Infocharger(ICC & ICH)
Contents
1. DC LEAKAGE In the event of error Total alarm Vin out of limit Vbat OUL Vload OUL relays become unenergized and other relays become active 19 8 Maintenance The Infocharger unit does not need maintenance If you want to make cleaning on the unit than you should perform the following Disconnect the loads Bring all the fuses on the unit to 0 position Wait for capacities to discharge for 10 minutes Clean the unit with a slightly moistened cloth IN Do not drop any liquid and solid foreign substance inside the unit Do not use a cleaning powder or any other material that may damage the plastic parts 20 9 Trouble Shouting In this section procedures that should be followed are explained during an abnormal condition of the unit Before you inform the technical service read and apply carefully things explained in detail in this section If the fault led on front panel is on then go to the main menu on front panel and check what the fault is If the LEDs on front panel are all off please check input fuses If you can read the battery and load voltage on front panel but can not measure the same voltage at battery and load then check the battery and load fuses If there is an over temperature failure please check the ventilator if it is running If there is a problem with the batteries boiling or over heating please check the battery charge current and volta2. sseesesseessssesssseeeseseessseeessseeeseseesssseeesseeessseeeseseeesseeessseeeseseeeseo 10 Ath1 System Switch ON REAA 4th2 System Switch OFF Operating Ins tructiOns i iessessseesassecsesessesnncosecadesensvonagsasssvessevncatgeassedesegeasteeasseaesonaessecedssoveseadessagansees 1 Shl i Wit OPeratl ssop E ERTO E ERT EE ETVE EE OCR ECEN C RT CR ONE ERROR 11 Sth Operation m des sreo nen o nOA EEE 11 5th2 Displays a12 5th2 1 1 LCD Display 2512 5th2 1 2 MENU STRUCTURE u 0s000scesscnssensenscensensseneenssensunssensunssens nnsensenesunseneeuneenseunsnneensnnsennsensssnsnnsesassnssnsennsennesussensedsee 13 CAEL EDS BUMS Un nn ee ee 15 There are mainly four buttons in the front panel The functionalities of the buttons are given below sssssssss 15 Operating Procedures for Parallel Systems Optional zsssssssssssnnnnsnnsssnsnsnsnnnnnnnnnssnnnnnnsnnnnnnnsnnnnnn 17 Optional Modules zeeeeeesssnssssnsnnsssnnsensssnnsnnsnnnsnnsnnnnsnnssnnsnnnsnnsssnsnnnssnnsnssssnnsnsssnnssnsssnnsnssssnnsnssssnssssssensnnn 19 Maintenance ccsecccccsssssecessreeeeessecesesseeeecesseseccnseeeeesseeecceseeeceeseeeeeesseeeecessesecenseesesesseseceensesecesseeeeeeneeees 20 Trouble Shouting iome eap aeron ean Nanon Ke A r ENNE a S EESOTSAS 21 Technical Specifications uuussssssuusssnnnnnsssnsnnnsnsnnnnnnnsnnnsnssnnnnsnssnnnsnsssnnnsnsssnnnsnssnnnssnsssnnsssssnnnsssssnnssnsnnen 22 Block Did grams si u aaa bea sisb ecb sens tuse
3. If needed to move the battery charger it is obligatory to pack the unit It is suggested to keep the original packing 3rd2 Storage Please store the battery charger in an environment where the temperature is between 15 C and 70 C no receipt of direct sunlight far from the heating in a dry place Environmental humidity must be between 20 and 95 non condensing 3rd3 Positioning Infocharger and battery cabinet if any have to be positioned in an environment No direct sun access Must be dry Par from the heating equipments No excessive dust Well ventilated In order to maintain adequate ventilation of Infocharger and battery cabinets if any ensure the air vents are not blocked and leave at least 20 cm space at the rear side of the unit for ventilation nN 3rd4 Connections Connections must be done by authorized technical service staff Life risk for user Temperature changes such as from cold to hot environment can cause condensation It is dangerous to operate the Infocharger Please wait at least two hours before making the connections Connection terminals are on the front side of ICC models and on rear side of ICH models Please take out the cover of the rear side to make the connections Standard Infocharger connections are shown below ICC Models Load L Gray Ground Yellow Green Battery L Gray Input Phase Gray Load L Blue Input Neutral Blue Battery L Blue
4. 2 System Description DC Power Supply Operation Mode If the equipment is being ordered as DC Power Supply then the unit supplies a limited voltage and current value that is adjusted from the front panel to the connected DC load The output voltage and current limits can be easily adjusted separately from the SETTINGS menu on the LCD panel Battery Charger Operation Mode The equipment that is ordered as battery charger has the following specifications This operation mode has 4 grades charging level depending on the battery type These are initial charge float charge boost charge and temperature or auto controlled charging types The charge voltages per cell are for initial charge 2 04V for float charge 2 23V for boost charge 2 375V for temperature controlled charge 2 17V at 0 C 2 29V at 50 C These values are factory set but only temperature controlled charging values can be set from front panel according to the battery type LVD Low Voltage Disconnector is available as an option This function protects the batteries from deep discharge by disconnecting them from output during battery mode when the mains is absent Additionally the optional dry contact alarm card provides automation functionality to the device AC INPUT OUTPUT EMI EMI DC FILTER BETEN a OPTIONAL ICC SYSTEM BLOCK DIAGRAM AC INPUT ICH SYSTEM BLOCK DIAGRAM Input EMI filters Optional These filters prevent electrom
5. ICC BLOCK DIAGRAM zu zum ZISLAXYVSI LV TIOd OF A muse O TIO I LYT 410d OF I Lyi TIOd 91 I ADI DTIC TA ASFITITNO A NFO TEMO Q VOT TORLNOS NIVI 25 ICH BLOCK DIAGRAMS 1 PHASE BLOCK DIAGRAM 26 3 PHASE BLOCK DIAGRAM 27
6. Infocharger ICC amp ICH DC POWER SUPPLY BATTERY CHARGER Important Notices Thank you for choosing this charger system This product can be used for both battery charger and DC power supply applications C For the staff and equipment safety it is necessary for the users to fully read and save this manual before working on this equipment Description of the Symbols Se IMPORTANT NOTICE Please follow the instructions AN LIFE RISK Please follow the instructions N DANGER Please follow the instructions otherwise the unit can be damaged or user can be hurt 3 os on A 1 3rd1 Handling BAD Storage asus AE EEEE E 3143 Positioningzau r ensisesesun se na 6 3144 COMMCCHONS oies esevecaicscuysesasevasvecssveadsevsvaiescevvisdectsvessceeva sovacexesuscweuls ETER EEEE SRE EAS Se E RESPE EAEE RA S EAEE E eerie I 3rd4 1 Ground Earth Connection unssesensensnsenensenensenennensnnenennenennenennensnnenensensnsensnsensnnensnsensnsensnsensnsensnsensnsensnnensnsensnnens 9 3td4 2 Input cOnmect Onis siscedesecccasseisecadscsastedestdetedesasstadadasesedecisesadestiavugeansastdednceadadasadatastiavedestoesacedasaijatasesedecasedugansntudes 9 Std 4 3 Battery CONMECHON sessevercessesasceastccesssebessteavvsesatesvertasevecusbetcbesssitavetessbtsetedessctsesstseusaebeberesttesstessbuspietonuerdassredebueseteres 9 Std 4 4 Output CoA e UO asp e ra EE nike En trans utes ERDE 9 Switch ON and Switch OFF procedures
7. 3 Allswitches should be in OFF 0 position 4 Switch on DC units Note DC units are factory parallel configured 5 After allDC units starts operating in parallel on the LCD panel MS master and Sx x defines no of slave unit messages should be observed 18 7 Optional Modules There are mainly two optional modules for the Infocharger These are 1 LVD Module This module prevents the loads and batteries to be deeply discharged A relay is used for the separation of the batteries from the load This relay is on B side The voltage level of this separation process can be chosen on the control panel This voltage level can not be less than 1 65V which is the minimum voltage level per cell 2 Relay Module This module is designed for the automation processes and has 9 relay output These are as follows a TOTAL ALARM Total Alarm b CUR LIM Operating within the current limit c FAN FAILURE FAN FAILUE Available only on ICC d TEMP HIGH Ventilator temperature is out of limit e WLOAD OUL Load voltage is out of limit f VBAT OUL Battery voltage is out of limit g VIN OUL Mains voltage is out of limit h DC LEAKAGE Leakage current to the earth at output string i DC LEAKAGE Leakage current to the earth at output string 1 i R20 R21 X403 INF561 Y59 M475 1 01 3 O OX O VIN OUT O LIMI UBAT DU K ULOAD OUL K6 TEMP RIGH K5 AN FAILU K3 CUR LIM Poe TOTAL ALARM
8. NORMAL Max Charge Time Low Voltage Charge Step 16 6 Operating Procedures for Parallel Systems Optional Infocharger can be purchased with parallel option for supplying the very critical load to increase the reliability Maximum 7 identical power and specification Infocharger can be connected in parallel Procedure for Commissioning and Start Up First Installation 1 The AC inputs of all units in the parallel system are connected to the same mains and all the DC outputs are connected to each other The critical load and batteries are connected to the common output of the parallel system Ph InfoCharger 1 InfoCharger 2 OUTPUT CONNECTION OF PARALLEL CHARGER SYSTEMS 2 There ate also some signal cable connections between the charger units necessary for parallel operation The Communication of parallel systems is made according to communication protocol Before starting up the DC units make the connection of communication cables between units as per below diagram 17 COMMUNICATION CABLE CONNECTION BETWEEN PARALLEL CHARGERS CAUTION Do not remove the communication cables between the Chargers during parallel operation In case this communication cable is removed or damaged during parallel operation and the communication is lost then the slave DC unit which cannot communicate with the master DC unit shall still supply the load at float mode It shall not receive any further commands from Master unit
9. 1 PHASE INPUT Battery connection terminal is available with LVD option ICH Models Load L Gray Ground Yellow Green Battery L Gray Input Ph G nput Phase Gray Load L Blue Input Neutral Blue Battery L Blue 1 PHASE INPUT Ground Yellow Green Load L Gray Input R Phase Gray Input S Phase Gray Input T Phase Gray Input Neutral Blue Battery L Gray Load L Blue Battery L Blue 3 PHASE INPUT Battery connection terminal is available with LVD option Please follow the instructions as explained below 3rd4 1 Ground Earth Connection IN Inforcharger ground earth connections have to be done The input ground terminals of the Infocharger should be connected to a reliable low resisted ground The grounding connection of the loads can be done over the output grounding contactor The grounding connection of the external battery cabinet if any should be done over the same battery grounding contactor The connection between the grounding unit of the Infocharger and the ground can be made according to the minimum cross sectioned cables which are given in the technical specifications table below 3rd4 2 Input connection The connections between the distribution frame and Infocharger for phase neutral and ground are explained as below FOR ICC The Phase Neutral and ground must be connected to their contactors on the front panel with a 2 5 mm cross section mult
10. agnetic interference between Infocharger mains and loads EMI electromagnetic interference Your battery charger and loads are protected against high voltage Bridge Rectifier This unit converts the AC voltage from mains to DC voltage Available with ICH system DC AC Inverter The inverter helps to obtain a very constant AC voltage level at the output by using DC voltage at the boost s rectifier output Rectifier This unit draws on the mains the power required to supply the inverter and to recharge the batteries The alternating input voltage is rectified and distributed to the batteries Low Voltage Protection Optional This type of protection is used as optional to prevent the deep discharge of the loads in the absence of the power at mains and this voltage level can be adjustable at the front panel Your Battery Charger features and benefits Feature Benefit SMPS technology Compact design small dimensions and low weight Transformerless design gt To use all the sources in optimum level Microprocessor controller x gt To observe carefully the failure conditions High input power factor gt To consume low reactive power PFC technology only for ICC gt Not to load the installation extra cables transformers generators etc Clean power for the mains This helps to reduce battery usage and guarantees battery to be fully charged and extends the battery life time Wide input vol
11. batteries to be charged please switch off the all automatic fuses in the front panel 5 Operating Instructions 5thl1 Unit Operation Infocharger is designed for the usage as a Battery Charger or DC Power Supply Output current voltage and the float charge limits are adjustable on the front control panel easily 5th1 1 Operation modes e Battery Charger The device charges batteries by converting AC voltage to DC voltage Current limit output voltage and charging temperature can be adjustable from front panel The battery current and voltage characteristics are shown in the figure below Time Charge Voltage and Current Float Charge Stable Power Zone Charging Voltage and Current Charging Voltage s Charging Current Battery current is controlled in a way to keep stable the power transferred to batteries in direct charge zone If the voltage passes a certain value float charging starts It is applied fixed voltage 2 23V per battery Float charging takes 30 minutes Then it passes to tampon charging During the tampon charging it is applied fixed voltage 2 25V per battery in 25 C environment temperature Auto charge voltage is adjustable according to the environment temperature e DC Power Supply The device supplies the DC load by converting AC voltage to DC voltage Current limit and output voltage can be adjustable from front panel 11 5th2 Displays The front panel of the Infocharger is sh
12. ery voltage is below the adjusted value EEPROM When the memory log is not functioning INVERTER When a fault occurs on inverter side 4 UNIT INFORMATION Type One of the following device type ICC 24V 60A 48V 30A 110V 15A ICH 24V 200A 48V 100A 110V 50A 220V 25A Address Binary system is used Between 001 110 Sx Slave up to 6 units 111 Master Unit Ver Microprocessor software version Seri no Serial number 5 MODULE INFORMATION Only monitored during parallel mode Analog values and present alarms of the other units can be monitored 6 SYSTEM SWITCH ON SWITCH OFF It is used of turning ON or OFF device 7 LANGUAGE SELECTION Language English Turkish 14 5th2 1 3 Buttons There are mainly four buttons in the front panel The functionalities of the buttons are given below m a Esc 4 button button button button Scroll down to next line Scroll up to previous line Exit from the active menu Enter to active menu 15 MENU STRUCTURE OF INFOCHARGER MENU SCREEN ANALOG VALUES SETTINGS ALARM STATUS SYSTEM INFO LANGUAGE Vbat VDC Batt Tp XXXX Alarm Status Type 110 VDC Ibat Idc Batt Capacity Ah Vbat NORMAL ADRESS 111 Vinput VAC Char Cur A Tred NORMAL Version 1 6 Tred C Low Voltage Tenvrm NORMAL Seri No Tamb C Charge with Temp LVD NORMAL 0 C Volt Value EEPROM NORMAL 50 C Volt Value INVERTER
13. ge on the front panel If you still have problems please call technical service Please note the model and the serial number of the unit which are present on the rear panel label Describe the problem with full information 21 10 Technical Specifications ICC MODELS Dimensions Height 28 cm Width 25 cm Depth 42 cm Weight 11 6 kg Environmental Conditions Operating 0 40 C Operating 5 90 Temperature Relative Humidity Storage 15 70 C Storage 0 95 Electrical Specifications Connection cable s section area BATTERY INPUT 24V 60A 10mm2 2 5mm2 48V 30A 6mm2 2 5mm2 110V 15A 4mm2 2 5mm2 Input Nominal Voltage 220V Nominal Frequency 50Hz Input voltage range at mains running 90 265 V Input frequency range at mains running 50 Hz 60 Hz 10 Power factor at nominal input voltage gt 0 99 full load Current Total Harmonic Distortion THD Yo lt 3 Efficiency gt 90 Output Output voltage 24VDC 48VDC 110VDC Initial charge 24 5V 49V 112V Float charge 26 75V 53 5V 122 6V Fast charge 28 5V 57V 130 6V DC Supply 0 30V 0 60V 0 140V Short circuit current 110 110 110 Output current 60A 30A 15A Output Voltage fluctuations lt 300mV lt 600mV lt 1V Dynamic response 2 lt 2 lt 2 lt Electronically short circuit protection over curtent protection reverse Outp
14. i vein cable FOR ICH For single phase models the Phase Neutral and ground must be connected to their contactors on the back panel with a 10 mm cross section multi vein cable For three phase models the R S T Neutral and ground must be connected to their contactors on the back panel with a 4 mm cross section multi vein cable AN Changes on distribution panel have to be done by authorized persons only 3rd4 3 Battery connection The batteries must be connected to the L positive and L negative points properly If LVD is used with device the batteries must be connected to B and B terminals The DC power supply type Infocharger does not have this connection The batteries have to be connected with an external circuit breaker 3rd4 4 Output connection The terminal on the equipment can be used for the and output points The cables to these terminals are connected to the fuses and the protection is over the L point 4 Switch ON and Switch OFF procedures 4th1 System Switch ON After making all the connections mentioned in the previous chapter e First switch on input fuse and check output voltage e Then switch on output fuse and battery fuse if any If mains voltage is within the limits the unit switches on InfoCharger makes self test for few seconds to check if everything is normal and then starts to charge the batteries or supply the load 4th2 System Switch OFF To stop the load to be supplied or the
15. own below Overload Fault Infocharger control panel is composed of LCD Display Liquid Crystal Display LEDs Buttons 5th2 1 1 LCD Display There are mainly four display sections on the control panel as follows Operation Status Battery Charger LCD Display u Output current and voltage values Operation Mode Battery Charger ST Standalone MS Master Sx x Slave module Aut Automatic Charge Dre Initialize Charge Flo Float Charge Bst Boost Charge On the Operation status section of the display parallel operating mode is monitored ST If InfoCharger operates in single mode standalone this message is monitored MS If InfoCharger operates in parallel mode and is assigned as master this message is monitored 87 Operating modes can be adjusted on only MS master unit 12 Sx If InfoCharger operates in parallel mode and is assigned as slave this message is monitored Slave units operate in Float mode and operation mode can not be adjusted when parallel communication is cut On the Operation mode section of the display the actual operating mode can be monitored On the left part of this display section the following messages can be observed 5th2 1 2 DRC Initial Charging FLO Float Charging BST Boost Charging AUT Automatic Charging MENU STRUCTURE 1 ANALOG VALUES Vbatt Battery voltage VDC Ibatt Battery current Idc Vinput Input vol
16. sectlebesesstessvecsbesevesstasceessbessseaadesesessbesvuaesesess 25 I 1 Safety AN For the staff and equipment safety it is necessary for the users to fully read and IN understand this manual for DC Power Supply Battery Charger before installation and operation Avoid the sudden temperature changes which can cause condensation inside the battery charger Otherwise wait at least for two hours before switching on This product should be installed according to the instructions defined at chapter 3 3 Positioning Do not close ventilation holes or other openings Keep away the liquid and solid object entry inside the unit Installation and commissioning have to be done by authorized technical service Earth Ground connection should be done Do not plug in off the communication interface cables during bad weather conditions with lightning To avoid the risk of fire all the connections have to be done according to the suggested cable cross sections The cables should be isolated type and properly installed Do not connect exceeding load than charger s nominal power to the output Maintenance and service of the equipment should be done by authorized technical service staff In case of emergency damage of the cabinet front panel or connections etc switch off the battery charger disconnect the input supply and inform the authorized technical service staff The unit should be packed properly if it is needed to be moved
17. tage VAC Tred Internal temperature of the charger C Tenv Environmental ambient temperature C 2 ADJUSTMENTS BATTERY CHARGER Battery Type Maintenance Free Lead Acid Ni Cd Battery Capacity Between 0 1000 Ah adjustable Charging Current Between 0 100 adjustable Low Voltage Protection Active or Passive Temperature Charging Active ot Passive 0 C voltage value Depends on type Temperature Charging voltage value 0 C 50 C voltage value Depends on type Temperature Charging voltage value 50 C Max Charging Duration 0 120 minutes adjustable for ICH 0 10 hours adjustable for ICC Low Voltage Limit LVD low limit Adjustable between 19 22 38 44 86 92 172 184 VDC Charging Limit Direct Float Boost Automatic charging limits 13 DC POWER SUPPLY Vout The output voltage is adjustable between 0 30 60 150 300VDC Tout It is adjustable between 0 255 3 ALARMS Vinput In case of the voltage at mains is out of limit value Vbatt In case of the battery current is out of limit value Vload In case of the load voltage is out of limit value Tcharger In case of the measured value over the ventilator is higher than limit value Tamb In case of the operating temperature is higher than the limit value CURRENT LIMIT Shows the output current value is equal to nominal current or greater than the nominal current LVD When the charger is at charger mode it shows that the batt
18. tage tolerance On line operation even the mains is between 90 265 V for ICC and 176 265 V for ICH The output voltage of the Infocharger is DC Infocharger input total harmonic distortion is very low This is very important for both the systems and batteries which are supplied by Infocharger On line double conversion topology To calculate overloading time in a reliable way Temperature Management gt To protect against over temperature Parallel connection is available up to 7 units if you use InfoCharger Modular System Architecture ICH model as battery charaet gt Provides monitoring of your InfoCharger from your automation by Dry Contact Information relays and microprocessor Effective output voltage regulation output voltage is not affected by changes on the mains input and load level High efficiency low power consumption 3 Installation Check if the Infocharger has been subjected to any damage before unpacking it If you notice any Se damage please contact to transport firm Check if all the additional parts have been supplied with the battery charger Please make sure that the packing contains the following Infocharger User Manual Test Report Before the installation please check if your Infocharger is customized following your special requirements if any C The standard unit s output voltage can be adjustable between 0 30 60 150 300VDC 3rd1 Handling
19. ut protection voltage protection Standards Protection Class IP 20 EMC EN 50091 2 Performance EN 62040 3 EN 50091 3 Safety EN 50091 1 Product Certification CE TSEK 22 ICH MODELS Dimensions Environmental Specifications mee Br Teen Temperature Electrical Specifications Connection Cable Cross Section ee ae ee Terre es A A En EIER 1 22 INPUT Nominal Voltage 220V Ph N or 380 Ph Ph 50Hz Nominal Frequency Input voltage range at mains running 176 265 V Input frequency range at mains running 50 Hz 60 Hz 10 Power factor at nominal input voltage gt 0 8 full load Efficiency gt 90 Dynamic response 2 lt 2 lt Output protection Electronically short circuit protection over current protection reverse voltage protection Standards Protection Class IP 20 EMC EN 50091 2 Performance EN 62040 3 EN 50091 3 Safety EN 50091 1 Product Certification CE TSEK 2 4 x un Q 2 E 5 gt fe Ss ei o S fo F os o ie ss 2 co B Dn 23 Cable cross section area mm2 Current value absorbed by the load Amp 1 5 18 4 34 6 44 10 61 16 82 25 108 35 135 50 168 70 207 95 250 120 292 150 335 185 382 240 453 300 504 THESE UNITS ARE GIVEN FOR THE MULTI VEINS CABLES THE CABLE SIZE SHOULD BE INCREASED PROPORTIONALLY REGARDING TO THE DISTANCE 24 11 Block Diagrams
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