battery test, click on the Battery Test button. The user cannot access any other tabs until battery test is complete. The status box will be updated during the battery test, and the progress bar will visually show the progression of the test. See Figure 13. The results of the latest battery test since the charger powered up will be displayed in the fields below the progress bar, also shown in Figure 13. The results will automatically update after completion of a GUI initiated battery test. The results can be refreshed by clicking on the Battery Test tab.

NOTICE
During the first 24-hour operation period, the battery is automatically tested every two hours . After that, when ac power is present and the charger is turned on, the battery is tested once a day at midnight (per the time on the charger) . If the battery is powering the charger due to a loss of ac source, a battery test will occur every two hours . The battery test is used to measure effective battery capacity and can be started remotely with the GUI application Battery Test command, as shown in Figure 12, by the Battery Test Start input relay through the J2 connector, or by the BAT TEST pushbutton on the charger, as described in Appendix A on page 24 .

S C 661 500 Three Phase Battery Charger - FIGURE 7

Battery Test History Tab
The Battery Test History tab enables the user to view automated test reports. Manually initiated tests are not displayed in the Battery Test History screens. The latest battery test results since charger power up can be seen on the Battery Test tab (see Figure 14) or on the LCD screen.
The report subtabs in this screen are as follows:
First 12 Test Records–Displays the first 12 battery test records that are automatically initiated (Manual battery tests are not captured in this record.)
First Year Monthly Records–Displays the battery test records from the first year
Latest 1 Year Monthly Records–Displays the battery test records of the present year

The reports will show the date, time, battery status, temperature, voltage, and impedance.
Complete the following steps to view the battery test history reports:

STEP 1.
Select a report subtab (First 12 Test Records, First Year Monthly Records, or Latest 1 Year Monthly Records).
STEP 2.
Click on the Test History button. This will display the subtab report.
NOTICE
If the data does not appear, click on the Test History button again to refresh the data .
STEP 3.
If desired, the user can export the data as a CSV file by clicking on the Export To CSV button. A pop-up window will appear and display the directory where the file is saved on the computer.
STEP 4.
When the file is located, the user can open it using software such as Microsoft Excel®, Notepad, Google Sheets, etc. See Figure 15.

S C 661 500 Three Phase Battery Charger - FIGURE 8

Power Switch Operation and Configuration
The charger has three power switches, as shown in Figure 16:

A CHARGER POWER switch
A SINGLE-PHASE 120-VAC power switch
A THREE-PHASE VOLTAGE SENSORS power switch

Complete the following steps to turn on the charger (assuming all power sources are connected to the charger):
STEP 1.
Turn on the desired power switch to power the charger from an ac source (either the THREEPHASE VOLTAGE SENSORS power switch or the SINGLE- HASE 120-VAC power switch).
STEP 2.
After the desired power source switch is turned on, turn on the CHARGER POWER switch. The LCD screen will turn on and the charger will power on.

S C 661 500 Three Phase Battery Charger - FIGURE 9

NOTICE
If the charger has a battery connection, a 120Vac single-phase power source connection, and a three-phase power source connection, and all three switches are turned on, the charger will be powered by the 120-Vac single-phase power source as a default . If the charger has a battery connection, but no 120Vac single-phase power source connection and no three-phase power source connection, and all three switches are turned on, the charger will be powered by the battery .

Connecting and Powering On the Charger with a 24-Volt Battery
Complete the following steps to connect and power on the charger with a 24-Vdc battery:

STEP 1.
Make sure the SINGLE-PHASE 120 VAC power switch, the THREE-PHASE VOLTAGE SENSORS power switch, and the CHARGER POWER switch are in the Off position. See Figure 17 on page 17.
STEP 2.
Making sure the two-pin connector is disconnected, use a small flathead screwdriver to confirm the 24-Vdc battery wires to the charger are connected. The battery positive wire should be connected to pin 1 and the battery negative wire should be connected to pin 4 of the J2 connector. See the J2 connector pinout label on the charger faceplate for exact pin locations to terminate the wires.
STEP 3.
Connect the two-pin connector. See Figure 18. Before turning on the charger, use a voltmeter to confirm the voltage at the J2 connector. Voltage across pin 1 (battery positive) and pin 4 (battery negative) should be between 20 Vdc and 26 Vdc (depending on the battery state of charge). See Figure 19.
STEP 4.
Turn the CHARGER POWER switch to the On position. The charger will turn on, and the LCD screen will display the charger and battery status. See Figure 20.

S C 661 500 Three Phase Battery Charger - FIGURE 10

NOTICE
With the CHARGER POWER switch on, the battery will power the charger if no 120-Vac single-phase power source or three-phase power source is supplied to the charger, regardless of the SINGLE-PHASE 120 VAC or THREE-PHASE VOLTAGE SENSORS power switch positions.

Removing the Battery for Maintenance or Replacement
Complete the following steps to remove a battery:
STEP 1.
Disconnect the two-pin connector separating the battery from the charger. See Figure 18 on page 18.
STEP 2.
Run a battery test by clicking on the Battery Test button in the Battery Test tab. See Figure 12 on page 15.
STEP 3.
Confi rm the No Battery message appears on the Battery Status screen.
STEP 4.
To install a new battery or to rewire the existing battery to the charger, follow Steps 2 through 4 on page 18.
STEP 5.
Using the Battery Status tab in the GUI application (Figure 9 on page 13), click on the Alarm Reset button to reset the charger. A pop-up window will ask, “Do you want to override the BAT (battery) records?” Selecting the No option means the battery records will not be overwritten. Selecting the Yes option means all battery records will be deleted and new battery records will be stored. This enables the charger to connect to the battery.

Connecting and Powering On the Charger with a 120-Vac Single-Phase Source
Complete the following steps to connect and power on the charger using a 120-Vac single-phase source:
STEP 1.
Make sure the SINGLE-PHASE 120 VAC power switch, the THREE-PHASE VOLTAGE SENSORS power switch, and the CHARGER POWER switch are in the Off position. See Figure 17 on page 17.
STEP 2.
Using a small flathead screwdriver, connect the 120-Vac power source wires to the J3 connector by connecting the ground wire to pin 10, the line (hot) wire to pin 9, and the neutral wire to pin 8. See the J3 connector pinout label on the charger faceplate for exact pin locations to terminate the wires. See Figure 21.
STEP 3.
Plug in the 120-Vac source and use a voltmeter to confirm the voltage at the J3 connector before turning the SINGLE-PHASE 120 VAC power switch On. The voltage between pin 10 (ground wire) and pin 9 (line wire) should be 120 Vac +/10%. See Figure 22(a). The voltage between pin 10 (ground wire) and pin 8 (neutral wire) should be less than 1 Vac. See Figure 22(b).
STEP 4.
Making sure the two-pin battery connector is disconnected, use a small flathead screwdriver to secure the 24-Vdc battery wires to the charger by connecting the battery positive wire to pin 1 and battery negative wire to pin 4 of the J2 connector. See the J2 connector pinout label on the charger faceplate for exact pin locations to terminate the wires. Now, connect the tropine connector so the battery is connected to the charger. See Figure 18 on page 18.
STEP 5.
Before turning on the charger, use a voltmeter to confirm the voltage at the J2 connector. Voltage at pin 1 (battery positive) and pin 4 (battery negative) should be between 20 Vdc and 26 Vdc (depending on the battery state of charge). See Figure 19 on page 18.
STEP 6.
Turn the SINGLE-PHASE 120 VAC power switch to the On position. See Figure 23.
STEP 7.
Turn the CHARGER POWER switch to the On position. The charger will turn on, and the LCD screen will display the charger and battery status. See Figure 24 on page 21.

S C 661 500 Three Phase Battery Charger - FIGURE 11

NOTICE
If all three power switches are turned on and the sources are present, the charger is powered by the 120-Vac single-phase power source .

Connecting and Powering On the Charger with S &C Three-Phase Voltage Sensors
Complete the following steps to connect and power on the charger with S&C three-phase voltage sensors:
STEP 1.
Make sure the SINGLE-PHASE 120 VAC power switch, the THREE-PHASE VOLTAGE SENSORS power switch, and the CHARGER POWER switch are in the Off position. See Figure 17 on page 17.
STEP 2.
Using a small flathead screwdriver, connect the three-phase voltage sensor power source wires to the J3 connector by connecting the Phase 1 ground wire to pin 1, Phase 1 line wire (hot) to pin 2, Phase 2 ground wire to pin 5, Phase 2 line wire (hot) to pin 6, Phase 3 ground wire to pin 3 and Phase 3 line (hot) to pin 4. See Figure 25.
STEP 3.
Use a voltmeter to confi rm the voltage at the J3 connector before turning the THREE-PHASE VOLTAGE SENSORS power switch to the On position. Voltage between pin 1 and pin 2, pin 3 to pin 4, and pin 5 to pin 6 should be in between 5 Vac and 6.5 Vac (depending on the system line voltage). See Figures 26(a), 26(b), and 26(c).
STEP 4.
Making sure the two-pin battery connector is disconnected, use a small flathead screwdriver to connect the 24-Vdc battery to the charger by connecting the battery positive lead to pin 1 and the battery negative lead to pin 4 on the J2 connector. Now, connect the two-pin battery connector so the battery is connected to the charger. See Figure 18 on page 18.
STEP 5.
Before turning on the charger, use a voltmeter to confirm the voltage at the J2 connector. Voltage at pin 1 (battery positive) and pin 4 (battery negative) should be between 20 Vdc and 26 Vdc (depending on the battery state of charge). See Figure 19 on page 18.

S C 661 500 Three Phase Battery Charger - FIGURE 12

STEP 6.
Turn the THREE-PHASE VOLTAGE SENSORS power switch to the On position. See Figure 27.
STEP 7.
Turn the CHARGER POWER switch to the On position. The charger will turn on and the LCD screen will display the charger and battery status. See Figure 28.

S C 661 500 Three Phase Battery Charger - FIGURE 13

NOTICE
If all three power switches are turned on and there is no 120-Vac single-phase power source connected to the charger, the charger will be powered by the three phase power source.
If there is a 120-Vac single-phase power source connected to the charger, the 120-Vac single-phase power source will power the charger as a default .

Troubleshooting Tips
Any issues the charger and battery have are displayed on the LED indicators on the charger, on the LCD screen on the charger, or on the Battery Status screen of the GUI application software. Table 7 shows action items that can resolve issues with the charger and battery.

Table 7. Troubleshooting Tips

Issue	Reason
The UNDERVOLTAGE and OVERVOLTAGE LEDs are lit on the charger	This error

indicates BAT BAD. During the battery test, if the battery voltage is less than 23 Vdc and the battery impedance is more than 700 mohms, the BAT BAD error will occur. The charger will disconnect the battery by default.
In the GUI application under the Settings tab, if the user selects the No option to disconnect the battery from the charger if the voltage is under 17.5 Vdc, or if the charger is in the BAT BAD condition, then the battery will not be disconnected from the charger if ac is present.
Troubleshooting Tip: Reset the charger by using the GUI application or by using the RESET pushbutton to clear the error. Conduct the battery test again to check whether the BAT BAD error message appears again. If it appears again, change the battery.
Data not loading into the GUI application software| This is a possible error with the DB9 connection.
Troubleshooting Tip: Close and reopen the GUI application. Check the communication cable (connecting the charger and PC) for loose connections. Restart the computer and reopen the GUI application if issues persist. If these actions do not resolve the issue, contact S&C Electric Company.
“BAT LOW” appears on the LCD screen or in the GUI application| Battery voltage is less than 22 Vdc during a battery test.
Troubleshooting Tip: Make sure ac power is present. The charger will charge the battery and, when the battery voltage is greater than 22 Vdc, the BAT LOW warning will clear.
“CHR UV” appears on the LCD screen or in the GUI application| This occurs when the charger is providing a voltage that is lower than the threshold. The charger will still work normally.
Troubleshooting Tip: Verify the ac source wiring is connected to the charger. Reset the charger to clear the warning. If the warning still appears after multiple resets, contact S&C Electric Company.
“CHR OV” appears on the LCD screen or in the GUI application| This occurs when the charger is providing a voltage that is higher than the threshold. The charger will still work normally.
Troubleshooting Tip: Verify the ac source wiring is connected to the charger. Reset the charger to clear the warning. If the warning still appears after multiple resets, contact S&C Electric Company.

Appendix A

Using the Charger Pushbuttons for Manual Operation
NOTICE
S&C recommends using the GUI application software to operate and configure the battery charger . See pages 11 to 16 for configuration instructions .
There are settings displayed on the LCD screen that are configured by S&C Electric Company and are not configurable by the user via the pushbuttons or the GUI application software . The only configurable values are the battery charger current, date, and time .
There are four pushbuttons to manually confi gure or operate the charger. The UP and DOWN pushbuttons are used for the LCD screen. The RESET and BATTERY TEST pushbuttons are used to perform the operation function for the charger. See Figure 29.

S C 661 500 Three Phase Battery Charger - FIGURE 14

UP and DOWN Pushbuttons
The UP and DOWN pushbuttons can be used to manually configure the battery charger current, date, and time via the LCD screen.
NOTICE
S&C recommends using the Settings tab in the GUI application software to configure the battery charger.
See page 14 for configuration instructions.
Complete the following steps to manually set the battery charger current:
STEP 1.
Push and hold the DOWN pushbutton until the SET I mode appears on the LCD screen. When the mode appears, immediately release the pushbutton.
STEP 2.
When the pushbutton is released, SET I mode is active and the configured current value will be displayed. Push the DOWN pushbutton for a short time to select the digit position to adjust. The flashing digit position moves to the right once per push. The UP pushbutton increases the value of the flashing digit by 1. At 9, the next push goes to 0. The current can be set between 0.000 and 0.500 amps.
STEP 3.
When the desired value is entered, repeatedly push the DOWN pushbutton until the screen displays “SAVE.”
STEP 4.
If the battery charger current is correct, push the UP pushbutton to store this value.

Complete the following steps to manually set the date:

STEP 1.
Push and hold the DOWN pushbutton until the RTC DAT mode is displayed on the LCD screen. When the mode appears, immediately release the pushbutton.
STEP 2.
When the pushbutton is released, the RTC DAT mode is active and the configured date will be displayed. The date is in the MM.DD.YYYY format. The month digits will be flashing, showing the month is ready to be configured. Push the UP pushbutton once to increment the digit by 1, if necessary.
NOTICE
The UP pushbutton increases the value of the digit by 1 . At the maximum value (12 for month), the next push rolls over to the minimum value (1 for month) . Certain digit positions within the configurable value do not follow the 0-through-9 concept; they instead have their own configurable values .
STEP 3.
To select the subsequent day or year positions, push (or repeatedly push) the DOWN pushbutton to move the flashing position to the desired position. When the month, day, or year position is selected, repeatedly push the UP pushbutton to select the desired number.
STEP 4.
When the date is correctly entered, repeatedly push the DOWN pushbutton until the screen displays “SAVE.”
STEP 5.
To save the date entered, push the UP push-button to store the desired value.

Complete the following steps to manually set the time of day:

STEP 1.
Push and hold the DOWN pushbutton until the RTC TIM mode displays on the LCD screen. When the mode appears, immediately release the pushbutton.
STEP 2.
When the pushbutton is released, RTC TIM mode is active, and the configured time will be displayed. The time is in 24-hour format (HH:MM:SS). The hour position will be flashing and is ready to be configured. Repeatedly push the UP pushbutton to increment the number, if necessary.
NOTICE
The UP pushbutton increases the value of the digit by 1 . At the maximum value (23 for hour), the next push goes to the minimum value (0 for hour) . Certain digit positions
within the configurable value do not follow the 0-through-9 concept; they instead have their own configurable values .
STEP 3.
To select another position, push the DOWN pushbutton, which will move the flashing position to the right. Push it again to go to another position to change its value.
STEP 4.
When the desired value is entered, repeatedly push the DOWN pushbutton until the screen displays “SAVE.”
STEP 5.
If the time of day is correct, push the UP pushbutton to store this value.

RESET Pushbutton
The RESET pushbutton is used to clear external alarms caused by these battery conditions:

Battery Bad
Battery Removed/Battery with Open Cells

NOTICE
If the battery has been replaced or rewired to the charger, the user is required to push the RESET pushbutton to allow the battery to connect to the charger .
Pushing the RESET pushbutton does not cycle the power to the charger .
The RESET pushbutton will not clear all alarm conditions. The following alarm conditions do not require a push of the RESET pushbutton but will clear when the condition
is no longer active:

Battery under voltage
Battery over voltage
Ac present
Charger over voltage

BATTERY TEST Pushbutton
NOTICE
The battery test can also be done remotely by applying external 24-Vdc to pin 6 (positive) and pin 7 (negative) of the J2 connector .
During the first 24-hour operation period, the battery is automatically tested every two hours . After that, when ac power is present and the charger is not turned off, the battery is tested once a day at midnight (per set charger time) . If the battery is powering the charger because of a loss of the ac source, a battery test will occur every two hours .

To test the 24-Vdc battery without the use of a computer, the BATTERY TEST pushbutton can be used.
Complete the following steps to test the battery:
STEP 1.
Press and hold the BATTERY TEST pushbutton for three seconds.
STEP 2.
After releasing the pushbutton, the battery test will start in about five seconds. Looking at the LCD screen, the user will see a status bar during testing. When the status bar on he LCD screen is full, the test will be complete.
STEP 3.
When the test is complete, the user can see the results of the battery test on the LCD screen by waiting until a “br” (battery record) text appears at the top of the LCD screen as the parameters scroll. Every parameter the “br” text is displayed over is the result of the test. The following parameters are measured/recorded:

Battery status
Date
Time
Temperature
VL (voltage under load)
BZ (battery impedance)

NOTICE
The battery test results on the LCD screen will be overwritten by the results of subsequent battery tests . The battery test results on the LCD screen are also cleared if the charger is turned off and then turned back on .
When the battery charger is powered from battery only (no ac present during testing), battery impedance (BZ) will display NA (not applicable) . When ac is present during testing, battery impedance (BZ) displays in ohms.

Appendix B

Connector Pin Descriptions
Relay Input Voltage
The Battery Test Start (J2 connector, pins 6 and 7) and Alarm Reset (J2 connector, pins 8 and 9) contacts must be powered with 24 Vdc. Voltage must be applied for at least three seconds for the contact command to be recognized. See Table 8, Table 9 on page 29, and Table 10 on page 30.

Table 8. J2 Connector Input Definitions

Upper Row

Table 9. J3 Connector Input Definitions

Upper Row

Table 10. J4 Connector Input Definitions

Upper Row

Pin Number| Connection Name| Description
1| UNDER VOLTAGE INDICATOR COMMON 1| Relay dry contacts for Battery Under Voltage condition indicator. The relay will turn on when the battery voltage is below 23 V when an ac source is present and 22 V when an ac source is not present. The relay will be latched until conditions are cleared.
2| UNDER VOLTAGE INDICATOR NO 1
3| UNDER VOLTAGE INDICATOR NC 1
4| BAT CHECK INDICATOR COMMON 2| Relay dry contacts for Battery Test indicator. The relay will turn on during the battery test and turn off when the battery test is complete.
5| BAT CHECK INDICATOR NC 2
6| BAT CHECK INDICATOR NO 2
7| BAT CHECK INDICATOR NO 1| Relay dry contacts for Battery Test indicator. The relay will turn on during the battery test and turn off when the battery test is complete.
8| BAT CHECK INDICATOR NC 1
9| BAT CHECK INDICATOR COMMON 1
10| OC INDICATOR NO 1| See details on pin 19 and 20
Lower Row
Pin Number| Connection Name| Description
11| UNDER VOLTAGE INDICATOR NO 2| Relay dry contacts for Battery Under Voltage condition indicator. Relay will turn on when the battery voltage is below 23 V when an ac source is present and 22 V when an ac source is not present. The relay will be latched until conditions are cleared.
12| UNDER VOLTAGE INDICATOR NC 2
13| UNDER VOLTAGE INDICATOR COMMON 2
14| (+24) VDC OUTPUT| Positive supply to RTU
15| (-24) VDC OUTPUT| Negative supply to RTU
16| AC INDICATOR COMMON 2| Relay dry contacts for an ac source being present. The relay will turn on when there is no ac source (either 120 Vac or three- phase current source) supplying the charger. The relay will be latched until conditions are cleared.
17| AC INDICATOR NC 2
18| AC INDICATOR NO 2
19| OC INDICATOR COMMON 1| Relay dry contacts for Open Cell or Battery Not Connected condition indicator. Relay will turn on when there is no battery connected to charger or if a battery has open cell(s). The relay will be latched until the alarm is reset.
20| OC INDICATOR NC 1

Appendix C

System Line-to-Ground Voltage Calibration
To calibrate the system line-to-ground voltage:
STEP 1.
Record the voltage-sensor magnitude ratios of each voltage sensor in Table 11. The voltage-sensor magnitude ratio can be found on the Voltage-Sensor Data Yellow card (G-6244R6, page 2) shipped with the system.
Table 11. Voltage-Sensor Magnitude Ratios

Voltage-Sensor Magnitude Ratios

Phase 1| Phase 3| Phase 2
| |

STEP 2.
Turn the THREE-PHASE VOLTAGE SENSORS power switch to the Off position and wait for 10 seconds. Using a voltmeter, measure the voltage (Vac) at the J3 connector and record the measurements in Table 12.
Table 12. Input Voltage

Input Output Voltage

Phase 1 (J3-1 to J3-2)| Phase 3 (J3-3 to J3-4)| Phase 2 (J3-5 to J3-6)
| |

STEP 3.
Turn the THREE-PHASE VOLTAGE SENSORS power switch to the On position and wait for 10 seconds. Using a voltmeter, measure the voltage (Vac) at the J2 connector and record the measurements in the Table 13.
Table 13. Analog Output Voltage

Analog Output Voltage

Phase 1 (J2-20 to J2-17)| Phase 3 (J2-20 to J2-19)| Phase 2 (J2-20 to J2-18)
| |

STEP 4.
Calculate the system line to ground voltage using the formula below. Record the line-to-ground voltage for each phase in Table 14.
System line-to-ground voltage = 1.006 × Input Voltage (Table 12) × Voltage- Sensor Magnitude Ratios (Table 11)
Table 14. System Line-to-Ground Voltage

System Line-to-Ground Voltage

Phase 1| Phase 3| Phase 2
| |

STEP 5.
Calculate and record the adjust voltage-sensor ratios for each phase in Table 15. These adjust voltage-sensor ratios must be entered into the RTU to offset unit-to-unit variations in the charger when voltage sensors power the charger.
Adjust voltage-sensor ratios = System line-to-ground voltage (Table 14) ∕ Analog output voltage (Table 13).
Table 15. Adjust Voltage-Sensor Ratios