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Integritas
8600092587P
Wall Mount
Bracket
(top and
bottom)
Controller
IO Module
Input Box
Bottom Feed Charger with BATT & DC Load Breakers
Read and follow all safety statements, warnings, and precautions in this guide.
Basic Features:
All DC outputs are floating - not referenced to ground.
DC output Ground Fault Detection. Set at factory default adjustable at site, if necessary.
Monitored class II AC input surge device included in addition to surge capability of IP rectifier units.
Monitored Class III output surge device included.
Full-featured charger control unit.
Page 1
© 2021 ABB. All rights reserved.
TM
Battery Charger
Control Panel
Door Latch
(Lock option)
IP Rectifier
slots (3)
Output
Ground faiult
Output Box
Output
Signal Unit
Air Filter
Drip/Drop Shield
Chassis
Ground Lug
Signal Wire Knockouts
(top and bottom)
Input
Box
IO Module
slot
Controller slot
Top Feed Charger with 2 DC Breakers
Door Latch
(Lock option)
Output
Signal Unit
DC Output
Box
Output Ground
Fault Unit
IP Rectifier
slots (3)
Air Filter
Version 6.0
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Summary of Contents for ABB Integritas
- Page 1 DC output Ground Fault Detection. Set at factory default adjustable at site, if necessary. Monitored class II AC input surge device included in addition to surge capability of IP rectifier units. Monitored Class III output surge device included. Full-featured charger control unit. Page 1 Version 6.0 © 2021 ABB. All rights reserved.
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Page 2: Table Of Contents
Power Units ......................20 Maintenance ....................... 21 Troubleshooting ....................21 Parts List ......................21 Specifications & Application ................22 Reference Documents ..................22 Notes……………………………………………………………… ..…… ....23 Page 2 Version 6.0 © 2021 ABB. All rights reserved. - Page 3 QUICK START GUIDE Important Safety Instructions 1. SAVE THESE INSTRUCTIONS – This document contains important safety and operating instructions for the Integritas battery charger. 2. Before using battery charger, read all instructions and cautionary markings on battery charger, battery, and all connected equipment.
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Page 4: Installation
1. Remove charger rear panel—6 screws: 3 each top and bottom. 2. Move both Shunt Jumpers HDR11 and HDR12 to RMT (External) position—pins 2-3. 3. Replace charger rear panel. Secure with 6 screws. Jumpers in External (RMT Positions Page 4 Version 6.0 © 2021 ABB. All rights reserved. -
Page 5: Mount The Charger
2. Attach the system to the frame using a minimum of twelve (six on each side) 12-24 screws (provided). Torque to 35 in-lb (4.0 Nm) using a 5/16” socket wrench. Page 5 Version 6.0 © 2021 ABB. All rights reserved. -
Page 6: Ground The Chassis
2. Choose the next step to match AC input voltage marked on the charger ratings label. AC Input per Charger Label AC Input Option Follow Step 120/240 Step 4A Single Phase 200/240 Step 4B Three Phase Page 6 Version 6.0 © 2021 ABB. All rights reserved. -
Page 7: Single Phase
Minimum Minimum Rectifier Positions Powered Rectifiers Feed Feed Wire Wire per Feed Protector Protector 14AWG 14AWG 8AWG 8AWG 6AWG 6AWG 4AWG 4AWG 100A 2AWG 100A 2AWG 120A 1AWG 120A 1AWG Page 7 Version 6.0 © 2021 ABB. All rights reserved. - Page 8 - Gnd, L, N, L1, and L2. a. Strip 1/4” (10mm). b. Insert into terminal block. c. Torque screw to 13 in-lb (1.5 Nm). d. Pull wire to verify. Go to Step 5 120V 240V Page 8 Version 6.0 © 2021 ABB. All rights reserved.
- Page 9 Recommended External Protection and Minimum Wire Size - 6 AWG max. 240V~ Phase to Phase 19” 3 rectifier configuration (2725W per rectifier max) Three-Phase Rectifiers Maximum Rectifiers External Feed Rectifier Positions Powered Minimum Wire per Feed Protector 14AWG 8AWG 6AWG Page 9 Version 6.0 © 2021 ABB. All rights reserved.
- Page 10 - Gnd, L, N, L1, and L2. a. Strip 1/4” (10mm). b. Insert into terminal block. c. Torque screw to 13 in-lb (1.5 Nm). Bottom d. Pull wire to verify. Feed Go to Step 5 240V Page 10 Version 6.0 © 2021 ABB. All rights reserved.
- Page 11 - Gnd, L, N, L1, and L2. a. Strip 1/4” (10mm). b. Insert into terminal block. c. Torque screw to 13 in-lb (1.5 Bottom Feed Nm). d. Pull wire to verify. Go to Step 5 277V Page 11 Version 6.0 © 2021 ABB. All rights reserved.
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Page 12: Connect Loads
LOAD1+ LOAD1– Battery TB Load TB Screws Screws Behind Battery TB Battery TB Top Feed with 1 DC Load breaker Bottom Feed with 2 DC Load breakers (Shown as 125VDC) Page 12 Version 6.0 © 2021 ABB. All rights reserved. -
Page 13: Connect Batteries
Ready LED Output Signal Unit Output Signal Unit Battery TB Screws Battery TB Top Feed Bottom Feed with 2 DC Load breakers with 1 DC Load breaker (Shown with +/- 125VDC) Page 13 Version 6.0 © 2021 ABB. All rights reserved. -
Page 14: 8A - Pulsar Xl Controller
OPTIONAL #24VDC CONTROLLER BACK-BIAS INPUT TB24 ALT-BIAS 24VDC-IN PIN 4; ALT-BIAS 24VDC-IN RTN PIN 5 RECT DATA RS485 / GALAXY PROTOCOL RECTIFIER SERIAL BUS IP843G IO Module 10/100 BASE-T ETHERNET Page 14 Version 6.0 © 2021 ABB. All rights reserved. -
Page 15: 8B - Nebula Controller
1-WIRE TEMP PROBES; 1-WIRE SIGNAL ON PIN1; RETURN ON PIN2 OPTIONAL #24VDC CONTROLLER BACK-BIAS INPUT TB23/24 ALT-BIAS 24VDC-IN PIN 4; ALT-BIAS 24VDC-IN RTN PIN 5 RECT DATA RS485 / GALAXY PROTOCOL RECTIFIER SERIAL BUS IP943G IO Module Page 15 Version 6.0 © 2021 ABB. All rights reserved. -
Page 16: Connect Output Signals Unit Signals
Cables not provided - see Information Interlock Cable Recommendations. 1. Remove factory installed jumper from Remote Interlock connector. 2. Insert interlock signal cable into Remote Interlock connector. DC Output Box Output Signal Unit Bottom Feed shown Page 16 Version 6.0 © 2021 ABB. All rights reserved. -
Page 17: Install Rectifiers
If there are no alarms, make required adjustments to the default settings on the controller for this installation. Step 12 - Configure Controller Verify and edit controller basic configuration parameters per site engineering instructions. See Information: IP843G Controller Basic Operation. IP843G Product Manual provides additional detail. Page 17 Version 6.0 © 2021 ABB. All rights reserved. -
Page 18: Controller - View And Change Parameters And Alarm Severity
C. LAN port in Network mode (web pages) D. Craft Port via laptop and EasyView2 software or HyperTerminal. Easy View2 (GUI) software can be downloaded from https://abbpowerconversion.com See Pulsar Plus G3 Controller Product Manual for details. Page 18 Version 6.0 © 2021 ABB. All rights reserved. -
Page 19: Controller Alarm Relay Jumpers
Static is the factory default setting and the typical setting for most networks. Controller Alarm Status: The display changes colors; Green = Normal, Amber = Minor Alarm, Red = Critical/Major Alarm Page 19 Version 6.0 © 2021 ABB. All rights reserved. - Page 20 Web pages or EasyView2 - Installation Tab for Date, Time. Site ID and Site Description. Settings Tab > Battery Management for Battery Type and number of battery strings installed. Status LEDs Control Panel Menu Navigation Display Web Home Page Front Display Menu Map Page 20 Version 6.0 © 2021 ABB. All rights reserved.
- Page 21 Settings Tab > Battery tab for Battery Type and number of battery strings installed. Status Indicators Display Menu Craft Port Navigation USB port for mouse/ Web Home Page keyboard Controller - Front Panel Network Port Front Display Menu Map Controller - Back Panel Page 21 Version 6.0 © 2021 ABB. All rights reserved.
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Page 22: Interlock Cable Recommendations
Alarm R4 (default is GFI) Common Alarm R5 (default is SPD, DC, and AC) Common Alarm R6 (default is BTA “Battery Test Active”) Common TB10 Alarm R7 (default is “Check Battery”) Common Page 22 Version 6.0 © 2021 ABB. All rights reserved. - Page 23 Description—Signal on Pin 1 Pin 2 RECT DATA Connection to isolated rectifier RS485 Galaxy protocol serial bus. not applicable 1-WIRE DATA Connection to 1-Wire temperature probes. 1-Wire signal on pin 1. 1-Wire Return Page 23 Version 6.0 © 2021 ABB. All rights reserved.
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Page 24: Maintenance
3. Replace air filter carrier with filter—secure with 2 thumb screws. Filter Washing 1. Wash filter in soap water. 2. Gently wring out by hand. 3. Air dry for at least 24 hours before installing into filter carrier. Page 24 Version 6.0 © 2021 ABB. All rights reserved. -
Page 25: Troubleshooting
Integritas Wall Charger, Hot- Swappable 48VDC Controller Module with secure protocols 1600093509A IP843G_125V_S CONTROLLER MODULE Integritas Wall Charger, Hot- Swappable 125VDC Controller Module with secure protocols 1600093511A IP843G_IO MODULE Integritas Wall Charger, Input / Output Module (Compatible with all charger voltages) Thermal Probes Comcode Description Application 1600093512A DTP873_AMBIENT... -
Page 26: Specifications & Application
• Installation Environment - Install where NEC applies. Reference Documents These documents are available at https://abbpowerconversion.com Document Title 8600092588P Pulsar XL Product Manual 850049786 Pulsar Plus Controller Family Troubleshooting 0001258890 Integritas Industrial Battery Chargers Ordering Guide Page 26 Version 6.0 © 2021 ABB. All rights reserved. -
Page 27: Notes
QUICK START GUIDE Notes Page 27 Version 6.0 © 2021 ABB. All rights reserved. - Page 28 QUICK START GUIDE Notes Page 28 Version 6.0 © 2021 ABB. All rights reserved.
- Page 29 QUICK START GUIDE Notes Page 29 Version 6.0 © 2021 ABB. All rights reserved.
- Page 30 Updated as per template, Added information for 23" 6 rectifier configuration in Step 4A. Added tables in step 4B for different configurations, Added step 4C, Added Step 8b for Nebula Controller. Page 30 Version 6.0 © 2021 ABB. All rights reserved.
- Page 31 – in whole or in parts – is to purchase orders, the agreed particulars shall prevail. forbidden without prior written consent of ABB. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this Copyright©...