PROGRAMMABLE HIGH FREQUENCY CHARGER USER`S MANUAL
Contents
1. 19 THERMAL PROTECTION CHARGER desde ses 13 THERMAL PROTECTION BATTERY 14 ANTI ARC PROTECTION OPTIONAL ins 14 ARR ee ae cte 15 ENERGIC Plus CBC USER S MANUAL 1 INTRODUCTION This manual contains instructions and suggestions for the users of Energic plus CBC battery chargers Before to install use or repair the charger it s necessary to read and understand this manual completely It s recommended to keep the manual in good condition for all the lifetime of the charger It should be kept in a dry and clean place always available to the users Throughout this manual the following special annotations have been used to indicate important information WARNING Gives important information regarding possible personal injury CAUTION Gives important information regarding possible equipment damage RESPONSIBILITY DISCLAIMER The manufacturer of the Energic plus CBC battery charger will not be responsible for damages and or injuries caused by the charger in these situations The charger is not installed properly by a qualified electrician Maintenance operations are not done by a qualified electrician The charger is not used according to the instructions included in this manual The charger is not connected to the correct input supply see data label2. nm nn Aer ae _ ee ee md m eee ES CORNE CNE CONS EO ee ee CES CNRS a CS ER eT HS eee A Es GE a eee I ES EE L D PROGRAMMABLE HIGH FREQUENCY CHARGER CBC USER S MANUAL OWM CBC 261006 ENERGIC Plus CBC USER S MANUAL TABLE OF CONTENTS 1 INTRODUCTION in 1 RESPONSIBILITY DISCLAIMERS 822 is an 1 2 SAFETY INSTRUCTIONS AND WARNINGS nn rrrrrmmmnnnne 2 ene ee eee ee ea 2 SHOCK PREVENTION spirus 2 BURN AND BODILY INJURY PREVENTION janceiccocesistnisedeaaciunincnanscantotrmncnastacsuceavennte 3 FIRE AND EXPLOSION PREVENTION 3 MEDICAL AND FIRST AID TREATMENT ue 3 EQUIPMENT WARNIN ABERS x nn ee ne 3 PN 4 A 6 GROUNDING AND LINE CONNECTION nn Men eas 7 9 OPERATION 8 PR LIMINARYCHECRS 2 8 PROGRAMMA TIN aaa eh at cd ee ae nat ee 8 BATTERY CONNECTION VOLTAGE CHECK AND AUTOSTART ccecce 10 CHARGE CYCLE S 11 SAFETY TIMERS EMERGENCY S TOP nn nine teen 12 AUTOMATIC AND MANUAL CHARGE 12 EQUALIZATION 12
3. or OPEN connect the power cable coming from the charger to the switch and then install the fuses in the switch ENERGIC Plus CBC USER S MANUAL 5 OPERATION IGBT CHARGE CONTROLLER Charging 80 Charged Complete Equalize A Enter Fault Alarm ____ Manual STOP amp ay Enter PROGRAMMING MODE Enter BATTERY RECOVERY MODE PRELIMINARY CHECKS Inspect the charger completey for loose screws electrical connections or other damages Check that all the ventilation slots are not obstructed to assure proper air flow Make sure that the charger is installed as instructed in this manual and in accordance with any applicable national or local Code PROGRAMMATION CAUTION It s necessary to program the charger BEFORE to connect the battery If the programmation is not made properly the battery can be DAMAGED The CBC can be programmed through the User Interface The programmation is password protected and the procedure is quick and easy Before to start the programmation it s necessary to collect the relevant battery data Battery nominal voltage V Battery type Lead Acid or GEL Battery capacity Ah ENERGIC Plus CBC USER S MANUAL PROGRAMMATION PROCEDURE Turn on the charger by moving the main switch to position 1 The digital display shows Charger Model and Sofware Version Then it shows the message NO BATTERY SYSTEM READY Press button DOWN and keep it presse
4. Input contactor 0202961 0202961 0202962 0202962 Output contactor 0203241 0203241 0203241 0203241 Output fuse 0201079 0201081 0201081 0201081 Front door 02032915 02032915 02032915 02032915 Right panel 02032985 02032985 02032985 02032985 Left panel 0203299 0203299 0203299 0203299 Rear panel 0203295 0203295 0203295 0203295 Top panel 0203296 0203296 0203296 0203296 Base 0203297 0203297 0203297 0203297 END OF MANUAL 17
5. WARNING DON T disconnect the battery from the charger while it is being charged ARCING AND BURNING OF CONNECTORS OR BATTERY EXPLOSION MAY RESULT The EQUALIZATION function is useful to keep all the cells of the battery at the same voltage level even after years of continuous work When a battery is charged discharged everyday it s suggested to equalize it weekly The charger after a normally completed charge cycle will add 4 extra charges of 30 minutes with 15 hours interval between each charge MAINTENANCE The MAINTENANCE function is useful to keep the battery in perfect condition when it s not used for an indefined time weeks months It is sufficient to leave the battery connected to the charger the control board will keep the battery voltage under control and will activate the charger automatically when the voltage falls below a predefined minimum theshold THERMAL PROTECTION CHARGER The CBC Power Regulation Board incorporates a thermal protection system that may reduce the output current of the charger down to zero in case of overheat of the charger power circuits When the temperature of the power circuits returns to a safe level the output current of the charger returns to the normal value automatically 13 ENERGIC Plus CBC USER S MANUAL THERMAL PROTECTION BATTERY OPTIONAL The CBC battery charger can be equipped with two types of optional temperature probes for the protection of the
6. 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 ENERGIC Plus CBC USER S MANUAL IBURN 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 anything that is metallic on top of any battery To preve
7. depending on the actual status of the battery CURRENT VOLTAGE START CURRENT GASSING VOLTAGE FINISHING CURRENT IUla CHARGE CURVE EQUAL MAINTENANCE REFRESH ENERGIC Plus CBC USER S MANUAL 4 INSTALLATION Conditions of use Operating Storage temperature 5 C to 45 C Relative humidity less than 75 WARNING The charger can be installed by qualified personnel only To avoid the risk of injuries 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 CAUTION Allow adequate air circulation to prevent internal heat buildup Do not place the unit near materials that may block the ventilation slots Do not insta
8. 15 12V 120 A 200 A 200 A 200 A 24 V 120 A 200 A 200 A 200 A 36 V 120 A 150 A 180 A 200 A 48 V 120 A 120 A 150 A 200 A 72V 80 A 80 A 110A 160A 80 V 70 A 70 A 100 A 150 A 96 V 60 A 60 A 80 A 120 A 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 programmation and data review A unique feature of the CBC is the ASSISTED PROGRAMMATION of the charge curve the user just needs to enter the basic info about the battery Type Voltage Capacity and the time available for charging it from 6 to 24 hours The CBC charge controller calculates automatically the ideal charge curve for the given parameters While the programmation and operation of the CBC can be totally assisted and automatic expert users have the possibility to adjust the charge parameters and options without limitations Gassing Voltage Equalization Mode Refresh Mode Language and other The charge curve of the CBC is based on the IUla or IEI system but instead of applying a pre defined charge curve to the battery the IGBT CHARGE CONTROLLER calculates all the curve parameters Currents Voltage Limits Maximum Times according with the Battery Data and User Programmation Moreover the curve is dynamically adjusted while the charge is in progress
9. battery THERMAL SWITCH A submersible thermal switch can be connected to a dedicated terminal block that is installed ON REQUEST inside of the unit near the battery cable connections This thermal switch will suspend the charge if the battery temperature exceeds the trip value of the thermal switch Contact your dealer for more info TEMPERATURE PROBE NTC 100k A NTC 100k can be connected to a dedicated terminal block that is installed ON REQUEST inside of the unitt on the IGBT Charge Controller When the CBC is equipped with this type of thermal probe it s possible to set the max temperature allowed for the battery directly on the charger control panel Contact your dealer for more info ANTI ARC PROTECTION OPTIONAL The CBC battery charger can be equipped with an ANTI ARC protection system that eliminates the risk of arcing between the connectors in case of battery disconnection while the charge is in progress It s sufficient to add a loop circuit using two wires and two auxiliary contacts on the charger and battery connectors The two wires of the loop circuit can be connected to a dedicated terminal block that is installed ON REQUEST inside of the unit near the battery cables connections Contact your dealer for more info 14 ENERGIC Plus CBC USER S MANUAL STATS At the end of each charge cycle the IGBT CHARGE CONTROLLER saves the relevant charge data into the DATA LOGGER memory In any moment it s possibl
10. d for 3 seconds The display shows the message PASSWORD Press the buttons in this exact sequence UP DOWN UP DOWN UP The display shows the message OPERATOR MODE Press button UP to scroll between the charge parameteres until the display shows BATTERY VOLTAGE 24 In order to modify this parameter press button ENTER and keep it pressed for 3 seconds This will enable the EDIT MODE a cursor will blink on the voltage value Select the battery voltage using the buttons UP DOWN When the correct battery voltage is displayed press ENTER and keep pressed for 3 seconds in order to SAVE the modified value and exit EDIT MODE Press button UP to proceeed to the next parameters The procedure to modify a parameter is the same for all the programmable parameters Press ENTER and keep it pressed for 3 seconds to enter EDIT MODE Use UP DOWN to modify the value Press ENTER and keep it pressed for 3 seconds to SAVE the value The next parameters to be programmed are BATTERY TYPE PE Battery TYPE Pb GEL BATTERY CAPACITY Battery CAPACITY 50 to 2000 Ah 500 Ah TIME AVAILABLE FOR CHARGE 6 to 24 hours TIME AVAILABLE 1 When the BASIC parameters have been programmed BATTERY TYPE VOLTAGE CAPACITY and TIME AVAILABLE FOR CHARGE the IGBT CHARGE CONTROLLER is able to calculate the basic charge curve and charger is ready to charge the battery Anyway it s also possible to continue with the programmation o
11. e to access the DATA LOGGER memory to review the saved data by selecting the menu STATS with the UP DOWN buttons and and pushing ENTER Each record is visualized in this format N10 250Ah 30 1 BOO 067356 47 OV LINE 1 Number of saved charge cycle the last cycle has the highest number Capacity returned to the battery Battery voltage at the beginning of the charge LINE 2 Charge Termination Code see next paragraph Total time of charge Battery voltage at the end of the charge CHARGE TERMINATION CODE Each record saved in the DATA LOGGER memory contains a Charge Termination Code that gives a detailed description of the result of each cycle ended Each Charge Termination Code is composed by a letter and a number The letter indicate the reason why the charge ended and it can be 7 Charge completed normally B Battery Disconnected by User E gt Manual or Emergency Stop If the charge is completed normally the letter T can be followed by these numbers T3 gt Charge completed normally T23 Charge completed normally but constant voltage stage exceeded 3 hours If the Equalization has been performed an additional letter E is added to the code T3E Charge completed normally equalization done 15 ENERGIC Plus CBC USER S MANUAL If the battery has been disconnected while the charge was in progress the letter B can be followed b
12. es 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 right values The chopper has a negligible output ripple The IGBT CHARGE CONTROLLER is the main control unit of the CBC It s a microprocessor based electronic board of the last generation 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 for the IGBT The startup sequence the thermal protection and the polarity protection of the charger are managed by the POWER REGULATION BOARD which receives signals from several sensors that are located inside of the charger ENERGIC Plus CBC USER S MANUAL The four CBC models available K5 K8 K10 K15 are all multivoltage 12 to 96 V but have different power ratings therefore they can give different maximum currents depending on the voltage of the battery MAXIMUM OUTPUT CURRENTS BATTERY VOLTAGES K5 K8 K10 K
13. f the OPTIONAL PARAMETERS Gassing Voltage Equalization Refresh Mode ENERGIC Plus CBC USER S MANUAL Press button UP to REVIEW the CALCULATED parameters It s now possilble to review the charge parameters START CURRENT 11 FINISHING CURRENT 12 MAXIMUM TIMES for each charge period T1 T2 T3 When the programmation is complete press buttons UP and DOWN contemporarily to exit the programmation and return to NORMAL MODE When the buttons are released the display shows NORMAL MODE Turn off the charger by moving the main switch to position 0 Turn on the charger by moving the main switch to position 1 The digital display shows Charger Model and Sofware Version Then it shows the message NO BATTERY oo aM READ BATTERY CONNECTION VOLTAGE CHECK AND AUTOSTART Turn on the charger The display shows the message NO BATTERY 10 ENERGIC Plus CBC USER S MANUAL Connect the battery to the charger using an adequate connector The IGBT Charge Controller verifies the battery voltage and polarity and the display shows the message BATTERY CONNECTED START CHARGE If the battery voltage is below the minimum threshold of 1 62 V cell the charger will not start and the display will show the error message BLow Press button ENTER and keep it pressed for 3 seconds to start a RECOVERY DESULPHATION CYCLE The display will show the message DESULPHATION The RECOVERY DESULPHATION c
14. ll the unit near heat sources such as radiators or air ducts or in a place subject to direct sunlight excessive dust mechanical vibration or shock ENERGIC Plus CBC 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 conductor 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 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 Check that the charger is disconnected from AC input and battery Open the cabinet Mount the input cable and connect the four power conductors three phase ground to the terminal blocks Close the cabinet With disconnect switch on AC input power line on position OFF
15. ndicates the charge status with a visualization of this type CURRENT I1 SAFETY TIMERS EMERGENCY STOP The IGBT CHARGE CONTROLLER calculates maximum safety times for each charge periods according with the programmed data If the battery doesn t reach the gassing voltage within the calculated time the the charge is terminated by the Emergency timer The display will show the error message T1max and the buzzer will give audible alarm and the LED Fault Alarm will light on If this error message appear it s recommended to verify the battery status and the programmation of the CBC AUTOMATIC AND MANUAL CHARGE TERMINATION WARNING DON T disconnect the battery from the charger while it is being charged ARCING AND BURNING OF CONNECTORS OR BATTERY EXPLOSION MAY RESULT AUTOMATIC CHARGE TERMINATION When the charge has been normally completed the power stage turns off automatically and it s possible to disconnect the battery The LED Complete Equalize turns on and the display continues to show the last charge parameters 47 0 V 250Ah OA Hesse While the charge is in progress it s possible to suspend it in any moment by pressing the button UP and keeping it pressed for 3 seconds The charge current will reduced to zero and the display will show the message MANUAL STOP At this point it s possible to disconnect the battery ENERGIC Plus CBC USER S MANUAL EQUALIZATION
16. nt 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 ENERGIC Plus CBC USER S MANUAL 3 DESCRIPTION The CBC is a high frequency IGBT battery charger of the latest generation It combines outstanding electrical performances complete programmability and real universal charging capability It features a complete active protection system which includes Reverse Polarity Short Circuit Overtemperature Wrong Battery Anti Arcing and more The electrical structure of the CBC is represented in the following block schematic 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 provid
17. on the box The battery is damaged during the charge The charger has been modified without the authorization of the manufacturer Non original spare parts are used in the charger Wrong spare parts are used in the charger ENERGIC Plus CBC USER S MANUAL 2 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 equipment Check the da
18. ta 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 capacitors and if there is
19. y these numbers 66 B00 Battery disconnected immediately B01 Battery disconnected during first stage Constant Current 11 B02 Battery disconnected during second stage Constant Voltage V1 B03 Battery disconnected during third stage Constant Current 12 B07 Thermal protection activated and battery disconnected after restart If an error occurred and the charge has been stopped in emergency condition the letter E can be followed by these numbers E01 Charger stopped by user during first stage Constant Current 11 E02 gt Charger stopped by user during second stage Constant Voltage V1 E03 Charger stopped by user during third stage Constant Current 12 E05 Max time T1 exceeded Gassing Voltage not reached E06 Battery Voltage higher than 2 80 V cell during the charge E07 Thermal protection activated and battery disconnected before restart 16 ENERGIC Plus CBC USER S MANUAL 6 SPAREPARTS TABLE Power Transformer 0207205 0207205 0207210 0207215 Output inductor 0207305 0207310 0207310 0207310 Rectifier 0201863 0201863 0201943 0201945 Power stage 0100358 0100360 0100360 0100360 Fan 0204002 0204002 0204002 0204002 Aux transformer 0205572 0205572 0205572 0205572 Power Regulation Board 0205590 0205590 0205590 0205590 Digital control board 0206100 0206100 0206100 0206100
20. ycle is completely automatic and it may take up to 4 hours At the completion of the cycle the battery voltage is verified again and if it s high enough a normal charge cycle starts If the battery voltage is higher than the maximum threshold of 2 60 V cell the charger will not start and the display will show the error message BHigh In this case it s impossible to start the charge and it s recommended to verify that the programmed battery voltage is correct If the battery voltage is between the minimum and maximum thresholds the charger will turn on automatically after 5 seconds The output current will ramp slowly to the right value and the display will show the charge parameters BATTERY VOLTAGE CAPACITY RETURNED TO THE BATTERY CHARGE CURRENT CHARGE TIME in a visualization of this type SAT HN 1 Ah 150 A O00 1 E CHARGE CYCLE While the charge is in progress the charge parameters continuously showed on the display The LEDs indicate the charge status Period T1 Const I the LED Charging blinks Period T2 Const V the LEDs Charging and 80 Charged blink simultaneously Period Const the LED 80 Charged remains on while the LEDs Charging and Complete Equalize blink simultaneously In any moment it s possible to scroll between the menu parameters by pressing the buttons UP and DOWN 11 ENERGIC Plus CBC USER S MANUAL A dedicated menu page i
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