User Manual for EMC Series Charger
Contents
1. LITEPOWER 5 O L U T I 5 User M anual for EMC Series Charger 1 Overview The EMC series chargers are suitable for charging lithium ion battery packs such as those used in electric vehicle applications The EMC series chargers are designed to work seamlessly with Elite Power Solutions Energy Management System through the CAN interface or digital input for safe battery charging Standard safety features include protection against a short circuit on the charger output reverse polarity over charging over temperature etc eS Fee a 2 technical Parameters 2 1 Specifications Model Efficiency Input voltage Input voltage range Frequency Communication Vibration Water resistance Power factor 2 1 Operating Environment Altitude Temperature Installation Stress Humidity Storage environment EMCXX YY XX Output Voltage YY Output Amps 288 110V AC 220V AC available as special order AC 95 130V AC 195 242V 40 60Hz CAN and 12V Digital Input SAEJ1378 IP31 20 75 lt 2000 Meters 30 C 55 C lt level 5 5 70 RH Non Condensing keep away from exposure to moisture 30 C 60 C Keep away from combustible materials 3 Charging Status and Alarm Status Indication 3 1 Alarm Indication e Reverse polarity or low voltage Charger over heating Ambient temperature too high Charging time out Over Voltage Protection BMS alarm charging2. beled 12V and 12V these wires are the digital input used to control the charger from the EMS CPU Connect the 12V to the OV connection on the EMS CPU and the 12V to the GND connection on the EMS CPU The EMS CPU will output a 12 volt signal from the OV terminal whenever a pack normal situation is detected During charging if a cell exceeds the maximum voltage limit this will drop to 0 volts which will trigger the charger to temporarily pause charging until the high voltage cell can return to a normal voltage All green LED s on the charger will flash when this occurs 12V Connects to GND 12V Connects to OV For a CAN communication connection connect the CANH CANL and CAN GND to the matching connection on the CAN connection on the EMS CPU The white connector may be cut off of the cable however note which wires are which before doing so CANH CANL CAN GND If both the CAN communication and the digital inputs are connected CAN communications will take priority over the digital input for charge control CAN communications requires the optional CAN board be installed on the EMS CPU Caution The EMS CPU has a programming port on it marked Rx Tx RES VSS Do not attempt connect the CAN communication connection to this port TREPOWE ros V Tom Y 3 elitepowersolutt mse con Management Syst gt 6 Cautions Make sure charger voltage outpu
3. int default 3 7V or above the charger reduces the charge current to zero amps for five minutes to allow the EMS to balance the battery pack The charge will resume after five minutes at half the previous charge current and will again charge until it receives a signal from the EMS that a cell has reached the recharge set point These recharge cycles continue until the charging current reaches the minimum charging current to complete the charging process 4 7 Digital alarm input 0 0V 2 0V Charging stopped 2 5V 12 0V Enable charging or resume charging 4 8 When both CAN and the digital control signals are available the charger is controlled by the CAN communication signal 5 Connections 5 1 IEC Connector For EMC chargers which output 10A or less the charger comes with an IEC type connector for the output The connections to the battery pack are made as follows 6A and 10A Charger Connector Labeled N Battery Pack Positive Labeled L Battery Pack Negative Not Used 5 2 Anderson SB50 Connector EMC Chargers with output greater than 10A come with an Anderson SB50 style connector for the output These connectors are labeled and A mating connector comes with the charger 5 3 CAN and Digital Input Controls A five wire connector connects to the charger for interfacing with the BMS Three wires have a white connector attached these three wires are the CAN interface The other two wires are la
4. interruptions 3 2 Charging Status Indication Shutdown status Charging stage e Battery presence not detected Charging complete 4 Functions 4 1 Output short circuit protection 4 2 Over temperature protection Red light blinking 20 light on Red light blinking 40 light on Red light blinking 60 light on Red light blinking 80 light on Red light blinking 100 lights on All LED s blinking Six lights blinking Percent light indicating pack voltage vs max charging voltage Red light blinking 20 light on All green lights on Temperature less than 83 C Full charging power Temperature is 85 C to 95 C Power reduced to 50 Temperature is greater than 95 C No output 4 3 Reverse polarity protection charger will not turn on if the battery pack is connected backwards or less than 5V 4 4 A switch on the charger marked Override is used to select either external or internal controlled charging Override Off Use with EMS system either CAN or digital input Override On Charger program based on pack voltage only recommended for testing purposes only do not use for normal charging 4 5 When external control is selected and a CAN signal is used if any cell reaches the recharge set point default 3 7V as signaled by the EMS the charger will automatically enter the final recharge cycles 4 6 Recharge cycles When the EMS detects any cell has reached the recharge set po
5. t matches to the number of cells in the battery pack Make sure positive output of the chargers is connected to a positive connection to the battery pack and the negative output of the charger is connected to a negative connection of the battery pack After a complete charge disconnect the power source from the charger and then disconnect the connection between the charger and the battery pack A BMS system must be used during the charging process either through CAN communication or through the digital alarm input to prevent over charging 7 Troubleshooting The charger must be installed in a cool well ventilated area which is free of dust If the charger is not charging unplug the charger from the AC line and battery pack then check for poor connections short circuits over heating conditions as well as alarm status from the Energy Management System If charger does not display any LED s when plugged in and charging does not occur the fuse may be blow Unplug the charger from the battery pack and AC line and check the fuse by unscrewing the cap with a 2 Philips screw driver If the fuse is blown replace with an equivalent size fuse of the same voltage and amperage rating If the charger finishes charging too early make sure that the connection from the charge to the battery pack is good and does not have high resistance
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