Installation Manual
Contents
1. 60 Manual Rev2e Printed in The Netherlands Battery temperature is too low or too high only relevant when the battery temperature sensor is installed There is a short circuit on the charger output Charger overload or Battery error keeps on appearing Charger is being overloaded in Forced float mode voltage alarm settings using TBS Dashboard Check and try to correct the the battery Check if the temperature sensor is not damaged Check DC wiring Check battery condition When the charger is used in battery attached not the load ambient temperature around Forced float mode without a recommended try to reduce Charge voltage is too low Charge current is too low The charge voltage is being compensated by the battery temperature sensor to protect your battery Wrong charge program selected by the dipswitches or custom charge program needs to be re adjusted DC cables too thin Battery load current is higher than the charger s output current High ambient temperature Charger is operating in the absorption charging stage service Do nothing or try to cool down the ambient temperature around the battery Select the correct charge program or adjust the custom charge program using TBS Dashboard Install larger DC cables See the DC cable size table in the installation guide Reduce or remove the battery load Try to c2. Note Do not turn off the the charger Keep the charger away from direct sunlight or heat producing equipment 24V 40A 4A 60A 4A 20A 2 5A 30A 2 5A IUoUOP intelligent 4 stage temperature compensated Nominal output voltage Total output current Aux Charge characteristic charger when it s operating Too high ambient Move the charger to a cooler Absorption voltage 28 8V O O Battery error keeps on Battery voltage is too low or Check the battery for in an High temperature temperature environment or provide m E E E appearing too high damaged or shorted cell s error The charger needs additional cooling by an Float voltage 27 0V Y Universal Remote Control optional Check if DC bus voltage is this error time to cool down external fan Equalize voltage 31 0V being pushed by another charging device Charger error keeps on An internal error is Please return the charger to Supported Battery types Flooded GEL AGM Custom p Check low or high battery appearing detected your nearestidealer tor Recomm battery capacity 80 400Ah_ 120 600Ah 50 200Ah_ 70 300Ah Always connect the temperature sensor on the minus terminal of the main battery WARNING MAIN BATTERY Battery temperature sensor for temperature compensated charging 000000000 Alarm Output Expander optional OC20
3. life support devices or systems that can potentially harm humans and or the environment The customer is always responsible when implementing TBS products in these kind of applications TBS does not accept any responsibility for any violation of patents or other rights of third parties resulting from the use of the TBS product TBS keeps the right to change product specifications without previous notice Examples of improper use are Too high AC input voltage applied Connecting wrong batteries too high battery voltages Mechanical stressed enclosure or internals due to harsh handling and or incorrect packaging Contact with any liquids or oxidation caused by condensation 9 Declaration of conformity MANUFACTURER TBS Electronics BV ADDRESS De Marowijne 3 1689 AR Zwaag The Netherlands Declares that the following products PRODUCT TYPE MODELS Professional programmable battery charger 0C12 40 OC 12 60 OC24 20 OC24 30 Conforms to the requirements of the following Directives of the European Union EMC Directive 2004 108 EC Low Voltage Directive 2006 95 EC The above product is in conformity with the following harmonized standards EN61000 6 3 2001 EMC Generic Emissions Standard EN61000 6 2 2005 EMC Generic Immunity Standard EN60335 1 1999 Generic safety standard EN60335 2 29 2004 Safety requirements for battery chargers INSTALLATION GUIDE Please read this document very carefully to avoid charger m
4. open A remote switch w must be connected and switched ON in order to activate the charger The local on off switch on the frontpanel always overrides the remote switch So in order to use the remote switch the local on off switch must be in the power on or forced float position 3 Charge programs All standard selectable charge programs using dipswitches 2 and 3 perform a four stage IUoUoP charging process comprising of a Bulk an Absorption a Float and a Pulse stage The image below visualizes the four stage charging process Ss Bulk Absorption Float Pulse Float Bulk V 12V 4 ACAV E a E Ds pmb eccerehs 28 8V feed 13 5V pe 27 0V AEV bev eee cece 125 0V battery load turned on Iload gt Imax restart three stage charging process Y float time out absorption time out 7 days max 4hrs global charge time out max 8hrs 10 Imax eterinis Perret ere a gt t In the Bulk stage the charger delivers full output current and typically returns approximately 80 of charge back into the battery once the absorption voltage is reached During this stage indicators and lad will be lit depending on the Bulk charge progress When the absorption voltage has been reached the Absorption stage will be entered and indicator fil will be lit This stage will return the final 20 of charge to the battery The output volt
5. switch in the O Off position and disconnect the AC supply to the charger If possible disconnect or switch off all loads from the battery Connect the battery to the charger Switch on the AC supply and activate the charger by pushing the charger switch in the I power on position After a two tone beep the charger will start the charging proces 5 After charging is completed push the charger switch in position O and switch off the AC supply again before disconnecting the battery Or keep all connections and the charger switch position untouched and just re connect all battery loads PON 5 Forced float mode The forced float mode can be activated by pushing the main switch into position II In this mode the output voltage of the charger is set constantly to the float voltage value is depending on selected battery type while being able to deliver full rated output current Since no automatic charging programs are activated in this mode it can be used for constant voltage charging or operating the charger as a battery buffered power supply 6 Equalizing a flooded battery If you are using a flooded lead acid battery an occasional equalization charge cycle may be recommended by the manufacturer This might also be true when the flooded battery has been very deeply discharged or often charged inadequately During equalization the battery will be charged up to 15 5V or 31V for 24V models at a reduced output cur
6. age is kept at a constant level and the charge current decreases as a function of the battery s state of charge When the charge current has dropped below a certain value or when the maximum absorption timer has been expired the Float stage will be entered Indicator fii will be lit and an acoustical message will sound indicating that the battery is full In this stage the battery voltage will be held constant at a safe level for the battery It will maintain the battery in optimal condition for as long as the battery remains connected to the activated charger Connected battery loads will be directly powered by the charger up to the charger s maximum output current level When even more current is drawn the battery must supply this which results in a declining battery voltage At a certain battery voltage level the charger jumps back to the Bulk stage and will finalize a complete three stage charging process again once the battery load consumption has dropped below the charger s maximum output current level The fourth stage called Pulse will perform a short refresh charge of approximately 1 hour each 7 days while the charger operates in the Float stage This will keep the battery in optimal condition while prolonging it s lifetime The battery can remain connected to the activated charger continuously without risk of overcharging When the battery temperature sensor is installed the charger automatically compensates the charge voltages aga
7. alfunction shock and or fire hazards This document provides a brief overview of a stand alone charger installation For long term safe and troublefree operation it is very important to read the owner s manual on the rear side of this paper as well Please follow the exact installation sequence as given below Skipping one or more steps could result in charger malfunctioning or shock and or fire hazards CHARGER MOUNTING UNPACKING The charger package should contain the following items Approved o Not recommended CONNECTION COMPARTMENT WIRING DETAILS For explanation on the dipswitch settings please consult chapter 2 of the owner s Battery charger manual 5m temperature sensor This Installation guide Owner s manual Safety flyer 0 200v WAIN BATTERY AUXILIARY WEEE flyer eln fu 12i F OD 7aA OD Please feed all connection 2x M8 crimp terminals OJ F compartment wiring through the 4x Mounting screws After unpacking check if the charger shows any mechanical aion damage Never use the charger when the enclosure shows any visual Ga e a a vertical wall mounting IP21 i vertical wall mounting upside down
8. ay be reduced automatically
9. ft CRIT battery cables to the battery 126mm All 2 5mm AWG13 Always connect the negative cable directly on the negative terminal of the battery or drilling template on the loadside of a current shunt Always keep positive and negative cables close to Caution each other to minimize electromagnetic fields BOTTOM SIDE CONNECTIONS Troubleshooting guideline Technical specifications Parameter 0C12 40 0C12 60 0C24 20 0C24 30 Yodo Problem Possible cause Remedy Problem Remedy i Input voltage 100 260VAC 47 63Hz PF gt 0 95 Recessed pushbutton location to activate or charger is not working all Power switch in OFF 0 Push the power switch in the High charger temperature Airflow around the charger Make sure there is at least Full load consumption 700VA 1050VA 700VA 1050VA i deactivate the equalisation charge mode see indicators are off position F or Il position error keeps on appearing is obstructed 10 centimeters of clearance x chapter 6 of the owner s manual around the charger Remove AC input current 115V 230V 6A 3A 9A 4 5A 6A 3A 9A 4 5A o No or too low AC input Check AC wiring and input any items placed on or over Full load efficiency 91 o O voltage Remote switch or remote control have deactivated the charger voltage level Activate the charger remotely or check dipswitch 4 for correct setting
10. horizontal wall mounting Access the connection compartment by removing the two screws and sliding the red cover downwards This charger must be earthed Always connect the PE wire caution Ubber grommets and plastic gland When all connections are made and i CE use 1mm AWG17 wire size max length 50m 150ft double checked slide the red connection compartment cover to it s original position again and relocate the two screws Remote on off switch damage caused by harsh handling or WARNING when it has been dropped accidentally PE EARTH 60V max Contact your local supplier for further 1A fuse information GFCI RCD Main battery cable sizes N Alarm indicator ae light 1A max Model lt 3m 10ft 3 6m 10 20ft 3 EE KI ENS boos Fuse 0C12 40 16mm AWG5 25mm AWG3 Use a wire size of ret 2 2 a 1 5mm AWG15 return 0C12 60 25mm AWG3 35mm AWG2 e e peers as eA shia m OC24 20 6mm AWG9 10mm2 AWG7 AUXILIARY OR OC24 30 10mm AWG7 16mm AWG5 Ji STARTER Pa A F floor mounting ceiling mounting Double check for earrect MAIN BATTERY BATTERY Auxiliary battery cable sizes polarity before connecting the OPTIONAL Model 0 6m 0 20
11. inst battery temperature This means that the charge voltages are slightly increased at lower temperatures and decreased at higher temperatures 30mV C at 12V chargers and 60mV C at 24V chargers This way overcharging is prevented which prolongs your battery s lifetime A connected battery temperature sensor also enables the battery temperature protection which stops the charging process when the battery s temperature is below 20 C or above 50 C When the standard selectable charging programs do not satisfy your requirements or when different voltage and current levels are needed you can use the optional TBSLink communication kit and create your own charge programs using TBS Dashboard Up to 8 different stages can be linked together and all individual stages can be configured extensively Please contact your TBS equipment supplier for further information on the TBSLink communication kit The Auxiliary battery output always follows the charge process of the Main battery automatically You can use this output to charge a second smaller battery like a starter battery It is not possible to use this output when the Main battery is not connected 4 Charging batteries Before you start to charge batteries read all enclosed safety instructions and warnings while following all safety precautions about working with batteries The list below globally describes the steps to follow for charging batteries Push the charger
12. n chapter 1 The alarm relay de activates again when the error mode has been cleared and the charger is running in normal operating mode again On pins 1 2 and 3 of the 5 pins screw terminal located in the connection compartment both normally closed and normally open contacts are available Please make sure not to exceed the maximum relay contact rating of 60V and 1A to avoid damaging the relay 8 Warranty conditions TBS Electronics TBS warrants this charger to be free from defects in workmanship or materials for 24 months from the date of purchase During this period TBS will repair the defective charger free of charge TBS is not responsible for any costs of the transport of this charger This warranty is void if the charger has suffered any physical damage or alteration either internally or externally and does not cover damage arising from improper use or from use in an unsuitable environment This warranty will not apply where the product has been misused neglected improperly installed or repaired by anyone other than TBS TBS is not responsible for any loss damage or costs arising from improper use use in an unsuitable environment improper installing of the charger and charger malfunctioning Since TBS cannot control the use and installation according to local regulations of their products the customer is always responsible for the actual use of these products TBS products are not designed for use as cricital components in
13. ndows software f Setting ON The local dipswitch settings of dipswitch 2 and 3 are ignored and 1 configuration must be done externally Setting OFF The local dipswitch settings are used factory default 1 2 amp 3 BATTERY Select the type of lead acid battery that you wish to charge Each TYPE setting represents the best charging voltages for the given battery type listed below If there are still other voltage levels or different charging programs needed for your battery please use the TBS Dashboard software to create your own and store this as Custom setting inside the charger DS2 DS3 BATTERY TYPE 12V 24V fi fi Flooded factory default 2 3 absorption voltage 14 4V 28 8V float voltage 13 5V 27 0V fi a GEL 2 3 absorption voltage 14 2V 28 4V float voltage 13 5V 27 0V f fa AGM 2 3 absorption voltage 14 3V 28 6V float voltage 13 3V 26 6V f m Custom 2 3 not available when dipswitch 1 is set to OFF LOC Invalid battery type settings can cause serious damage to your batteries and or connected battery loads Always consult your battery s documentation for the cmon Correct charge voltage settings 4 BYPASS REMOTE Bypasses the remote switch connection when no remote switch is connected f Setting ON remote switch connection terminals are bypassed factory default z fi Setting OFF remote switch connection terminals are
14. on normal operation battery error charger overload high charger temperature charger error return for service continuous green flashing red 1 flash per sec flashing red 2 flashes per sec flashing red 3 flashes per sec flashing red 4 flashes per sec note 1 When the switch is in position O it does not interrupt any internal AC or DC sources This means that there are still lethal voltages present inside the charger In position O the charger will still consume a small amount of AC current A battery error can appear for several reasons These are battery voltage is too low too deeply discharged or too high and battery temperature is too low or too high only available when battery temperature sensor is connected The charger will not restart automatically in battery error mode except when this error was generated due to a too low battery voltage or a too low battery temperature The charger automatically restarts when the temperature is below an acceptable level note 2 note 3 power on off forced 2 Dipswitch settings During step 3 of the installation sequence you can alter the factory settings of the dipswitches to change the charger s functionality on a few points The following settings can be made 1 LOC EXT Choose to configure the battery type locally using dipswitch 2 and 3 or override these settings and setup the charger externally using the TBS Dashboard for Wi
15. ool down the ambient temperature around the charger Do nothing The battery is almost fully charged and consumes less current by itself P lt BMA 5mA lt 4mA 20 C 50 C humidity max 95 non condensing 40 C 80 C humidity max 95 non condensing DC current draw charger off Operating temp range Storage temp range Cooling Variable speed fan controlled by temperature and load TBSLink enabled Yes Protected against Low AC voltage output short circuit high temperature battery overcharging and reverse polarity fuse Indications Power on output current bar state of charge bar error DC output connections M8 bolts main output Screw terminals auxiliary output Screw terminals 351 x 210 x 114mm 5 8 kg IP21 mounted in upright position CE marked meeting EMC directive 2004 108 EC and LVD 2006 95 EC complying with EN60335 1 EN60335 2 29 AC input connections Enclosure body size Total weight Protection class Standards Note the given specifications are subject to change without notice Maximum output current tolerance is 3 Maximum setpoint voltage deviations are 0 1V for 12V and 0 2V for 24V models All setpoint voltages are temperature compensated when battery temperature sensor is connected Value is programmable Always consult battery manufacturers specifications for maximum allowable charge current At higher ambient temperatures gt 40 C maximum output current m
16. rent level Before starting an equalization charge cycle the following caution statements must be read carefully Equalization should only be performed on a flooded wet lead acid battery Therefore the Omnicharge chargers only allow equalization when the battery camion type dipswitches are set to Flooded Other battery types like GEL or AGM will be damaged by this process Always follow the battery manufacturer s instructions when equalizing flooded fs batteries During equalization the battery generates explosive gasses Follow all the battery safety precautions enclosed with your charger Ventilate the area around the caution battery sufficiently and ensure that there are no sources of flames or sparks in the vicinity Disconnect all loads connected to the battery during equalization The voltage applied to the battery during this process may be above safe levels for some loads The Omnicharge chargers cannot automatically determine when to stop the equalization of a battery The user must monitor the battery s specific gravity camion throughout this process to determine the end of the equalization cycle The internal 2 hours time out timer of your charger is only intended as a safety feature but may not be sufficiently short to prevent battery damage Therefore equalizing a battery is always a process that must continuously be supervised by the user When equalizing the main battery the smaller battery connected to the auxiliar
17. tbs electronics Professional programmable battery chargers omnicharge OC12 40 12V 40A omnicharge OC12 60 12V 60A omnicharge OC24 20 24V 20A omnicharge OC24 30 24V 30A ND Thank you for purchasing a TBS Electronics professional programmable battery charger Please read this owner s manual for information about using the product correctly and safely Keep this owner s manual close to the charger for future reference Owner s manual TBS ELECTRONICS BV De Marowijne 3 1689AR Zwaag The Netherlands http www tbs electronics com Before proceeding with this owner s manual please make sure you have carefully read the enclosed safety flyer and the installation guide on the backside of this paper 1 Omnicharge display and control overview omnicharge Charge status bar 12 60 A rough indication of the charging progress 100 m o MB 100 full ready output current bar past me fm 80 full indicates the percen 50 full tage of delivered 50 fel 50 fu C empty output current 25 im 5 float switch When in position O the charger is off When switched to I the charger switches on in normal charging mode When switched to Il the charger operates in forced float mode See chapter 5 for more details on the forced float mode power on charger on forced float charger on or error indicator indicator mode description power
18. y battery output will be equalized as well When this is not desirable please caution disconnect this battery before starting the equalization cycle Since equalization is only allowed for flooded wet lead acid batteries the Omnicharge chargers will only allow this function to be available when the Flooded charging program is selected see chapter 2 Besides this the charger also needs to have a full charge cycle completed and is operating in the Float mode When these two conditions are met the equalization charge mode can be activated by pressing the recessed pushbutton on the bottom side of the charger see installation guide step 4 for 3 seconds until all charge status indicators start flashing The charger will allow a maximum equalization time of 2 hours before it automatically jumps back to Float mode If the specific gravity of each cell does not match the battery manufacturer s specifications yet you can initiate a new 2 hours equalization cycle by pressing the pushbutton for 3 seconds again Always keep on checking the specific gravity of each cell repeatedly during the equalization process When these values are correct you can manually exit the equalization process by pressing the recessed pushbutton once The charger will then return to the Float mode 7 Alarm relay This charger is equipped with a potential free alarm relay This relay will be activated when the charger shuts down and jumps to an error mode as described i
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