OEM Product Manual for:

PBC10UL (24V)

Battery Charger
OPERATION & MAINTENANCE GUIDE

THIS MANUAL REFERS TO THE FOLLOWING MODELS

G150 12V
G300 12V
G300 24V
G600 24V
EG150 12V
EG300 12V
EG300 24V - Olympian PBC10UL (24V)
EG600 24V
For safe and correct use of the unit read the safety instructions which precede the operating instructions for the above units.

THIS GUIDE CONTAINS 6 PAGES (including this one) IF ANY PAGES ARE MISSING -
CONTACT THE BATTERY CHARGER SUPPLIER OR MANUFACTURER

Guardian Installation Instructions - April 04

 IMPORTANT SAFETY INSTRUCTIONS -
SAVE THESE INSTRUCTIONS - SAFETY INSTRUCTIONS
This manual contains important safety and operating instructions for models G150, G300, G600, EG150, EG300 and
EG600.
Do not expose charger to rain or snow
Use of an attachment not recommended or sold by the battery charger manufacturer may result in risk of fire, electric
shock, or injury to persons.
Do not operate charger if it has received a sharp blow, been dropped, otherwise damaged in any way; return to suppli-
er.
Do not disassemble charger, return to supplier when service or repair is required. Incorrect reassembly may result in a
risk of electric shock or fire.
WARNING - RISK OF EXPLOSIVE GASES
WORKING IN VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE
GASES DURING NORMAL BATTERY OPERATION.
To reduce the risk of battery explosion, follow these instructions and those published by battery manufacturers and man-
ufacturer of any equipment you intend to use in vicinity of the battery. Review cautionary marking on these products and
on any attached equipment.
PERSONAL PRECAUTIONS
(i) Someone should be within range of your voice or close enough to come to your aid when you work near a lead-acid
battery.
(ii) Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing or eyes.
(iii) Wear complete eye protection and clothing protection. Avoid touching eyes while working near batteries.
(iv) If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eyes, immediately flood
eyes with running cold water for at least 10 minutes and get medical attention immediately.
(v) NEVER smoke or allow a spark or flame in vicinity of battery.
(vi) Be extra cautious to reduce risk of dropping a metal tool onto battery. It may spark or short-circuit the battery or other
electrical part that may cause explosion.
(vii) Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a lead-acid bat-
tery. A lead-acid battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing a
severe burn.
(viii) Use charger only for charging batteries as stated on the charger. Do not use battery charger for charging dry-cell
batteries that are commonly used with home appliances. These batteries may burst and cause injury to persons and
damage to property.
(ix) NEVER CHARGE A FROZEN BATTERY
PRIOR TO INSTALLATION / COMMISSIONING
Clean battery terminals. Be careful to keep corrosion from coming in contact with eyes.
Add distilled water in each cell until battery acid reaches level specified by battery manufacturer. This helps purge exces-
sive gas from cells. Do not overfill. For a battery without cell caps, carefully follow manufacturer’s recharging instructions.
Study all battery manufacturer’s specific precautions such as removing or not removing cell caps while charging and rec-
ommended rates of charge.
Determine voltage of battery by referring to engine manual and ensure matches charger’s output voltage.
CHARGER LOCATION AND CONNECTION
Never place charger directly above battery being charged, gases from battery will corrode and damage charger.
Never allow battery acid to drip on charger when reading specific gravity or filling battery.
Do not operate charger in a closed-in area or restrict ventilation in any way.
The battery charger should be connected to a grounded, metal, permanent wiring system; or an equipment-grounding
conductor should be run with circuit conductors not connected to equipment-grounding terminal on battery charger.
Connections to battery charger should comply with all local codes and ordinances.
G150, G300 & G600 - These battery chargers should be installed so that they are not likely to be contacted by people.
EG150, EG300 & EG600 - The AC wiring should be independent of the DC and alarm wiring. Use 2x 2.5mm2 (total wire
ø=5mm2 ) or larger wire for DC (charger to battery) leads. Use 2.5mm2 or larger for input and ground connections.

For safe and correct use of the unit follow the following steps, should you have any problems and the unit does not function as
expected consult our troubleshooting guide at the end of these instructions.

Visually inspect unit for any signs of damage, caused by transport or storage
Mount charger as outlined above, paying attention to ambient temperature
Ensure mains supply is isolated and connect observing the correct rated input voltage
Ensure unit is earthed at the marked earth stud
Check batteries in accordance with manufacturer guidelines
Check charger is correct for battery type and voltage
Connect unit to batteries, observing correct polarity and ensuring a secure and tight connection
Switch on unit at mains supply

Guardian Installation Instructions - April 04 - Page 2 of 6

Battery Charger
Installation Instructions
GENERAL INFORMATION
Please read the following information before installing. A visual inspection of this product for damage during shipping is
recommended before installation. It is your responsibility to ensure that qualified mechanical and electrical technicians
install this product. If in doubt, please contact your local Computronic representative.

Product Specification
Power Supply:

nominal operating voltages 120V Units

240V Units
permissible voltage variation ± 6% of nominal
BEFORE BEGINNING INSTALLATION OF THIS PRODUCT
Disconnect all electrical power to the charger nominal operating frequency 50/60Hz

Make sure the charger cannot operate during installation DC Charge Output:
Follow all safety warnings of charger and battery manufacturers
maximum current ADC 20 20
Read and follow all installation instructions nominal voltage VDC 24 12

float / boost voltages

Description These are factory preset for specified batteries,
typical settings are as follows: -
The Guardian range provides automatic, current Float Voltage
limited and voltage controlled charging of vented lead acid or 12V 24V
NiCd batteries. The units may be used in a wide range of Vented Lead Acid 13.7V 27.2V
industrial charging applications, including standby engines, 12V 10 Cell 24V 20 Cell
pumps and generators. NiCad 14.1V 28.2V
The charger is supplied in either an open frame construction, Boost Voltage
designed for surface mounting in an enclosed panel or as a 12V 24V
wall mounted enclosure with charging indication via an amme- Vented Lead Acid 14.1V 28.2V
ter and voltmeter. (Note: In event of no AC supply to charger, the voltmeter 12V 10 Cell 24V 20 Cell
will display the DC voltage of any connected DC equipment) Each unit con- NiCad 14.6V 29.2V
sists of a transformer, rectifier and thyristor control circuit. The
control circuit ensures that the charger maintains a battery volt- Charge Fail Output:
age at the pre-calibrated float level, while supplying any addi-
tional load current up to the specified maximum. relay type volt free SPDT contacts
Auto Boost (Equalising) Operation relay de-energised on fault
Auto boost operation provides an increased output voltage contact rating 1A @ 30VDC (resistive load)
when batteries are below a preset point. Once the batteries
have reached the boost voltage the charger reverts to its float General:
voltage. This operation equalises the batteries, maximising
battery life and capacity.
transformer Single Phase 50-60Hz Class 155 (F)
Boost Initiate Operation operating temperature -10 to +55°C
The boost initiate switch forces the charger to enter an auto
boost cycle (see above) even if battery voltage is above the OPEN FRAME MODELS
preset point, once this operation is completed the charger G150 & G300
returns to it’s float voltage. dimensions 126mm/4.9”(W) x 124mm/4.9”(D) x 126mm/4.9”(H)
Temperature Compensation weight 4.5Kg / 10lb
The remote temperature compensation provides control of the G600
output voltage based upon temperature, as temperature dimensions 126mm/4.9”(W) x 124mm/4.9”(D) x 156mm/6.1”(H)
increases the charging voltage is decreased at a negative weight 7.8Kg / 17.3lb
coefficient of 3mV/°C/Cell. WALL MOUNTED ENCLOSURE MODELS
Charge fail & alarms option EG150 & EG300
A self diagnostic 'charge fail' circuit and relay output is provid- dimensions 278mm/10.9”(W) x 120mm/4.7”(D) x 280mm/11”(H)
ed along with under and over voltage warnings. The volt free weight 8.4Kg / 17.9lbs
relays de-energise in the event of a charging fault or high/low EG600
battery state. dimensions 300mm/11.8”(W) x 300mm/11.8”(D) x 210mm/8”(H)
Electrical connection of the AC and DC supply and alarms are weight 15Kg / 31.8lbs
via spring-clamp terminals. (For more information on these ter- EMC emission / immunity EN58801-2 / EN50082-2
minals see Computronic Controls Product Change Ref: CCL PC
Release 1 - April03)
Guardian Installation Instructions - April 04 - Page 3 of 6
 GENERAL INFORMATION (ctd)
Current Limiting Battery Charged Condition
The Guardian Battery Charger is current limited and will When charged the battery will only accept a charge to
only output the rated current of the charger (see chart replace the losses within the battery (approx. 1mA per AH of
below) battery). If there is a standing load (i.e. the panel controller
etc) the charger will output the standing load plus the losses
GUARDIAN CURRENT RATINGS to the battery i.e. if a standing load of 1A is present with
50AH Vented Lead Acid batteries then charger will supply
MODEL RATING 1.05 amps.
G150 12V & G300 24V 10A
A charged battery with open circuit terminals (i.e. no load
EG150 12V & EG300 24V 10A
connected) will always be higher than nominal battery volt-
G300 12V & G600 24V 20A age (i.e. 12.6 on a 12V lead acid battery)
EG300 12V & EG600 24V 20A

Dimensions
figure 1a - Open frame models figure 1b - Wall mounted enclosed models

D W H Weight D W H Weight

126mm 124mm 126mm 4.5Kg 278mm 120mm 280mm 8.4Kg

G150 & G300 EG150 & 300
4.9” 4.9” 4.9” 10lbs 10.9” 4.7” 11” 11.9lbs
126mm 124mm 156mm 7.8Kg 300mm 300mm 210mm 15Kg
G600 4.9” 4.9” 6.1” 17.3lbs EG600 11.8” 11.8” 8.3” 31.8lbs

IMPORTANT ASSEMBLY INSTRUCTIONS -

SAVE THESE INSTRUCTIONS

OPEN FRAME MODELS -

G150, G300 & G600
The charger must be mounted as shown in Figure 2a, with heatsink fins
in vertical position.
Four screws should be used to mount charger to panel. Ensure screws
are tightened firmly as as not to become loose during normal use on
engine.
Adequate consideration should be given to ventilation for proper heat
dissipation.
WALL MOUNTED ENCLOSURE MODELS -
EG150, EG300 & EG600
The charger must be mounted as shown in Figure 2b.
By unscrewing the fixing screws the faces can be opened on their G300 G600 Fixing hole dimensions:
hinges, to allow access to the internal connections. All models (mm) All models (mm)
Width (between holes) - 173mm (6.8”)
Cable entry is via knock-outs on either side of the unit, these must be
A 70 90 Height (between holes)- 255mm (10”)
carefully removed from the enclosure sides.
A suitable cable-gland (20mm/0.8” DIA) should be used to prevent Fixing holes Ø=6mm (0.2”)
B 90 120
damage to cables and stop unwanted entry into inner part of charger.
See “Electrical Connection” for details of terminal connections. Figure 2a - Figure 2b -
The lower face should be firmly screwed to the charger before use. open frame models wall mounted enclosure models
Four screws should be used to mount charger to panel. Ensure screws
are tightened firmly as as not to become loose during normal use on
engine.
Adequate consideration should be given to ventilation for proper heat
dissipation.

CAUTION: When handling chargers, care should be taken not to place excessive strain on either the heatsink, PCB,
transformer or connecting wires. Unit should be handled by transformer frame (open frame models) or steel enclosure
(enclosed models).

Guardian Installation Instructions - April 04 - Page 4 of 6

 IMPORTANT OPERATING INSTRUCTIONS -
SAVE THESE INSTRUCTIONS

Before operating the battery charger, ensure that the charger is assembled and installed as per the
section listed in these instructions.

Terminal Connection Information

OUTPUT BOOST CHARGE FAIL OVER VOLTS UNDER VOLTS INPUT

Com

Com

Com
N/O

N/C

N/O

N/C

N/O

N/C
- + N L

Output: To battery
CAUTION: Observe correct polarity
Input: AC supply
CAUTION: Observe correct voltage as stated on unit
ALARM INDICATION - Over Voltage, Under Voltage and Charge Fail
Com - Common
N/O - Normally Open
N/C - Normally Closed
(See notes on connection of alarms - see right)
Boost: Boost Initiate - Linking these two connectors will force
the charger from into a single boost cycle of operation. Connection to Mains Supply:
(Once the charger has completed a single boost cycle Ensure supply is isolated before connection is made to charging unit
as outlined on page 3 of these instructions the charger Ensure unit is properly earthed at earth stud on chargers metal chassis
returns to it’s normal mode of operation) CAUTION: Ensure correct AC voltage is supplied to unit, applying 240VAC on a
120VAC unit will destroy it and could cause serious personal injury.
Connection to Batteries:
Ensure mains supply is isolated before connecting charger to batteries
Ensure battery type and voltage are correct before connecting to batteries
WARNING: Charging either different voltage or type of batteries from stated type
Stripped wire is introduced just may result in damage to both the charging unit and/or batteries and
before the clamping unit. could result in serious personal injury.
Disconnection of Batteries:
Ensure mains supply is isolated before disconnecting charger from batteries
WARNING: Disconnecting the batteries whilst mains supply is connected to the
charger could result in a spark at battery terminals, this could ignite
The clamp spring is pressed down the hydrogen given off from the batteries.
and wire is introduced into the Boost Initiate Connection:
clamping unit immediately The charger will be in it’s normal mode of operation whilst the boost link is bro-
ken, upon connecting the two boost initiate terminals the charger will perform a
single auto-boost cycle, whereby the charger outputs a higher voltage, once bat-
tery voltage has reached this point, the charger returns to it’s normal float mode
of operation.
Over Voltage, Under Voltage and Charge Fail Connection:
The clamp spring is released - the
In a de-energised state the COM - N/C contact is alarmed. The relay energises
conductor is automatically clamped on power up and changes state to COM - N/O. These contacts are volt-free con-
tacts rated at 1A @ 30VDC.
Fuses:
All Guardian models are fitted with mains input fuses at the required ratings (see
NB. All connections, including AC input and DC output are made via markings on chargers). Before replacing any fuses, ensure charger is isolated
spring-clamp connections as outlined above. from mains supply.

The G150 12V, EG150 12V, G300 12V, EG300 12V, G300 24V and EG300 24V models are fitted with a self-resetting polyfuse on the dc output. If reverse
polarity or short circuit faults are made, isolate supply, disconnect the outputs and allow fuse to self-reset. The charger can then be re-connected and
switched back on. No replacement of output fuse should be necessary. If fuse fails to reset, the charger should be returned to supplier. The G600 and
EG600 models are fitted with an Automotive type blade fuse. Ensure correct rating when replacing fuses.

AUTOMATIC BATTERY CHARGER

The Guardian range is an automatic battery charger, if battery voltage falls below a preset voltage (12.2V on a 12V lead-acid battery) the charger will
automatically enter an increased charging voltage state (boost). Once the batteries have reached this point, the charger will switch to it’s normal “float”
voltage. this prevents over-charge, which inturn prevents the battery from over-gassing and subsequently maximises battery life.

WARNING: The Guardian range is not USER SERVICEABLE. No attempt should be made to replace or repair the charger, any attempt to do so may
invalidate any warranties and could cause serious personal harm or injury as well as damage to both the battery charger and any connected devices.
In event of failure the charger should be returned to supplier.

ELECTRICAL CONNECTION

WARNING: DANGER OF INJURY OR DEATH. Before connection, disconnection or handling

of GUARDIAN battery charger, ensure that all AC power supplies are isolated. Connection to or discon-
nection from live wiring can also cause damage to internal components.

Guardian Installation Instructions - April 04 - Page 5 of 6

 TROUBLESHOOTING FLOWCHART
START HERE

YES
Are batteries charging? PROBLEM SOLVED

MEASURING CHARGING VOLTAGE AND CURRENT

To check charger is working, follow these steps then consult expected conditions
+ A for relevant battery type below.
+
CHARGER BATTERY V (1) VOLTAGE - Place voltmeter across battery terminals (V on fig ii)
-
- (2) CURRENT - Break the positive line to the battery and place an ammeter
between positive from charger and positive of battery (A on fig ii)
Figure (ii)
CURRENT FLOW FROM CHARGER TO BATTERY CURRENT FLOW FROM CHARGER TO BATTERY
Lead Acid @ 20ºC

If voltage at terminals is less than nominal battery voltage then the maximum rated charger current should The current should stay constant or near to constant
be present. whilst charging.

Wet NiCad
Note: Once battery is fully charged, output current should be between 0/1% and 0.5% of battery's AH
capacity plus any standing loads. VOLTAGE RISE AT BATTERY TERMINALS
VOLTAGE RISE AT BATTERY TERMINALS A gradual rise of voltage should be seen until float
A gradual rise of voltage should be seen slowing as float voltage is reached. - batteries should NOT be voltage is reached, once fully charged a slight drop in
boost charged continuously (see page 3) battery voltage will be measured - batteries should
Note: If the battery voltage increases rapidly during charge and no or minimum current is measured then NOT be boost charged continuously (see page 3)
NO the battery may have become sulphated and will not hold charge and may be unrecoverable

NO
Is a battery charger
Connect battery charger
connected?

YES

NO
Is correct mains supply Check mains supply, fuses
present on terminals? and wiring.

YES

NO
Is output voltage correct for Replace with correct voltage
batteries? charger.

12V 24V 12V (10 Cell) 24V (20 Cell)

NiCad
Lead
Acid

Wet

Float: 13.8V 27.6V Float: 14.1V 28.2V

Boost: 14.5V 29.0V Boost: 14.6V 29.2V

YES Typical output with no battery or load connected:

All Guardin Models - The precalibrated float voltage should be present

NO
Is output voltage correct
Check fuses and wiring.
polarity on terminals?

YES

NO
Is battery charger correct size Replace with correct size
for battery? charger.

Refer to genset manual for sizing of battery chargers to generator set. If Min Charge Current = AH Capacity of batteries
installing your own chargers, battery manufacturers recommend the
Wet NiCad
Lead Acid

following: - 10
Minimum charge current should be approximately 5% battery AH capacity
YES Maximum charge current to be equal to 25% battery AH capacity Max Charge Current = AH Capacity of batteries
NOTE: When batteries are normally charged by a charging alternator, a
float battery charger rated at lower than the minimum charge current is 5
sufficient to keep batteries in fully charged state.

NO YES YES
Is there a standing load
Are electrolyte levels correct? Are batteries at end of life? Replace batteries
present?

FACTORS CONTRIBUTING TO Two possible methods:

ELECTROLYTE LOSS (1) Using Hydrometer or (2) Using a digital DC voltmeter
• Physical damage to cells can cause
Step 1. Fully charge the batteries
electrolyte to leak or evaporate
YES • High charging voltages will evaporate
Step 2. Disconnect batteries and leads and leave for 24 hours
Step 3. Measure either specific gravity (hydrometer) or terminal voltage
electrolyte
(voltmeter) and compare with table below.
Is standing load current Check charging voltage against battery type
greater than charger output and voltage
% Charge Specific Gravity Voltage (DC) on a 12V battery
current?
Lead Acid

WARNING: If the batteries are being used 100 1.265 12.8

at above 20 DEGREES CELSIUS the 75 1.225 12.5
REMINDER NO chargers output voltage should be 50 1.19 12.4
The battery charger will need temperature compensated at -3mV/ºC/Cell 25 1.155 12.0
to provide both the standing Discharged 1.12 11.5
load and minimum charge If the voltage across the terminals shows around 10.5V, this may indicate
current a shorted cell is present.
I.e. if a charging current of 2A Step 4. If time is limited due to on-site testing, remove surface charge by
is required, and the standing either applying a 20A load for 3 minutes or crank engine for 10 seconds,
load is 1A then the charger then disconnect batteries and leads and leave for minimum of 10 mins.
needs to be able to output a NOTE: On this method, providing batteries have been sized correctly for
YES NO
total of 3 amps engine and charged correctly, an open terminal voltage of 12.5V or
greater should be present.

Battery Charger may be faulty

- Contact manufacturer
Top up batteries as per
manufacturers
recommendations
Replace charger with correct
size unit.

Guardian Installation Instructions - April 04 - Page 6 of 6