V-Force SCR Service & Parts Manual

SMC-C CHARGER NAMEPLATE
TABLE OF CONTENTS
SECTION 1.0: SMC-C SERIES INDUSTRIAL BATTERY CHARGERS 5
SECTION 2.0: INTRODUCTION 6
SECTION 3.0: RECEIVING CHARGER 6
SECTION 4.0: LOCATION AND INSTALLATION OF CHARGER 6
SECTION 5.0: AC ELECTRICAL SUPPLY 7

5.1: AC FUSE MOUNTING 7
5.2: INPUT VOLTAGE CHANGE 7
5.3: AC VOLTAGE CONNECTIONS 7
5.4: GROUND CONNECTION 8
SECTION 6.0: DC OUTPUT 8
SECTION 7.0: APPLICATION 9

7.1: FAULT AND DISPLAY CODES 9
SECTION 8.0: CABINET OUTLINE/DIMENSIONS FOR SMC-C MODEL CHARGERS 10
SECTION 9.0: SMC-C STANDARD CHARGER OPERATION 11

9.1: SMC-C CHARGER FUNCTIONAL DESCRIPTION 12
9.1.1: DELAY STAGE 12
9.1.1.1:DELAY CIRCUIT 12
9.1.1.2: DELAY LED 12
9.1.1.3: DELAY OVERRIDE 12
9.1.2: CHARGING 13
9.1.2.1: DIAGNOSTIC STAGE 13
9.1.2.1: CHARGING LED 13
9.1.2.3: 80% CHARGED LED 13
9.1.2.4: CHARGE COMPLETE LED 13
9.1.2.5: FAULT LED 13
9.1.3: DISPLAY 13
9.1.4: STOP PUSHBUTTON 13
9.1.5: BATTERY COOLDOWN OPERATION STAGE 13
9.1.6: REFRESH CHARGE STAGE 13
9.1.7: EQUALIZE STAGE 14
9.1.7.1: EQUALIZE PUSHBUTTON 14
9.1.7.2: EQUALIZE LED 14
SECTION 10.0: OPPORTUNITY CHARGING 14
SECTION 11.0: CHARGE TIME 14
Instr. 4780-65-95025-54 Page 1 Rev.01, Jan. 10, 2010

SECTION 12.0: AC POWER FAILURE 14
SECTION 13.0: MAINTENANCE 14
SECTION 14.0: CHARGER TECHNICAL INFORMATION 15

14.1 SMC COMPONENT IDENTIFICATION 16
14.2: ELECTRICAL SCHEMATICS 17
14.2.1: SINGLE PHASE SMC-C BATTERY CHARGER SCHEMATIC 17
14.2.2: 3 PHASE SMC-C BATTERY CHARGER SCHEMATIC 18
14.3: TECHNICAL DATA 19
14.4: INPUT VOLTAGE CONFIGURATION 20
14.4.1: SINGLE PHASE 20
14.4.2: 3 PHASE 21
14.5: CONTROL CARD DIP SWITCHES PROGRAMMING 22
SECTION 15.0 TROUBLESHOOTING 25

15.1: SMC-C BATTERY CHARGER DISPLAY AND FAULT INDICATORS 26
15.2: SMC-C FAULT INDICATORS INTERPRETATION 27
15.2.1: No LED or Display indicators with AC power connected, without a battery 27
15.2.2: OFF/Lo/rEJ (red fault LED) 27
15.2.3: OFF/HI/rEJ (red fault LED) 27
15.2.4: FAC/OFF - Failure of AC power (red fault LED) 27
15.2.5: Fdc/OFF – Fuse dc open (red fault LED) 28
15.2.6: OFF/rEJ - rEJect (red fault LED) 28
15.2.7: FCC - Failure of Charge Cycle (red fault LED) 28
15.2.8: FOC - Failure of Overall Charge timer (red fault LED) 28
15.2.9: FFF - Fatal Failure (red fault LED) 28
15.2.10: FCA - Failure of DC CAble disconnection (red fault LED) 29
15.2.11: FCd - Failure of Cool down 29
15.2.12: Cycling Lamp Test 29
15.3: AC FUSES OPEN 30
15.4: FFF TROUBLESHOOTING 31
15.5: SCR/Diode Module Troubleshooting 33
15.5.1: Shorted Diodes 33
15.5.2 Shorted SCR 33
15.5.3 Leaking SCR 33
15.5.4 SCR not firing 34
SECTION 16.0 COMPONENT PART REPLACEMENT AND VERIFICATION SET UP 37

16.1: REPLACING TRANSFORMER (T1) 38
16.2: REPLACING SCR/DIODE MODULE 39
16.2.1: Torque Specifications for SCR/DIODE Modules 40
16.3: REPLACING DC FUSE 41
16.4: REPLACING THE SHUNT 42
16.5: CALIBRATING DC SHUNT 42
16.6: REPLACING MAIN CONTROL (E1) 43
16.7: CHARGER START UP AND VERIFICTION PROCEDURE 44

SECTION 17.0: PARTS BREAKDOWN 45
17.1: PARTS BREAKDOWN FOR SMC SINGLE PHASE 46
17.1.1: PARTS BREAKDOWN FOR SMC SINGLE PHASE 12-1-865 50
17.2: PARTS BREAKDOWN FOR SMC THREE PHASE 54
17.4: OPTIONAL SERVICE ONLY COLOR CONNECTORS/CONTACTS 61
SECTION 18.0: TEST/VERIFICATION FORMS 63

18.1: SMC ISSUE REPORT FORM 64
18.2: CONTROL (E1), SCR & DIODE RESISTANCE VERIFICATION FORM 65
18.3: NO LOAD TEST ON TRANSFORMER (T1) FORM 66
18.4: SMC START UP VERIFICATION REPORT FORM 67

SECTION 1.0: SMC-C SERIES INDUSTRIAL BATTERY CHARGERS
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 may indicate “OFF/FCA”. To restart the
charger, plug in the next battery. Do not connect the next battery before you see indication
“OFF/FCA”.
e) Only qualified, trained and authorized Personnel shall operate and 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 lead-acid batteries ONLY.
I) Do not operate this unit if it has received a sharp blow, been dropped or otherwise damaged. Contact
your service center.
j) Do not disassemble the charger. Have the charger examined by a service representative or local
qualified service facility. Incorrect re-assembly of the charger may result in an explosion, electric shock
or fire.
k) The charger profile is set at the factory for a charger DC cable length of 9 ft and a battery DC cable
length of 25 in. If DC cable lengths are adjusted please contact you local service representative.
l) Never charge a frozen battery
m) Operating environment should not contain any contaminations that may cause corrosion or
contamination that would degrade the performance of a charger

SECTION 2.0: INTRODUCTION
The SMC-C battery chargers are convection cooled, solid state, and micro-processor controlled. SCR
regulated chargers are designed to make battery charging simple. They are factory set for Flooded lead-
acid batteries. A charger set for Flooded batteries may be re-configured by a service representative for
Sealed batteries.
The charger has a comprehensive self-diagnostic program to control all charger functions, monitor the
quality of charge and check its own safety conditions. Large easy to read LEDs, and 7-segment LED
display report on charger and battery status.
SECTION 3.0: RECEIVING CHARGER

Examine the charger thoroughly before using, to make sure that no parts have been loosened or damaged
during shipment. If any shipping damage is found, file a claim with the carrier without delay and take any
necessary steps to protect your rights. Before installing check that the charger nameplate data
corresponds to the packing slip and to the model specified on the original sales order.
The SMC-C chargers are delivered on skids for easy handling using a fork lift truck.
SECTION 4.0: LOCATION AND INSTALLATION OF CHARGER
Proper installation is important in order to achieve good charger performance and long troublefree
operation and to prevent damage to the charger and batteries. The charger should be located in a clean,
cool, normal ambient room temperature (minimum 32°F/0°C and maximum 104°F/40°C) dry and well
ventilated area. In order to permit free air flow for convection cooling allow four inches minimum between
the charger and any wall, six inches from other equipment, and never store anything beneath and on top of
the charger.
WARNING: THE ABOVE PROCEDURES MUST BE FOLLOWED EXACTLY TO AVOID INJURY OR

RISK OF ELECTRIC SHOCK.
WARNING: TO REDUCE THE RISK OF FIRE, INSTALL BATTERY CHARGER ON A FLOOR OF

NON-COMBUSTIBLE MATERIAL SUCH AS STONE, BRICK, CONCRETE OR METAL. IF THIS IS NOT
AVAILABLE, A FLOOR PLATE OF AT LEAST 1.43 mm (0.056 in.) GALVANIZED OR 1.6 mm (0.063 in.)
UNCOATED STEEL EXTENDED AT LEAST 150 mm 5.90 in.) BEYOND THE EQUIPMENT ON ALL
SIDES MUST BE INSTALLED.

SECTION 5.0: AC ELECTRICAL SUPPLY
The charger must be connected to either a single phase, or three phase 60 Hertz AC power source, per
nameplate. the following options are available:
TABLE 1 – INPUT VOLTAGE CHOICES

Single phase Three phase
208/240/480VAC, 60Hz 208/240/480VAC, 60Hz
Only the AC input wire configuration for multi-input chargers can be changed. This change SHALL be
done by a qualified electrical contractor.
5.1: AC FUSE MOUNTING
The charger comes with a fuseblock rated high enough to accommodate the highest possible current and
voltage for that particular model. Proper fuse ratings can be found in Section 14.3: Technical Data See
Section 17.0: Parts Breakdown for part numbers of AC input fuses (F1, F2 for single phase input or F1,
F2, F3 for three phase input). Fuses with an ampere rating of 30A or less will require fuse reducers when
placed in a 60A fuseblock.
5.2: INPUT VOLTAGE CHANGE
BEFORE PROCEEDING CHECK WHICH TRANSFORMER TAP CONFIGURATION YOU HAVE. When changing the taps
on the input side 208, 240, 480 VAC for either Single or 3 Phase units, ensure that the wires and/or
jumpers are changed according to the drawings in Section 14.4: Input Voltage Configuration
Once done, replace AC input fuses per Table 1 or Table 2 in Section 14.3
NOTE: Upon completion and proper verification of the input voltage change, markings on the internal door
label must be revised (crossing out factory set markings); re-mark the label with a permanent marker to
reflect new input voltage.
NOTE: Incorrect voltage tap wiring can result in damage to the transformer and/or charger. To ensure
proper wiring after changing tabs, verify that the input current is no greater than 110% of nameplate rating
at full load. If wiring is as per schematic and current is above 110% SHUT DOWN CHARGER AND CALL
AN AUTHORIZED SERVICE TECHNICIAN IMMEDIATELY.
NOTE: Connection of AC mains to transformer configured to different voltage can permanently damage
control card and /or chargers
5.3: AC VOLTAGE CONNECTIONS
To connect the input AC voltage, route the AC conduit through the knockout hole provided. Continue the
AC wiring to fuseholder terminals L1 (N) and L2 (L) (single phase input) or L1, L2, and L3 (three phase
input). Secure wires to fuseholder to proper torque value as per wire size and termination used (Torque
value indicated on fuseholder).
Note: No plug is supplied on models with optional AC input cable

5.4: GROUND CONNECTION
It is a requirement to ground the chassis while the charger is connected to AC power. The charger comes
with a ground lug attached to the stud, clearly marked on the chassis. To ensure good continuity keep the
contact area clean. See gounding method shown below in figure 1. Connect grounding conductor to GND
lug and secure it. Torque screw to approx. 25 in-lb.
WARNING: DO NOT OPERATE THE UNIT WITHOUT PROPER GROUNDING. IMPROPER

GROUNDING CAN RESULT IN THE RISK OF AN ELECTRIC SHOCK.
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” upon start-up, it
means that there is a low or high AC voltage or AC phase missing. Refer to the Troubleshooting section
for more details.
FIGURE 1: GROUNDING METHOD
SECTION 6.0: DC OUTPUT
The DC charging cable has a polarized battery connector. ALWAYS ensure that the polarity of both the
charger and battery connectors are the same. The BLACK DC cable must be connected to the battery
negative (-), and the RED DC cable must be connected to the battery positive (+). The charger will not
operate in a reversed polarity condition.
The DC output fuse is a "fast-acting" fuse used to protect the power semiconductors of a charger.
NOTE: Use only replacement fuses obtainable from your service representative

SECTION 7.0: APPLICATION
The charger will automatically charge a battery per the Ah rating set at the factory. The charger can be re-
set for anywhere between 65% to 200% of the nameplate Ah rating per Tables 2 and 8 in Section 14.5:
Control Card DIP Switches Programming. Ensure that battery and charger are matched. Keep in mind if
the charger is set for more than 100% of Ah of the charger rating the charging time will increase
proportionately. For battery sizes not listed, contact your local service representative.
7.1: FAULT AND DISPLAY CODES
Refer to Section 15.1: SMC-C BATTERY CHARGER DISPLAY AND FAULT INDICATORS for a
complete list of codes.

SECTION 8.0: CABINET OUTLINE/DIMENSIONS FOR SMC-C MODEL
CHARGERS
CABINET DIM. A DIM. B DIM. C

B 584mm (23 in) 686mm (27 in) 584mm (23 in)

SECTION 9.0: SMC-C STANDARD CHARGER OPERATION
LED DISPLAY DESCRIPTION

(NONE)
OFF/FLd CHARGER SET FOR FLOODED BATTERIES.
OFF/SLd CHARGER SET FOR SEALED BATTERIES.
PLUG IN BATTERY TO COMMENCE CHARGING
DELAY (Orange), dEL, then OFF DELAY MODE, PRESS “START” BUTTON TO
delay time remaining in Hours. OVERRIDE. (Section 9.1.1)
minutes dEL
time
CHARGING (Orange) DIAGNOSTIC STAGE (Section 9.1.2)
XXX
(DISPLAY OF FINISH RATE CURRENT)
CHARGING (Orange) HIGH RATE CHARGING
XXX
(DISPLAY OF CHARGE CURRENT)
80% CHARGED (Yellow) FINISH RATE CHARGING
XXX
(DISPLAY OF FINISH RATE CURRENT)
OPPORTUNITY CHARGING CYCLE
OPC WHEN CHARGER IS IN OPC MODE IT WILL ALWAYS
INDICATE OPC IN ADDITION TO STANDARD INDICATION.
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 (i.e.
XXX FAC, Fdc, Lo, HI, etc.)
CHARGE COMPLETE (Green) CHARGING IS COMPLETE. ONCE COOLDOWN

flashing, remaining cool down OFF TIME IS FINISHED, UNPLUG THE BATTERY.
time displayed in Hours.minutes
COL
time
CHARGE COMPLETE (Green) BATTERY CAN BE UNPLUGGED AND USED.
on (not flashing), remaining OFF
refreshing time displayed in
Hours. minutes rFr
time
PRESS “EQUALIZE” BUTTON TO EQUALIZE THE
BATTERY. PRESS AGAIN TO CANCEL.
EQUALIZE (Orange) XXX DURING EQUALIZE STAGE LED EQUALIZE IS
BLINKING AND PUSH BUTTON EQUALIZE
DISABLED
(DISPLAY OF FINISH RATE CURRENT
9.1: SMC-C CHARGER FUNCTIONAL DESCRIPTION
This section gives a brief description of each LED, pushbutton, and the delay function on the SMC-C type
charger front control panel.
9.1.1: DELAY STAGE
9.1.1.1:DELAY CIRCUIT
1. The delay circuit enables the user to set a delay of up to eight hours between battery plug in and the start
of charge.
2. The delay time must be set prior to charging. This can be done via the slide switches located on the
charger’s control card. Refer to Table 2 below for details.
CAUTION: HAZARDOUS VOLTAGES INSIDE. DO NOT ATTEMPT TO CHANGE THE SLIDE SWITCHES
ON THE CONTROL CARD UNTIL ALL AC POWER IS DISCONNECTED FROM THE UNIT AS WELL AS
THE BATTERY IS UNPLUGGED FROM THE CHARGER. USE PROPER TOOL TO OPEN THE CABINET
DOOR.
CAUTION: DO NOT TOUCH THE OTHER SLIDE SWITCHES OF THE CONTROL BOARD. THESE ARE
FACTORY SET AND CAN ONLY BE CHANGED BY A QUALIFIED SERVICE REPRESENTATIVE.
TABLE 2
SW5 1 2 3 START DELAY
(HOURS)
ON ON ON 0 (DEFAULT)
OFF ON ON 1
ON OFF ON 2
OFF OFF ON 3
ON ON OFF 4
OFF ON OFF 5
ON OFF OFF 6
OFF OFF OFF 8
9.1.1.2: DELAY LED
This LED indicates that the charger is in the delay mode and charging will not start until the delay time has
elapsed. A flashing Delay LED indicates that the delay is in progress.
9.1.1.3: DELAY OVERRIDE
The pushbutton START will override the charger delay mode and charging will start immediately.

9.1.2: CHARGING
9.1.2.1: DIAGNOSTIC STAGE
The charge cycle starts with Finish Rate current. If the voltage reaches 2.18VPC within 5 minutes, the
charger goes to the Refresh Charge Stage. If it does not reach the above voltage in 5 minutes the charger
will go to the High Rate charging stage.
Diagnostic Stage can be cancelled by pressing Equalize pushbutton twice.
9.1.2.1: CHARGING LED
This LED indicates that the charger is ON.
9.1.2.3: 80% CHARGED LED
This LED indicates that the battery has reached 80% charge.
9.1.2.4: CHARGE COMPLETE LED
When this LED is continuously lit it indicates that the charging cycle is complete. The battery may now be
safely disconnected. In the event this LED is flashing, it indicates that cooldown is in progress.
9.1.2.5: FAULT LED
This LED is associated with any fault that is described in SMC-C BATTERY CHARGERS. LIST OF DISPLAY
CODES . It indicates that there is a problem prior to or during the battery charging operation.
9.1.3: DISPLAY
The display shows the charging current to the battery during the charging process. The display will show
additional messages as the charging is progressing or a fault occurs.
9.1.4: STOP PUSHBUTTON

This pushbutton will STOP the charge cycle. The battery can then be safely unplugged. The red fault LED will
light to indicate that the charge cycle was interrupted.
9.1.5: BATTERY COOLDOWN OPERATION STAGE
A cooldown period is incorporated in the charge cycle. This stage serves to cool down the battery before
being placed back in service. During this time the display will alternate between “COL” and time remaining in
this stage. If the battery is unplugged during cooldown the display will show “FCD”. During the cooldown
period, Equalize can be activated by pressing the Equalize button. If this occures, cooldown will not start until
after Equalize charging is complete.
9.1.6: REFRESH CHARGE STAGE
If a battery is left connected to the charger after cooldown, 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.

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. If pressed a
second time, it will cancel the request for equalize charge.
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.
SECTION 10.0: OPPORTUNITY CHARGING
The charger is equipped with a separate profile for applications that utilize opportunity charging.
Within 5 seconds the charger will start charging until the gassing voltage is reached. At this point the
charging will stop until the battery voltage drops to a specified level. The charger then will operate at finish
rate current until the battery reaches a second specified voltage. The charger will continue through this cycle
until the battery is disconnected.
SECTION 11.0: 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 3.5 hours after finish rate (in case of an 8 hour charge
time) or less if terminated by dv/dt.
SECTION 12.0: 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.
SECTION 13.0: 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 Section 14.3 for proper fuse ratings

SECTION 14.0: CHARGER TECHNICAL INFORMATION

14.1 SMC COMPONENT IDENTIFICATION
INPUT FUSE
Identified as “F” on the schematic.
ISOLATING TRANSFORMER
Identified as “T1” on the schematic.
a) Input:
1) For 1PH labeled as “L1”, “L2”
2) For 3PH labeled as “L1”, “L2”, “L3”
b) Secondary: labeled as “A1, A2, A3”
c) Control winding:
1) For 1PH labeled as “C1”, “C2”, “C3”, “C4”
2) For 3PH labeled as “C1”, “C2”, “C3
SCR/DIODE BRIDGE
a) SCR:
1. For 1PH labeled as “Q1”, “Q2”
2. For 3PH labeled as “Q1”, “Q2”, “Q3”
b) Diode
1. For 1PH labeled as “D1”, “D2”
2. For 3PH labeled as “D1”, “D2”, “D3”
VARISTOR
Identified on schematic as:
1. For 1PH labeled as “Z1”
2. For 3PH labeled as “Z1”, “Z2”, “Z3”
DC FUSE
Identified as “Fn” where n equals number. Some units may have more than one DC Fuse.
SHUNT mV = output current of charger)

Identified as “SH1” on schematic.
CONTROL
Identified as “E1” on schematic.
CHARGE CABLE ASSY

Identify as adjoining lines to “Battery”
FOR REPLACEMENTS OF PARTS REFER TO SECTION 17.0

14.2: ELECTRICAL SCHEMATICS
14.2.1: SINGLE PHASE SMC-C BATTERY CHARGER SCHEMATIC

14.2.2: 3 PHASE SMC-C BATTERY CHARGER SCHEMATIC

14.3: TECHNICAL DATA

14.4: INPUT VOLTAGE CONFIGURATION
14.4.1: SINGLE PHASE

CONNECTION FOR 480 VOLTS SINGLE PHASE
ASSOCIATED (FACTORY PRESET)
MODELS
(ON CHARGER
NAMEPLATE)
12-1-475
12-1-600
12-1-750
12 -1-865
18-1-600
18-1-750
CONNECTION FOR 240 VOLTS SINGLE PHASE
Note: CONNECTION FOR 208 VOLTS SINGLE PHASE

Jumper wires not required
for 208 and 240 Single
Phase Input voltage
connection and can be
discarded when
configuring a unit to
either of these voltages.
DO NOT STORE THESE
JUMPERS OR ANY
OTHER LOOSE
COMPONENTS IN THE
CHARGER

14.4.2: 3 PHASE
CONNECTION FOR 480 VOLTS 3-PHASE
ASSOCIATED (FACTORY PRESET)
MODELS
(ON CHARGER
NAMEPLATE)
12-3-475
12-3-600
12-3-750
12-3-865
12-3-965
12-3-1050
18-3-750
18-3-865 CONNECTION FOR 240 VOLTS 3-PHASE

18-3-965
18-3-1050
18-3-1200
24-3-750
24-3-865
24-3-965
24-3-1050
CONNECTION FOR 208 VOLTS 3-PHASE

14.5: CONTROL CARD DIP SWITCHES PROGRAMMING
NOTE: Remove AC power from unit and disconnect the Battery prior to programming DIP switches.
*
* Set GV to Special for Batteries operating at temperatures below 40 deg. F.
Note: Check battery specifications first prior to setting.
4

NOTE: Remove AC power from unit and disconnect the Battery prior to programming DIP switches.

SECTION 15.0 TROUBLESHOOTING
WARNING:
This equipment may only be installed and serviced by qualified and trained
personnel who are familiar with all pertinent safety, installation and
troubleshooting precautions.
Qualified personnel are defined as THOSE:
• Having completed training, gained experience and have received instructions on the
operation, troubleshooting and repair of this equipment.
• Familiar with the pertinent safety standards, rules/regulations, personal protective
equipment (PPE) and accident prevention guidelines necessary to ensure the safety
of themselves, others and the equipment.
• Capable of understanding, recognizing and preventing dangers which could cause
harm as a result of their actions.
NOTE:
• This equipment contains High Voltage and Energy levels capable of causing serious
injury or death.
• Always remove AC power and disconnect the battery from the equipment before
replacing any parts.
• Always use extreme caution while troubleshooting the equipment with AC power
and/ or the Battery connected.
• Never leave the equipment unattended with door open or any covers or panels
removed.
• Use ALL required Personal Protective Equipment (PPE) when troubleshooting a
unit.
• Never attempt to troubleshoot service or repair this equipment if you are unsure of
the risks involved or are not aware of the safety precautions necessary to avoid
injury or other hazard.
When it is required to remove AC power from the charger always ensure that the circuit
breaker or switch has been locked in the off position to prevent others from accidentally
re-energizing the circuit.
Always test before touching any part or component within the charger.

15.1: SMC-C BATTERY CHARGER DISPLAY AND FAULT INDICATORS
Indication Abbreviation Interpretation

1.00 1 hour delay set Delay before charge starts
SLd SeaLed Charger set to Sealed batteries

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 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
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)
FLd FLooded Charger set for Flooded batteries
FOC Failure of Overall Overall charge cycle timer protection

Charge timer
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
OPC OPportunity Charge Charger set to Opportunity Charge Cycle

Cycle
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
15.2: SMC-C FAULT INDICATORS INTERPRETATION
Note: The following FAULT codes indicate a potential charger malfunction. Use them as a guide when
toubleshooting the charger.
15.2.1: No LED or Display indicators with AC power connected, without a battery

POSSIBLE CAUSE(S): 1. Low AC voltage applied to the charger (example: 208Vac applied to a
charger configured for 480Vac).
2. An AC input fuse is open on a single phase unit or more than one AC fuses are
open for three phase units.
15.2.2: OFF/Lo/rEJ (red fault LED)

INTERPRETATION: Indicates that the battery voltage is less than 1.70VPC.
POSSIBLE CAUSE(S): 1. The battery is fully or almost fully discharged and has a voltage of < 1.7VPC.
2. The battery has one or more shorted or dead cells.
3. The battery number of cells does not match charger (example: 12 cell battery
connected to an 18 cell charger).
15.2.3: OFF/HI/rEJ (red fault LED)

INTERPRETATION: Indicates that the battery voltage is greater than 2.25VPC.
POSSIBLE CAUSE(S): 1. The battery is fully or almost fully charged and has a voltage > 2.25VPC.
2. The battery number of cells does not match charger (example: 18 cell battery
connected to a 12 cell charger)
15.2.4: FAC/OFF - Failure of AC power (red fault LED)

INTERPRETATION: Indicates an AC Failure.
POSSIBLE CAUSE(S): 1. Open AC fuse (F).
2. Problem with AC mains supplying the charger.
3. Shorted Diode (D1, D2 for single phase, D1, D2, D3 for three phase)
4. Shorted SCR (Q1, Q2 for single phase, Q1, Q2, Q3 for three phase)
5. Open control fuse (typically caused by incorrect input voltage applied to the
charger. (example: 480Vac applied to a charger configured for 208Vac or
240Vac).
REFERENCE: Section 15.3: AC FUSES OPEN
Section 15.5.1: SHORTED DIODES
Section 15.5.2: SHORTED SCR

15.2.5: Fdc/OFF – Fuse dc open (red fault LED)
INTERPRETATION: Indicates that the DC fuse (F1) is open and charging has stopped.
POSSIBLE CAUSE(S): 1. Loose or open sense wire to shunt.
2. Poor connection at MH5 pins 1 and 2.
3. Loose connections on DC fuse.
4. Shorted SCR.
5. This indication could also result from the Disconnecting the battery during a
charge cycle and re-connecting the battery before the control indicated FCA.
REFERENCE: Section 15.5.2: SHORTED SCR
15.2.6: OFF/rEJ - rEJect (red fault LED)

INTERPRETATION: Indicates that the battery voltage failed to reach 1.70VPC after 5 minutes and
charging has stopped.
POSSIBLE CAUSE(S): 1. Defective battery or defective charger.
15.2.7: FCC - Failure of Charge Cycle (red fault LED)

INTERPRETATION: Charger failed to reach Gassing voltage or End voltage within the specified
charging time.
POSSIBLE CAUSE(S): 1. The charger is configured for a smaller Ahour battery then the one which is
connected to it. (example: The charger is configured for a 475 Ahour battery but
is connected to a 750Ahour battery).
2. The battery is defective.
3. The charger is not outputting is rated current or voltage.
15.2.8: FOC - Failure of Overall Charge timer (red fault LED)

INTERPRETATION: Overall charge cycle timer protection.
POSSIBLE CAUSE(S): 1. Defective Control
REFERENCE: Section 16.6: REPLACING MAIN CONTROL (E1)
15.2.9: FFF - Fatal Failure (red fault LED)

INTERPRETATION: Indicates that Control card detected a fatal error and has stopped charging.
POSSIBLE CAUSE(S): 1. When the battery is disconnected during High rate mode, a large voltage spike
can cause FFF.
2. Incorrect adjustment or calibration of the shunt
3. Improper reinstallation of the shunt will generate more mV than required.
ACTION: To reset the FFF code disconnect the battery, turn off AC power. Wait 5 to 10
seconds, and return AC power.
REFERENCE: Section 15.4: FFF TROUBLESHOOTING

15.2.10: FCA - Failure of DC CAble disconnection (red fault LED)
INTERPRETATION: Indicates that the battery was disconnected from the charger while charging.
POSSIBLE CAUSE(S): 1. DC Cable disconnected from the battery without pressing the Stop button to stop
the charge cycle.
REFERENCE: Section 9.1.4: STOP PUSHBUTTON
15.2.11: FCd - Failure of Cool down

INTERPRETATION: Charger cool down timer was interrupted.
POSSIBLE CAUSE(S): Indicates that the battery was disconnected from the charger while prior to
completing the cool down period.
REFERENCE: Section 9.1.5
15.2.12: Cycling Lamp Test

INTERPRETATION: All LEDs briefly turn on and Display briefly indicates 888.
POSSIBLE CAUSE(S): Leaky SCR.
REFERENCE: Section 15.5.3

15.3: AC FUSES OPEN
WARNING: Determination of an open AC fuses requires performing measurements on the charger while
AC power and/or the battery are connected to the charger. Observe all safety precautions while working
on a live unit. Do not attempt these procedures if you have not read, understood or agree with the warning
at the beginning of this section.
1. Disconnect the battery from the charger output connector.

2. With AC power still applied, carefully measure the AC voltage across each fuse. An open fuse will
result in a measurable voltage across the fuse.
3. Measure the AC input voltage supplying the charger and ensure that it is within +6%/-10% of the
nameplate rating.
4. Remove AC power from the unit and keep the Battery disconnected from the charger output
connector.
5. Verify that the charger is correctly configured for the input voltage measured in step 3. Refer to
Section 15.
6. Verify that there are no shorted Diodes. Section 15.15.1
7. Verify that there are no shorted SCRs. Section 15.5.2
8. Make any repairs necessary prior to replacing fuses.
9. Replace ALL AC input fuses. Even if only one fuse has opened, the others have been stressed and
will no longer be reliable and may open prematurely.
10. Perform a NO LOAD VOLTAGE TEST ON TRANSFORMER (T1) per Section 18.3
If any measurement is outside of the range specified in Section 18.3, then Remove AC power from the
unit and keep the Battery disconnected from the charger output connector, Remove the AC fuses
from the charger and contact an AEG Power Solutions service representative prior to continuing.
11. If the results of item 10 above are acceptable, Remove AC power from the unit and keep the Battery
disconnected from the charger output connector if not previously done and reconnect the transformer
secondary wires to the busbars per Section 16.1. Ensure that all connections are properly torqued and
that no wires have been left unconnected.
12. Verify that all connections to the shunt, DC fuse, charge cables etc. are fastened properly and that no
connection is loose.
13. Verify that there is continuity between the shunt control wires and MH5 pins 1 and 2 on the Control
card (E1). Also verify that the connection polarity is correct. (Red wire MH5-1 connected to Negative
DC cable side of shunt).
14. If all checks are satisfactory, verify that all fuses have been replaced and are properly inserted, close
the door, connect a partially discharged battery and apply AC power to the charger.
15. Verify that the charger is operating normally and begins charging the battery.
16. Press the equalize button 2 times to bypass the Diagnostic Stage to get the charger into Stage 2
(High Rate Current), measure the DC output current and verify that it matches the nameplate. If it is
not within 3% of the nameplate rating, follow the Shunt Calibration procedure in Section 16.5

15.4: FFF TROUBLESHOOTING
WARNING: The following troubleshooting procedure requires performing verification on the charger while
If a FFF indication appears on the charger display, the following tests shall be performed before replacing
Control Card of SMC charger.
1. Remove AC power from the unit and disconnect the battery from the charger output connector.
Ensure that proper measures are in place to ensure that no power goes to the unit.
2. Verify that the battery cable has a reliable connection both at battery and connector side of the battery
cable.
3. Verify that charger charge cable has reliable connection at connector side of the charger cable.
4. Ensure hands are clean and free of contamination prior to handling of control card.
5. Open door of the charger to get access to Control Card.
6. Verify that no AC voltage present on input terminals of AC fuse block.
7. Verify that crimp contacts of all wires of MH4 and MH5 housing are completely inserted into housing:
push gently each wire individually to completely insert each contact into housing.
8. Verify that wires connected to DC shunt are secured reliably. Do not move the sliding contact of the
shunt.
9. Locate head of white Nylon standoff between connectors MH4 and MH5 along long side of the board.
Pressing this head with point finger, gently move MH5 housing (a part with wires connected to MH5)
3-4 mm (1/8”) up, tilting it along long side.
10. Press gently housing of MH5 down, tilting it along the long side to completely mate it with header MH5
on the PCB.
Note: steps 12 and 13 only apply to boards with IC’s mounted in sockets
11. Insert point finger under Control Card in such way that it will come under Microcontroller IC (square IC
inserted into square IC socket), located near 4 potentiometers.
12. Providing support with a finger under PCB, press gently Microcontroller IC at all 4 sides and then at
the middle to ensure full insertion of IC into socket.
Do not touch contacts of IC or the socket.
Do not touch surface of the socket.
13. Record all DIP switches that are in ON position. Move twice each ON switch that is ON to OFF
position; return all DIP switches that were in ON position to ON position.
14. Verify that DIP switch settings and position of gray wire at connector MH5 matches battery number of
cells, AH rating and type (flooded or sealed).

15. Connect AC mains to the charger. Record indication of the charger (LEDs and display).
16. Measure battery voltage and record it.
17. Connect voltmeter to charger cable inside of the charger.
18. Connect AC clamp to measure charge current, if available.
19. Connect battery to the charger and observe operation of the charger.
a. During first 30s of operation, monitor thoroughly voltage and current of the battery and
indication (LEDs and display) of the charger.
b. If charger continues to operate normally, press twice pushbutton Equalize to force charger in
High Rate Current mode. Monitor thoroughly voltage and current of the battery and indication
(LEDs and display) of the charger for next 30s of operation.
20. If indication FFF re-appears complete an SMC issues report in Section 18.1 including the following
details:
a. Time from the battery connection to FFF indication.
b. Operation of the charger from time of battery connection, including indication before battery
connection, battery voltage before connection, indication of the charger (LEDs and Display), as
well as battery voltage and current during operation of the charger before FFF indication.
c. Provide this and all other available information (battery type, age, type of usage, how long
charger is in service, etc.)
21. Call the AEG Power Solutions Service Technician prior to replacing Control (E1)
22. If authorized by the AEG Power Solutions Service Technician, replace Control (E1) strictly following
Replacement Instructions in Section 16.6. Pay special attention on support of the PCB during removal
and insertion of connectors.
23. Connect AC mains and battery to the charger and observe operation of the charger as described
above.

15.5: SCR/Diode Module Troubleshooting
15.5.1: Shorted Diodes

A shorted diode will result in an open AC Fuse.
To determine if a diode is shorted Remove AC power from the unit and disconnect the Battery from the
charger output connector.
To check for a shorted diode, use a multimeter on Diode check and connect the positive meter lead to the
shunt inside the charger or to the negative charge cable and connect the negative meter lead to each of the
transformer secondary wires (A1, A2, A3) in turn.
The meter will indicate a short if one or more diodes are shorted; if all diodes are in order, the meter will
indicate 0.3 to 0.6 typically, when positive lead connected to the shunt and negative to A1 or A2 or A3, and
OL (OverLoad) with the leads connected in reverse.
If short is detected, disconnect secondary wires of transformer A1, A2 and A3 and then check the diode of
each module: keep the positive meter lead on the shunt and apply the negative meter lead to the diode
cathode terminal of each module, in turn. Mark the module(s) with a shorted diode. Replace the defective
module per Section 16.2. Reconnect all of the disconnected transformer secondary wires to the modules
being careful to connect A1 to Q1/D1 module and A2 to Q2/D2 module on so on. Important: Do NOT change
location of secondary wires A1, A2 or A3 as this will result in charger malfunction and / or failure.
For module replacement, refer to Section 16.2.
15.5.2 Shorted SCR

A shorted SCR will result in voltage being present on the charger output connector even when no battery is
connected.
To determine if an SCR is shorted Remove AC power from the unit and disconnect the Battery from the
charger output connector.
To check for a shorted SCR, use a multimeter on Diode check and connect the positive meter lead to the DC
fuse inside the charger or to the positive charge cable and connect the negative meter lead to each of the
transformer secondary wires (A1, A2, A3) in turn.
The meter will indicate a short if one or more SCRs are shorted; if all SCRs are in order, the meter will
indicate OL (OverLoad).
If a short is detected, disconnect the secondary transformer wires, A1, A2 and A3 and then check the SCRs
of each module: keep the positive lead of the meter at the DC fuse and apply the negative meter lead to the
SCR anode terminal at each module in turn. Mark module(s) which have a shorted SCR and replace the
module per Section 16.2. Reconnect all of the disconnected transformer secondary wires to the modules
being careful to connect A1 to Q1/D1 module and A2 to Q2/D2 module on so on. Important: Do NOT change
location of secondary wires A1, A2 or A3 as this will result in charger malfunction and / or failure.
For module replacement, refer to Section 16.2.
15.5.3 Leaking SCR

WARNING: Determination of a leaking SCR requires performing measurements on the charger while AC
power and/or the battery are connected to the charger. Observe all safety precautions while working on a
live unit. Do not attempt these procedures if you have not read, understood or agree with the warning at
the beginning of this section.
A leaking SCR will also cause voltage to appear on the charger output connector when no battery is
connected. This will be evident by the control card performing a lamp test in a repetitive mode while no
battery is connected.
To check for a leaking SCR, disconnect the battery from the charger output connector.
Connect a multimeter set for DC voltage to the output terminals of the charger. A voltage of > 9V
indicates a leaky SCR.
For Single and Three phase units:
To determine which SCR is leaking follow the following procedure:
connector.
2. Disconnect the leftmost transformer secondary winding (A1) from the busbar which connects to the
SCR/Diode module. Using some small jumper cables (18-14 AWG) with alligator clips at both ends,
and a new SCR/Diode Module, connect the new SCR anode terminal to the disconnected
transformer secondary lead (A1). Using a second jumper, connect the new SCR cathode terminal
to the positive charge cable wire (or DC Fuse). Place the new SCR/Diode module in a location
where it can not come into contact with the chassis or any other component or wire within the
charger. Also ensure that it is so located that it will not be touched accidently during the following
step.
3. Reconnect AC power to the charger, leave the battery disconnected, and measure the voltage on
the charger output terminals. If the voltage has dropped to below 9V, then the leaking SCR has
been located. Remove AC power from the unit and keep the Battery disconnected from the charger
output connector and follow the procedure in Section 16.2 for module replacement.
4. If the voltage is still >9V, Remove AC power from the unit and keep the Battery disconnected from
the charger output connector, Disconnect the new SCR/Diode module from A1 and the DC fuse.
5. Reconnect the transformer secondary lead to the anode terminal of the SCR/Diode module.
6. Repeat Steps 1 through 4 for each transformer secondary lead in turn until the leaky SCR in found.
15.5.4 SCR not firing

WARNING: Determination of an SCR not firing requires performing measurements on the charger while
For Single Phase units:

If it is suspected that an SCR is not firing, follow the following procedure:
1. With AC power and the battery connected, measure and record the secondary AC current in
transformer leg A1.
2. Remove AC power from the unit and disconnect the Battery from the charger output connector.
3. Using a piece of wire 22AWG to 18AWG, carefully short out MH1 pins 1 and 2 with the connector
still connected to the control card. Special care must be taken not to bend or distort the pins or to
exert too much force on the control card.
4. Connect the battery and reconnect AC power to the charger.
5. Measure and record the secondary AC current in transformer leg A1. If the current changed
significantly, Q1 (the SCR connected to MH1-1&2 is firing correctly. If A1 current did not change
significantly, Q1 is not firing or Diode D2 is open. Disconnect the battery and perform a diode
check on D2 to ensure that it is not open.
7. Remove the short across MH1 pins 1 and 2 and apply the short to MH1 pins 4 and 5.
9. Measure and record the secondary AC current in transformer leg A1. If the current changed
significantly, Q2 (the SCR connected to MH1-4&5 is firing correctly. If A1 current did not change
significantly, Q2 is not firing or Diode D1 is open. Disconnect the battery and perform a diode
check on D1 to ensure that it is not open.
For Three Phase units:
An SCR not firing will cause a secondary AC current unbalance between transformer secondary windings
A1, A2 and A3.
If it is suspected that an SCR is not firing, follow the following procedure:
3. Measure and record the secondary AC current in transformer leg A1, A2 and A3.
5. Using a piece of wire 22AWG to 18AWG, carefully short out MH1 pins 4 and 5 with the connector
still connected to the control card. Special care must be taken not to bend or distort the pins or to
exert too much force on the control card.
7. Measure and record the secondary AC current in transformer legs A1, A2 and A3. If the currents
changed significantly, Q1 (the SCR connected to MH1-4&5 is firing correctly. If the currents did not
change significantly, Q1 is not firing.
A non-firing SCR can be caused by a malfunctioning SCR, an open wire between the control card and the
SCR gate or a defective control card.
To check for an open wire between the SCR gates and the control card,
For Single Phase:

2. Take note of the location of Q1 gate lead, and disconnect the lead.
3. Ensure that the resistance measured between MH1 pin 2 and Q1 gate wire (disconnected) is very
low.
4. Reconnect Q1 gate lead being careful to insert in the proper location.
low.

For Three Phase:
low.
low.
low.
11. If a faulty SCR is suspected, remove the SCR per Section 16.2 and test the SCR using a suitable
SCR tester.
To check for a defective control card, refer to CONTROL (E1) SIGNAL RESISTANCE check in Section 18.2

SECTION 16.0 COMPONENT PART REPLACEMENT AND VERIFICATION SET UP
WARNING:
This equipment may only be installed and serviced by qualified and trained
personnel who are familiar with all pertinent safety, installation and
troubleshooting precautions.
Qualified personnel are defined as THOSE:
• Having completed training, gained experience and have received instructions on the
operation, troubleshooting and repair of this equipment.
• Familiar with the pertinent safety standards, rules/regulations, personal protective
equipment (PPE) and accident prevention guidelines necessary to ensure the safety
of themselves, others and the equipment.
• Capable of understanding, recognizing and preventing dangers which could cause
harm as a result of their actions.
NOTE:
• This equipment contains High Voltage and Energy levels capable of causing serious
injury or death.
• Always remove AC power and disconnect the battery from the equipment before
replacing any parts.
• Always use extreme caution while troubleshooting the equipment with AC power
and/ or the Battery connected.
• Never leave the equipment unattended with door open or any covers or panels
removed.
• Use ALL required Personal Protective Equipment (PPE) when replacing a
component.
• Never attempt to troubleshoot service or repair this equipment if you are unsure of
the risks involved or are not aware of the safety precautions necessary to avoid
injury or other hazard.
When it is required to remove AC power from the charger always ensure that the circuit
breaker or switch has been locked in the off position to prevent others from accidentally
re-energizing the circuit.
Always test before touching any part or component within the charger.
NOTE:
Ensure the correct replacement components are installed as listed in Section 17.
Ensure ALL the applicable test reports are completed and returned along with the replaced
component to AEG Power Solutions.
16.1: REPLACING TRANSFORMER (T1)
1. Prior to replacing the transformer, consult troubleshooting guide, Section 15.0

2. Remove AC power from the unit and disconnect the Battery from the charger.
3. When removing components, keep track of all hardware and ensure that no piece falls into the unit where
it could cause a hazard. In most cases, hardware must be re-used so keep track of where each piece
belongs.
4. If it is necessary to move the charger, disconnect the AC mains wires to the fuse block and remove any
conduit which would prevent the charger from being moved.
5. If necessary, use a lift truck and move the charger away from the wall to provide a working area behind
the charger.
6. Remove the top cover and the rear panel.
7. Disconnect the primary wires which connect the transformer to the fuse block. (Take special note of the
input voltage configuration which must be configured on the new transformer).
8. Disconnect the transformer secondary wires A1, A2 (and A3 for three phase models).
9. Disconnect the transformer control wire connector.
10. Unbolt the transformer mounting bolts from the base.
11. Using proper equipment, slowly remove the transformer from the charger making sure that the
transformer, leads or control wires do not catch on anything. Also be careful not to scratch the paint while
removing the transformer.
12. Using proper equipment, slowly install the transformer into the charger making sure that the transformer,
leads or control wires do not catch on anything. Also be careful not to scratch the paint while removing the
transformer.
13. Securely fasten the transformer mounting bolts to the base.
14. Connect the primary wires from the fuse block to the transformer and configure the transformer per the
correct input voltage. Refer to Section 14.4
15. Connect the transformer control wire connector.
16. Connect the transformer secondary wires A1, A2 (and A3 for three phase models).
17. Check all connections to ensure that they are secure and that they match the appropriate electrical
schematic. Refer to Section 14.2.
18. Install the rear panel and the top cover.
19. Reposition the charger to its former location ensuring that ALL items in Section 4.0 are followed.
20. Reconnect the AC mains wires to the fuse block and reinstall any conduit which had to be removed in
order to relocate the charger.
21. Follow the charger start up and verification procedure to ensure that the charger is functioning correctly.

16.2: REPLACING SCR/DIODE MODULE
2. Loosen the transformer secondary (A1, A2 or A3) to bus bar fastening nut as this will allow for easy
movement of AC bus bar that connects to the module which is to be replaced
3. Remove the three screws that secure the bus bars to the module.
4. Loosen the screws securing the large bus bars to the other module(s). This will make it easier to slide
the defective module out.
5. Gently remove the gate wire from module paying special attention to where it connects.
6. Remove the two mounting screws securing the module to the heatsink. Clean any thermal compound
residue off of the screw threads and inspect them for damage as these screws are to be reused if
they are in good condition.
7. Lift the module away from the heatsink and gently slide the module up until it clears the bus bar and
remove the module.
8. Clean off any old thermal compound from the heatsink using a clean dry cloth or soft paper towel. Do
not use any thinners, solvents or other chemicals or abrasives to remove the compound as this could
result in scratches on the surface of the heatsink. After cleaning, the heatsink should be free from
compound, dust or any other particles.
9. Apply a small amount of thermal compound to the metal part of the module mounting base. The
recommended thermal compounds are DC340 by Dow Corning or equivalent. Spread out the
compound using a small paint brush or straight edged hard rubber spatula or squeegee to create
THIN, EVEN and UNIFORM layer of compound over the ENTIRE metal mounting surface of the
module. Follow 2 basic principles: “Deposit as little thermal compound as possible, to allow metal to
metal contact” and “Deposit enough thermal compound to displace all air between case and heat
sink”.
For modules that have both plastic and metal parts at their base (such as IXYS) wipe off any traces
of compound from the plastic.
10. Install the new module in the correct orientation as per fig.1: Module Orientation Guide with the
gate lead pins away from the small bus bar. Ensure that the compound does not spread over the
heatsink when mounting the module. The base of the module must not come into contact with the
heatsink except at its intended mounting position. This would cause a reduction in the thickness of
the thermal compound and may introduce contamination or particles to the remaining compound.
11. After the module is located in its final mounting position, press it gently against heat sink and move it
2 times to the left & right and up & down approximately 1 mm to evenly spread compound and wet
down the heat sink mounting surface. Do NOT move it more to avoid a reduction of the compound
layer thickness and to avoid depositing compound into the mounting holes.
12. Install the two module to heatsink mounting screws previously removed from the defective module.
Tighten both screws to approximately 1/3 of required torque as listed in section 16.2.1. Repeat this
for each screw, in turn, twice, so that the final torque is applied gradually for both screws. Do NOT
apply the final value of torque in 1 step. Also monitor the spread of compound around the base of the
module. The thickness of the applied compound layer is appropriate if only a very small amount of
thermal compound shows all around the edge of the mounting surface of the module.
13. Fasten bus bars and gate wire (as per schematic and Module Orientation Guide) to the module using
the screws that came with new module. Secure screws as per the torque specifications as per
section 16.2.1
14. Securely fasten the transformer secondary lead (A1, A2 or A3) to the bus bar.
15. Re-torque the other module(s) to bus bar screws and any other screws which where previously
loosened.
16. Follow the charger start up and verification procedure in Section 16.7 to ensure that the charger is
functioning correctly.

Figure 1: Module Orientation Guide
16.2.1: Torque Specifications for SCR/DIODE Modules
Manufacturer Model Mounting – Module to Terminal Mounting

Heatsink (in in.lb) (in in.lb)
Eupec TD106N 30.3 – 40.9 32.1 – 39.1
IXYS MCD95-08108B 22.3 – 35.6 22.3 – 35.6
IXYS MCD162-08 20.1 – 24.4 40.1 – 48.9
Semikron SKKH106 37.9 – 51.1 22.7 – 30.7
Semikron SKKH162 37.9 – 51.1 22.7 – 30.7
Semikron SKKH172 37.9 – 51.1 22.7 – 30.7
Vishay/IR VSKH162 35.6 – 53.4 35.6 – 53.4

16.3: REPLACING DC FUSE
1. Prior to replacing the DC fuse, follow the troubleshooting guide in Section 15.0 to ensure that other
components are not the cause of the DC fuse being open. Paying special attention to the Possible
Cause(s) outlined in Section 15.2.5 (Fdc).
3. When removing components, keep track of all hardware and ensure that no piece falls into the unit
where it could cause a hazard. In most cases, hardware must be re-used so keep track of where each
piece belongs.
4. Verify that the fuse is the correct rating. Refer to Parts Breakdown in Section 17.0
5. Remove fuse from the stack assembly noting where the wires are connected.
6. Install the fuse, connect all wires in their correct location as per the appropriate schematic in Section
14.2 and secure the fuse.
7. Follow the charger start up and verification procedure Section 16.7 to ensure that the charger is
functioning correctly

16.4: REPLACING THE SHUNT
1. Prior to replacing the Shunt, follow the troubleshooting guide in Section 15.0, to be certain that the
shunt is the only failed component.
3. When removing components, keep track of all hardware and ensure that no piece falls into the unit
where it could cause a hazard. In most cases, hardware must be re-used so keep track of where each
piece belongs.
4. Unfasten the shunt from stack assembly noting hardware assembly and how and where the control
wires (red and black) are connected.
5. Install the new shunt (referring to the previous disassembly) and control wire connections. Securely
fasten the shunt into position and securely fasten the black control wire. Position the red control wire
finger tight at the leftmost edge of the shunt.
6. Follow the shunt calibration procedure to adjust the output current to be equal to the original charger
setting.
16.5: CALIBRATING DC SHUNT
WARNING: Calibrating the Shunt of requires performing measurements and making adjustments to shunt
while AC power and the battery are connected to the charger. Observe all safety precautions while
working on a live unit. Do not attempt these procedures if you have not read, understood or agree with the
warning as outlined in the beginning of this Section.
1. To properly calibrate the shunt in the field, a properly rated battery with a minimum 40% DOD is
required.
2. Extreme caution is required while calibrating the shunt. If the shunt sense wire (small red wire) does
not maintain contact with the shunt, the output current to the battery will become excessive and could
result in damaged SCR/Diode modules, open AC fuse(s) or an open DC fuse.
connector if not already done, and ensure that the black sense lead (small black wire) is securely
fastened to the shunt. Make sure that the red sense lead (small red wire) is snuggly fastened to the
leftmost side of the adjustment slot in the shunt. Moving the red wire all the way to the left will result in
the lowest output current and all the way to the right will result in the highest output current.
4. Connect the battery and apply AC power to the charger.
5. Connect a DC clamp-on meter around one of the DC charge cable wires in a location which will be
visible while adjusting the shunt.
6. Wearing insulating gloves, use the finger of one hand to prevent the screw holding the red sense lead
connection to the shunt from turning. Apply pressure to the screw pressing it tightly against the shunt.
Use an appropriately sized nut driver in the other hand to slightly loosen the red sense wire nut and
slide it slowly to the right until the measured DC output current is equal to the nameplate rating +/-2%.
7. Securely tighten the nut and ensure that the DC current is still equal to the nameplate rating. If it does
not, return to step 6.
9. Follow the charger start up and verification procedure Section 16.7 to ensure that the charger is

16.6: REPLACING MAIN CONTROL (E1)
The control board contains surface mount technology. Special care should be taken to avoid flexing the
printed circuit board when removing and installing the control.
connector.
2. Carefully remove all connectors from the control board. When removing connectors, always support
the printed circuit board by placing a finger on the pcb and applying mild pressure to prevent the
board from flexing while pulling out the connector. Always grasp the connectors by their housings.
Never pull or apply force to the wires as this could damage the pins.
3. Carefully remove all hardware securing the control board to the door and take special note of where
all of the hardware was located. This hardware will be reused for the new control board.
4. With the hardware removed, gently slide the control board away from the door until it is free from the
standoffs.
5. If the new control board did not come with plastic standoffs located near the small drive transfomers,
gently remove the plastic standoffs from the old control board and carefully install them on the new
control board being careful not to flex the printed circuit board.
6. Gently install and fasten the new control board to the door using the hardware previously removed.
Ensure that all fiber washers and locking washers are in place,
7. Using the old control card as a guide, set up all dip switches on the new control card and verify that
the settings are correct using the Control Card Dip Switch Programming tables of Section 14.5.
8. Reinsert all connectors onto the control board placing a finger under the connection point and
applying mild upward pressure to prevent the board from flexing while installing the connectors.
9. Follow the charger start up and verification procedure in Section 16.7 to ensure that the charger is

16.7: CHARGER START UP AND VERIFICTION PROCEDURE
WARNING: The charger start up and verification procedure requires performing measurements while AC
power and the battery are connected to the charger. Observe all safety precautions while working on a
live unit. Do not attempt these procedures if you have not read, understood or agree with the warning as
outlined in the beginning of this Section.
1. With AC power applied and the Battery disconnected from the charger output connector.
2. Verify that the display indicates OFF/FLd or OFF/SLd depending on the type of battery the charger is
set up for. If there is a delay set, the display will also indicate this and the Delay LED should be lit.
3. Verify that all LEDs are off, with the exception of the delay LED if there is a delay timer set.
4. Connect a DC clamp-on current meter across one of the charger DC output cables.
5. Connect a battery to the charger output connector.
6. Verify that the control performs a Lamp test when the battery is connected. (all LEDs briefly light and
the display briefly indicates 888).
7. If the charger is configured for a delay, press the Start button to override the delay feature.
8. Verify that the charger starts, the charging LED should turn on and the display should indicate a
current of approximately 5A/100Ahour for flooded batteries or 3A/100Ahour for Sealed batteries.
9. Press the Equalize button twice to bypass the diagnostic stage and go directly to Stage 2 (high rate
current stage).
10. Verify that the charger output current increases to within 2% of the Ahour rating the charger is
configured for. If the charger is configured to charge a oversized battery, the output current will be
limited to the nameplate rating +/-2%.
11. Using an AC clamp-on current meter, verify that the charger AC input current in each phase is not
greater than 110% of the charger nameplate rating.
12. If any of the above steps fail, return to troubleshooting procedure or contact an AEG Power Solutions
service technician for assistance.
13. Complete an SMC START UP AND VERIFICATION REPORT (Section 18.4) and return form along
with a completed SMC ISSUES REPORT (Section 18.1) to AEG Power Solutions

SECTION 17.0: PARTS BREAKDOWN

17.1: PARTS BREAKDOWN FOR SMC SINGLE PHASE
ASSOCIATED MODELS
12 - 1 - 475 12 - 1 - 600
12 - 1 - 7500 18 - 1 - 750
18 - 1 - 600

PARTS BREAKDOWN FOR SMC SINGLE PHASE
DRWG
REF DESCRIPTION 12-1-475 QTY 12-1-600 QTY 12-1-750 QTY
1 FUSE CLIP REDUCER (480) – FACTORY PRESET N/A - N/A - 395000 2
(240) N/A - N/A - N/A -
(208) N/A - N/A - N/A -
2 SMC DOOR 395030 1 395030 1 395030 1
3 CHARGER CABLE ASSEMBLY 084570-100 10.5’ 084570-100 10.5’ 084571-100 10.5’
4 TIE DOWN RUBBER WITH TWO (2) HOOKS 395023 1 395023 1 395023 1
5 SMC SIDE PANEL LEFT 395031 1 395031 1 395031 1
6 SMC TOP PANEL 395032 1 395032 1 395032 1
7 SMC REAR PANEL 395033 1 395033 1 395033 1
8 TX HR 1PH 60HZ 208\240\480V 395034-001 1 395034-002 1 395034-003 1
9 BRG INST ASY SINGLE PHASE 395035-001 1 395035-001 1 395035-002 1
10 SMC SIDE PANEL RIGHT 395036 1 395036 1 395036 1
11 SMC BASE 395037 1 395037 1 395037 1
12 FUSE '
R'CLASS TIME DELAY (480) – FACTORY PRESET 340018-010 2 340018-012 2 340018-015 2
(240) 340018-020 2 340018-025 2 340018-030 2
(208) 340018-020 2 340018-025 2 340018-035 2
13 FUSE BLOCK 2P XXA 600V 395017-004 1 395017-004 1 395017-003 1
14 CONTROL SMC-G 1PH B/C CAB 395004-001 1 395004-001 1 395004-001 1
15 MOUNTING STRAP 1" BUNDLE DIA 1.1" X 1.1" BASE 395018 1 395018 1 395018 1
16 SMC SINGLE PHASE CONTROL WIRE HARNESS 395039 1 395039 1 395039 1
17 TRANSFORMER PRIMARY TO FUSE BLOCK CABLE 395040 1 395040 1 395040 1
CONNECTOR SBXXX. (Note: Refer to Section 17.4 for
18 connector color options) 078723-002 1 078723-002 1 078723-003 1
DRWG
REF DESCRIPTION 18-1-600 QTY 18-1-750 QTY
1 FUSE CLIP REDUCER (480) – FACTORY PRESET 395000 2 395000 2
(240) N/A - N/A -
(208) N/A - N/A -
2 SMC DOOR 395030 1 395030 1
3 CHARGER CABLE ASSEMBLY 084571-100 10.5’ 084571-100 10.5’
4 TIE DOWN RUBBER WITH TWO (2) HOOKS 395023 1 395023 1
5 SMC SIDE PANEL LEFT 395031 1 395031 1
6 SMC TOP PANEL 395032 1 395032 1
7 SMC REAR PANEL 395033 1 395033 1
8 TX HR 1PH 60HZ 208\240\480V 395034-005 1 395034-005 1
9 BRG INST ASY SINGLE PHASE 395035-002 1 395035-002 1
10 SMC SIDE PANEL RIGHT 395036 1 395036 1
11 SMC BASE 395037 1 395037 1
12 FUSE '
R'CLASS TIME DELAY (480) – FACTORY PRESET 340018-020 2 340018-020 2
(240) 340018-035 2 340018-040 2
(208) 340018-040 2 340018-045 2

13 FUSE BLOCK 2P XXA 600V 395017-003 1 395017-003 1
14 CONTROL SMC-G 1PH B/C CAB 395004-001 1 395004-001 1
15 MOUNTING STRAP 1" BUNDLE DIA 1.1" X 1.1" BASE 395018 1 395018 1
16 SMC SINGLE PHASE CONTROL WIRE HARNESS 395039 1 395039 1
17 TRANSFORMER PRIMARY TO FUSE BLOCK CABLE 395040 1 395040 1
CONNECTOR SBXXX. (Note: Refer to Section 17.4
18 for connector color options) 078723-001 1 078723-001 1
BRIDGE ASSSEMBLY FOR SMC SINGLE PHASE
ASSOCIATED MODELS
12 - 1 - 475 12 - 1 - 600
12 - 1 - 750 18 - 1 - 750
18 - 1 - 600

BRIDGE ASSSEMBLY FOR SMC SINGLE PHASE
DRWG
19 HEATSINK 420MM 395041-001 1 395041-001 1 395041-001 1
20 INSULATOR RED HEXAGONAL 395019 6 395019 6 395019 6
21 THYRISTOR/DIODE MODULE 395042-001 2 395042-001 2 395042-002 2
22 SMC AC BUSBAR 395043 2 395043 2 395043 2
23 SMC -VE BUSBAR 395044-001 1 395044-001 1 395044-002 1
24 SMC +VE BUSBAR 395045-001 1 395045-001 1 395045-002 1
25 SHUNT 135A 50mV 0.045" THICK 395021 1 395021 1 395021 1
26 FUSE VERY FAST XXXA 125V 340016-150 1 340016-150 1 340016-200 1
27 VARISTOR ASSY 395046 1 395046 1 395046 1
DRWG
REF DESCRIPTION 18-1-600 QTY 18-1-750 QTY
19 HEATSINK 420MM 395041-001 1 395041-001 1
20 INSULATOR RED HEXAGONAL 395019 6 395019 6
21 THYRISTOR/DIODE MODULE 395042-002 2 395042-002 2
22 SMC AC BUSBAR 395043 2 395043 2
23 SMC -VE BUSBAR 395044-002 1 395044-002 1
24 SMC +VE BUSBAR 395045-002 1 395045-002 1
25 SHUNT 135A 50mV 0.045" THICK 395021 1 395021 1
26 FUSE VERY FAST XXXA 125V 340016-200 1 340016-200 1
27 VARISTOR ASSY 395046 1 395046 1

17.1.1: PARTS BREAKDOWN FOR SMC SINGLE PHASE 12-1-865
ASSOCIATED MODELS
12 - 1 - 865

PARTS BREAKDOWN FOR SMC SINGLE PHASE
DRWG
REF DESCRIPTION 12-1-865 QTY
1 FUSE CLIP REDUCER (480) – FACTORY PRESET 395000 2
(240) N/A -
(208) N/A -
2 SMC DOOR 395030 1
3 CHARGER CABLE ASSEMBLY 084571-100 10.5’
4 TIE DOWN RUBBER WITH TWO (2) HOOKS 395023 1
5 SMC SIDE PANEL LEFT 395031 1
6 SMC TOP PANEL 395032 1
7 SMC REAR PANEL 395031 1
8 TX HR 1PH 60HZ 208\240\480V 395034-004 1
9 BRG INST ASY SINGLE PHASE 395035-003 1
10 SMC SIDE PANEL RIGHT 395036 1
11 SMC BASE 395037 1
12 FUSE '
R'CLASS TIME DELAY (480) – FACTORY PRESET 340018-015 2
(240) 340018-030 2
(208) 340018-035 2
13 FUSE BLOCK 2P XXA 600V 395017-003 1
14 CONTROL SMC-G 1PH B/C CAB 395004-001 1
15 MOUNTING STRAP 1" BUNDLE DIA 1.1" X 1.1" BASE 395018 1
16 SMC SINGLE PHASE CONTROL WIRE HARNESS 395039 1
17 TRANSFORMER PRIMARY TO FUSE BLOCK CABLE 395040 1
18 connector color options) 078723-003 1

BRIDGE ASSEMBLY FOR SMC SINGLE PHASE
ASSOCIATED MODELS
12 - 1 - 865

BRIDGE ASSEMBLY BREAKDOWN FOR SMC SINGLE PHASE
DRWG
REF DESCRIPTION 12-1-865 QTY
19 HEATSINK 420MM 395041-003 1
20 INSULATOR RED HEXAGONAL 395019 7
21 THYRISTOR/DIODE MODULE 395042-003 2
22 SMC AC BUSBAR 395043 2
23 SMC -VE BUSBAR 395044-002 1
24 SMC +VE BUSBAR 395045-002 1
25 SHUNT 135A 50mV 0.045" THICK 395021 2
26 FUSE VERY FAST XXXA 125V 340016-300 2
27 VARISTOR ASSY 395046 1

17.2: PARTS BREAKDOWN FOR SMC THREE PHASE
ASSOCIATED MODELS
12 - 3 - 475 12 - 3 - 600
12 - 3 - 750 12 - 3 - 8650
12 - 3 - 965 12 - 3 - 1050
18 - 3 - 750 18 - 3 - 865
18 - 3 - 965 18 - 3 - 1050
18 - 3 -1200 24 - 3 - 750
24 - 3 - 865 24 - 3 - 965
24 - 3 - 1050

PARTS BREAKDOWN FOR SMC THREE PHASE
DRWG REF DESCRIPTION 12-3-475 QTY 12-3-600 QTY 12-3-750 QTY

1 FUSE CLIP REDUCER (480) – FACTORY PRESET N/A 1 N/A 1 N/A -
(240) N/A - N/A - N/A -
(208) N/A - N/A - N/A -
2 SMC DOOR 395030 1 395030 1 395030 1
6 SMC TOP PANEL 395032 1 395032 1 395032 1
7 SMC REAR PANEL 395033 1 395033 1 395033 1
8 TX HR 3PH 60HZ 208\240\480V 395034-006 1 395034-006 1 395034-007 1
9 BRG INST ASY THREE PHASES 395035-004 1 395035-004 1 395035-005 1
11 SMC BASE 395037 1 395037 1 395037 1
FUSE '
R'CLASS TIME DELAY (480) – FACTORY
12 PRESET 340018-005 3 340018-007 3 340018-008 3
(240) 340018-010 3 340018-012 3 340018-015 3
(208) 340018-012 3 340018-015 3 340018-020 3
13 FUSE BLOCK 3P XXA 600V 395017-001 1 395017-001 1 395017-001 1
16 SMC THREE PHASES CONTROL WIRE HARNESS 395039-003 1 395039-003 1 395039-003 1
17 TRANSFORMER PRIMARY TO FUSE BLOCK CABLE 395040-003 1 395040-003 1 395040-003 1

1 FUSE CLIP REDUCER (480) – FACTORY PRESET N/A - N/A - N/A -
(240) N/A - N/A - N/A -
(208) N/A - N/A - N/A -
2 SMC DOOR 395030 1 395030 1 395030 1
6 SMC TOP PANEL 395032 1 395032 1 395032 1
7 SMC REAR PANEL 395033 1 395033 1 395033 1
8 TX HR 3PH 60HZ 208\240\480V 395034-007 1 395035-009 1 395035-009 1
11 SMC BASE 395037 1 395037 1 395037 1
FUSE '
R'CLASS TIME DELAY (480) – FACTORY
12 PRESET 340018-010 3 340018-010 3 340018-010 3
(240) 340018-020 3 340018-020 3 340018-020 3
(208) 340018-020 3 340018-025 3 340018-025 3
13 FUSE BLOCK 3P XXA 600V 395017-001 1 395017-001 1 395017-001 1


1 FUSE CLIP REDUCER (480) – FACTORY PRESET N/A - N/A - 395000 3
(240) N/A - N/A - N/A -
(208) N/A - N/A - N/A -
2 SMC DOOR 395030 1 395030 1 395030 1
6 SMC TOP PANEL 395032 1 395032 1 395032 1
7 SMC REAR PANEL 395033 1 395033 1 395033 1
8 TX HR 3PH 60HZ 208\240\480V 395035-008 1 395035-010 1 395035-011 1
11 SMC BASE 395037 1 395037 1 395037 1
12 FUSE '
R'CLASS TIME DELAY (480) – FACTORY PRESET 340018-012 3 340018-012 3 340018-015 3
(240) 340018-025 3 340018-025 3 340018-030 3
(208) 340018-025 3 340018-030 3 340018-035 3
13 FUSE BLOCK 3P XXA 600V 395017-001 1 395017-001 1 395017-002 1
DRWG REF DESCRIPTION 18-3-1050 QTY 18-3-1200 QTY

(240) N/A - N/A -
(208) N/A - N/A -
2 SMC DOOR 395030 1 395030 1
6 SMC TOP PANEL 395032 1 395032 1
7 SMC REAR PANEL 395033 1 395033 1
8 TX HR 3PH 60HZ 208\240\480V 395035-011 1 395035-013 1
9 BRG INST ASY THREE PHASES 395035-006 1 395035-007 1
11 SMC BASE 395037 1 395037 1
12 FUSE '
(240) 340018-030 3 340018-040 3
(208) 340018-035 3 340018-045 3
13 FUSE BLOCK 3P XXA 600V 395017-002 1 395017-002 1
16 SMC THREE PHASES CONTROL WIRE HARNESS 395039-003 1 395039-003 1
17 TRANSFORMER PRIMARY TO FUSE BLOCK CABLE 395040-004 1 395040-004 1
18 connector color options) 078723-001 1 078723-001 1


(240) N/A - N/A -
(208) N/A - N/A -
2 SMC DOOR 395030 1 395030 1
6 SMC TOP PANEL 395032 1 395032 1
7 SMC REAR PANEL 395033 1 395033 1
8 TX HR 3PH 60HZ 208\240\480V 395035-012 1 395035-012 1
11 SMC BASE 395037 1 395037 1
12 FUSE '
(240) 340018-030 3 340018-035 3
(208) 340018-035 3 340018-040 3
13 FUSE BLOCK 3P XXA 600V 395017-002 1 395017-002 1
CONNECTOR SBXXX. (Note: Refer to Section 17.4 for connector color
18 options) 078723-006 1 078723-006 1

(240) N/A - N/A -
(208) N/A - N/A -
2 SMC DOOR 395030 1 395030 1
6 SMC TOP PANEL 395032 1 395032 1
7 SMC REAR PANEL 395033 1 395033 1
8 TX HR 3PH 60HZ 208\240\480V 395035-012 1 395035-014 1
11 SMC BASE 395037 1 395037 1
12 FUSE '
(240) 340018-040 3 340018-040 3
(208) 340018-045 3 340018-045 3
13 FUSE BLOCK 3P XXA 600V 395017-002 1 395017-002 1
CONNECTOR SBXXX. (Note: Refer to Section 17.4 for connector color
18 options) 078723-006 1 078723-006 1

BRIDGE ASSEMBLY FOR SMC THREE PHASE
ASSOCIATED MODELS
12 - 3 - 475 12 - 3 - 600
12 - 3 - 750 12 - 3 - 8650
12 - 3 - 965 12 - 3 - 1050
18 - 3 - 750 18 - 3 - 865
18 - 3 - 965 18 - 3 - 1050
18 - 3 - 1200 24 - 3 - 750
24 - 3 - 865 24 - 3 - 965
24 - 3 - 1050

BRIDGE BREAKDOWN FOR SMC THREE PHASE
DRWG
19 HEATSINK 420MM 395041-004 1 395041-004 1 395041-002 1
22 SMC AC BUSBAR 395043 2 395043 2 395043 2
23 SMC -VE BUSBAR 395044-001 1 395044-001 1 395044-002 1
24 SMC +VE BUSBAR 395045-001 1 395045-001 1 395045-002 1
25 SHUNT 135A 50mV 0.045" THICK 395021 1 395021 1 395021 1
27 VARISTOR ASSY 395046-003 1 395046-003 1 395046-003 1
28 SMC AC BRIDGE BUSBAR 395045-003 1 395045-003 1 395045-003 1
DRWG
19 HEATSINK 420MM 395041-002 1 395041-005 1 395041-005 1
22 SMC AC BUSBAR 395043 2 395043 2 395043 2
23 SMC -VE BUSBAR 395044-002 1 395044-002 1 395044-002 1
24 SMC +VE BUSBAR 395045-002 1 395045-002 1 395045-002 1
25 SHUNT 135A 50mV 0.045" THICK 395021 2 395021 2 395021 2
27 VARISTOR ASSY 395046-003 1 395046-003 1 395046-003 1
DRWG
19 HEATSINK 420MM 395041-002 1 395041-002 1 395041-005 1
22 SMC AC BUSBAR 395043 2 395043 2 395043 2
23 SMC -VE BUSBAR 395044-002 1 395044-002 1 395044-002 1
24 SMC +VE BUSBAR 395045-002 1 395045-002 1 395045-002 1
25 SHUNT 135A 50mV 0.045" THICK 395021 1 395021 2 395021 2
27 VARISTOR ASSY 395046-003 1 395046-003 1 395046-003 1

BRIDGE BREAKDOWN FOR SMC THREE PHASE
DRWG
19 HEATSINK 420MM 395041-005 1 395041-006 1 395041-002 1
22 SMC AC BUSBAR 395043 2 395043 2 395043 2
23 SMC -VE BUSBAR 395044-002 1 395044-003 1 395044-002 1
24 SMC +VE BUSBAR 395045-002 1 395045-004 1 395045-002 1
25 SHUNT 135A 50mV 0.045" THICK 395021 2 395021 2 395021 1
27 VARISTOR ASSY 395046-003 1 395046-003 1 395046-003 1
DRWG
19 HEATSINK 420MM 395041-002 1 395041-005 1 395041-005 1
22 SMC AC BUSBAR 395043 2 395043 2 395043 2
23 SMC -VE BUSBAR 395044-002 1 395044-002 1 395044-002 1
24 SMC +VE BUSBAR 395045-002 1 395045-002 1 395045-002 1
25 SHUNT 135A 50mV 0.045" THICK 395021 2 395021 2 395021 2
27 VARISTOR ASSY 395046-003 1 395046-003 1 395046-003 1

17.4: OPTIONAL SERVICE ONLY COLOR CONNECTORS/CONTACTS
COLOR CONNECTOR SB175

CONNECTOR SB175 BLACK N/A
CONNECTOR SB175 GREY 078723-002
CONNECTOR SB175 BLUE 078723-008
CONNECTOR SB175 ORANGE 078723-010
CONNECTOR SB175 YELLOW 078723-004
CONNECTOR SB175 RED 078723-007
COLOR CONNECTOR SB350

CONNECTOR SB350 GREY 078723-001
CONNECTOR SB350 BLACK N/A
CONNECTOR SB350 BLUE 078723-006
CONNECTOR SB350 RED 078723-003
CONNECTOR SB350 YELLOW 078723-009
CONNECTOR SB350 ORANGE 378723-015
CONTACTS FOR SB175/SB350

CONTACT SB350 1/0 078724-006
CONTACT SB350 2/0 078724-001
CONTACT SB175 1/0 078724-002

SECTION 18.0: TEST/VERIFICATION FORMS
• APPLICABLE FORMS ‘MUST’ BE COMPLETED AND RETURNED TO AEG POWER

SOLUTIONS WHENEVER ANY TROUBLESHOOTING AND COMPONENT REPLACMENT
IS DONE ON A SMC UNIT
• Observe all safety precautions while working on a live unit. Do not attempt to carry
out any troubleshooting or component replacement procedures if you have not
read, understood or agreed with the warning as outlined in both Sections 15.0 and
16.0 of this Service Manual
Instr. 4780-65-95025-54 Page 63 Rev.00, Oct. 31, 2008

18.1: SMC ISSUE REPORT FORM

18.2: CONTROL (E1), SCR & DIODE RESISTANCE VERIFICATION FORM

18.3: NO LOAD TEST ON TRANSFORMER (T1) FORM

18.4: SMC START UP VERIFICATION REPORT FORM

NOTES:

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SMC-C CHARGER NAMEPLATE

SECTION 1.0: SMC-C SERIES INDUSTRIAL BATTERY CHARGERS 5

SECTION 2.0: INTRODUCTION 6

SECTION 3.0: RECEIVING CHARGER 6

SECTION 4.0: LOCATION AND INSTALLATION OF CHARGER 6

SECTION 5.0: AC ELECTRICAL SUPPLY 7

SECTION 6.0: DC OUTPUT 8

SECTION 7.0: APPLICATION 9

SECTION 8.0: CABINET OUTLINE/DIMENSIONS FOR SMC-C MODEL CHARGERS 10

SECTION 9.0: SMC-C STANDARD CHARGER OPERATION 11

SECTION 10.0: OPPORTUNITY CHARGING 14

SECTION 11.0: CHARGE TIME 14

Instr. 4780-65-95025-54 Page 1 Rev.01, Jan. 10, 2010

SECTION 13.0: MAINTENANCE 14

SECTION 14.0: CHARGER TECHNICAL INFORMATION 15

SECTION 15.0 TROUBLESHOOTING 25

SECTION 16.0 COMPONENT PART REPLACEMENT AND VERIFICATION SET UP 37

Instr. 4780-65-95025-54 Page 2 Rev.01, Jan. 10, 2010

SECTION 18.0: TEST/VERIFICATION FORMS 63

Instr. 4780-65-95025-54 Page 3 Rev.01, Jan. 10, 2010

IMPORTANT OPERATING AND SAFETY INSTRUCTIONS

h) This charger is factory set to charge lead-acid batteries ONLY.

l) Never charge a frozen battery

Instr. 4780-65-95025-54 Page 5 Rev.01, Jan. 10, 2010

SECTION 3.0: RECEIVING CHARGER

SECTION 4.0: LOCATION AND INSTALLATION OF CHARGER

WARNING: THE ABOVE PROCEDURES MUST BE FOLLOWED EXACTLY TO AVOID INJURY OR

WARNING: TO REDUCE THE RISK OF FIRE, INSTALL BATTERY CHARGER ON A FLOOR OF

Instr. 4780-65-95025-54 Page 6 Rev.01, Jan. 10, 2010

TABLE 1 – INPUT VOLTAGE CHOICES

5.1: AC FUSE MOUNTING

5.2: INPUT VOLTAGE CHANGE

5.3: AC VOLTAGE CONNECTIONS

Note: No plug is supplied on models with optional AC input cable

Instr. 4780-65-95025-54 Page 7 Rev.01, Jan. 10, 2010

WARNING: DO NOT OPERATE THE UNIT WITHOUT PROPER GROUNDING. IMPROPER

After electrical connection is completed, the charger is ready for operation.

FIGURE 1: GROUNDING METHOD

SECTION 6.0: DC OUTPUT

Instr. 4780-65-95025-54 Page 8 Rev.01, Jan. 10, 2010

7.1: FAULT AND DISPLAY CODES

Instr. 4780-65-95025-54 Page 9 Rev.01, Jan. 10, 2010

CABINET DIM. A DIM. B DIM. C

Instr. 4780-65-95025-54 Page 10 Rev.01, Jan. 10, 2010

LED DISPLAY DESCRIPTION

OFF/SLd CHARGER SET FOR SEALED BATTERIES.

PLUG IN BATTERY TO COMMENCE CHARGING

FAULT (Red) CHARGE CYCLE WAS INTERRUPTED BY

CHARGE COMPLETE (Green) CHARGING IS COMPLETE. ONCE COOLDOWN

9.1.1: DELAY STAGE

9.1.1.2: DELAY LED

9.1.1.3: DELAY OVERRIDE

Instr. 4780-65-95025-54 Page 12 Rev.01, Jan. 10, 2010

Diagnostic Stage can be cancelled by pressing Equalize pushbutton twice.

9.1.2.1: CHARGING LED

This LED indicates that the charger is ON.

9.1.2.3: 80% CHARGED LED

9.1.2.4: CHARGE COMPLETE LED

V-Force SCR Service & Parts Manual

V-Force SCR Service & Parts Manual

V-Force SCR Service & Parts Manual