artop - Energic plus
Contents
1. 12 hours I 15 26 of C Default value Usually specified at the order If not specified default value is D Page 14 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL NOTES This parameter allows to adjust the finishing rate of the charger depending on the matching Current VS Capacity that has been chosen at the order The proper setting of this parameter is useful to maximize the electrical efficiency of the system and to minimize the temperature rise of the battery during the finishing charge EXAMPLE 1 If the battery capacity is 600 Ah and the time available for charging it is 10 12 hours the recommended AR TOP charger should have a nominal current of 100A 16 of C and the default curve D Wa Finishing charge 4 hours will be correct EXAMPLE 2 If the battery capacity is 420 Ah and the time available for charging it is 7 8 hours the recommended AR TOP charger should have a nominal current of 100A 25 of C and it should be programmed to operate with charge charging curve A WSa Automatic Algorithm EXAMPLE 3 If the battery capacity is 720 Ah and the time available for charging it is 7 8 hours the recommended AR TOP charger should have a nominal current of 120A 16 of C and the default curve D Wa Finishing charge 4 hours will be correct PARAMETER 6 EQUALIZE INTENSITY Programmable values from to 8 hours Default value 2 hours NOTES This parameter allows to adjust the dur2. 9 FULL CHARGE OVERCHARGE TIME WINDOW Programmable values From 00 00 to 23 59 Default value From 00 00 to 23 59 NOTES This parameter sets a time window during the day in which the charger is allowed to fully charge the battery Usually this parameter is used in opportunity charging applications with the purpose of avoiding useless gassing of the battery during the opportunity charging cycles and to program a full charge of the battery during the night PARAMETER 10 and 11 EQUALIZE TIME WINDOW Programmable values Any day from 00 00 to 23 59 Default value From SATURDAY at 12 00 to SUNDAY at 22 00 NOTES These parameters set a time window during the week in which the charger is allowed to fully charge and Equalize the battery It s recommended to set a minimum Equalize time of 12 hours after the normal completion of the charge cycle Page 16 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL PARAMETER 12 WBM ENABLE Programmable values Enabled Disabled Optional Default value Disabled NOTES This parameter sets the operation of the charger with the Wireless Battery Identification module WBM optional Three different operating modes are selectable Enabled When a battery is connected the charger establishes a communication with the WBM and uses the information stored into the WBM to optimize the charge cycle Only batteries with WBM installed and properly configured will be charged Disabled The
3. communication of the charger with WBMs is disabled and any battery with correct voltage will be charged Optional When a battery is connected the charger tries to establish a communication with the WBM Ifa WBM is found it s used to optimize the charge cycle and to add the battery ID tag on the charge history log Ifa WBM is not found the battery will be charged anyway PARAMETER 13 WIRED IP ADDRESS RS 485 RESET TEST WIRELESS Programmable values 1 to 254 Hexadecimal Default value 1 NOTES This parameter sets the IP address of the charger when it s connected to a wired www DoctorFleet com management network Page 17 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL 5 OPERATION CONNECTION OF THE BATTERY AUTOMATIC START Connect the Battery to the charger using a connector of adequate size When the battery is correctly connected the charger visualizes the following message BATTERY CONNECTED WIRELESS CONNECTION TO BATTERY IDENTIFICATION MODULE OPTIONAL If the Battery Identification Module is enabled a few seconds after the connection of the battery the charger will try to establish a wireless connection And the display will visualize the message BATT ID MODULE SRARCHING When the wireless connection is active the charger is ready to start the charging cycle The display visualizes the message BATT ID MODULE CONNECTED At this point the battery information are tran
4. voltage exceeded during the finishing charge 62 Emergency Stop Maximum voltage exceeded during the equalize cycle 63 Emergency Stop Gassing voltage not reached within the predetermined time limit 64 Charge never started Battery voltage was too LOW 65 Charge never started Battery voltage was too HIGH Page 30 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL 66 Emergency Stop Maximum Current Limit Exceeded 67 Emergency Stop Maximum voltage exceeded during the refresh cycle 68 Emergency Stop Maximum temperature exceeded before to reach the gassing voltage 69 Emergency Stop Maximum temperature exceeded during the finishing charge 70 Emergency Stop Maximum temperature exceeded during the equalize cycle 71 Emergency Stop Maximum temperature exceeded during the refresh cycle 72 Emergency Stop When a battery is connected the WBM communicate that the voltage of battery is not compatible with this charger 76 Emergency Stop Maximum temperature exceeded during desulphation GROUP 5 WARNING MESSAGES 80 Maximum finishing charge time safety timer exceeded Charge termination criteria dV dt not reached 82 The battery has been disconnected while the charge was in progress in a generic state 83 Output fuse blown 85 Communication problem with Wireless Battery Module 99 Black out of the AC input Page 31 32 END OF MANUAL Page 32 32
5. 1 USER S MANUAL pioclEM CHECK PLEASE WAIT SYSTEM READY xxx VY a A HOW TO ACTIVATE USER PROGRAMMING MODE e Press the button DOWN and keep it pressed for 3 seconds The display will show the message EDIT PASSWORD Enter the Programming Password UP_DW_UP_DW_UP The display will show the message MOD SETTING HOW TO MODIFY A VALUE Scroll between the programmable values using the UP DOWN buttons e In order to modify a value press ENTER and keep it pressed for 2 seconds until the cursor will start blinking over the value that can be modified e Modify the value using the UP DOWN buttons e Confirm the modified value by pressing ENTER for 2 seconds until the cursor will disappear At this point the new value will be saved HOW TO RETURN TO NORMAL MODE e Press the buttons UP and DOWN simultaneously PARAMETER 1 NOMINAL OUTPUT VOLTAGE Programmable values 12 24 36 48 72 80 96 120 Volts Default value Nominal voltage of the charger NOTES This parameter should be changed only after replacing the control board of the charger Page 13 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL PARAMETER 2 NOMINAL CHARGING CURRENT Programmable values From 10 to 500 Amps Default value Nominal output current of the charger NOTES This parameter should be changed only after replacing the control board of the charger PARAMETER 3 GASSING VOLTAGE Programmable values from 2 35 t
6. AL 6 PROGRAMMING BATTERY ID MODULES When a battery ID module is installed on a battery for the first time it must be initialized and programmed by following this procedure Connect the battery to a AR TOP charger the Battery Recognition mode must be set to BATTERY ID MODULE or OPTIONAL The AR TOP charger will establish a communication with the New Battery ID module and it will show the message BATT ID MODULE CONNECTED At this point using the UP DOWN buttons it s possible to edit the battery ID information ID Number 8 alphanumeric digits to be confirmed individually by pressing ENTER for 3 seconds Nominal Voltage e Capacity Type Once all the parameters are set correctly push the buttons UP DOWN Simultaneously in order to save the data to the ID module The programming sequence may take up to 3 minutes while the charger display will show the message BATT ID MODULE PROGRAMMING When the programming sequence is completed the display will show the message BATT ID MODULE SET OK At this point it s possible to disconnect the battery from the charger If the battery is left connected a charge cycle will be initiated The Battery ID Module will keep the information in memory for an unlimited time In order to erase the memory it s necessary to disconnect the ID module from the battery Page 24 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL PROGRAMMIN
7. ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL PROGRAMMABLE BATTERY CHARGER AR TOP USER S MANUAL Page 1 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL 1 SAFETY INSTRUCTIONS AND WARNINGS GENERAL Battery chargers can cause injury or death or damage to other equipment or property if the user does not strictly observe all safety rules and take precautionary actions Safe practices must be learned through study and training before using this equipment Only qualified personnel should install use or service this battery charger SHOCK PREVENTION Bare conductors or terminals in the output circuit or ungrounded electrically live equipments can fatally shock a person To protect against shock have competent electrician verify that the equipment is adequately grounded and learn what terminals and parts are electrically HOT The body s electrical resistance is decreased when wet permitting dangerous current to flow through the body Do not work in damp area without being extremely careful Stand on dry rubber mat or dry wood and use insulating gloves when dampness or sweat cannot be avoided Keep clothing dry INSTALLATION AND GROUNDING Electrical equipment must be installed and mantained in accordance with all the applicable national and local codes A power disconnect switch must be located at the equipment Check the data label for voltage and phase requirements If only 3 phase power
8. G HARDWARE RULES During installation and programming activity it is necessary to ensure that the position of the battery power cables and charger cables are correct As illustrated below it is important that the cables are not overlapping or entwined in the cables of another battery fig 1 correct position of the cables fig 2 incorrect position of the cables Failure to comply with these instructions may disturb the communication signals from the battery module if this occurs the charger will generate the following alarm EMERGENCY STOP DRAPED CABLES Page 25 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL 7 HISTORY LOG The internal memory of the AR TOP charger contains a log of the last gt 250 charge cycles The most significative parameters can be visualized on the display of the charger while the complete history log can be accessed and downloaded through DoctorFleet com management system The history log can be accessed at any moment even while a charge cycle is in progress It s sufficient to scroll the menu using the UP DOWN buttons until the display will visualize the first page of the most recent history log that will have a format of this type O1 24 0V 31 3V 2008706701 10230 At this point press ENTER for 3 seconds until the cursor will start blinking over the number 01 on the top left of the display The results of each charge cycle are represented on two or three
9. ation of the weekly Equalize cycle In most of the cases the default value of 2 hours works well but sometimes it can be useful to modify this setting depending on the status of the battery and on the operating cycle IMPORTANT The battery will be equalized only during the programmed time window See parameters 10 and 11 If the Equalize time window is not set or it s set too short the battery will not receive a sufficient Equalize PARAMETER 7 DATE and TIME Programmable values Day Month Year Hour Minute Default value Chargers with European Specs are set by default at GMT 1 Chargers with North American Specs are set by default at GMT 5 NOTES It s fundamental to keep the Real Time Clock set to the correct date and time in order to use all the time base functions It s necessary to adjust the Clock manually in Daylight saving time periods The Charger calculates the Day of the Week automatically Page 15 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL PARAMETER 8 START TIME WINDOW Programmable values From 00 00 to 23 59 Default value From 00 00 to 23 59 NOTES This parameter sets a time window during the day in which the charger is allowed to start a new charge cycle Ifa battery is connected outside of this time window the charger will remain in stand by mode until the programmed Start time will be reached Once the charge cycle has begun this time window is not considered anymore PARAMETER
10. e to override the warning message and to start the charge manually by pushing the button DOWN for 5 seconds The AR TOP will activate an automatic DESULPHATION RECOVERY cycle after that a standard charging cycle will begin CHARGE CYCLE When the preliminary controls are complete the charge starts automatically and the display visualizes the following information e Battery Voltage Volt e Charging Current Amps Time of Charge hours minutes e Capacity Returned Ah Page 19 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL The AR TOP Charger performs an exclusive charge cycle that is composed by stages at constant current and stages at pulsed current with cool down pauses in between The management of the charging curve is totally automatic Depending on the programming of the Full Charge time window Parameter 9 when the battery approaches the gassing voltage the charger may suspend the charge typical opportunity charge cycle In this situation the display visualizes the message DELAYED OVERCH hh mm A gt hh mm B Where hh mm A represents the real time at that moment and hh mm B represents the beginning of the Full Charge Overcharge time window If the charging curve WSa is selected the charger will alternate charging pulses and cool down pauses during the finishing charge During the pauses the display visualizes the message Cooling EMERGENCY STOP If the batte
11. ful to keep the battery in perfect condition when it s not used for an long period weeks months It is sufficient to leave the battery connected to the charger After a normal termination of the charge and the equalize cycle the control board will activate the charger automatically for 15 minutes of refresh charge every day While the charger waits before to activate a Refresh cycle the display shows the messages R END NR XxX E e Battery Voltage Volt e Nrof Refresh cycles already given to the battery e Total Time of Charge hours minutes e Total Capacity Returned Ah During cycle Refresh the display shows the same set of information that are visualized during the normal charge cycle Page 22 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL DISCONNECTION OF THE BATTERY DURING THE CHARGE WARNING DON T disconnect the battery from the charger while it is being charged ARCING AND BURNING OF CONNECTORS OR BATTERY EXPLOSION MAY RESULT If it s necessary to disconnect the battery while it s being charged press the button UP for five seconds in order to stop the charger manually The charger will suspend the charge and the display will show the message MANUAL STOP At this time it s possible to disconnect the battery Eventually the charge can be restarted by pressing the button UP for 5 seconds Page 23 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANU
12. is available connect single phase equipment to ONLY TWO WIRES of the 3 phase line DO NOT CONNECT the equipment grounding conductor to the third live wire of the 3 phase line as this makes the equipment frame electrically HOT which can cause a fatal shock If a grounding conductor is part of the power supply cable be sure to connect it to a properly grounded switch box or building ground If not part of the supply cable use a separate grounding conductor Don t remove a ground prong from any plug Use correct mating receptacles Check ground for electrical continuity before using equipment The grounding conductor must be of a size equal to or larger than the size recommended by Code or this manual CHARGING LEADS Inspect leads often for damage to the insulation Replace or repair cracked or worn leads immediately Use leads having sufficient capacity to carry the operating current without overheating BATTERY TERMINALS Do not touch battery terminals while equipment is operating SERVICE AND MAINTENANCE Shut OFF all power at the disconnect switch or line breaker BEFORE inspecting adjusting or servicing the equipment Lock switch OPEN or remove line fuses so that the power cannot be turned ON accidentally Disconnect power to equipment if it is to be left unattended or out of service Disconnect battery from charger Measure voltage on capacitors and if there is any voltage reading wait 5 minutes before to proceed Keep inside
13. net of the battery charger must be properly grounded to protect personnel against hazard of electrical shock in case of fault on the charger The grounding conductor must have a current carrying capacity equal or higher than the current carrying capacity of the AC input wires If the charger is to be connected to the AC power supply with a flexible jacketed cable one having a separate grounding conductor should be used If for any reason an input cable which does not include a grounding conductor is used the equipment must be grounded with separate conductor Minimum size and color coding requirements must be in accordance with any applicable national or local code Page 11 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL 4 HOW TO USE THE CHARGER PRELIMINARY CONTROLS e Inspect the charger completey for loose screws electrical connections or other damages e Check that all the ventilation slots are not obstructed to assure proper air flow e Make sure that the charger is installed as instructed in this manual and in accordance with any applicable national or local Code PROGRAMMING MODE Turn on the charger by moving the main switch to position 1 The charger will perform an automatic test of the control circuits and will wait for a random delay on start The display will visualize the following messages ENERGIC Plus AR TOP CHARGER Page 12 32 ENERGIC Plus AR TOP V 140 January 201
14. o 2 50 V Cell Default value 2 40 V cell NOTES This charging algorithm of the AR TOP charger is adaptive so it s capable of adjusting the charging curve even if the gassing voltage of the battery deviates significantly from the programmed value For this reason this parameter should be modified only when using non standard batteries or if the operating temperature is extremely low or high PARAMETER 4 MAXIMUM VOLTAGE Programmable values from 2 40 to 2 80 V Cell or DISABLED Default value 2 80 V cell NOTES This parameter sets a maximum limit for the cell voltage If this limit is reached the charge is terminated and a specific warning message is given PARAMETER 5 CHARGING CURVE Programmable values A WSa Automatic Algorithm 7 8 hours I 22 26 of C B Wa Finishing Charge 2 Hours Wa Finishing Charge 3 Hours Wa Finishing Charge 4 Hours 10 12 hours I 15 26 of C 10 12 hours I 15 26 of C 10 12 hours I 15 26 of C E Wa Finishing Charge 5 Hours F Wa Finishing Charge 6 Hours G Wa Finishing Charge Proportional 25 H Wa Finishing Charge Proportional 33 D Wa Finishing Charge Proportional 50 J Wa Finishing Charge Proportional 66 K Wa Finishing Charge Proportional 75 10 12 hours I 15 26 of C 10 12 hours I 15 26 of C 10 12 hours I 15 26 of C 10 12 hours I 15 26 of C 10 12 hours I 15 26 of C 10 12 hours I 15 26 of C 10
15. p to reduce the charging factor to the minimum value so the duration of the overcharge gassing phase and the average temperature of the battery are minimized The AR TOP Charger is equipped with a built in Real Time Clock which allows the user to program the desired start time of the day the full charge time window and to schedule the weekly equalize cycles It is possible to connect the charger to the Fleet Management System DoctorFleet com which allows to monitor program and configure the complete fleet through a WEB based interface at any time of the day and from anywhere in the World to send automatic messages by email in case of problems The AR TOP charger features an extensive set of advanced functionalities including an automatic algorithm for the compensation of the voltage drop of the charging leads These functionalities are programmable through an Advanced Configuration Menu Please call your service technician for more details Page 4 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL 3 INSTALLATION OF CHARGER Conditions of use e Operating Storage temperature 5 C to 45 C e Relative humidity less than 75 WARNING The charger can be installed by qualified personnel only To avoid the risk of injuries the user is not allowed to open the cabinet Always refer to qualified electricians for installation and service operations WARNING To prevent fire or shock hazard do not expose the charge
16. pages Use the UP DOWN buttons to scroll between each record PAGE A ALWAYS VISUALIZED No VSTART VSTOP Start Date and Time Where No Number of cycle 1 is the most recent Vstart Battery Voltage at the connection Vstop Battery Voltage at the end of the charge Start Date and Time Date and Time of the BEGINNING of the charge Page 26 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL BATT OO O OOO 4 TYPE VOLTAGE CAP Where XXXXXXX Identification number of the battery ZZZZZZZ if ID module was not found TYPE Battery Type VOLTAGE Battery Nominal Voltage CAP Battery Capacity PAGE C Always visualized End Date and Time TT HH MM AHRET Where End Date and Time Date and Time of the TERMINATION of the charge TT Charge Termination Code see next paragraph HH MM Total charge time AHRET Total capacity Returned to the battery Page 27 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL 8 CHARGE TERMINATION CODES GROUP 1 CHARGE COMPLETED 00 Battery modules recognized Start charging 01 Charge completed successfully 02 Charge completed successfully Equalize NOT executed because battery was disconnected 03 Charge completed successfully Equalize started but not completed because battery was disconnected during the cool down time before the Equalize cycle 04 Charge completed successfully Equalize started but not completed beca
17. parts clean and dry Dirt and or moisture can cause insulation failure This failure can result in high voltage at the charger output Page 2 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL BURN AND BODILY INJURY PREVENTION The battery produces very high currents when short circuited and will burn the skin severely if in contact with any metal conductor that is carrying this current Do not permit rings on fingers to come in contact with battery terminals or the cell connectors on top of the battery Battery acid is very corrosive Alwais wear correct eye and body protection when near batteries FIRE AND EXPLOSION PREVENTION When batteries are being recharged they generate hydrogen gas that is explosive in certain concentrations in air the flammability or explosive limits are 4 1 to 72 hydrogen in air The spark retarding vents help slow the rate of release of hydrogen but the escaping hydrogen may form an explosive atmosphere around the battery if ventilation is poor The ventilation system should be designed to provide an adequate amount of fresh air for the number of batteries being charged This is essential to prevent an explosion Always keep sparks flames burning cigarettes and other sources of ignition away from the battery recharging area Do not break live circuits at the terminals of batteries Do not lay tools or anything that is metallic on top of any battery To prevent arcing and burning of
18. r to rain or moisture Do not use the e charger in presence of flammable gas because it can generate sparks Do not install the charger near flammable materials WARNING To reduce the risk of fire the charger must be installed on a floor of non combustible material If this is not possible a floor plate of at least 1 6mm steel extended at least 150mm beyond the charger on all sides must be installed Page 5 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL EQUIPMENT WARNING LABELS Inspect all precautionary labels on the equipment Order and replace all labels that cannot be easily read Energic plus AR TOP battery chargers have been designed to charge lead acid batteries These units can convert the AC input voltage to a DC voltage at the correct level in order to charge the battery cells The digital electronic control is used to monitor the state of the charge to automatically turn off the charger when the charge is complete and to visualize all the necessary information All the features of the digital control will be explained in the next chapters These are the principal devices included in the charger available to the user External box Control panel with digital display STOP pushbutton 0 1 No 2 Cables for battery connection No 1 Cable for main supply connection External box Control panel with digital display Stop pushbutton 0 1 N 1 Cable for main supply connec
19. re to reach the gassing voltage 32 Successful Opportunity charging cycle The battery reached the gassing point the charger entered in stand by mode waiting for the Full Charge Overcharge time window and at that point the battery has been disconnected 33 The battery has been disconnected during the finishing charge while it was cooling between two charging pulses 34 The battery has been disconnected during the finishing charge while it was receiving a charging pulse Page 29 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL 36 Charge never started The battery has been disconnected while the charger was trying to establish a wireless connection with the Battery Identification Module WBM 37 Charge never started The battery has been disconnected while the charger was communicating with the Battery Identification Module WBM 38 Desulphation cycle NOT completed The battery has been immediately disconnected at the beginning of the Desulphation cycle 39 Desulphation cycle NOT completed The battery has been immediately disconnected before to complete the programming of the Desulphation cycle 40 Desulphation cycle NOT completed The battery has been disconnected while the Desulphation cycle was in progress GROUP 4 EMERGENCY STOP 60 Emergency Stop Maximum voltage limit exceeded during first part of the charge before to reach the gassing voltage 61 Emergency Stop Maximum
20. ribed in this chapter are fundamental for the good functionality of the charger Improper settings can cause severe damage to the charger and the battery Before to install the charger Check that the charger input voltage V is identical to your AC power supply voltage Check that the charger max input power KVA is available from your AC power supply Page 8 32 AC VOLTAGE SELECTION 3 x 220 380 V The BOARD FOR INPUT VOLTAGE SELECTION is composed by six terminal blocks to be connected in one of the two configurations represented on the picture inside the charger PROCEDURE Check that the charger is disconnected from AC input and battery Open the cabinet and move the three wires WHITE in position 220V or 380V Close the cabinet STEP 1 INTERNAL AUX TRASFORMER in the middle of the picture a 220V 380V 14 0 14 0 l l 400 X 230 230 0 400 X 230 230 0 GRAY WIRE Page 9 32 AAC INPUT VOLTAGE ADJUSTMENT The local AC input voltage must be measured with an adequate voltmeter then the charger input must be adjusted by moving the three wires marked with the letters A B C on the PLUGS FOR INPUT VOLTAGE ADJUSTMENT PROCEDURE Check that the charger is disconnected from AC input and battery Open the cabinet and move the wires A B C to the desired position Close the cabinet Page 10 32 GROUNDING AND LINE CONNECTION WARNING The cabi
21. ry doesn t reach the gassing voltage within a predetermined time the charger will suspend the charge and it will visualize the message EMERGENCY STOP VGAS NOT REACHED In this case the charge cannot proceed and it s necessary to disconnect the battery It s recommended to control the battery for damaged cells AC INPUT BLACK OUT If there is a black out of the AC input while the charge is in progress the charger will shut down while the charge parameters will remain in memory When the AC input will be recovered the charger will restart the charge cycle automatically and the display will show the message RESTART AFTER POWER SUPPLY OFF Page 20 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL OVERCURRENT PROTECTION If the AC input voltage is abnormally high and or the AC input adjustments have not been done correctly See Chapter INSTALLATION the charging current may reach an excessive value In this case the charger will suspend the charge and the display will visualize the message CURRENT TOO HIGH The charge will not proceed and it s necessary to disconnect the battery It s recommended to control the AC input connections of the charger as explained in Chapter 3 INSTALLATION It s recommended to verify the condition of the battery as it may have one or more cells in short circuit CHARGE COMPLETE The charger shuts down automatically when the charge is correc
22. sferred to the charger and are visualized on the display The charger is now ready to start Depending on the programmed start time window Parameter 8 the charger may enter in stand by mode and the display visualizes the message DELAYED START hh mm A gt n m B Where hh mm A represents the real time at that moment and hh mm B represents the programmed start time When the charge begins the display visualizes the message PREPARING TO CHARGE Page 18 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL BATTERY VOLTAGE TOO HIGH If the battery voltage is higher than a maximum threshold the charge will not start and the display visualizes the message BATTERY VOLTAGE TOO High if If this message appears it s recommended to verify that the nominal battery voltage matches the nominal voltage of the charger Probably a wrong battery has been connected BATTERY VOLTAGE TOO LOW If the battery voltage is lower than a minimum threshold the charge will not start and the display visualizes the message BATTERY VOLTAGE TOO LOW If this message appears it s recommended to verify that the nominal battery voltage matches the nominal voltage of the charger Probably a wrong battery has been connected It s also possible that the battery has been deeply discharged bringing the voltage below the minimum value required for the automatic start the charge In this case it s possibl
23. the connector contacts be sure the charger is OFF before connecting or disconnecting the battery The digital display must be completely OFF MEDICAL AND FIRST AID TREATMENT First aid facilities and a qualified first aid person should be available for each shift for immediate treatment of electrical shock victims EMERGENCY FIRST AID Call phisician and ambulance immediately and use First Aid techniques recommended by the American Red Cross In case of acid in the eyes flush very well with clean water and obtain professional medical attention immediately EQUIPMENT WARNING LABELS Inspect all precautionary labels on the equipment Order and replace all labels that cannot be easily read Page 3 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL 2 DESCRIPTION The AR TOP Charger is suitable to charge lead acid motive batteries The operation is completely automatic and it s managed by a microprocessor control system composed by a Main Control Board installed inside of the charger and an optional wireless Battery Identification Module WBM that is permanently connected to the battery The AR TOP has two selectable charging curves Wa and WSa Wa typical charge time 10 12 hours typical start rate 15 18 of the battery capacity C 5 WSa typical charge time 7 8 hours typical start rate 23 26 of the battery capacity C 5 The power conversion system of the AR TOP and its optimized charging algorithm hel
24. tion N 2 Cable for battery connection Page 6 32 Inside of the charger there are the following devices not available to the user Power contactor Power transformer Microprocessor controlled electronic board e Output fuse Plugs for input voltage selection Plugs for input voltage adjustment Power Contactor Plugs for input Plugs for input voltage adjustement voltage selection NOTE The PLUG BOARD FOR INPUT VOLTAGE SELECTION is present only in chargers with 3x 220 380 Vac input and it s NOT present in chargers with 3x440 Vac input The PLUGS FOR INPUT VOLTAGE ADJUSTMENT are present in all the chargers Page 7 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL The charger is marked with a technical label containing the following data e Model Serial number S N Weight kg and Ibs Input voltages V Maximum input current A Maximum input power KVA Input frequency Hz Battery voltage V Maximum output current A on CAUTION Allow adequate air circulation to prevent internal heat buildup Do not place the unit near materials that may block the ventilation slots Do not install the unit near heat sources such as radiators or air ducts or in a place subject to direct sunlight excessive dust mechanical vibration or shock onl CAUTION The operations and settings desc
25. tly complete and it will visualize the message CHARGE COMPLETE At this time it s possible to disconnect the battery EQUALIZE CYCLE AUTOMATIC clock mode At the end of the charge if the battery is left connected to the charger for a sufficient time the charger activates the Equalize cycle automatically based upon the programmed schedule If the charge cycle ends outside of the programmed Equalize time window the charger remains in stand by mode and the display shows the message DELAYED EQUALIZE DAY TIME Where DAY and TIME represent the beginning of the programmed Equalize time window Page 21 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL EQUALIZE CYCLE MANUAL During the charging of the battery the operator can scroll the menu of the display and he can force a EQ manual cycle at the end of this cycle FORCE MANAUL EQ ENABLED DESULFATION The operator can every time interrupt the standard charging and enable with a easy procedure a special desulfation cycle During the charging the operator can press Enter few seconds and the display shows a desulfation menu in this menu the operator can select the time during of desulfation and the type of restart of desulfation infact sometimes it is strategic important to complete a standard charging after a completed desulfation cycle With AR TOP special desulfation function this is very easy REFRESH MAINTENANCE This function is use
26. use battery was disconnected while the Equalize was in progress 05 Charge completed successfully Over range maximum time during pulsed 06 Desulphation cycle completed successfully 07 Charge completed successfully Equalize completed successfully Refresh Cycle NOT executed because battery was disconnected 08 Charge completed successfully Equalize completed successfully Refresh Cycle started but not completed because battery was disconnected while the Refresh was in progress 09 Charge completed successfully Equalize completed successfully Refresh Cycle completed successfully 10 Gassing voltage reached successfully Full charge NOT executed because time window Disabled Page 28 32 ENERGIC Plus AR TOP V 140 January 2011 USER S MANUAL 12 Charge completed successfully Equalize completed successfully GROUP 2 MANUAL STOP 11 Charge stopped manually during a generic cooling state 20 Charge stopped manually before to reach the gassing voltage 21 Charge stopped manually during the finishing charge 22 Charge stopped manually during eq 23 Charge stopped manually during refresh 24 Charge stopped manually during desulphation GROUP 3 BATTERY DISCONNECTED 30 The battery has been disconnected before the begin of the charge while the charger was waiting for the programmed Start Time window 31 The battery has been disconnected during the first part of the charge befo
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