Eaton FDF120 Technical Data Manual

O & M Manual IM05805019K-002 EATON Diesel PlusEffective April 2015 Diesel Engine Fire Pump Controller4 EATON INDUSTRIES CANADA COMPANY www.chfire.comCAUTIONDo not apply an AC voltage to these terminals.Terminals 60 through 95, located on the I/O Board, are forconnection of all output relay functions.NOTEAll field connections and AC wiring must be brought into the enclosurethrough the lower right or bottom right side ONLY (refer to labels affixedinside enclosure). *OTHERWISE WARRANTY IS VOID.*2.3.1 Wire SizesFor control wiring, use #14 AWG wire for all electricalconnections.For power wiring sizes refer to Appendix K.2.4 System Pressure ConnectionThe FD120 is supplied with a Pressure Sensor, or as an option, aPressure Switch.The “TEST” drain connection, located to the left of the systempressure connection, should be piped to a drain or to waste.NOTEWater lines to the drain valve and pressure switch must be free from dirtand contamination.The main controller panel interfaces with either the pressuresensor or the optional pressure switch. The controller must beprogrammed for the appropriate device.Using the standard pressure sensor, the actual pressure isdisplayed on the top left hand corner of the LCD display. Precisestart and stop pressure set points can be programmed into thecontroller via the membrane keypad. Pressure readings are alsorecorded in the memory during alarm situations or pressuredeviations.With the Pressure Switch option, the LCD will display “OK” ifthe pressure is satisfied, and “LOW”, if the contacts on thepressure switch change state. The message history will record“Low Pressure” when the pressure drops below the set point.3. HARDWARE DESCRIPTION3.1 GeneralThe purpose of this section is to familiarize the reader with theDiesel Plus Controller hardware, its nomenclature, and to listthe unit’s specifications.3.1.1 Battery ChargersBattery chargers are independent of each other and produce amaximum of 10 amps each at full rate. Each battery charger isfully electronic and will protect itself by shutting down during ashort circuit condition.The maximum current draw that the chargers will draw whenoperating at 100% charging rate is:12 Volt System 24 Volt System1.6 amps - 120V 3.2 amps - 120V0.8 amps - 240V 1.6 amps - 240V3.1.2 Three Step ChargeThe battery chargers incorporate a three step charge toguarantee the fastest charge times while optimizing battery life.The three steps are referred to as Bulk mode, Overcharge Modeand Float mode.BulkIn Bulk mode, a current of 10 Amps is delivered into the batteryuntil the voltage reaches 2.4 Volts per cell for Lead AcidBatteries. (14.4 Volts for a 12 Volt battery). At this point, thebattery has recovered approximately 90% of its capacity.When the charger senses this state, it switches to theOvercharge mode.The bulk mode charging may take up to 24 hours depending onthe battery capacity and the level to which it was discharged.The charge mode is recorded in the Diesel Plus messagehistory.OverchargeIn the Overcharge mode, the voltage on the battery is held at14.4 Volts and the current into the battery declines. This mode ismaintained until the current into the battery declines to1.5 Amps. At this moment, the battery is approximately 99%charged and the charger will change to Float Mode.The overcharge mode charging may take up to 12 hoursdepending on the battery capacity and the level to which it wasdischarged. The charge mode is recorded in the Diesel Plusmessage history.FloatIn Float Mode, the charger maintains the battery voltage at2.23 Volts per cell for a lead acid battery (13.4 Volts for a 12 Voltbattery). Once Bulk and Overcharge modes are completed, thecharger will maintain the battery charge in Float mode byregulating to 13.3V. If the charger cannot maintain the batterycapacity while in Float mode, the charger will begin a newcharging sequence by entering Bulk mode.3.1.3 Charger Shut DownThe charger will automatically shut down if there is no loadconnected to the output or if there is a short on the load side ofthe charger. In addition, the charger will not operate if a batteryis connected incorrectly or if the wrong voltage of battery isconnected.