CH4100 Series High Efficiency Intelligent Charger User Manual Ver
Contents
1. matching Needle No Wire Color Wire core diameter Description 1 brown 2 5 mm L Live wire 2 blue 2 5 mm N Neutral wire Yellow 3 2 5 mm PE Protective grounding wire and green Output Cables Terminal Model SB50 Needle No Wire Color Wire core diameter Description red 6 mm Output positive pole black 6 mm Output negative pole 8 Signal Cables Needle No Wire Color Wire core diameter Description Needle No 1 brown external LED DJ7031Y 2 3 11 2 Blue DJ7031Y 2 3 21 indicator interface 3 yellow 4 urple Battery Temperature DJ7021 1 5 21 DJ7021 1 5 11 sensor interface S white ink 6 Yellow and TH Serial green DJ7043 2 21 communication DJ7043 2 11 Blue and 8 interface white Green and 9 white 10 prange Forbidden signal DJ7021 2 11 interface DJ7021 2 21 11 normal close Wire core diameter 0 5 mm2 for all Signal wires 9 Signal Cables Terminal Diagram J4 DJ7031Y 2 3 21 DJ7021 1 5 21 DJ7043 2 21 DJ7021 2 11 Direction of view form the cables to terminal el eal DJ7031Y 2 3 11 DJ7021 1 5 11 DJ7043 2 11 DJ7021 2 21 10 Vill Charging Indicator Information Description The charger installed a LED indicator internally this built in indicator display information through the window on t2. Enpower crearway Electric Systems CH4100 Series High Efficiency Intelligent Charger User Manual Ver 1 5 JWT GREATWAY ELECTRIC CO LTD www igreatway com Table Of Contents T Produict Overview 1 M Safety Instructions ee 2 Leakage and 3 1 Correct use of Breakers Sockets and 3 2 Correct Use of Input 4 3 Charging Environment 4 TV Regularly Maintenance cccccccssccssseessceseceeeeeeseeeeeeseeeseeeaes 5 TV Product Modi liegir A A 5 V Technical 6 Beene eas 7 VII Input and output 8 VIU Charging Indicator Information 11 Methods of 12 X Appearance and Installation 1 5 13 XI Faults amp sol tionS onei ai i 14 X Se ES a O Moot a EEE 16 www igreatway com Email info igreatway com Product Overview CH4100 series high efficiency intelligent charger is designed to charge power batteries of electric vehicles This series of products adopt the most advanced technologies such as LLC reson
3. and limit the extension cable length within 10m 5 Don t place the charger in water or rain position otherwise there is a danger that may cause electric shock and damage to the charger 6 The charger s DC output plug should be connected reliably to the socket if they are damaged or loose please replace them immediately otherwise it will cause overheating in the plug position and even cause serious fire 7 If the charger product any abnormal sound or smell during working please unplug the power plug immediately and contact the service department Do not attempt to open the shell of charger to prevent electric shock 8 Make sure that all air vents are unobstructed to prevent charger overheating Do not place 2 the charger near a heat source the charger should be left enough space to ensure ventilation and use of connectors 9 Please disconnecting the charger s AC input power if you need to move it 10 Make sure that AC power supply voltage matches chargers input voltage For inquiries please contact your supplier or local power Supply Corporation 11 Battery voltage and the nominal voltage of the charger must be matched otherwise it will damage the charger or batteries 12 Do not pull twist or shake the cables to avoid damage to the charger s cables and connection terminals If the cable is worn please replace it immediately Preventing Leakage and Fire 1 Correct use of Breakers Sockets and C
4. color word represents that the LED of this color lights for 0 2s 2 R red G green Y yellow IX Methods of 1 Connect the output terminal of the charger to the battery terminal 2 Connect the input plug of the charger to AC power socket until the charger turns into normal charging process observe the LED Indicator then Charger will automatically charge the batteries When fully charged the charger will automatically shut down and display full power 3 If observed the battery become overheating or ballooning during charging process you should stop the charger immediately by unplug the plug from the AC socket 12 X Appearance and Installation Dimensions 13 If cables of the charger need to be bended the length from bending place to the shell should not be less than 50 mm as shown in Figure Leave at least 50mm away from cooling fan of the charger to other obstructions to improve heat radiating of the charger as shown in Figure XI Faults amp solutions If your charger can not work correctly you can refer to table below Fault Phenomenon Analysis Solutions Battery temperature Sensor Fault External battery temperature sensor is fault or not connected Check sensor connection or change a new one Battery not connected Battery is not connected or reverse connected Check and connect the battery correctly Over temperature pro
5. 00 6435 CH4100 7225 CH4100 7230 CH4100 9620 CH4100 9625 a structure code B such as CH4100 4825B V Technical Specifications Rated input voltage Input voltage range Input Current Power Factor Total Harmonic Current Nominal output voltage Un Maxim output voltage Rated output current Ir Voltage regulation accuracy Current regulation accuracy Conversion efficiency Protection class Audible Noise Seismic rating 220Vac 50 60Hz 85 265Vac Note When the Input voltage is lower than 185Vac the output power will be limited to 1 5K W lt 16 Note except models of CH4100 9625 0 99 220Vac input full power output lt 5 220Vac input full power output See Model Description 140 Un See Model Description lt 0 5 lt 2 gt 95 220Vac input full power output IP66 lt 40dB Designed according to IEC60335 2 29 2004 Part 21 6 Working temperature 25 55 C Note models whose output power greater than 2KW will ensure 2K W output at 60 C Storage temperature 40 80 C Recognition certificates CE SGS VI parts list A input Cables B DC output cables Signal Cables D Charging indicator E Mounting plate F Shell G Cooling fan and fan cover 7 VII Input and output interface Input Cables Terminal Model DJ7031 4 8 11 Direction of view form the cables to terminal Terminal Model for DJ7031 4 8 21
6. Cables are too long or too thin Between the charger and battery resume The output cables back to initial state Charging time becomes too short or too long Battery is aging Replace the battery Charger overheating protection Check if there are foreign matters around the fan and remove them Check whether the cooling fan is working correctly or contact us to replace the fan LED indicator lights but no charging Connectors are not connected firmly or the polarity is reversed Battery is disconnected Connect all connectors correctly and recharge Battery is broken Replace new battery LED indicator doesn t light AC input is not connected firmly Check AC power supply and chargers input cables Charger is broken inside Please contact us If your charger still cannot work correctly after above treatment please record the state of the fault phenomenon and charging indicator information then contact us 15 XII Services If the charger has quality problems you can change a new one within two months and can be repaired within one year free of charge If the fault is caused by follow reasons it cannot be repaired free of charge 1 Damage caused by illegal operation 2 Without authorization open the shell or repair lead to damage 3 Damage caused by improper transportation such as knocking collision or falling 4 Damage cause
7. ables Leakage protection air breaker Leakage protection air breaker PE Protective Grounding Wire N Neutral Wire L Live Wire 1 Its required to use a leakage protection air breaker with leakage protection function 2 Its required to use reliable qualified 16A three hole socket to connect the charger to AC power 3 Input cables of leakage protection air breaker is required to use copper core cables with flame retardant jacket the cables core diameter is not less 2 5mm 3 4 The cables between leakage protection air breaker 16 socket are required to use copper core cables with flame retardant sheath the cables core diameter is not less than 2 5mm 5 Prevent plugs sockets from dripping or splashing Note According to statistics 80 fire accident caused by an electric car occurred during charging main reasons for this are insufficient core diameter size of cables poor quality plugs and sockets poor contact of plugs and sockets poor flame retardant sheath or shells of breakers plugs and sockets and so on 2 Correct Use of Input Connections 1 It s required to use a dedicated 16A power plug for the charger 2 It s required to use copper core cables with flame retardant sheath the cables core diameter is not less than 2 5mm 3 Make sure that the plug is clean no dirty and no damage before char
8. ant active power factor correction microcomputer measurement and control digital adjusting fully sealed waterproof technology and so on Its features include wide input voltage range adapted to global general voltage High input power factor that significantly reduces the input current as well as heat generated by input cables so the charger can be safely used in family Low harmonic current that reduces interference to other electric equipment Full range soft switching is realized to achieve high conversion efficiency and slight electromagnetic interference the charger is more energy saving and money saving to use the charger is designed according to IP66 protection grade and achieved high waterproof performance Another feature includes small size light weight quiet operation beautiful appearance simple installation operation and maintenance and so on The charger adopts microcomputer measurement and control technology embedded CPU can accurately detect various states of battery Advanced multi stage charging mode can prevent the battery from be over charged and over discharged minimize overheating and water loss phenomenon caused by over charge slow down polar plate vulcanization phenomenon caused by over discharge extend the service life of batteries The charger will stop automatically after fully charged The charger has functions of temperature compensation automatically shut down after fully charged battery reverse connection pro
9. d by water inlet immersion damp or other irresistible natural calamities 5 Damage caused by instantaneous over voltage in power grid 25 higher than Rated input voltage 6 Damage caused by pulling input or output cable seriously For better services please follow attentions below 1 In warranty period if faults occur in condition that all operations are according to user s manual we will replace or repair free of charge 2 Warranty period and maintenance mode From date of purchase within 12 month free of charge to repair Users need to pay for reparation beyond warranty period 3 If faults happen within warranty period in follow cases cost of material and service need be paid appropriately A Guarantee paper does not have the seal of distributor Fault caused by improper operation Fault caused by improper safekeeping and maintenance Damages cause by accident or disaster such as natural disaster war or lightning strike moaw Guarantee paper is damaged or cannot be distinguished clearly 4 Out of warranty period users need to pay for cost of material and service spare parts can have guarantee for 3 month from the date of reparation 5 If the guarantee paper does not record purchase date warranty period will be 12 month from date of delivery from factory 16
10. ging 3 Charging Environment Requirements 1 Spacious and airy 2 No flammable materials prohibited charging in warehouse 3 Keep away from valuables such as automobiles 4 Keep away from bedroom when charging at night 5 Prohibit placing the charging plugs charging cables or charger itself on car cabs 4 plastics chairs and other inflammable objects IV Regularly Maintenance 1 Check 16A sockets regularly if the connection between the socket and the plug is loose or poor contacting they should be firmly connected or replaced before the charger be used The poor contact may result in overheating and burning of the plug and socket and even cause a fire 2 Check the leakage protection air breaker regularly using the test button to ensure its protection function is valid 3 Make sure to use a dedicated input cable and plug for the charger 4 Make sure that there are no foreign matters between the charger s shell and the cooling fan to avoid damage to the fan 5 Make sure that the appearance of battery is not ballooning the battery is not overheating when charging IV Product Models 1 Naming Rules CHA100 KX XX Ko pases sete ress nents 2 Available Product Models CH4100 4825 4100 6025 4100 6425 CH4100 7220 CH4100 9615 Note Portable versions are available for above models these models will be ended with CH4100 4830 CH4100 4835 CH4100 6030 CH4100 6035 CH4100 6430 CH41
11. he shell of charger Besides the charger provides an external LED indicator interface that can connect the optional external LED indicator Internal and external LED indicator can light synchronously with red green yellow three colors the LED indicator can express a variety of working conditions of the charger with different color combinations The following table is a description of indicator information LED Indicator Information Description I Charging Process Information 1 Low battery power R 2 Battery charge lower than 80 R 3 Battery charge between 80 90 Y 4 Battery charge between 90 100 G 5 Full charge Normal process of continuous Green light charging Battery temperature Green light 3S Yellow light 0 3s sensor fault Alarm Information Battery Not connected R G 2 Charger over temperature protection R G Y 3 Input fault protection R G Y Y 4 Charging timeout R G Y Y Y 5 Battery Overheating R G Y Y Y Y 11 6 Pre Charge timeout R G Y Y Y Y Y 7 Internal temperature sensor fault R G Y Y Y Y Y Y 8 Output voltage feedback fault R G Y Y Y Y Y Y Y 9 Low temperature start delay R G Y Y Y Y Y Y Y Y When the internal temperature of charger is between 20 to 30 C the charger will delay starting for 1 2 minutes Note represents led that does not light for 0 55 a
12. tection Charging environment temperature is too high cooling fan is fault air vents are obstructed Place the charger in lower temperature environments and recharge Check whether cooling fan is fault or air vents are obstructed Input fault protection Poor contact of charger s input side Charger is broken If no poor contact phenomenon occurs please contact us Charging timeout Battery is damaged or aging Check and replace battery Battery Overheating Battery is damaged or aging Check and replace battery Pre charge timeout Internal temperature sensor fault Battery is damaged or aging Charger is broken inside Check and replace battery Please contact us Output voltage feedback fault Charger is broken inside Please contact us Full Power after short charging Battery is broken Poor contact between charger and battery Check whether the battery is damaged battery connecting cables are firm the battery is 14 Battery has been fully charged fully charged Battery temperature becomes more than 50 Battery is aging Battery voltage is lower than the Check the battery and replace bad battery Reselect charger C produces a lot that match battery voltage nominal voltage of the charger of bubbles level Battery is aging Replace the battery Low battery capacity after fully charging
13. tection output short circuit protection AC input under voltage protection overheating protection and so on and these functions can ensure safe and reliable use 1 ll Safety Instructions Please read these instructions carefully before you use the charger 1 For safety consideration the charger adopts AC single phase three wire inputs which contain live neutral and protective grounding wire The shell of charger connects protective grounding wire When using the charger you should connect it to power grid with a quantified 16A three hole socket which contains a grounding pole and controlled by a leakage protection air breaker with leakage protection function to prevent leakage and fire 2 Please use dedicated 16A plug and socket of reliable quality for the charger Socket requirements flame retardant shell and cables of the socket thick internal springs that not less than 0 8mm and has a good elasticity or it may burn the plug and socket even cause severe fire Copper core cables thicker than GB 2 5mm are suggested to be used as power connections to prevent the cables from becoming too hot when charging so to prevent fires 3 Please do not disassemble the charger this may cause electric shock or other injuries 4 If the charger need to be connected to AC power supply with extension cables please make sure that the extension cable can withstand the maximum input current GB 2 5mm copper core cable is recommended to be used
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