Guardian series

UL/CSA Approved Automatic Battery Chargers

INSTALLATION AND OPERATION
THIS MANUAL REFERS TO THE FOLLOWING MODULES

G1501210
G3001220
G3002410
G6002420
EG1501210
EG3001220
EG3002410
EG6002420

For safe and correct use of these chargers, read and save the safety
information that precedes the installation and operation instructions.
This guide contains 8 pages (including this one). If any pages are missing,
contact the battery charger supplier or manufacturer for replacement
documentation.

Guardian, open frame (G series) Enclosed Guardian (EG series)

41 – 46 Railway Terrace, Nechells, Birmingham, B7 5NG, United Kingdom

tel: +44 121 327 8500
fax: +44 121 327 8501
email: sales@computroniccontrols.com
A division of Frank W Murphy Ltd. web: www.computroniccontrols.com

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 IMPORTANT SAFETY INFORMATION – READ AND SAVE THESE INSTRUCTIONS
This manual contains important safety and operating instructions for models G150, G300, G600, EG150, EG300
and EG600.

• Do not expose the battery charger to rain, snow or wet environments.

• The use of any 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, or otherwise damaged in any way: return to
supplier.
• Do not disassemble the charger: return to supplier when service or repair is required. Incorrect re-assembly may result
in a risk of electric shock or fire.
WARNING – RISK OF EXPLOSIVE GASES
WORKING IN THE 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 the battery manufacturers and
the manufacturer of any equipment you intend to use in the vicinity of the battery. Review cautionary marking on these
products and 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 whilst 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 immediate medical attention.
• (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 on to the 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
battery. A lead–acid battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing
a severe burns.
• (viii) Use the charger only for charging batteries as stated on the charger. Do not use the 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 into contact with eyes.
• Add distilled water in each cell until the battery acid reaches a level specified by battery manufacturer. This helps
purge excessive gas from the cell. 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
recommended rates of charge.
• Determine the voltage of battery by referring to engine manual and ensure this matches the charger’s output voltage.
CHARGER LOCATION AND CONNECTION
• Never place the charger directly above battery being charged: gases from the battery will corrode and damage the
charger.
• Never allow battery acid to drip on to the charger when reading specific gravity or filling battery.
• Do not operate the 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 the battery charger.
• Connections to the 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 2.5mm (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 charger, follow the following steps. Should you have any problems or 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 the charger as outlined above, paying attention to ambient temperature.
• Ensure the mains AC supply is isolated, and ensure the correct rated input voltage before connection.
• Ensure the charger is earthed at the marked earth stud.
• Check batteries in accordance with the manufacturer’s guidelines.
• Check that the charger is correct for battery type and voltage.
• Connect the charger to the batteries, observing correct polarity and ensuring a secure and tight connection.
• Switch on charger at the mains AC supply.
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 GENERAL INFORMATION
Please read the following 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. Failure to follow the recommended installation instructions will invalidate the
product warranty. If in doubt, please contact your local Computronic representative.
Product specification

W A R N IN G
power supply:
operating voltages 110 – 120 VAC ±6% or
230 VAC ±10% (specify)
operating frequency 50 or 60 Hz (specify)
DC charge output:
BEFORE BEGINNING INSTALLATION OF THIS PRODUCT nominal voltage 12 or 24 V DC
Disconnect all electrical power to the charger float / boost voltages see table below
Make sure the charger cannot operate during installation maximum current limit:
(E)G150-12V, (E)G300-24V 10 A
Follow all safety warnings of the battery manufacturer (E)G300-12V, (E)G600-24V 20 A
Read and follow all installation instructions voltage ripple < 1%
alarm outputs:
Description & operation charge fail, low volts & SPDT volt free contacts
The Guardian range provides automatic, current limited high volts relays
and voltage controlled charging of vented lead acid, sealed contact rating 1A @ 30 V DC (resistive load)
lead acid or NiCd batteries. The units may be general:
used in a wide range of industrial charging applications, operating temperature -10 to +55°C
including standby engines, pumps and generators.
dimensions see ‘dimensions/assembly’ overleaf
Each charger consists of a transformer, rectifier and weight see ‘dimensions/assembly’ overleaf
thyristor control circuit. The Guardian range is available as EMC emission / immunity EN61000-6-4 / EN61000-6-2
either an open frame module for mounting in an enclosed
panel, or as a wall-mounted enclosure with DC charge Output calibration
ammeter and voltmeter. (Note: In the event of no AC Battery type float volts boost volts
supply to the charger, the voltmeter displays the DC voltage (V DC) (V DC)
of the battery or connected DC equipment.) 12V Vented lead acid (6 cells) 13.5 14.1
Electrical connection of the AC supply, battery and Calcium-Calcium (6 cells) 13.8 15.6
VRLA, AGM (6 cells) 13.5 14.4
(boost/alarm) control circuits is via spring-clamp terminals.
VRLA, Gel (6 cells) 13.5 13.8
(For more information on these terminals, see Computronic
NiCd (10 cells) 14.1 14.5
Controls Product Change Ref: CCL PC Release 1 – April 24V Vented Lead acid (12 cells) 27.0 28.2
2003) Calcium-Calcium (12 cells) 27.6 31.2
VRLA, AGM (12 cells) 27.0 28.8
Float charge operation VRLA, Gel (12 cells) 27.0 27.6
In normal charging mode, the Guardian maintains the NiCd (18 cells) 25.6 26.1
battery at a pre-calibrated float voltage (see table right), NiCd (20 cells) 28.2 29.0
while supplying any additional DC load up to the specified
Note: Calibration figures at 20 deg C. Output voltage automatically
current limit (see Specification right).
decreases by 3mV per cell per 1°C increase in temperature.
When fully charged, a battery will only accept the charge
required to replace internal losses (approx. 1mA per AH of
battery). E.g. for a system with a 1 Amp standing load and enabled, output voltage decreases as ambient temperature
a fully charged 50 AH lead acid battery, Guardian will increases at a rate of 3mV/°C/cell (see calibration table
typically supply 1.05 Amps. above for figures at 20°C).

Auto boost (equalising) operation Alarm outputs

Auto boost operation gives a temporary increase in output Guardian provides 3 x NFPA110 compliant alarm relay
voltage (see table right), equalising the charge between outputs: battery low volts and battery high volts (each with
cells and maximising battery capacity and service life. a 120 sec delay), and charge fail.
Once the batteries have reached the boost voltage level,
Guardian automatically reverts to its normal float charge Warranty and servicing
mode, preventing battery over-charge and gassing. Guardian chargers are supplied with a 2 year warranty on
Auto boost is triggered automatically when the battery falls parts and workmanship.
below a preset voltage. An Auto Boost cycle can also be WARNING: Guardian battery chargers contain
manually initiated (regardless of battery voltage) by linking no user serviceable parts, and should be
two ‘boost’ terminals, e.g. via a panel switch or push-button. returned to the supplier in the event of failure.
Temperature compensation No attempt should be made to repair the
For both lead acid and NiCd batteries, the optimum charge charger. Any attempt to do so may invalidate
voltage varies with ambient temperature. On all Guardian warranties, cause damage to the charger and
models, circuit board links allow output compensation to be equipment, and result in serious personal injury.
disabled, or enabled with an on-board temperature sensor,
or enabled with a remote sensor (RTC option, with 3 metre
lead for mounting on or near the battery). With this feature

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 DIMENSIONS AND ASSEMBLY

CAUTION: When handling chargers, care should be taken not to place excessive weight or strain on either
the heatsink, circuit boards, transformer or connecting wires. The units should be handled by the transformer
frame (open frame models) or steel enclosure (enclosed models). Care should also be taken not to handle
static sensitive components on the circuit board.

OPEN FRAME MODELS: WALL MOUNTED ENCLOSURE MODELS:

G150, G300, G600 EG150, EG300, EG600
BACK (FIXING PLATE) VIEW FRONT VIEW SIDE VIEW
SIDE VIEW
up front up
W2 2 x fixing holes, 6mm H2
X

Y
H1
H2 F F H1
H1 Y hinged
sections

F A V F

4 x fixing slots, 6mm X

W
H3
2 x fixing slots, 6mm
D D1
D2
fuse F1, AC supply
EG150, EG300 EG600
AC supply series series
earth stud
W1 Overall:
TOP VIEW W 275mm / 10.83” 335mm / 13.19”
front H1 280mm / 11.02” 310mm / 12.20”
G150, G300 G600 H2 75mm / 2.95” 85mm / 3.35”
series series H3 90mm / 3.54” 100mm / 3.94”
Overall: D1 125mm / 4.92” 145mm / 5.71”
W1 152mm / 5.98” 152mm / 5.98” D2 190mm / 7.48” 210mm / 8.27”
H1 125mm / 4.92” 142mm / 5.59” Fixing holes:
D 170mm / 6.69” 220mm / 8.66” X 172mm / 6.77” 223mm / 8.78”
Fixing plate: Y 255mm / 10.04” 285mm / 11.22”
W2 125mm / 4.92” 130mm / 5.12”
Weight 10.0 Kg / 22.0 lb 17.5 Kg / 38.5 lb
H2 110mm / 4.33” 130mm / 5.12”
X 70mm / 2.76” 95mm / 3.74” • These chargers are designed for wall or frame mounting
Y 92mm / 3.62” 110mm / 4.33” in the orientation shown above, with enclosure air vents
uppermost. For safe heat dissipation, allow a minimum
Weight 7.0 Kg / 15.4 lb 12.5 Kg / 27.5 lb air-gap clearance of 40mm above/below and 25mm at
sides. Adequate consideration should be given to
• These chargers are designed for mounting on a vertical
ventilation for proper heat dissipation.
facia or plate inside a control panel or housing. For safe
heat dissipation, mount the product in the orientation • Mounting is via the enclosure back-plate, using 2 slots
shown with a minimum air-gap clearance of 40mm (Ø 6mm) on the back-plate lower edge and 2 holes
above/below and 25mm at sides. Consideration must (Ø 6mm) on the upper edge. Ensure that the mounting
be given to ventilation for proper heat dissipation. studs/bolts/nuts/screws adequately support the charger
weight, and are tightened sufficiently to not to work loose
• 4 chassis slots (Ø 6mm) are provided for mounting.
during normal use (e.g. due to engine/equipment
Ensure that the mounting studs/bolts/nuts/screws
vibration).
adequately support the charger weight, and are tightened
sufficiently to not to become loose during normal use • Access to the electrical connection terminals is via hinged
(e.g. due to engine/equipment vibration). sections on the front facia. Remove the 4 x securing
screws (marked F above), and rotate the upper and lower
sections through 90 degrees.
• Electrical cable entry is via knock-outs on either side of
the enclosure, which must be carefully removed from the
enclosure sides. A suitable cable-gland (20 mm / 0.8”
diam.) must be used to prevent damage to cables and
stop unwanted entry into inner part of charger.
• Connect the charger wiring as detailed in the following
section, “Electrical connection”. When wiring is complete,
and before using the charger, re-secure the hinged
sections using the 4 fixing screws.
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 ELECTRICAL CONNECTION
WARNING: DANGER OF INJURY OR DEATH. During normal operation, Guardian is
connected to high voltage AC circuits. Before connection, disconnection or handling of
these chargers, ensure isolation of all AC power supplies. Connection or disconnection with
DANGER !
HIGH VOLTS live wiring can also cause hazardous sparking and component damage.
General DC Output
Electrical connection is via labelled spring-clamp terminals Before DC connection or disconnection:
on the Guardian circuit board.
• Ensure AC supply input is isolated.
For G150/G300/G600 (open chassis) models: - Disconnecting the batteries while the
AC supply is live can result in sparking at
the battery terminals, ignition of battery
gasses and serious personal injury.
• Check that the charger output is compatible
with battery type & voltage. Incompatibility
may result in damage to the charger,
batteries and serious personal injury.
Connect the Guardian output to the battery terminals,
observing the warnings above and the correct DC polarity.
The Guardian DC charge output uses an automotive type
fuse for protection of reverse polarity and short-circuit
For EG150/EG300/EG600 (enclosed) models, remove the faults. In the event of these faults, isolate the AC supply
upper 2 screws on the panel front facia (on the plate and disconnect the output terminals. Ensure the external
containing product labelling), then rotate the front plate fault has been corrected, replace the fuse (see product
upwards to expose the electrical terminals. Compared with labelling for the correct rating), then re-connect and
the open-chassis version above, note the reverse orientation switch on the charger. If the fuse continues to blow,
of the EG series terminals: return the charger to the supplier for evaluation.
Boost Initiate
The Guardian Auto Boost feature provides an automatic
increase in output voltage, as described on page 3.
In addition, the operator can manually initiate a single
Auto Boost cycle (at any time, regardless of battery
voltage), by linking the 2 terminals marked ‘boost’,
e.g. using a momentary push button or panel switch.
Alarm outputs: Charge Fail, Low Volts, High Volts
Guardian is fitted with three alarm relay outputs, each with
SPDT volt-free contacts, rated 1 Amp max. at 30V DC.

During normal operation:

Spring-clamp terminal connection is as follows: • Charge fail and low volts relays are energised (COM
closes to NO contact).

• The high volts relay is de-energised (COM closes to

NC contact).

During fault conditions:

Strip and position Press down on the Release the clamp • The charge fail relay de-energises immediately
the wire just clamp spring and spring and check following a charging fault, e.g. loss of mains supply.
before the insert the wire into that the wire is
clamping unit. the clamp. secure. • The low volts relay de-energises on low battery
voltage, and the high volts relay energises on high
battery voltage. A 120 second delay applies to both
relays, allowing for normal battery voltage
fluctuations (e.g. caused by engine cranking).

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 ELECTRICAL CONNECTION (cont.)

Temperature Compensation & RTC option The RTC sensor should be connected as
close as practicable to the battery being
All Guardian models include circuit board pin-header links
charged. The sensor is supplied with a 3
that allow configuration of the temperature compensation
Meter lead, wired to the Guardian circuit
feature, i.e. the automatic adjustment of charge voltage
board through a pin-header connector (white
according to measured ambient temperature.
connector J2 shown left, located just below
When the circuit board is viewed component side up, with the PL7 configuration links).
connectors and fuses uppermost, the 3 pairs of links
(ident label “PL7”) are located at the lower right corner of Use this option to give an optimum charge
the board: voltage when battery temperature deviates
significantly from 20°C/68°F.
INT Internal. This configuration gives automatic
charge voltage compensation similar to EXT
above, but with temperature measured by an
Temperature on-board sensor (instead of the RTC remote
Compensation sensor).
Links
Use this option if the battery temperature is
likely to deviate significantly from 20°C, AND
the charger remains at a similar temperature
to the battery.
WARNING: DO NOT use this option if the
charger (i.e. sensor) and battery ambient
Guardian is supplied with a link across one vertical pair of temperatures are significantly different, e.g.
pin-headers (see default settings below). To reconfigure batteries in a cool environment, with charger in
the temperature compensation, use small, long-nosed a warmer, enclosed panel. (Note: the charger
pliers to remove and refit the link: itself may cause significant ambient warming.)
Link Operation
position AC Input (power supply)
ident
Before AC connection, disconnection or fuse
NON None. This is the default configuration for replacement:
standard Guardians without the RTC option
• Isolate the AC supply
remote sensor. With this configuration, the
charge output voltage does not vary with • Ensure a good earth connection to the earth
ambient temperature. stud on the charger’s metal chassis.
• Ensure the AC supply voltage is compatible
Use this option if the batteries are maintained
with the charger’s supply rating. Exceeding
at a stable temperature around 20°C/68°F.
the rated voltage may result in damage to
EXT External. This is the default configuration for the charger and connected equipment,
units supplied with the RTC option remote and cause serious personal injury.
temperature sensor.
All Guardian models are fitted with mains AC input fuses,
In this mode, Guardian charge voltage
with ratings as labelled on each charger.
automatically varies according to ambient
temperature, as measured through the RTC
remote sensor. For each °C increase in
temperature, output voltage automatically
decreases by 3mV per cell, e.g. by 18mV for
a 12V (6 cell) lead acid battery pack.

Typical Connection
Note: terminal orientation shown for Guardian (open-board); reverse orientation applies for Enclosed Guardian models

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 TROUBLESHOOTING FLOWCHART

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 41 – 46 Railway Terrace, Nechells, Birmingham, B7 5NG, United Kingdom
tel: +44 121 327 8500
fax: +44 121 327 8501
email: sales@computroniccontrols.com
A division of Frank W Murphy Ltd. web: www.computroniccontrols.com

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CCL Guardian series installation and operation ci0003 issue 3 29 January 2010 p8/8