to the LITHIUM User Manual for your 1.5kw
Contents
1. Check the temperature at the external thermal sensor If overheated the charger will start the k protection A Incorrect AC Input Voltage Check that the AC input voltage is in accordance with the requirement A External Thermal Sensor Fault Ensure connect the thermal sensor correctly A Communication Interface Fault Make sure the communication have been correctly connected or if it is damaged A Charger Overheated Check if the ambient temperature is too high or the ventilation is smooth A Charger Relay Fault Repair A Charger Itself failure Repair Connection Instruction for Control Interface I Charger s Communication Connector oem eserptiom O 2 GND po 12V 12V internal power supply 12V Load lt 50mA pa LED Red CS LED Green P1312 5 O6 RX Serial Communication Receiver for charger TX Serial Communication Sender for charger II Security Tips 1 Do not allow the lead from any PIN to contact the battery positive or negative 2 Never attempt to connect any two wires from the SP1312 connector that not be connected 3 Applied power supply or load above 50mA to 12V PIN3 is forbidden 4 Internal impedance of PIN1 ENABLE is 10K with allowable range 0 16V Please connect a series resistance of 10 K when controlling by an external 24V supply Refer to manufacturer first III Charger s Connection Instruction for Control Interface TC charger can have CAN communication contr2. Enclosure IP46 a Input 100 240VAC 50 60Hz 14 8 1A The rated input current is 14A at 115VAC and 8 1A at 220VAC b Output 48V 25A 220VAC 48V 24 5A 115VAC The maximum current is 25A at input 220VAC and 24 5A at input 115VAC cc Will add CAN after the model if the charger controlled by CAN module E g TCCH H58V4 25A CAN iii LED Label It is the important symbol to evaluate whether the charger works normally Red Green flash one second a a Disconnected V Common Faults amp Solutions In case of the charging fails please examine all the outside lines carefully to make sure that they are connected correctly If circuits failure have been excluded you can check the failure code of charging LED and handle it according to the following table LED Flashing Sequence One Cycle Indication Wrong Battery Overcharged Battery Overheated RGRG R_ Incorrect AC Input Voltage RGRGR G DONN External Thermal Sensor Fault Le RGRGRGR _ Communication Interface Fault 7 GR Charger Overheated Note 1 R red G green 2 denotes one second pause 3 Above LED flashing sequence is one cycle the LED will flash repeatedly if the fault has not been removed Solutions A Wrong Battery Verify the battery voltage range matching with charger or inspect the battery for damage A Overcharged Confirm the battery capacity and the selected curve are matched or if the battery is defective A Battery Overheated
3. HF PFC 1 5KW Lithium Battery Charger Models Lithium Battery Vout Max lout Max Charger Models TCCH H35 40 TCCH H51 33 TCCH H65 25 TCCH H90 20 TCCH H104 16 104V wii R alata nan ae eae HF PFC On board Charger Lithium Battery Charger Product Summary amp Application Scopes The charger is applicable for various lithium batteries like LiFePO4 LiMn204 etc It features light weight small volume stable performance high efficiency and reliable security etc It can be switched automatically between the floating and balancing charging and also has the protection functions of reverse connection output short circuit and overload and so on The charger is widely used for battery charging cycles in electric vehicles such as electric forklift golf cars electric trucks electric tour bus electric yacht cleaning machines or Uninterruptible Power Supply UPS solar energy wind power dynamo and electric communication system on the railway etc Il Technical Target Mechanical Shock amp Vibration Resistance Level Conformance to SAEJ1378 Standard Environmental Enclosure Operating Temperature 40 C 55 C 104 F 131 TF Storage Temperature 40 C 100 C 104 F 212F Charging Control Via CAN bus or ENABLE Ill Protection Features 1 Thermal Self Protection When the internal temperature of the charger exceeds 75 C the charging current will reduce automatically If it exceeds 85 C the charger will shutdown protec
4. hen the control voltage is reduced under 1 5V the charger returns to the stop mode 2V 5V on ENABLE corresponds linearly to output current from 0 to 100 For example When it is 2V between PIN 1 and PIN 2 maximum output current of the charger is 0 When 3V between them it is 33 of the maximum output current When 4V between them it s 66 of it When above 5V between them it s 100 b If control only of the maximum charging current is required use two resistors R1 R2 to divide voltage and get a fixed DC voltage to ENABLE and the charger operates at the corresponding current Output current is determined by the voltage that divided by resistors It s also possible to use the external relay control or Optical couple control The output capacity of optical couple should be more than 10mA and total value of two resistors should not be less than 1500 Ohms Control Load GN H R1 c If the maximum charging current need to be altered at any time it can be accomplished by changing the voltage between ENALBE and BMS Control Board GND Generally use PWM to drive the optical couple The output of optical couple goes through RC filter and then connect to ENABLE The Schematic below shows another way of altering the voltage between ENABLE and GND using PWM output from the BMS Control Load BMS Control Board maoo ENABLE input pee es 12V internal power supply ad SP1310 P Select PINs 1 2 3 when
5. ing 4 SCHEMATIC Work Mode Diagram of ENABLE Control Option AC Power 120R40 VAC fo Ignition l bro 12V bamer Control Load Battery Protection Board ee BHS Borer with Switching Hode Wand 5 ENABLE CONTROL THREE METHODS vY ENABLE CONTROL method 1 USING RELAY CONTROL The charger provides 12V red and ENABLE black from 7 PIN connector A relay can be connected with BMS according to the Schematic below Charging is controlled by connecting or disconnecting 12V and ENABLE If ENABLE is disconnected charging will cease Upon re connection the charger will recommence charging BMS Control Board ILE Charger Y ENABLE CONTROL method 2 Optical couple Control Alternatively an Optical coupling device can be connected with the BMS according to the Schematic below Charging is controlled by connecting or disconnecting 12V and ENABLE If ENABLE is disconnected charging will cease Upon re connection the charger will recommence charging Control Load Charger Control Board Vv ENABLE CONTROL method 3 USING 2 5V CONTROL a Control of charging current and stop charging can be controlled by altering the DC voltage on ENABLE PIN 1 It is possible to control the the maximum output current from 0 to 100 of the charger maximum capability During the stop mode lt 1 5V if the voltage rises above 2V between ENALBE PIN 1 and GND PIN2 charger will enter into working mode In this working mode w
6. ivery hasis 3 A Standard CAN module with cable length 225mm and the mating connector car PIN 1 connects to CAN L PIN 3 connects to CAN H See below Aps 250k CET CAN 91108 4 TC 619B V3 1 CAN communication module s interface Diagram SFP1310 PT Connection Cable w k A cs e CAN Module i T Ge o oH E j 1H CANL 3 2H CAN H 5 SCHEMATIC Work Mode Diagram of CAN Module Option to Ignition AC Power LAMO WAC hto 12V battery aurea Wih CANDus Interface Control mode No 2 USING THE ENABLE CONTROL 1 Charging process Constant current this current is controllable charging mode is applied first then constant voltage charging when the battery reaches the specified voltage point The voltage does not increases in the constant voltage stage and the charge current will gradually reduce Charging ceases automatically when the current falls to a preset value generally one tenth of maximum charging current If ENABLE signal is removed at any time charging ceases 2 The ENABLE 12V wires can be used to control the charger by an ON OFF signal from a battery management system 3 Alternatively the voltage between ENABLE and GND can be used to linearly control the charger output current When it is above 2V charger commences charging Applying 2 5V can control the maximum output current Below 1 5V the charger will cease charging re applying above 2V will re enable charg
7. ol or ENABLE control modes TCcharger company will configure either before delivery as per customer s requirement Note that the control interface can not be active at the same time in different modes The customer should select the appropriate control mode according to the battery management system BMS type and the battery requirement BMS Category ee Mode of Connection Brief Description BMS with CAN CAN communication Module BMS controls the charging process by the commands Control mode No 1 communication function Model TC 619B V3 1 sent from CANbus Use normally open contacts of relay to control the Relay control charging enable wires Closed Enable Open Disable Battery protector broad or Use optoelectronic coupled devices to control the Optocoupler device control BMS without CAN Control mode No 2 charging enable wires communication function Use 2 5V dividing by resistance controlling the charging 2 5V control enable wires and stop charging and be able to set up the output current from 0 to 100 for the charger Control mode No 1 USING THE CAN COMMUNICATION CONTROL 1 The charger can be controlled by CAN communication when the BMS has functionality The CAN communication module is required TC 619B V3 1 and can be connected with the BMS CANbus 2 The customer should specify CAN communication protocol when ordering Specified CAN ID CAN module type and CAN communication protocol supported are set up before del
8. tively When the internal temperature drops it will resume charging automatically 2 Short circuit Protection When the charger encounters unexpected short circuit it will automatically stop to output When fault removes the charger will re start in 10 seconds 3 Reverse Connection Protection When the battery is polarity reversed the charger will cut off the connection between the internal circuit and the battery and refuses to start It can avoid any destroy 4 Input Low voltage amp Over voltage Protection When the AC input Voltage is lower than 85V or higher than 265V the shutdown protectively and automatically resume working with the voltage is normal again IV Appearance Labels Please check carefully the labels on the casing of the charger before using in order to completing the transaction check the charger before using it can provide some help for you to understand the performance and the specification of the charger i Bar Code Label Attaches on the output terminal of the charger For example SN10071001 ll III 1007 Production batch number 1001 Bar code number 48 25 Hardware model SN1LOO71001 HD VER 1 6 Version number from the manufacturer AR 295 ii Model Label take the model TCCH H58V4 25A for example a ee INDUSTRIAL BATTERY 58 4Vmax CHARGER Input 100 240VAC 50 60Hz 14 8 1A Output 48V 25A 220VAC 48V 24 5A 115VAC Battery LiFePO4 16 cells Model TCCH H58V4 25A Environmental
9. using 2 5V to control Select PINs 1 3 when using Relay and optocoupler to control PIN 1 Black PIN 2 Green _PIN3 Red PIN 1 Black PIN 3 Red
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