Manual - Fullriver Battery
Contents
1. You are now ready to communicate with the QuiQ Charger PART THREE Using the QuiQ Programmer Step 1 Launch the QuiQ Programmer from the Windows Start Menu Click on Start gt Programs gt QuiQ Programmer and then select the QuiQ Programmer item Step 2 Select your COM port Gu Charger is connected to Please select the correct port to use and click OK to continue The latest version of the QuiQ USB Interface Module shows up as a QUIQCOM device Older versions show up as COM devices which are assigned by Windows and detected automatically Step 3 Verify communications with the charger See screen image below The No Charger Detected message indicates that the QuiQ Programmer is unable to communicate with your charger This could be due to one of the following reasons 1 The charger is not connected properly to the PC Check that all wires are connected and not touching each other 2 The wrong communication device is selected Close the QuiQ Programmer and try again with another communication device 3 The charger does not have AC power 4 The QuiQ USB Interface Module driver was not installed correctly KA Oui Programmer 7 Cente Charger Software Yersions Battery Charge Algonthms Q 5 T Default Delete from Charger Folder IC C Program Files DeltaQ QuiQ Programmer sss i isSSCS Files Delta Q QuiQ Program2. not use high pressure Do not use a pressure washer gt e e Ne QUQ Internal Fault This fault indicates that the batteries will not accept charge ZINN ZIN Current or an internal fault has been detected in the charger This fault will nearly always be set within the first 30 seconds of operation If it occurs after the charger has started charging normally be sure to make a note of it e Try to clear the fault by unplugging AC power waiting 30 seconds and reconnecting the AC e Check all battery connections Look for a high resistance connection The most likely reason for this fault is a fault in the battery such as a bad battery connection an open cell or insufficient water e This fault will occur if an internal fuse inside the charger blows If the green wire is shorted to ground even momentarily this fuse will blow To check the fuse measure with an ohmmeter between the green and red wires with the AC disconnected If a short circuit is not measured the fuse has blown Return unit to a service depot to have this fuse replaced e For software revision 0 81 or older this fault may indicate that the input or output voltage went out of range Check input and output connections before returning the unit to a service depot Charger may need to be brought to a service depot to have its software upgraded Refer to the lower right hand corner on the back of the Product Manual to determine the software revision e If this fault
3. problem and return charger chars is OK ote that the interlock i s not functioning and return charger an On oe See IN MOTION Delta Q Technologies Corp Unit 3 5250 Grimmer Street www delta q com T 604 327 8244 delta q Burnaby BC Canada V5H 2H2 info delta q com F 604 327 8246 TECHNOLOGIES QuiQ Programmer User Manual PART ONE Install QuiQ Programmer PART TWO Connecting a QuiQ charger to Software and Drivers your computer Insert the QuiQ Programmer Installation CD After installing the necessary software see into your PC The setup program should above you are ready to connect your QuiQ begin automatically if not run D Setup exe charger to the computer with the QuiQ USB where D is your CD ROM drive Interface Module Follow the instructions on screen to complete Step 1 Disconnect AC power from QuiQ the installation of the software charger eras Step 2 Disconnect QuiQ charger from ees batteries and connect the crocodile clips Interface Module 900 0012 The actual connectors may be different than shown above NOTE For most reliable communications ensure that the bare leads do not touch each other or anything metal Step 3 Connect USB connector to PC Windows automatically installs the correct drivers upon connection If Windows does not recognize the device then you will need to reinstall the drivers see PART ONE above Step 4 Re connect AC power
4. extended for every increment connection must be made using corrosion resistant hardware Incrementing beyond the last Algorithm Table 1 e g a 10 stainless steel machine screw with at least two moves back to the first Algorithm threads of engagement and if required a paint piercing washer After desired Algorithm is displayed touch the charger connector to the battery positive until the output relay is 3 DC Battery Connection Procedure heard to click 10 seconds algorithm is now in permanent memory a The green wire outputs battery voltage when the charger is not Remove AC power from the charger and reconnect the charger positive plugged into AC to provide an interlock function see Fig 1 If connector to the battery pack It is highly recommended to check a newly used a user supplied 1A fast blow external fuse must be changed algorithm by repeating step 4 above installed inline to prevent damage Shorting or drawing more than 1A may damage charger and void the warranty Product warranty is two years please contact dealer of original equipment for warranty b Securely fasten the black ring terminal from the charger to the service negative terminal NEG NEGATIVE of the battery pack Note This is a Class A product In a domestic environment this product may cause radio c Check that the correct charge algorithm is being used refer to interference in which case the user may be required to take adequate me
5. occurs after battery charging has started confirm that AC power was not interrupted and that all battery connections are good e If all battery connections are good an internal fault has been detected and the charger must be brought to a qualified service depot Other Indications Indication Explanation and Solution AC On LED Lit Charger has detected a condition that does not allow it to charge Charger won t start charging Excessive Battery Watering or Strong Sulphur Rotten Egg Smell Difficulty Changing the Default Battery Charge Algorithm e Confirm battery connections are good e The nominal voltage for a lead acid battery is 2 V per cell For example a 48V battery will have 48 2 24 cells e If the battery voltage is greater than 2 5V per cell the charger will not start charging e lf the battery voltage is less than 0 5V per cell the charger will not start e For software revisions 0 81 or lower the charger will not start charging if the battery voltage is less than 1V per cell Refer to the lower right hand corner of the back of the Product Manual to determine the software revision e Check for any fault codes that might be set and refer to the descriptions above e A fully charged battery will draw very little current but will not show 100 charged immediately The charger will change to Absorption mode in under 5 minutes once the conditions for the end of bulk charge have been met The 80 LED will ill
6. QuiQ HF PFC Battery Charger SAVE THESE IMPORTANT AN A SAFETY INSTRUCTIONS This manual contains important safety operating and installation instructions read before using charger Battery Safety Information Warning Use charger only on battery systems with an algorithm selected that is appropriate to the specific battery type Other usage may cause personal injury and damage Lead acid batteries may generate explosive hydrogen gas during normal operation Keep sparks flames and smoking materials away from batteries Provide adequate ventilation during charging Never charge a frozen battery Study all battery manufacturers specific precautions such as recommended rates of charge and removing or not removing cell caps while charging Electrical Safety Information Danger Risk of electric shock Connect charger power cord to an outlet that has been properly installed and grounded in accordance with all local codes and ordinances A grounded outlet is required to reduce risk of electric shock do not use ground adapters or modify plug Do not touch uninsulated portion of output connector or uninsulated battery terminal Disconnect the AC supply before making or breaking the connections to the battery while charging Do not open or disassemble charger Do not operate charger if the AC supply cord is damaged or if the charger has received a sharp blow been dropped or otherwise damaged in any way refer all rep
7. air work to qualified personnel Not for use by children Operating Instructions Always use a grounded outlet When using an extension cord avoid excessive voltage drops by using a grounded 3 wire 12 AWG cord ale 2 Product Manual for QuiQ 912 24xx 36xx 48xx 72xx Unit 3 5250 Grimmer St Burnaby BC Canada V5H 2H2 Tel 604 327 8244 Fax 604 327 8246 www delta q com Q delta q TECHNOLOGIES INFORMATIONS IMPORTANTES DE SECURITE Conserver ces instructions Ce manuel contient des instructions importantes concernant la s curit et le fonctionnement Information de S curit de la Batterie Attention utiliser seulement sur les batteries 72V avec un algorithme appropri au type sp cifique de batterie voire le manuel D autres types de batteries pourraient clater et causer des blessures ou dommages Les batteries peuvent produire des gaz explosives en service normal Ne jamais fumer pres de la batterie et viter toute tincelle ou flame nue a proximit de ces derniers Fournisser la bonne ventilation lors du chargement Ne jamais charger une batterie gel e Prendre connaissance des mesures de precaution sp cifi es par le fabricant de la batterie p ex v rifier sil faut enlever les bouchons des cellules lors du chargement de la batterie et les taux de chargement recommand s Information de S curit lectrique Danger Risque de chocs lectriques Ne pas toucher les parties non isol
8. asures section 4 securely fasten the red ring terminal tothe positive July 2006 Delta Q Technologies Corp All rights reserved PN 710 xxxx Rev 1 V1 16 terminal POS POSITIVE of the battery pack y g p g coe POWER I N MOTION Delta Q Technologies Corp Unit 3 5250 Grimmer Street www delta q com T 604 327 8244 Burnaby BC Canada V5H 2H2 info delta g com F 604 327 8246 QuiQ Charger Troubleshooting Guide Delta Q s QuiQ charger is designed for a long trouble free service life Occasionally the user may encounter abnormal operation which can usually be corrected by following the procedures in this guide Indications on the Charger 10 LED Display LED indications following Power On Self Test Ammeter Solid Displays approximate scale of current Amber TW output during bulk phase a Also indicates algorithm 1 6 for 11 M seconds if no battery is connected iillll IIl Flashing High internal charger temperature om Current output reduced e Provide better airflow to the n charger ill _ e Try to move the charger to a cooler i location Confirm that dirt or mud is not blocking the cooling fins of the charger Clean the charger Rinse charger with low pressure hose if required Do not use high pressure Do not use a pressure washer 80 Charge Solid Bulk charge phase complete 80 Amber charged In Absorption phase Flashing With no battery connec
9. d after interrupting AC power for at least 15 seconds the charger must be brought to a qualified service depot Maintenance Instructions For flooded lead acid batteries regularly check water levels of each battery cell after charging and add distilled water as required to level specified by battery manufacturer Follow the maintenance and safety instructions recommended by the battery manufacturer Make sure charger connections to battery terminals are tight and clean Do not expose charger to oil dirt mud or to direct heavy water spraying when cleaning vehicle See flip side for Product Specifications and Installation Instructions for qualified personnel Specifications DC Output see Operating Instructions QuiQ Model 912 24xx_ 36xx_ Mechanical All models res Voltage nom V 72 Dimensions dn 28 0 X 24 5 x 11 0 cm 11 X 9 7 x 4 3 a O a em a ea a E ee A o O Enclosure IP46 i Battery Type Specific to selected algorithm Operating 30 C to 50 C 22 F to 122P derated Temperature ee eee aove 30 below oT sn Storage Temperature 40 C to 70 G 40 F to 158 F ACi input connector _ 1EC320 C14 require 21 8m localized cord DC output connector OEM specific w 12AWG wire _Reverse Polarity _Electronic protection auto reset Short Circuit Electronic current limit AC Input All models a a ee Frequency Hz 45 65 _ H Current max Arms 12A 104VAC
10. duced to avoid high input currents Models 912 xx0x AC LED and Models 912 xx1x single LED both flash YELLOW If the ambient temperature is too high then the charging power will also be reduced to maintain a maximum internal temperature Models 912 xx0x bargraph flashes and Models 912 xx1x single LED flashes YELLOW When the battery is at approximately 80 state of charge the bulk stage has completed and an gt 80 charge indication is given Models 912 xxOx turn on the 80 LED and Models 912 xx1x will flash its LED GREEN on more than off In the next phase known as the absorption or constant voltage phase the last 20 of charge is then returned to the battery The charging could be terminated at this point if the vehicle requires immediate usage however it is highly recommended to wait until 100 charge indication is given to ensure maximum battery capacity and life A low current finish charge phase is next applied to return and maintain maximum battery capacity Models 912 xx0x will flash the 100 LED When Models 912 xx0x 100 LED or Models 912 xx1x single LED is continuously GREEN the batteries are completely charged The charger may now be unplugged from AC power always pull on plug and not cord to reduce risk of damage to the cord If left plugged in the charger will automatically restart a complete charge cycle if the battery pack voltage drops below a minimum voltage or 30 days has elapsed lf a fault occur
11. e relatively free of oil dirt mud or dust since accumulations within the fins of the charger will reduce their heat dissipating qualities Optimal cooling also occurs when the charger is mounted on a horizontal surface with the fins vertical More airflow from below the charger will help cool the fins so mounting above open areas or areas with cut outs for airflow is desirable Contact Delta Q for information on other mounting orientations a Disconnect Mie CHAGE ost connector from battery pack Apply AC As the charger may get hot in operation the charger must be 43 installed such that risk of contact by people is reduced The Pee and after the LED test the chargers AC plug must be located at least 18 above the floor Agora E will display Or i seconds ground surface and the status display must be visible to the user OTOC ange alg onttim TOUCA postive i connector during the 11 second display 2 Mounting Procedure period to the battery pack s positive J305 DV DT CP Mount the charger by the mounting plate using appropriate terminal for 3 seconds and then remove 6 DEKASG G fasteners i e 1 4 or M6 with locking hardware For UL2202 the Algorithm will advance after 3 compliance a 12AWG green bonding wire with ring terminals seconds Repeat until desired Algorithm must be attached from ti the bonding stud located on the front of the is displayed A 30 second timeout is charger identified by to the vehicle frame The vehicle
12. er waiting 30 seconds and reconnecting AC power To extend Battery Charge Algorithm Change Mode by 30 seconds 120 seconds on newer models connect the charger output to a good battery for approximately 1 second and then disconnect the battery again General Troubleshooting Should the condition of a charger be in doubt the flow chart on the next page should be followed to check the charger s operating condition 19Aprr07 chui delta q com Delta Q Technologies QuiQ Charger Troubleshooting Flow Chart Disconnect charger from batteries and connect to AC Power Does the Charger Turn On No Ensure 90 260VAC at Charger Input Does the No Charger Turn On Yes Vv Check for correct algorithm number refer to manual for procedure Does the algorithm match the batteries No Change algorithm to correct setting for batteries Yes Y Connect charger to batteries and plug charger into AC A Does the Red LED indicate a fault No Is there excessive boiling or other odd behaviour while charging Yes Yes problem z i Refer to troubleshooting guide to try and resolve Charger Input Failure Return Unit No Is the interlock functioning if used Yes If problem persists make note of the
13. es du connecteur de sortie ou les bornes non isol es de la batterie Toujours connecter le chargeur une prise de courant mise la terre Ne pas ouvrir ni desassembler le chargeur referer toute reparations aux personnes qualifi s Pas l usage des enfants The charger will automatically turn on and go through a short LED indicator self test Models 912 xx0x will flash all LED s in an up down sequence and Models 912 xx1x will alternatively flash its LED RED GREEN for two seconds If the charger is connected to battery pack a trickle current will be applied until a minimum voltage is reached If the charger is used in an off board application and the charger is waiting to be plugged into a battery pack the charging algorithm number will be displayed for 11 seconds see Check Change Charging Algorithm before ultimately displaying an under voltage fault fault disappears when plugged into battery pack Once a minimum battery voltage is detected the charger will enter the bulk charging constant current stage Models 912 xx0x will display the current to the battery on the bargraph and Model 912 xx1x will flash its LED GREEN off more than on to indicate lt 80 charge status The length of charge time will vary by how large and how depleted the battery pack is the input voltage the higher the better and ambient temperatures the lower the better If the input AC voltage is low below 104VAC then the charging power will be re
14. he charger voltage If this problem does not clear after the battery voltage is confirmed to be higher than 1V per cell and all connections are good return the charger for service This fault will clear automatically when the low battery voltage problem is rectified Charge Timeout Indicates the battery failed to charge within the allowed time This could occur if the battery is of larger capacity than the algorithm is intended for In unusual cases it could mean charger output is reduced due to high ambient temperature It can also occur if the battery is damaged old or in poor condition Check the battery for damage such as shorted cells and insufficient water Try the charger on a good battery If the same fault occurs on a good battery check the connections on the battery and connection to AC power and AC voltage Confirm that the nominal battery pack voltage is the same as the battery charger voltage If a charger displays this fault on a battery pack and the pack is of questionable status reset the charger by disconnecting AC power for 30 seconds and then reconnect the AC to start a new charge cycle After a few charge cycles this problem could stop occurring as the pack recovers This fault must be cleared manually by unplugging the AC waiting 30 seconds and reconnecting the ac power Check Battery This fault indicates the battery pack could not be trickle charged up to the minimum level required for the normal cha
15. mer Charger Status No eO ieee Algorithms Present Step 4 Update the charger See screen image below To selecting a different charge To delete a charge algorithm from algorithm for charging the charger Select which algorithm you would like Select the algorithm s you want to to set as the default charge algorithm remove from the Charger s list of from the Charger s list of Algorithms Algorithms Present and click the red Present then click the up arrow icon X icon The algorithm s will be The default algorithm will be updated removed from the charger To add a charge algorithm to the charger Select the algorithm s you want to add from the Computer s list of Battery Charge Algorithms and click the right arrow icon The algorithm s will be added to the charger It will take around 1 2 seconds to load Ofr To upgrade the software of the Copyright 2007 Select the version of software you Delta Q Technologies Corp want to add from the Computer s list of Charger Software Versions and click the right arrow icon It will take around 45 seconds to load
16. red anytime during charging a fault indication is given by flashing RED with a code corresponding to the error There are several possible conditions that generate errors Some errors are serious and require human intervention to first resolve the problem and then to reset the charger by interrupting AC power for at least 15 seconds Others may be simply transient and will automatically recover when the fault condition is eliminated To indicate which error occurred a fault indication will flash RED a number of times pause and then repeat 1 FLASH Battery Voltage High auto recover 2 FLASH Battery Voltage Low auto recover 3 FLASH Charge Timeout the charge did not complete in the allowed time This may indicate a problem with the battery pack voltage not attaining the required level or that the charger output was reduced due to high ambient temperatures 4 FLASH Check Battery the battery pack could not be trickle charged up to the minimum level required for the charge to be started This may indicate that one or more cells in the battery pack are shorted or damaged 5 FLASH Over Temperature auto recover Charger has shutdown due to high internal temperature which typically indicates there is not sufficient airflow for cooling see Installation Instructions 1 Charger will restart and charge to completion if temperature comes within accepted limits 6 FLASH QuiQ Fault an internal fault has been detected If Fault 6 is again displaye
17. reduced 20 lt 104V _ EN 60335 1 2 29 baar e AONE oleate cere RANE ONTOS _ Current nominal Arms yr 10A 120VAC 5A 230VAC sae U ee Teasa N aing Sy sient Fauiprient S AC Power Factor 50 98 at nominal input current UL1564 2nd Edition Industrial Battery Charger CSA C22 2 No 107 2 Battery Chargers Industrial Operation FCC Part 15 ICES 003 Unintentional Radiators Class A AC ON acne sis sae ONO YELLOW oaa HED ACIE lt lt EN 55011 Radio disturbance charactenstics Class A k AC LOV meea ASh YELLOW J Flash YELLOW EN 61000 3 2 Limits for harmonic current emissions A Thermal Cutback Flash Bargraph Flash YELLOW EN 61000 3 3 Limits of voltage fluctuations and flicker d lt 80 Charge Indicator Z Short Flash GREEN E gt 80 Charge Indicator __ olid YELLOW Long Flash GREEN EN 61000 4 2 Electrostatic discharge immunity 100 Charge Indicator Solid GREEN Solid GREEN 7 EN 61000 4 3 Radiated radio frequency EMF immunity _ rault Indicator e Flash RED ha Flash RED 7 EN 61000 4 4 1 Electrical fast transient burst immunity PO AMMEIE elea ED Bargraph e EN61000 45 Surge immunity Bat Temp Compensation Automatic een Optional EN 61000 4 6 Conducted Immunity Maintenance Mode Auto restart if V lt 2 1Vpc or 30 days elapse Een ann aaah tCO N nc eee ee ee EN 61000 4 1 1 Voltage variations immunity Installation Instructions AN WARNING The output of chargers with grea
18. rge cycle to be started Check that none of the battery pack connections between modules are reversed or incorrectly connected Check that one or more cells in the battery are not shorted Confirm that the nominal battery pack voltage is the same as the battery charger voltage e Try the charger on a good battery e If this fault occurs the battery pack is likely in poor condition Try to recover the pack with a charger that can charge the individual cells such as an automotive charger Be sure to set this charger to the appropriate voltage 6V per 6V battery 12V per 12V string battery Ne eee Over Temperature This fault indicates the charger has become too hot during lt I gt 71S 7 s 1S operation This extra fault indication as opposed to the flashing ammeter described M above indicates an even higher temperature was reached inside the charger Though not damaging to the charger charge time will be extended significantly e This fault indication will not clear automatically but the charger will restart charging automatically when the temperature drops The fault indication must be cleared manually by unplugging the AC power waiting 30 seconds and reconnecting the AC e f possible install the charger in a cooler location or increase cooling air flow to the cooling fins e Confirm that dirt or mud is not blocking the cooling fins of the charger If required clean the charger by rinsing it with a low pressure hose Do
19. ted indicates algorithm selected by number of flashes 100 Charge Solid Charging complete Charger in Green Maintenance Mode Flashing Absorption phase complete In Finish phase AC On Solid AC Power good Amber a Flashing Low AC Voltage check voltage and extension cord length max 100 12 AWG or 50 14 AWG Fault Flashing Charger error Check code and refer to Red JA troubleshooting guide below Fault Indications Fault LED Flashes Red Xl LN SI ZIN Ny 7 N Vy ATS Ny 7 N Ny IN OLA ITN SI ZN Explanation and Solution High Battery Voltage Detected Check that the battery charger voltage is consistent with the battery pack voltage The first two digits of the four digit model name indicate the battery voltage the charger supports Check for wiring errors High battery voltage could also occur if there is another source charging the battery Disconnect any other sources during charging If this problem does not clear after the battery voltage is confirmed to be less than 2 4V per cell return the charger for service This fault will automatically clear and the charger will restart charging when this problem is removed Low Battery Voltage Detected Check the battery and connections to the battery Check the nominal battery voltage The first two digits of the four digit model name indicate the battery voltage the charger supports Confirm that a nominal battery voltage is the same as t
20. ter than 48V may Charger Interlock pose an energy and or shock hazard under normal use These Internal NO B units must be installed in the host equipment in such a Output O manner that the output cable and battery connections are B only accessible with the use of a tool by qualified personnel BLK WHT Figure 1 4 Check Change Charging Algorithm The charger comes pre loaded with algorithms for batteries as detailed in Table 1 If your specific battery model is not listed please contact Delta Q Each time AC power is applied with the battery pack NOT connected the charger enters an algorithm select display mode for approximately 11 seconds During this time the current Algorithm is indicated on the 80 LED Models 912 xx0x or on the single LED Models 912 xx1x A single digit Algorithm is indicated by the number of blinks separated by a pause A two digit Algorithm is indicated by the number of blinks for the first digit followed by a short pause then the number of blinks for the second digit followed by a longer pause To check change the charging algorithm pJ Battery Type 1 Determine Mounting Location While its sealed nature allows the charger to be mounted virtually anywhere the choice of mounting location and orientation is extremely important For optimum performance and shortest charge times mount the charger in an area with adequate ventilation The charger should also be mounted in an area that will b
21. uminate at this time During the final phase of charging the battery will only accept a very small current the charger is unable to accelerate this portion of the charge cycle without damaging the battery Overcharging or high battery temperature These symptoms are unlikely to be caused by too high a charge current since the maximum charge current of the charger will be small compared to even a moderately sized battery pack The most likely cause for this problem is incorrect charge algorithm setting and or high ambient temperatures e Confirm that the battery pack is not too small usually gt 50Ah e Confirm that the nominal battery voltage matches the charger output voltage e Confirm the correct battery charge algorithm If the battery pack is new the algorithm will need to be changed if the pack is not the same as the old one Refer to the Product Manual for instructions on how to determine and change the battery charge algorithm e If the output voltage of the charger seems excessive return the charger for service Contact Delta Q to get the expected battery voltage settings for the charger in question Be sure to have the charger s serial number and charge algorithm setting available when calling The mode to change the battery charge algorithm can only be selected during the first 10 seconds of operation Refer to the Product Manual for instructions If the 10 second window is missed cycle AC power by unplugging the charg
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