INSTALLATION & OPERATING

INSTRUCTIONS

SCR FLX SERIES

INDUSTRIAL BATTERY CHARGERS
PACIFIC CHLORIDE ®

GNB Industrial Power GNB Industrial Power Exide Technologies

Motive Power Motive Power Chloride Motive Power
829 Parkview Boulevard 8301 Keele Street P.O. Box 1, Salford Road
Lombard, IL 60148-3249 Maple, Ontario Over Hulton, Bolton BL5 1DD
U.S.A. Canada L6A 1T2 United Kingdom
Tel: 877.GNB.INFO Tel: 905.669.9326 Tel: 44.1204.661.230
Fax: 630.691.7869 Fax: 905.669.7688 Fax: 44.1204.652.100 www.gnb.com

GB-3889 RPT 11/01 Printed on recycled paper

TABLE OF CONTENTS

TITLE PAGE

1.0 IMPORTANT OPERATING AND SAFETY INSTRUCTIONS 2

2.0 INTRODUCTION 3

3.0 RECEIVING CHARGER 3

4.0 LOCATION AND INSTALLATION OF CHARGER 3

4.1 Stacking 3

5.0 AC ELECTRICAL SUPPLY 3

5.1 AC Fuse Mounting 3

5.2 Input Voltage Change 3

5.3 AC Voltage Connections 7

5.4 Ground connection 7

6.0 DC OUTPUT 7

7.0 APPLICATION 8

7.1 Display and Fault Codes 8

7.2 Options 8

TABLE 2 - SINGLE PHASE RATINGS 9

TABLE 3 - THREE PHASE RATINGS 11

8.0 CABINET OUTLINE/DIMENSIONS 13

9.0 SCRFLX CHARGER OPERATION 14

9.1 SCRFLX Charger Functional Description 15

10.0 CHARGE TIME 16

11.0 AC POWER FAILURE 16

12.0 MAINTENANCE 16

13.0 TROUBLESHOOTING 17

APPENDIX A: SCRFLX BATTERY CHARGERS. LIST OF DISPLAY INDICATIONS 19

APPENDIX B: ELECTRICAL SCHEMATIC DRAWINGS 21

Instr. 4770-65-95005-10 Page 1

Rev 15/08/2002
SCRFLX SERIES INDUSTRIAL BATTERY CHARGERS
1.0 IMPORTANT OPERATING AND SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS

a) Before using the battery charger, read all the instructions in addition to the CAUTION, WARNING, and DANGER
markings on the charger, battery and all the associated equipment.

b) Do not touch uninsulated parts of the DC output connector or the battery terminals, as there is a possibility of
electric shock.

c) Connect or disconnect the battery plug only when the charger output is off; ALWAYS press the STOP
pushbutton before unplugging the battery to prevent arcing or burning.

d) If the battery is unplugged during charging, the charger will indicate “OFF”. To restart the charger, plug in the next
battery.

e) Only qualified personnel should operate or service this equipment.

f) De-energize all AC and DC power connections before servicing this unit. If injury does occur, apply the prescribed
treatment for electrical shock and obtain medical attention immediately.

g) The charger is NOT for outdoor use. Do not expose the charger to rain or snow.

h) This charger is factory set to charge flooded lead-acid batteries only. Operating environment should not contain
any contaminations that may cause corrosion or contamination that would degrade the performance of a charger.

i) Do not operate this unit if it has received a sharp blow, been dropped or otherwise damaged. Take it to a qualified
GNB service center.

j) Do not disassemble the charger. Have the charger examined by a GNB service representative or local qualified
service facility. Incorrect re-assembly of the charger may result in an explosion, electric shock or fire.

Instr. 4770-65-95005-10 Page 2

2.0 INTRODUCTION STONE, BRICK, CONCRETE OR METAL. IF
THIS IS NOT AVAILABLE, A FLOOR PLATE OF
The GNB SCRFLX battery chargers are convection AT LEAST 1.43mm GALVANIZED OR 1.6mm
cooled, solid state, micro-processor controlled SCR
UNCOATED STEEL EXTENDED AT LEAST
regulated chargers designed to make battery charging
simple. They are designed to charge flooded lead-acid 150mm BEYOND THE EQUIPMENT ON ALL
batteries only. SIDES MUST BE INSTALLED.

The charger has a comprehensive self-checking 5.0 AC ELECTRICAL SUPPLY

diagnostic program to control all charger functions,
monitor the quality of charge and check its own safety The charger must be connected to either a single phase,
conditions. Large easy to read LEDs, three button or three phase, 50 or 60 Hertz (± 2%) AC power source.
keypad and LED display report on charger and battery The following options are available:
status.
TABLE 1 – INPUT VOLTAGE CHOICES
3.0 RECEIVING CHARGER Single phase Three phase
a) 120/208/240VAC, 60Hz d) 208/240/480VAC, 60Hz
Examine the charger thoroughly before using, to make b) 208/240/480VAC, 60Hz e) 480VAC, 60Hz
sure that no parts have been loosened or damaged c) 240VAC, 50Hz f) 380VAC, 50Hz
during shipment. Check the contents of the package g) 415VAC, 50Hz
against the delivery slip before disposing of the shipping
package. If any shipping damage or partial loss is Only the AC input wire configuration for multi-input
found, file a claim with the carrier without delay and take chargers can be changed. Follow Figure 1 (page 4) for
any necessary steps to protect your rights. Before single phase input or Figure 2 and Figure 3 (pages 5-6)
installing, check that the charger nameplate data for three phase input transformers. This change should
corresponds to the packing slip and to the model be done by a qualified electrical contractor.
specified on the original sales order.
The SCRFLX chargers are delivered on skids for easy
handling using a fork lift truck.
5.1 AC FUSE MOUNTING

The charger comes with a fuseblock rated big enough to

4.0 LOCATION AND INSTALLATION OF accommodate the highest possible current and voltage
CHARGER for that particular model. Proper fuse ratings can be
found in Table 2 and Table 3(see pages 9-12) for AC
Proper installation is important in order to achieve good input fuses (F1, F2 in case of a single phase input or F1,
charger performance, long troublefree operation and to F2, F3 in case of a three phase input). Fuses with an
prevent damage to the charger and batteries. The ampere rating of 30A or less are smaller and need fuse
charger should be located in a clean, cool, normal reducers when placed in a 60A fuseblock.
ambient room temperature (between +45°F/7.2°C and
90°F/32.2°C) dry and well ventilated area. To permit free 5.2 INPUT VOLTAGE CHANGE
air flow for convection cooling allow four inches Before proceeding check which transformer tap
minimum between the charger and any wall, six inches configuartion you have. When changing the taps on the
from other equipment, and never store anything beneath input side between 1) 120, 208, 240 VAC or 2) 208, 240,
or on top of the charger. 480 VAC (single phase input), be sure to change the
wires and/or jumpers according to Figure 1 (page 4).
4.1 STACKING Once finished, refer to Table 2 (pages 9-10) for the
When stacking chargers on top of each other, ensure correct size of AC input fuses. Similarly when changing
that cabinets are bolted together using properly sized input voltage between 208, 240, 480 VAC (three phase
black #1/4-20 UNC hardware provided in all four corners input) follow the schematics on Figure 2 or Figure 3
on top cover. The floor mounting must be done with (pages 5-6) whichever is applicable. Following that,
#1/4-20 UNC bolts (steel rack) or #1/4 lag screws and check Table 3 (pages 11-12) for the correct size of AC
anchors (concrete floor). All charger models with a Z, input fuses. Figure 3 applies to 12 cell 475, 600, 750,
SCRFLX-XX-XXXT1Z of SCRFLX-XX-XXX-S1Z, can be 865 Ah; 18 cell 475, 600, 750, 865, 965, 1050 Ah; and
stacked to a maximum of three high. 24 cell 475, 600, 750, 865Ah chargers only.

WARNING: THE ABOVE PROCEDURES MUST NOTE: Upon completion and proper verification of the
BE FOLLOWED EXACTLY TO AVOID INJURY input voltage configuration change, markings on the
OR RISK OF ELECTRIC SHOCK. door label and the unit nameplate must be revised
(crossing out factory set markings); re-mark the label
WARNING: TO REDUCE THE RISK OF FIRE, with a permanent marker to reflect new input voltage
INSTALL BATTERY CHARGER ON A FLOOR OF configuration and fuse size.
NON-COMBUSTIBLE MATERIAL, SUCH AS

Instr. 4770-65-95005-10 Page 3

FIGURE 1: SINGLE PHASE INPUT
WARNING: IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE DAMAGE TO THE
CHARGER AND BATTERY
120 VAC CONFIGURATION (120/208/240V INPUT) 208 VAC CONFIGURATION (208/240/480V INPUT)

BRN BLK BRN

BLK

L2 L1 L2 L1

208 VAC CONFIGURATION (120/208/240V INPUT) 240 VAC CONFIGURATION (208/240/480V INPUT)

BLK BRN
BLK

BRN

L2 L1 L2 L1

240 VAC CONFIGURATION (120/208/240V INPUT) 480 VAC CONFIGURATION (208/240/480V INPUT)

BLK BLK

BRN BRN

L2 L1 L2 L1

Instr. 4770-65-95005-10 Page 4

FIGURE 2: THREE PHASE INPUT
WARNING: IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE DAMAGE TO THE
CHARGER AND BATTERY
208VAC CONFIGURATION (208/240/480V INPUT)

L2 L1 L3 L2 L1
L3

240VAC CONFIGURATION (208/240/480V INPUT)

L2 L1 L3 L2 L3
L1

480VAC CONFIGURATION (208/240/480V INPUT)

L2 L1 L3 L2 L1
L3

Instr. 4770-65-95005-10 Page 5

FIGURE 3: THREE PHASE INPUT
WARNING: IMPROPER WIRE AND JUMPER CONNECTION MAY CAUSE SEVERE DAMAGE TO THE
CHARGER AND BATTERY

208VAC CONFIGURATION (208/240/480V INPUT) (SCRFLX- XX-XXXXT1Z ONLY)

L1
L1 L2 L3

L2 L3

240VAC CONFIGURATION (208/240/480V INPUT) (SCRFLX -XX-XXXXT1Z ONLY)

L1 L1
L2 L3

L2 L3

480VAC CONFIGURATION (208/240/480V INPUT) (SCRFLX -XX-XXXXT1Z ONLY)

L1 L2 L3 L1

L2 L3

Instr. 4770-65-95005-10 Page 6

5.3 AC VOLTAGE CONNECTIONS 6.0 DC OUTPUT

To connect the input AC voltage, route the AC conduit The DC charging cable has a commonly used battery
through the knockout hole provided. Continue the AC plug or receptacle. The polarity of the charger plug must
wiring to fuseholder terminals L1 (N) and L2 (L) (single be the same as the battery connector. The BLACK DC
phase input) or L1, L2, and L3 (three phase input), cable must be connected to the battery negative (-), and
ensuring that the AC source phases match the phase the RED DC cable must be connected to the battery
rotation on the AC input. For proper connection, torque positive (+). The charger will not operate in a reversed
the screws to approximately 25 inch-pounds. polarity condition.

5.4 GROUND CONNECTION The DC output fuse is a "fast-acting" fuse used to

protect the power semiconductors of a charger.
It is a requirement to ground the chassis while the
charger is connected to AC power. The charger comes NOTE: Use only identical replacement fuses obtainable
with a ground lug attached to the stud, clearly marked on from your GNB service representative
the chassis. To ensure good continuity keep the contact
area clean. The stud is designed for a 3/16” hardware.
See gounding method shown below (Figure 4.).

WARNING: DO NOT OPERATE THE UNIT

WITHOUT PROPER GROUNDING. IMPROPER
GROUNDING CAN RESULT IN THE RISK OF AN
ELECTRIC SHOCK AND ELIMINATES
CHARGER WARRANTY.

CAUTION: USE MINIMUM 75°C WIRING. FOR

SUPPLY CONNECTIONS, GROUND CHARGER
PROPERLY USING GROUNDING STUD (GND)
PROVIDED. USE COPPER-CLAD ALUMINUM,
ALUMINUM OR COPPER CONDUCTORS ONLY.

After electrical connection is completed, the charger is

ready for operation.

NOTE: The following applies to three phase chargers

only: if the charger indicates “FAC” or F3 upon start-up,
it means that there is a low or high AC voltage (+35%)
or AC phase missing. Refer to the Troubleshooting
Section (Section 13, page 17) for more details.

FIGURE 4: GROUNDING METHOD

Instr. 4770-65-95005-10 Page 7

7.0 APPLICATION convenient location for use. When installing the push
buttons ensure that there are no corrosive fumes
The charger will automatically charge a battery per the deteriorating the contacts. The Remote Stop / Equalize
Ah rating set at the factory. The charger can be re-set option is available for “Z” model chargers “B” and “C”
for anywhere between 65% to 200% of the nameplate cabinets, 6 – 36 cells only. For non “Z” models contact
Ah rating. Ensure that battery and charger are matched. your local GNB service representative.
Keep in mind if the charger is set for more than 100% of
Ah of the charger rating the charging time will increase
proportionately (up to 16 hours). For battery sizes not
listed, contact your local GNB service representative.

7.1 DISPLAY AND FAULT CODES

Refer to Appendix A (on page 19) for a complete list of

codes.

7.2 OPTIONS

7.2.1 JIC SWITCH ASSEMBLY

All SCRFLX battery chargers can come with a factory

installed fused JIC switch assembly option for extra
protection of the operator. In the "OFF" position, the door
can be opened but only AC power at the input of the
switch is present while everything downstream is dead.
In the "ON" position, AC power is supplied to the charger
but the door cannot be opened. See applicable drawing
4770-65-73041-05, 4770-65-73041-15 or 4770-65-
73041-17 for electrical schematic (Appendix B, pages
21-31). NOTE: Only HRCI-R type fuses (ECSR or
equivalent) with the notched ferrule at one end can be
used. A JIC type switch can only be factory installed and
it is available in a “B”, “C” or “D” size cabinet.

7.2.2 BATTERY WATERING OPERATION

AND END OF CHARGE

The SCRFLX battery charger has an available watering

control and end of charge option, in the form of a relay
contact at terminals TB10-1 to TB10-2 (supplied for
customer connection). The relay closes thirty minutes
after the charger reaches gassing voltage. It remains
closed for approximately ten minutes.

NOTE:These options require different control cards per

drawing 4120-65-68650-05 (see Appendix B, pages 21-
31).

RELAY CONTACT RATINGS:

- AC: 125V 0.6A 1.0PF maximum
- DC: 30V 2A resistive maximum

7.2.3 REMOTE STOP / EQUALIZE

The SCR100 battery charger can come with a factory

installed Remote Stop / Equalize assembly option (part-
number V16-31365-50) in case the charger is out of
reach for the operator. The end user will have to install
two separate push buttons to the appropriate terminals
on the Remote Stop / Equalize circuit board (see
schematic 4120-66-68650-50) and locate them to a
Instr. 4770-65-95005-10 Page 8
TABLE 2 – SINGLE PHASE TECHNICAL DATA
STANDARD MODEL
DC AC AMPS @ AC VOLTS CABINET WEIGHT
SCRFLX-XX-XXXX-S1Z
AMPS 120 208 240 480 TYPE LBS KGS
SCRFLX-06-260S1Z AMPS 12 7 6 3 A 76 34.5
40
FUSE 15 10 8 4
SCRFLX-06-475S1Z AMPS 19 11 9.5 5 A 120 54.4
74
FUSE 25 15 12 7
(50 Hz) AMPS X X 9.5 X A 130 59.1
74
FUSE - - 12 -
SCRFLX-06-600S1Z AMPS 26 15 14 7 B 190 86.2
93
FUSE 35 20 20 10
(50 Hz) AMPS X X 13.5 X B 205 93.2
93
FUSE - - 20 -
SCRFLX-06-865S1Z AMPS C.F. 20 18 9 B 255 116
134
FUSE - 25 25 12
SCRFLX-06-965S1Z AMPS C.F. 23 20 10 B 295 134
150
FUSE - 30 25 15
SCRFLX-09-475S1Z AMPS 26 15 14 6.5 B 160 72.5
74
FUSE 35 20 20 10
SCRFLX-09-600S1Z AMPS C.F. 19 16 8 B 210 95
93
FUSE - 25 20 10
SCRFLX-09-865S1Z AMPS C.F. 27 23.5 12 B 260 118
134
FUSE - 35 30 15
SCRFLX-09-965S1Z AMPS C.F. 30 26 13 B 300 136
150
FUSE - 40 35 20
SCRFLX-12-260S1Z AMPS 18.5 10.5 9 5 A 120 54.4
40
FUSE 25 15 12 7
(50 Hz) AMPS X X 9 X A 130 59.1
40
FUSE - - 12 -
SCRFLX-12-475S1Z AMPS C.F. 19.5 17 8.5 B 200 90.7
74
FUSE - 25 25 12
(50 Hz) AMPS X X 17 X B 212 96.4
74
FUSE - - 25 -
SCRFLX-12-600S1Z AMPS C.F. 25.5 22 11 B 225 102
93
FUSE - 35 30 15
(50 Hz) AMPS X X 22 X B 235 107
93
FUSE - - 30 -
SCRFLX-12-750S1Z AMPS C.F. 34 29 14.5 B 270 122
116
FUSE - 45 40 20
SCRFLX-12-865S1Z AMPS C.F. 34 29 14.5 B 270 122
134
FUSE - 45 40 20
SCRFLX-12-965S1Z AMPS C.F. 38 34 17 B 305 138
150
FUSE - 50 45 25
SCRFLX-18-260S1Z AMPS C.F. 16 14 7 B 195 88.5
40
FUSE - 20 20 10
SCRFLX-18-475S1Z AMPS C.F. 30 26 14 B 240 109
74
FUSE - 40 35 20

Instr. 4770-65-95005-10 Page 9

TABLE 2 – SINGLE PHASE TECHNICAL DATA
STANDARD MODEL DC AC AMPS @ AC VOLTS WEIGHT
SCRFLX-XX-XXXX-S1Z CABINET
AMPS 120 208 240 480 TYPE LBS KGS
SCRFLX-18-600S1Z AMPS C.F. 36.5 31.5 16 B 260 118
93
FUSE - 50 40 20
SCRFLX-18-750S1Z AMPS C.F. 48 44 22 C 260 118
116
FUSE - 60 60 30
SCRFLX-18-865S1Z AMPS C.F. 48 44 22 C 325 147
134
FUSE - 60 60 30
(50 Hz) AMPS X X 44 X C 340 155
134
FUSE - - 60 -
SCRFLX-24-260S1Z AMPS C.F. 22 19 10 B 300 135
40
FUSE - 30 25 15
SCRFLX-24-475S1Z AMPS C.F. 39 33.5 17 C 315 143
74
FUSE - 50 45 25
(50 Hz) AMPS X X 33.5 X C 340 155
74
FUSE - - 45 -
SCRFLX-24-600S1Z AMPS C.F. 48 41 21 C 380 172
93
FUSE - 60 60 30
(50 Hz) AMPS X X 41 X C 400 182
93
FUSE X X 60 X
NOTE: C.F.: CONTACT FACTORY; X: NOT AVAILABLE; -: DATA NOT AVAILABLE

Instr. 4770-65-95005-10 Page 10

TABLE 3 – THREE PHASE TECHNICAL DATA
AC AMPS @ AC VOLTS
STANDARD MODEL DC 60Hz 50Hz CABINET WEIGHT
SCRFLX-XX-XXXX-T1Z AMPS 208 240 480 380 415 TYPE LBS KGS
SCRFLX-06-475T1Z AMPS 5 4.5 2.2 C.F. C.F. B 170 77.1
74
FUSE 7 6 3 - -
SCRFLX-06-600T1Z AMPS 7 6 3.5 C.F. 3.5 B 190 86.2
93 FUSE 10 8 5 - 5
SCRFLX-06-750T1Z AMPS 9 8 4 C.F. C.F. B 220 99.8
116
FUSE 12 12 6 - -
SCRFLX-06-865T1Z AMPS 10 9 5 C.F. C.F. B 220 99.8
134
FUSE 15 12 7 - -
SCRFLX-06-965T1Z AMPS 11 10 5 C.F. C.F. B 235 107
150
FUSE 15 15 7 - -
SCRFLX-06-1050T1Z AMPS 12 11 5.5 C.F. C.F. B 245 111
163
FUSE 15 15 8 - -
SCRFLX-06-1200T1Z AMPS 12.7 11 5 C.F. C.F. C 260 118
186
FUSE 20 15 7 - -
SCRFLX-06-1450T1Z AMPS 15 14 7 C.F. C.F. C 290 132
225
FUSE 20 20 10 - -
SCRFLX-09-600T1Z AMPS 12 10 5 C.F. C.F. B 220 99.8
93
FUSE 15 15 7 - -
SCRFLX-12-475T1Z AMPS 9 8 4 5.5 5 B 215 97.6
74
FUSE 12 12 6 8 7
SCRFLX-12-600T1Z AMPS 11.5 10 5 7 7 B 220 100
93
FUSE 15 15 7 10 10
SCRFLX-12-750T1Z AMPS 15 14 7 9.2 9 B 250 113.5
116
FUSE 20 20 10 12 12
SCRFLX-12-865T1Z AMPS 16 14 7 10 9 B 255 116
134
FUSE 20 20 10 15 12
SCRFLX-12-965T1Z AMPS 21 18 9 C.F. C.F. C 260 118
150
FUSE 30 25 12 - -
SCRFLX-12-1050T1Z AMPS 22 19 9.5 12 C.F. C 270 122
163
FUSE 30 25 12 15
SCRFLX-12-1200T1Z 186 AMPS 26 22 11 C.F. C.F. C 298 135
FUSE 35 30 15 - -
SCRFLX-12-1450T1Z 225 AMPS 30 26 14 C.F. C.F. C 310 141
FUSE 40 35 20 - -
SCRFLX-18-260T1Z 40 AMPS 9 8 4 C.F. C.F. B 215 98
FUSE 12 10 6 - -
SCRFLX-18-475T1Z 74 AMPS 14 11 5.5 C.F. 8 B 255 116
FUSE 20 15 8 - 12
SCRFLX-18-600T1Z AMPS 16 14 7 C.F. 10 B / C* 300 136
93
FUSE 20 20 10 - 15
SCRFLX-18-750T1Z 116 AMPS 20 18 9 16 15 B / C* 310 141
FUSE 30 25 12 20 20
SCRFLX-18-865T1Z 134 AMPS 24 21 10.5 16 15 C 325 148
FUSE 35 30 15 20 20
SCRFLX-18-965T1Z 150 AMPS 26 22 11 18 17 C 340 155
FUSE 35 30 15 25 25

Instr. 4770-65-95005-10 Page 11

TABLE 3 – THREE PHASE TECHNICAL DATA

AC AMPS @ AC VOLTS
STANDARD MODEL DC 60Hz 50Hz CABINET WEIGHT
SCRFLX-XX-XXXX-T1Z AMPS 208 240 480 380 415 TYPE LBS KGS
SCRFLX-18-1050T1Z AMPS 28 24 12 19 17.5 C 380 163
163
FUSE 40 35 15 25 25
SCRFLX-18-1200T1Z AMPS 37 32 16 26 C.F. C 410 186
186 FUSE 50 45 20 35 -
SCRFLX-18-1450T1Z AMPS 47.5 41 21 27 26 C 450 204
225
FUSE 60 60 30 35 35
SCRFLX-18-1700T1Z AMPS 48 44 22 C.F. C.F. D 550 250
264
FUSE 60 60 30 - -
SCRFLX-24-475T1Z AMPS 17 15 7.5 C.F. 10 B / C* 290 132
74
FUSE 25 20 10 - 15
SCRFLX-24-600T1Z AMPS 21 18 9.5 15 12 C 320 145
93
FUSE 30 25 12 20 15
SCRFLX-24-750T1Z AMPS 28 24 12 18 15 C 345 157
116
FUSE 40 35 15 25 20
SCRFLX-24-865T1Z AMPS 31 27 14 18 17.2 C 380 173
134
FUSE 45 40 20 25 25
SCRFLX-24-965T1Z AMPS 40 36 18 C.F. 20 C 400 182
150
FUSE 60 50 25 - 30
SCRFLX-24-1050T1Z AMPS 44 38 18.5 24 22 C 425 193
163
FUSE 60 50 25 35 30
SCRFLX-24-1200T1Z AMPS 48 46 23 28 C.F. C 440 200
186
FUSE 60 60 30 40 -
SCRFLX-24-1450T1Z AMPS C.F. C.F. 27 27 22 C 490 222
225
FUSE - - 35 35 30
SCRFLX-24-1700T1Z AMPS C.F. C.F. 31 31 25 D 525 239
264
FUSE - - 40 40 35
SCRFLX-36-475T1Z AMPS 34 29 14.5 C.F. C.F. C 330 150
74
FUSE 45 40 20 - -
SCRFLX-36-600T1Z AMPS 41 35 18 21 20.5 C 420 190
93
FUSE 60 50 25 35 30
SCRFLX-36-750T1Z 116 AMPS 46 40 20 C.F. 27 C 460 209
FUSE 60 60 30 - 35
SCRFLX-36-865-T1Z 134 AMPS C.F. 46.5 23 C.F. 27 C 480 218
FUSE - 60 30 - 35

SCRFLX-36-965-T1Z 150 AMPS C.F. C.F. 27 C.F. 29.4 C 500 227

FUSE - - 40 - 40
SCRFLX-36-1450-T1Z 225 AMPS C.F. C.F. 37 C.F. 42 D 550 250
FUSE - - 50 - 60
SCRFLX-40-475-T1Z AMPS 39 34 17 C.F. 19.5 C 450 204
74
FUSE 50 45 25 - 25
SCRFLX-40-1200-T1Z 186 AMPS C.F. C.F. 33 C.F. C.F. D 500 227
FUSE - - 45 - -
SCRFLX-48-600-T1Z 93 AMPS 48 42 21 C.F. C.F. D 550 250
FUSE 60 60 30 - -
SCRFLX-48-865-T1Z 134 AMPS C.F. C.F. C.F. C.F. C.F. D 600 272
FUSE - - - - -
NOTE: C.F.: CONTACT FACTORY; X: NOT AVAILABLE -: DATA NOT AVAILABLE; *: 50Hz MODELS ARE IN A “C” CABINET

Instr. 4770-65-95005-10 Page 12

8.0 CABINET OUTLINE/DIMENSIONS FOR –Z MODEL CHARGERS ONLY

CABINET DIM. A DIM. B DIM. C

A 15.10” 20.65” 12.75”
B 22.70” 26.65” 22.25”
C 32.10” 26.65” 22.25”
D 24.30” 42.00” 23.65”
D (Mining) 24.30” 42.00” 23.65”
E (Mining) 24.30” 59.00” 31.50”

NOTE: Mining chargers are equipped with a drip cap and four lifting eyebolts for sling lifting. Add an additional
5.000” to the height. (DIM.B)

Instr. 4770-65-95005-10 Page 13

9.0 SCRFLX CHARGER OPERATION
LED DISPLAY DESCRIPTION

(NONE) PLUG IN THE BATTERY TO COMMENCE

OFF CHARGING
CHARGER SET FOR FLOODED BATTERIES
FLd*
DELAY (Orange), dEL, then DELAY MODE, PRESS “START” BUTTON TO
delay time remaining in Hours. OFF OVERRIDE. (Section 9.1.1, page 15)
minutes
dEL
time
CHARGING (Orange) HIGH RATE CHARGING
XXX
(DISPLAY OF CHARGE CURRENT)

80% CHARGED (Yellow) FINISH RATE CHARGING

XXX
(DISPLAY OF FINISH RATE CURRENT)

FAULT (Red) CHARGE CYCLE WAS INTERRUPTED BY

OFF PRESSING “STOP” BUTTON BEFORE
UNPLUGGING THE BATTERY

FAULT (Red) FAULT CONDITION EXISTS. UNPLUG THE

OFF/ BATTERY AND GO TO APPENDIX A FOR
DETAILS. *OTHER INDICATION DISPLAYED
XXX (i.e. FAC, Fdc, Lo, HI, etc.)

CHARGE COMPLETE (Green) CHARGING IS COMPLETE. ONCE

flashing, remaining cooldown time OFF COOLDOWN TIME IS FINISHED, UNPLUG
displayed in Hours.minutes THE BATTERY.
CoL*
time
CHARGE COMPLETE (Green) BATTERY CAN BE UNPLUGGED AND USED.*
on, remaining refresh time OFF
displayed in Hours. minutes
rFr*
time
EQUALIZE (Orange) PRESS “EQUALIZE” BUTTON TO EQUALIZE
XXX THE BATTERY. PRESS AGAIN TO CANCEL.

(DISPLAY OF CHARGE CURRENT)

∗
THESE DISPLAYS OR OPTIONS ARE AVAILABLE ONLY ON Z MODEL CHARGERS OR REPLACEMENT BOARDS

Instr. 4770-65-95005-10 Page 14

9.1 SCRFLX CHARGER FUNCTIONAL 9.1.2 CHARGING
DESCRIPTION
9.1.2.1 CHARGING LED
This section gives a brief description of each LED,
pushbutton, and the delay function on the SCRFLX type This LED indicates that the charger is ON.
charger front control panel.
9.1.2.2 80 % CHARGED LED
9.1.1 DELAY STAGE
This LED indicates that the battery has reached 80%
9.1.1.1 DELAY CIRCUIT charge.

CAUTION: HAZARDOUS VOLTAGES INSIDE. DO NOT 9.1.2.3 CHARGE COMPLETE LED

ATTEMPT TO CHANGE THE SLIDE SWITCHES ON
THE CONTROL CARD UNTIL ALL AC POWER IS When this LED is continuously lit it indicates that the
DISCONNECTED FROM THE UNIT AS WELL AS THE charging cycle is complete. The battery may now be
BATTERY IS UNPLUGGED FROM THE CHARGER. safely disconnected. In the event this LED is flashing, it
USE PROPER TOOL TO OPEN THE CABINET DOOR. indicates that cooldown is in progress.

1. The delay circuit enables the user to set a delay of up 9.1.2.4 FAULT LED
to eight hours between battery plug in and the start of
charge. This LED is associated with any fault that is described in
2. The delay time must be set prior to charging. This can Appendix A LIST OF DISPLAY INDICATIONS (page
be done via the slide switches located on the back of 19). It indicates that there is a problem prior to or during
the charger control card. Refer to Table 4 below for the battery charging operation.
details.
9.1.3 DISPLAY
CAUTION: DO NOT TOUCH THE OTHER SLIDE
SWITCHES ON THE BACK OF THE CONTROL The display shows the charging current to the battery
BOARD. THESE ARE FACTORY SET AND CAN ONLY during the charging process. The display will show
BE CHANGED BY A QUALIFIED GNB SERVICE additional messages as the charging is progressing or a
REPRESENTATIVE. fault occurs.

TABLE 4 9.1.4 STOP PUSHBUTTON

SW5 1 2 3 4 START DELAY This pushbutton will STOP the charge cycle. The battery
(HOURS) can then be safely unplugged. The red fault LED will light
ON ON ON ON 0 (DEFAULT) to indicate that the charge cycle was interrupted.
OFF ON ON ON 1
ON OFF ON ON 2 9.1.5 BATTERY COOLDOWN OPERATION
OFF OFF ON ON 3 STAGE
ON ON OFF ON 4
OFF ON OFF ON 5 A cooldown period is incorporated in the charge cycle.
ON OFF OFF ON 6 This stage serves to cool down the battery before being
OFF OFF OFF ON 8 placed back in service. During this time the display will
alternate between “COL” and time remaining in this stage.
9.1.1.2 DELAY LED If battery is unplugged during cooldown the display will
show “OFF”. During cooldown period, Equalize can be
This LED indicates that the charger is in the delay mode activated by pressing the Equalize button. If this occured,
and charging will not start until the delay time has cooldown will not start until after Equalize charging is
elapsed. A flashing Delay LED indicates that the delay is complete.
in progress.

9.1.1.3 START DELAY OVERRIDE 9.1.6 REFRESH CHARGE STAGE

This pushbutton will override the charger delay mode and If a battey is left connected to the charger after cooldown,
charging will start immediately. the charger will go into a refresh charge mode. This
means that 24 hours after a charging was finished the
battery will get a refresh charging for 10 minutes every 24
hours, at finish rate current.

Instr. 4770-65-95005-10 Page 15

9.1.7 EQUALIZE STAGE

9.1.7.1 EQUALIZE PUSHBUTTON

This pushbutton when pressed will extend the charge

cycle by 3.5 hours in the equalize mode after the finish
rate time has expired. If pressed a second time, it will
cancel the equalize charge mode.

CAUTION: DO NOT EQUALIZE MORE OFTEN THAN

REQUIRED BY THE CONDITION OF THE BATTERY,
AS SPECIFIED IN THE BATTERY MAINTENANCE
INSTRUCTIONS. EXCESSIVE EQUALIZING MAY
DAMAGE THE BATTERY.

9.1.7.2 EQUALIZE LED

This LED indicates that the equalize mode has been

selected. A flashing equalize LED indicates that it is in
process.

10.0 CHARGE TIME

The amount of time a battery charges will vary depending

on the depth of discharge (DOD). Once the battery has
reached 80% charge, the cycle will be terminated in 3.5
hours (in case of an 8 hour charge time) or less if
terminated by dv/dt. Normal charge cycles will average
about 8 hours total.

11.0 AC POWER FAILURE

If the AC power fails during a charge cycle the charger will

resume operation in progress as soon as the AC power is
restored.

12.0 MAINTENANCE

The charger requires minimum maintenance. ENSURE

THE CHASSIS IS SECURELY GROUNDED per the
local/federal Electrical Code. Do not allow excessive dust
to accumulate on the components inside. Blow out with
clean compressed air when necessary.

The AC input and DC output of the charger are fused and

should these fuses fail, the cause of the failure must be
determined and corrected before the fuse(s) is (are)
replaced. Never replace the fuse(s) with one of a higher
capacity than the one originally fitted (see Tables 2 and 3
pages 9-12).

Instr. 4770-65-95005-10 Page 16

13.0 SCRFLX TROUBLESHOOTING
1.Symptom => NO DISPLAY INDICATION AFTER CONNECTION OF AC POWER
Possible Cause Action
Charger connected to low AC voltage. Verify AC voltage per nameplate of the charger
1.1 and electrician’s tag.
Verify connection of primary windings of power
transformer and AC fuses of charger per
connected AC voltage and electrician’s tag.
Charger connected to high AC voltage. Verify AC voltage per nameplate of the charger
1.2 and electrician’s tag.
Verify connection of primary windings of power
transformer and AC fuses of charger per
connected AC voltage and electrician’s tag.
Check AC fuses of charger and replace if
needed.
Check fuse F2 of Control Card. If this fuse is
blown, replace Control Card.
2. Symptom => DISPLAY INDICATES FAC OR F3 AFTER CONNECTION OF AC POWER

Possible Cause Action

Charger connected to low / high AC voltage. Verify AC voltage per nameplate of the charger
2.1 and electrician’s tag.
Verify connection of primary windings of power
transformer and AC fuses of charger per
connected AC voltage and electrician’s tag.
AC power partially missing. Verify AC voltage at all primary windings of
2.2 power transformer and AC fuses of charger per
nameplate of the charger and electrician’s tag.
Failure of one or more of charger’s power fuses. Consult GNB technician.
2.3 Replace fault fuse. Verify input AC voltage and
output High Rate current.
Phase rotation. (Only if F3 is showing) Verify phase sequence of input AC source.
2.4 Ensure that it follows the sequence indicated at
the charger’s input.
3. Symptom => DISPLAY INDICATES FDC BEFORE CONNECTION OF BATTERY.
Possible Cause Action
3.1 Charge cycle was interrupted during charge by Do not interrupt charge by DC cable
DC cable disconnection with slow / bouncing disconnection. Use pushbutton Stop for this
disconnection of DC plug. purpose. Disconnection of DC cable during
charge is not safe because it produces
electrical arc.
If DC cable disconnection is used, disconnect
cable as fast as possible; never connect battery
before indication OFF appears at display (takes
about 2 s after disconnection of DC cable).
Disconnect battery and AC power for 5 sec.
Return AC power and then connect battery.
Charge cycle was interrupted by DC cable See above
3.2 disconnection during charge. Additionally, a
battery was connected back before charger
displayed OFF.
Indication FdC and FAULT LED is on.

Instr. 4770-65-95005-10 Page 17

Charger’s DC fuse blown. Disconnect battery and AC power.
3.3 Indication FdC and FAULT LED is on. Consult GNB technician.
4. Symptom => CHARGING LED DOES NOT LIGHT ON AFTER BATTERY CONNECTION
Possible Cause Action
4.1 Connection between charger and battery open. Repair or clean battery lugs.
Repair and/or change charger and /or battery
DC cables and contacts of DC connectors.
4.2 Battery with wrong number of cells connected to Replace with correct battery.
a charger.
Indication LO/rEJ or HI/rEJ and FAULT LED is
on.
4.3 Battery voltage too low. Consult GNB technician.
Indication LO/rEJ and FAULT LED is on.
4.4 A charger operates at Delay. Wait till end of Delay or press pushbutton Start.
Indication dEL/Remaining Delay Time, LED
Delay is on.
5. Symptom => DISPLAY INDICATES FCC OR F2 AT THE END OF CHARGE CYCLE
Possible Cause Action
5.1 Battery failed to reach gassing voltage. Consult GNB technician.
Check matching of charger and battery: Ah,
type.
6. Symptom => DISPLAY INDICATES FAC OR F3 DURING CHARGE CYCLE
Possible Cause Action
Complete or partial loss of AC power. Wait until AC returns: charger will automatically
6.1 complete charge cycle.
If needed, battery may be disconnected during
AC failure.
Failure of one or more of charger’s power fuses. Consult GNB technician.
6.2 Replace fault fuse. Verify input AC voltage and
output High Rate current.
Failure of Control Card. Consult GNB technician.
6.3 Verify input AC voltage. Replace fault Control
Card.
7. Symptom => DISPLAY INDICATES OFF (ONLY) AND FAULT LED IS ON
Possible Cause Action
Pushbutton Stop interrupted charge cycle. Use pushbutton Stop only when you want
7.1 interrupt charge cycle or disconnect battery.
Charger will start automatically after
connection of next battery.
8. Symptom => DISPLAY INDICATES FCS AFTER CONNECTION ON BATTERY

Possible Cause Action

8.1 Charger control board was set improperly. Prior Call your local GNB representative for
to connection the display indicated OFF/CHP not procedure to change this setting.
OFF/Fld

Instr. 4770-65-95005-10 Page 18

APPENDIX A: SCRFLX BATTERY CHARGERS. LIST OF DISPLAY INDICATIONS.
Indication Abbreviation Interpretation
1.00 1 hour delay set Delay before charge starts
2.00 2 hour delay set Delay before charge starts
3.00 3 hour delay set Delay before charge starts
4.00 4 hour delay set Delay before charge starts
5.00 5 hour delay set Delay before charge starts
6.00 6 hour delay set Delay before charge starts
8.00 8 hour delay set Delay before charge starts

CHP CHamPion Control board is set to 2.55VPC not 2.70VPC.

COL COoL Down Charger operates at Cool Down Stage

dEL dELay Delay set or Charger operates at Delay Stage

End End Charge Cycle complete

FAC or F3 Failure of AC power Failure of mains

FCA Failure of DC CAble DC cable disconnected from the battery during the
disconnection charge
FCC Failure of Charge Cycle Battery failed to reach Gassing Voltage (Stage 2)
or or
F2 Battery failed to reach End Voltage (Stage 3 of OPC)
FCd Failure of Cool down Battery unplugged during Cool Down Stage
FdC Failure of dC Fuse Output DC Fuse Failure
FFF F…Fatal Failure Fatal Failure of the charger (Overvoltage or
Overcurrent protection or multifunction of Start Stop
signal)
FOC Failure of Overall Charge Overall charge cycle timer protection
timer

FLd FLooded Charger set for Flooded batteries

HI High Voltage Rejection Battery connected has voltage more than 2.25VPC

LO LOw Voltage Rejection Battery connected has voltage less than 1.70VPC

OFF OFF Charger is OFF

rEJ rEJect Battery connected has voltage too low or too high
or
Battery failed to reach 1.70VPC after 5 min of
charge
rFr reFreshing Stage Charger operates at Refreshing Stage

Instr. 4770-65-95005-10 Page 19

Instr. 4770-65-95005-10 Page 20
APPENDIX B: ELECTRICAL SCHEMATIC DRAWINGS
Pages 21-31

Instr. 4770-65-95005-10 Page 21

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