USER`S MANUAL
Contents
1. Connect the battery to a IGBT charger the Battery Recognition mode must be set to BATTERY ID MODULE or AUTOMATIC The IGBT 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 e 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 27 34 V F70 January 2011 CHARGEUR IGBT User s Manual PROGRAMMING 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 belo2. Charge completed successfully Termination by maximum time limit during the Constant Voltage phase 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 26 Charge stopped manually during the constant voltage phase 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 Page 31 34 V F70 January 2011 CHARGEUR IGBT User s Manual 31 The battery has been disconnected during the first part of the charge before 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 34 The battery has been disconnected during the finishing charge 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 B
3. V F70 January 2011 CHARGEUR IGBT User s Manual MONTREAL CHARGEUR CHARGEUR IGBT USER S MANUAL Software Revision ver vF70 January 2011 www montrealchargeur com www doctorfleet com Page 1 34 V F70 January 2011 CHARGEUR IGBT 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 equi
4. in order to compensate the effect of the temperature of the electrolyte In order to activate this function it s sufficient to reduce the gassing voltage below 2 35 V cell In this case the message TEMP COMPENSAT will appear GASSING VOLTAGE TEMP COMPENSAT PARAMETER 7 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 error message is given PARAMETER 8 MAXIMUM TEMPERATURE Programmable values from 115 to 160 F or DISABLED Default value 140 F NOTES This parameter sets a maximum limit for the battery temperature If this limit is reached the charge is terminated and a specific error message is given This functionality requires the connection of an optional temperature probe Page 14 34 V F70 January 2011 CHARGEUR IGBT User s Manual PARAMETER 9 EQUALIZE DURATION Programmable values from 1 to 8 hours Default value 6 hours NOTES This parameter allows to adjust the duration of the weekly Equalize cycle In most of the cases the default value of 6 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 13 and 14 If the Equalize t
5. with the purpose of avoiding useless gassing of the battery during the opportunity charging cycles and to program a daily full charge of the battery PARAMETER 13 and 14 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 EO BEGIN TIME SAT 12 00 EO END TIME MON 03 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 PARAMETER 15 DISPLAY CONTRAST Programmable values From 10 to 100 Default value 90 NOTES This parameter sets the display contrast It can be modified in order to improve the visibility when the intensity of the ambient lighting changes Page 16 34 V F70 January 2011 CHARGEUR IGBT User s Manual PARAMETER 16 BATTERY RECOGNITION MODE Programmable values VOLTAGE DRIVEN BATTERY ID MODULE AUTOMATIC Default value VOLTAGE DRIVEN BATT INDENTIFIC VOLTAGE DRIVEN NOTES This parameter sets the method that the charger uses for the identification of the battery The VOLTAGE DRIVEN mode is based exclusively on the battery voltage at the moment of the connection to the charger The BATTERY ID MODULE mode is based exclusively on the presence of a battery ID module that stores the battery Type Voltage Capacity a
6. 5 seconds CHARGE CYCLE When the preliminary controls are complete the charge starts automatically and the display visualizes the following information Battery Voltage Volt e Charging Current Amps Time of Charge hours minutes Capacity Returned Ah The IGBT Charger performs an IEI charge cycle and the management of the charging curve is totally automatic Depending on the programming of the Full Charge time window Parameter 12 when the battery reaches the 100 state of charge the charger may suspend the charge opportunity charge cycle In this situation the display visualizes the message DELAYED FULLCH 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 time window While the charge is in progress it s always possible to scroll between different menu pages using the buttons UP DOWN Page 20 34 V F70 January 2011 CHARGEUR IGBT User s Manual e CHARGE STATE o Identifies the position in the charge curve with reference to the picture blow e TEMPERATURE o WVisualizes the temperature of the battery if the optional probe is connected HISTORY LOG o Visualizes the history log of the previous charge cycles Refer to Paragraph 6 History Log EMERGENCY STOP If the battery doesn t reach the gassing voltage within a predefined time limit the charger will suspend the charge and it w
7. TION AUTOMATIC START Once the battery has been recognized depending on the programmed start time window Parameter 11 the charger may enter in stand by mode and the display visualizes the message DELAYED START hh mm A gt hh mm B Where hh mm A represents the clock 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 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 IIi If this message appears it s recommended to verify that the nominal battery voltage matches the nominal voltage of the charger Page 19 34 V F70 January 2011 CHARGEUR IGBT User s Manual 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 111 If this message appears it s recommended to verify that the nominal battery voltage matches the nominal voltage of the charger Probably a wrong or damaged 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 possible to start the charge manually by pushing the button DOWN for
8. The charging curve of the IGBT charger is based on the IEI or IUIa system but instead of applying a pre defined charge curve to the battery the charger calculates all the parameters Currents Voltage Limits Maximum Times according with the Battery Data and the User programming Moreover the curve is dynamically adjusted while the charge is in progress depending on the real status of the battery The IGBT Charger is suitable for Conventional and Opportunity charging applications It s equipped with a 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 The IGBT Charger saves the results of the last 50 charge in the built in data logger In addition it s possible to connect the charger to the DoctorFleet com Fleet Management System which allows to monitor the complete fleet through a WEB based interface and to send automatic messages reports by email CURRENT VOLTAGE START CURRENT GASSING VOLTAGE IUla CHARGE CURVE EQUAL MAINTENANCE REFRESH _qoq Page 6 34 MONTREAL User s Manual ionen V F70 January 2011 CHARGEUR IGBT CHARGEUR 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 i
9. The it will visualize the standard charging parameters Page 29 34 V F70 January 2011 CHARGEUR IGBT User s Manual 9 CHARGE TERMINATION CODES CHARGE TERMINATION CODES GROUP 1 CHARGE COMPLETED 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 because battery was disconnected while the Equalize was in progress 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 Page 30 34 V F70 January 2011 CHARGEUR IGBT User s Manual 10 Gassing voltage reached successfully Full charge NOT executed because time window Disabled 12 Charge completed successfully Equalize completed successfully 13 Charge completed successfully Termination by maximum time dV dt not reached 14
10. attery 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 41 Battery disconnected during the preparation of the cycle Charge never started 42 Battery disconnected during the calculation of the cycle Charge never started 43 Battery disconnected during the initial identification sequence Charge never started 44 Battery disconnected during the constant voltage phase Page 32 34 V F70 January 2011 CHARGEUR IGBT User s Manual 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 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 66 Emergency Stop Maximum Current Limit Exceeded 67 Emergency Stop Maximum voltage exceeded during the refresh cyc
11. e that is supported by the charger it s possible to set the TYPE CAPACITY and desired START CURRENT For each supported battery voltage the display shows this setup page Battery Voltage Battery Type Capacity Start Current Start Rate It s possible to scroll between each battery voltage using the buttons UP DOWN The fields identified by the BLUE labels Type Capacity Start Current are editable while the fields identified by the RED labels are NOT editable as the battery voltage is fixed and the Start Rate is automatically calculated as percent of Current over Capacity A 100AH Programmable values TYPE FL Flooded Lead Acid GE Gel Cell AG AGM NN Type Unknown CAPACITY From 5 to 2500 Ah START CURRENT From 2A to the maximum supported by the charger NOTES The values programmed in these setup pages will be used when the charger recognizes the batteries automatically using the VOLTAGE DRIVEN MODE see next pages If the battery is equipped with Battery Identification module only the programmed START RATE value will be used Page 12 34 V F70 January 2011 CHARGEUR IGBT User s Manual EXAMPLE SETTINGS Battery A Lead Acid type 12 cells 24 V nominal 600 Ah Start Current 100A C 600Ah 16A 100Ah C 1000Ah 25A 100Ah In this example when batteries with nominal voltages 24 V or 36 V will be connected to the charger they will be always recognized as type A or t
12. ill 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 The IGBT charger adjusts the maximum time limits automatically depending on the battery capacity and the programmed charge current This function is important to provide the maximum protection for the battery in any type of application 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 21 34 V F70 January 2011 CHARGEUR IGBT User s Manual REVERSE POLARITY PROTECTION The IGBT chargers are equipped with an active protection against the connection of batteries with Reverse Polarity If a battery with reverse polarity is connected the charger remains in a safe Stand By mode DESULPHATION The charger shuts down automatically when the charge is correctly complete and it will visualize the message CHARGE COMPLETE At this time it s possible to disconnect the battery EQUALIZATION CYCLE At the end of the charge if the battery is left connected to the charger for a sufficient time the charger activa
13. ime window is not set or it s set too short the battery will not receive a sufficient Equalize PARAMETER 10 DATE and TIME Programmable values Month Day Year Hour Minutes Default value Eastern Time 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 The Charger calculates the Day of the Week automatically however it s necessary to adjust the Clock manually in Daylight saving time periods PARAMETER 11 START TIME WINDOW Programmable values From 00 00 to 23 59 Default value From 00 00 to 23 59 START BEG lt gt END OOTO a NOTES This parameter sets a time window during the day in which the charger is allowed to start a new charge cycle If a 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 Page 15 34 V F70 January 2011 CHARGEUR IGBT User s Manual PARAMETER 12 FULL CHARGE TIME WINDOW Programmable values From 00 00 to 23 59 Default value From 00 00 to 23 59 FULLCH BEG END 00r 00T 23 59 NOTES This parameter sets a time window during the day in which the charger is allowed to fully charge the battery and to let the battery go through the gassing overcharge process Usually this parameter is used in opportunity charging applications
14. in the following table while customized models are available on request MODEL VOLTAGE CURRENT from 12 to from 0 to IGBT 7 48 120 IGBT 11 48 200 IGBT 9 80 120 IGBT 13 80 200 IGBT 18 48 300 The control panel is complete and easy to use four coloured LEDs indicate the state of the charge while a 2x20 character dot matrix display gives complete information and error messages in plain text multilingual A three button flat membrane keyboard is used for programming and data review A unique feature of the IGBT charger is the automatic recognition of the battery This functionality can operate in three different modes it can recognize the batteries by voltage it can use optional battery identification modules or it can use a combination of the two systems For each battery the user can program the TYPE Flooded Lead Acid GEL AGM the CAPACITY from 5Ah to 2500Ah and the desired charging current The GBT charger calculates automatically the ideal charge curve for the given parameters Page 5 34 V F70 January 2011 CHARGEUR IGBT User s Manual While the programming and operation of the IGBT CHARGER can be done using a simplified and automatic form expert users have the possibility to adjust the charge parameters and options without limits Gassing Voltage Temperature Limits Equalization Mode Refresh Mode Language and much more
15. l Code PROGRAMMATION 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 MONTREAL CHARGER CHARGEUR IGBT Page 9 34 V F70 January 2011 CHARGEUR IGBT User s Manual SYSTEM CHECK PLEASE WAIT SYSTEM READY MAX XXX V XXX A SYSTEM READY DATE TIME Page 10 34 V F70 January 2011 CHARGEUR IGBT User s Manual USER PROGRAMMING MODE HOW TO ACTIVATE USER PROGRAMMING MODE Press the button DOWN and keep it pressed for 3 seconds The display will show the message EDIT PASSWORD Enter the Programming Password The display will show the message MOD SETTING HOW TO MODIFY A VALUE Scroll between the programmable values using the UP DOWN buttons 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 Modify the value using the UP DOWN buttons 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 Press the buttons UP and DOWN simultaneously Page 11 34 V F70 January 2011 CHARGEUR IGBT User s Manual PARAMETERS 1 2 3 4 5 BATTERY INFORMATION For each battery voltag
16. le 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 Page 33 34 V F70 January 2011 CHARGEUR IGBT User s Manual 73 Emergency Stop The charger was not able to keep the battery at constant voltage 74 Emergengy Stop Battery temperature exceeded maximum programmed value during the constant voltage phase 75 Emergengy Stop Wrong Unknown Battery 76 Emergency Stop Maximum temperature exceeded during desulphation GROUP 5 WARNING MESSAGES 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 86 Battery temperature probe malfunction 96 Battery voltage anonymous at the connection After 1 hour scale voltage to minus battery 97 Battery voltage anonymous at the connection Complete fast charging cycle at low current 98 Battery voltage out of range at the connection Recognition driven by voltage may not work correctly 99 Black out of the AC input www montrealchargeur com www doctorfleet com End of Manual Page 34 34
17. nd ID number In this operating mode if the battery ID module is absent the charger will not charge the battery The AUTOMATIC mode allows to combine the two modes When the battery is connected the charger tries to establish a wireless connection with the WBM Wireless Battery Module If the ID module is found the charger proceeds and it uses the information stored in the module for the calculation of the charging cycle If the ID module is NOT found within 5 minutes the charger recognizes the battery using the VOLTAGE DRIVEN mode then it uses the default Battery information that have been programmed Parameters 1 to 5 PARAMETER 17 WIRED NET TEST WIRELESS LOCAL USB NOTES This is an advanced function described on the IGBT CHARGER ADVANCED PROGRAMMING MANUAL It s used when the charger is equipped with a Communication Card to the fleet management system DoctorFleet com or when it s equipped with an Expanded Data Logger Card with USB connection Page 17 34 V F70 January 2011 CHARGEUR IGBT User s Manual 5 OPERATION CONNECTION OF THE BATTERY AND AUTOMATIC RECOGNITION 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 RECOGNITION WITH BATTERY ID MODULE OPTIONAL If the Battery Recognition mode is set to BATTERY ID MODULE or AUTOMATIC the charger will attemp
18. ng that is metallic on top of any battery To prevent arcing and burning of 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 34 V F70 January 2011 CHARGEUR IGBT User s Manual 2 DESCRIPTION The IGBT Charger is a series of battery chargers that are based on a new Hybrid power conversion system The two parts that are combined together to compose this Hybrid system are e Special isolation transformer with line frequency multiplication system High frequency switchmode converter based on IGBT technology This system offers very high electrical efficiency near unity power factor and very low output current ripple moreover it features a real universal charging capability multi voltage multi current multi application The electrical structure of
19. njuries 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 charger 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 CAUTION 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 7 34 V F70 January 2011 CHARGEUR IGBT User s Manual GROUNDING AND LINE CONNECTION WARNING The cabinet 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 conduct
20. of the most recent history log that will have a format of this type O1 24 0V 31 3V 2009 06 01 10 30 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 pages Use the UP DOWN buttons to scroll between each record PAGE A ALWAYS VISUALIZED No VSTART STOR 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 25 34 V F70 January 2011 CHARGEUR IGBT User s Manual Where Where BATT oo TYPE VOLTAGE CAP 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 TC HH MM AHRET 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 26 34 V F70 January 2011 CHARGEUR IGBT User s Manual 7 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
21. or 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 PROCEDURE e Read on the data label the AC current value corresponding to the line voltage to which charger is to be connected Using that current value select the proper fuses disconnect switch and power cable sizes according with any applicable national or local code e Check that the charger is disconnected from AC input and battery e Open the cabinet e Mount the input cable and connect the four power conductors three phase ground to the terminal blocks e Close the cabinet e With disconnect switch on AC input power line on position OFF or OPEN connect the power cable coming from the charger to the switch and then install the fuses in the switch Page 8 34 V F70 January 2011 CHARGEUR IGBT User s Manual IGBT CHARGE CONTROLLER Charging 80 Charged Complete Equalize a Fault Alarm _________ 98 Manual STOP amp RESTART a Enter PROGRAMMING MODE Enter BATTERY RECOVERY MODE PRELIMINARY CHECKS 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 loca
22. pment Check the data label for voltage and phase requirements If only 3 phase power 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 capacitor
23. r local dealer for more information Page 23 34 V F70 January 2011 CHARGEUR IGBT User s Manual REFRESH MAINTENANCE This function is useful 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 xx x V R END NR xxx Ah x L Battery Voltage Volt Nrof Refresh cycles already given to the battery Total Time of Charge hours minutes Total Capacity Returned Ah During cycle Refresh the display shows the same set of information that are visualized during the normal charge cycle Page 24 34 V F70 January 2011 CHARGEUR IGBT User s Manual 6 HISTORY LOG The internal memory of the IGBT charger contains a log of the last 200 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
24. s and if there is any voltage reading wait 5 minutes before to proceed Keep inside 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 34 V F70 January 2011 CHARGEUR IGBT 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 anythi
25. t to establish a wireless connection with the ID module And the display will visualize the message SEARCHING BATT ID MODULE 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 transferred to the charger and are visualized on the display and the charger is now ready to start NOTES The first time that a battery ID module is installed on a battery it has to be initialized and programmed Please refer to Paragraph 7 PROGRAMMING BATTERY ID MODULES VOLTAGE DRIVEN BATTERY RECOGNITION If the Battery Recognition mode is set to VOLTAGE DRIVEN the display will show the message BATTERY RECOGNITION Page 18 34 V F70 January 2011 CHARGEUR IGBT User s Manual At this point the battery information are transferred to the charger and are visualized on the display and the charger is now ready to start If the battery voltage cannot be recognized the charger shows the message BATT ANONYMOUS PLEASE WAIT In this condition the charger will wait the battery voltage stabilize and will retry the automatic recognition If the battery voltage is particularly low due to sulphation or overdischarge it s possible to activate a DESULPHATATION RECOVERY cycle by pushing the button ENTER for 5 seconds Please refer to Paragraph 8 BATTERY DESULPHA
26. tes 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 EQUALIZATION CYCLE MANUAL ACTIVATION 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 Page 22 34 V F70 January 2011 CHARGEUR IGBT 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 ANTI ARCING PROTECTION The IGBT charger is equipped with a built in Anti Arcing protection In order to activate this function it s necessary to add an optional wire loop using a battery connector equipped with Auxiliary Pins Contact you
27. the IGBT charger is represented in the following block diagram Transformer Rectifier Chopper Battery AC Input IGBT PWM Control Charge Data Processor Data User Logger Interface Charge Program Memory The TRANSFORMER reduces the AC input voltage and provides electrical insulation between the input and the output of the charger The RECTIFIER converts the AC output of the transformer to an unregulated DC voltage The CHOPPER operating at high frequency regulates the output voltage and current to the desired values It generates a perfectly constant output current with negligible ripple The IGBT CHARGE CONTROLLER is the main control unit of the IGBT Charger Page 4 34 V F70 January 2011 CHARGEUR IGBT User s Manual It s a microprocessor based electronic board and it contains the USER INTERFACE Display LEDs and Keyboard the CHARGE PROGRAM MEMORY where all the programmed parameters are saved the DATA LOGGER where the charge history is saved and the CHARGE DATA PROCESSOR which manages the entire charge process The POWER REGULATION BOARD controls the operation of all the power components It receives command signals from the IGBT CHARGE CONTROLLER and it generates the high frequency PWM control signal that drives the IGBT regulator The IGBT chargers are available in a variety of models with singlephase or threephase input The standard models are listed
28. w it is important that the cables are not overlapping or entwined in the cables of another battery A BY 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 28 34 V F70 January 2011 CHARGEUR IGBT User s Manual 8 BATTERY DESULPHATION The Battery Desulphation Recovery function is useful when batteries are overdischarged or they have been left unused for a long time The Desulphation Recovery cycle can be activated at any moment while a battery is connected by pushing the button ENTER and keeping it pressed for 3 seconds The display will show the message BATTERY DESULPHATATION At this point using the UP DOWN buttons it s possible to edit the battery desulphation parameters Desulphation Time o From 1 to 30 hours Desulphation Current o From 5 to 99 of the maximum output current of the charger Restart Mode o MANUAL After the desulphation the charger will stop o AUTO After the desulphation the charger will attempt to begin a full charge cycle Once all the parameters are set correctly push the buttons UP DOWN Simultaneously in order to start the Desulphation cycle The display will show the message STARTING DESULPHATATION
29. ype B using the VOLTAGE DRIVEN recognition mode If batteries with nominal voltages of 24 V or 36 V equipped with Battery Identification Modules will be connected to the charger the charger will receive all the information about the battery directly from the Battery Identification Module In this case the battery will be charged using the same start rate A 100Ah that has been set for the same voltage For example if a third type of battery GEL 12 cells 24 V nominal 200 Ah equipped with with Battery Identification Module will be connected it will receive a start rate of 32A correspondent to 16A 100Ah while all the other charge parameters will be calculated automatically by the charger based on the battery type and capacity Page 13 34 V F70 January 2011 CHARGEUR IGBT User s Manual PARAMETER 6 GASSING VOLTAGE Programmable values from 2 35 to 2 50 V Cell or TEMPERATURE COMPENSATED Default value 2 40 V cell GASSING VOLTAGE 2 40 V el NOTES The charging algorithm of the IGBT 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 When a battery temperature probe optional is used the charger can calculate the gassing voltage dynamically
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