USER AND MAINTENANCE MANUAL
Contents
1. automatically starts the charge In case of interruption between the charger and the battery unplug of connectors the charger automatically stops To manually start or stop the charge press the On Off button mS All the LEDs are high intensity to offer a simple visualization of the charging ON OFF status even from a certain distance HOW TO OPEN THE BATTERY CHARGER Box M NOTE The incorrect execution of the instructions or the fall of the devices could cause serious personal injuries and material damage The opening is to be executed only by skilled technicians Follow safety standards for security reported in the user instruction of the battery charger PHASE 1 Make sure that the supply cable and battery cables are not connected Remove the 4 Phillips screws on the left and right side of the battery charger as shown in the image To optimize the operation lay down the charger on a 6 5cm high stand which will hold the bottom in its position as soon as the top part is lifted PHASE 2 It is possible to check the integrity of the motherboard and if the supply connectors are properly plugged in as shown in the image it is possible to check if the ON OFF button connectors are properly plugged N B During the reassembling of the bottom make sure the connectors are reinserted properly in their slots PHASE 3 Once the top is lifted is possible to test the quality condition of the power fuse and verify if the bolts on th2. following occurs do not start the battery charger and have the battery checked Uneven electrolyte levels or high water consumption in individual cells means a possible fault Battery is overheating temperature over 55 C PROTECTING OTHERS While the charger is in function keep all non authorized personnel out of the working area If there are people near the charging area Warn them about all the dangers hazardous acids and gas danger from mains voltage and charging current etc Provide suitable protective equipment Before leaving the work area make sure it is safe even if the operator is absent SAFETY MEASURES IN NORMAL OPERATION The charger must only be operated on a mains supplied with a ground conductor and a socket with a ground conductor contact The manufacturer will not be held responsible for any damage caused by misusage Only operate the device in accordance with the degree of protection IP21 instructions Never operate the charger if there is any evidence of damage Any safety devices or parts that are not functioning properly in a condition that will not assure its proper functioning must be repaired before using the charger Never bypass or disable protection or safety devices INSTALLATION Install the charger in a dry place with a good airflow far from warm sources and corrosive environments alkaline acid Leave an empty space of 20 cm on the sides and 1 m in height You cannot reach more tha
3. have to define the charging current you would need calculating the 16 of the capacity of the battery in Ampere hour Ah Ex for a 600Ah battery you have to use a 100A battery charger T C E complete standard charge cycle Current A WA CURVE votage V1 The Wa curve displayed in the diagram is characterized by a decreasing trend of the charging soo voltage to the increasing of the battery tension The charger executed with Wa curve has a duration which changes from 10 to 12 hours At the end of the charge the equalization cycle takes place usually during weekends it allows the charger to eliminate little voltage differences between the battery elements that through time would considerably reduce its performances It takes place through extra charging cycles with a default duration and it starts 10 hours after the end of the charge Vmin start charge 80 Buik charge ABS charge Equalization Maintance Tempo s cha MAINTENANCE If the battery will not be used for long periods for example during holidays it would have to be maintained charged to not compromise its performances It is better to charge the battery before left unused for long periods To protect it from the auto discharge it is possible to complete the program with the maintenance function It maintains the battery at 100 charge even if it won t be used for months this function goes through the microprocessor which is able to autonomously put to u
4. the technician SE Series The battery charger does not light on Check the presence of the correct network voltage on the direct O O BVAS W RELAY A1 plug and the efficiency of the fuse o US WREN AT e Check that the network voltage is the same as the eta o PESEE A input of the transformer 380V 400V 420V 440V three o NAL e phase or 220V 230V 240V 250V single phase ON OFFO o E POS Verify the efficiency of the fuse in the battery charger Check the good connection between connectors and control 2 ENTER e e O card Check the continuity of the thermal probes of the transformer orange conductor dTie TR asovac Verify the correct lock of screws that tie the cables to the rectifier BATTERY z Func E 74 connection y Th Be Check the operation of the remote control switch and the auxiliary wiring e Verify the output tensions of the auxiliary transformer Check if the voltage arrives to the power transformer The connection to the battery cable does not exit only for Easy Wire e Check if it is not gone out from its slot Verify if something does not block the unwinding of the cable SINGLE PHASE SCHEMATIC LINE IN Single Phase 230 Vac 4 CONTROL CARD VISUALS AND OPERATIONS Box C S JA el LE Srl MODEL 487100 NO BATTERY V 6 BBY CHARGING 0 1 HES CH W 29 4b ERRUR NORMAL TIME bhelm HES TIME 4hbm When the battery charger i
5. ERY IS CONNECTED TO THE CHARGER The control card allows based on the battery status old reconditioned or new to increase the ABS time The older the battery the more hours it requires to charge Default setting is AUTO it selects the ABS time automatically SET ABS TIME HES TIMES AUTO SET LANGUAGE LANGUAGE ENG If the 2 buttons on the card are pushed at the same time for a few seconds the Set ABS time visual will appear Standard is AUTO the control card calculates the best ABS charge time to increase or fix the ABS time press the ENTER button until the desired charge time is reached 1 10 hours then press ON OFF for a few seconds to set it After the ABS visual the language visual will appear It is possible to change the language here by pushing ENTER to go through the languages available and then ON OFF for a few seconds HOW TO OPEN THE BATTERY CHARGER Box C S NOTE The incorrect execution of the instructions or the drop of the devices could cause serious personal injuries and material damage Only skilled technicians must execute the opening of this device Follow the safety standards for safety reported in the user instruction of the battery charger PHASE 1 Make sure that the supply cable and battery cables are disconnected Remove the two Phillips screw on the back top part of the battery charger PHASE 2 Let the top scroll backward for 15 mm to release it from the tracks and lift it upwards to rem
6. SE 1 0 10 15 USER AND MAINTENANCE MANUAL Dear Customer Thank you for your trust and for buying this high quality product These instructions will help you to know the battery charger A careful reading of these instructions will assure you to learn about the many features offered by this product Please note the safety standards to ensure the safety of use of the product A careful handling of the product will repay you with years of safe and reliable operation SAFETY RULES IMPORTANT Indicate the correct use of the machine and other useful information This sign does not stand for any dangerous nor threatening situation PROPER USE The device is manufactured using recognized safety standards Any incorrect use can cause Injury or death to the operator or to a third party Damage to the device itself and to other material or assets belonging to the company or in the environment near the charger Inefficient operations All personnel involved in commissioning operating maintenance service of this device must have a qualification read and follow this operating manual carefully wait 24h after opening the package before using the device All safety and danger warnings on the device must be in a legible state Not to be damaged Not to be removed Not to be covered or painted The device must be exclusively used for its intended purpose Any other use is deemed improper The manufacturer is not responsible for
7. any damage unexpected or incorrect results caused by such misuse The use of the charger includes reading and obeying all the operating instructions and safety danger warnings perform inspection and maintenance work following the instructions of the battery and vehicle manufacturers MAINS LINE CONNECTION Devices with a higher rating may affect the energy quality of the mains line due to their voltage input This may affect the battery chargers and cause connection restrictions like Insufficient network capacity Insufficient dimensioning of the electrical system If one of this things occurs the operator or the person using the device should check whether the device may be connected asking for a confirmation to a qualified technician Connect the battery charger to a power plug easily reachable in case of need NOTE Make sure that the mains line connection is grounded properly RISKS CAUSED BY MAINS VOLTAGE AND CHARGING CURRENT The user of the charger is exposed to many risks such as Risk of electrocution from mains voltage and charging current Dangerous electromagnetic fields which can risk the lives of those using cardiac pacemakers An electric shock can be deadly To avoid electric shocks while using the charger do not touch any live parts inside or outside the charger never touch the battery poles do not short circuit the charger lead or charging terminals All cables and leads must be secured undamag
8. e Shipment cost is not refunded unless the anomaly or malfunction of the device is caused by bad manufacture or problem related to the componenis The manufacturer can modify and update its devices without noticing to the customers but guaranteeing replacement parts for the older models Restorations or replaced parts are guaranteed for 6 six months The buyer agrees with the terms of warranty Relating to the manufacturer s responsibility it would be subjected to obligations on its products only if the technician would correctly execute user instructions and if the user would observe with scrupulousness the instructions found in the technical manual enclosed to the battery charger DICHIARA sotto la propria responsabilit che il prodotto Caricabatterie 50Hz DECLARES under his own responsibility that the product 50 Hz Battery Charger Realizzato per la ricarica di Batterie trazione Realized to charge Traction Batteries Per uso in ambiente Industriale To be used in environment Industrial Completo di Controllo elettronico Including Electronic control MODEL SERIAL NR YEAR DICHIARA in oltre che questo prodotto conforme ai requisiti essenziali di sicurezza delle seguenti ulteriori direttive CEE Also DECLARES that this product complies with basic safety requirements of the following CE directives CEE 73 23 93 68 89 336 CEI EN 50065 1 CEI EN 50081 2 CEI 70 1 CEI 14 4
9. e diode bridge are tight or loose In case of loose screws tight them PHASE 4 It is also possible to check the current of the power transformer 220V 230V 240V and to adapt the input voltage to the output one As shown in the example in the Network linking section SE 1 0 10 15 WARRANTY TERMS This battery charger is manufactured according to basic standards that assure its good quality Our skilled technicians check every assembling phase The warranty is recognized only in case of anomalies caused by bad manufacturing or components Complaints recognized under warranty terms cause the restoration or the replacement with an identical product without expense provided that the device is brought to the supplier s site Anything else that is not mentioned above won t be considered ex material or moral damages stop of devices Warranty duration is 24 months after the first use of the product or after 24 months of the date of the Commercial invoice The warranty duration can be extended up to 60 months under request Warranty duration is calculated according to a standard 12 hours day job if the battery charger is exposed to a double turn shift the duration is proportionally reduced Warranty is immediately revoked in these cases modification without permission illegible serial number and malfunctions caused by natural events corrosive or damaging environment for electric circuits unusual impact delivery damage and misus
10. ed insulated and adequately dimensioned Loose connections scorched damaged or inadequately dimensioned cables and leads must be immediately repaired RISKS FROM ACID GAS AND VAPOR Batteries contain acid which is harmful to the eyes and skin Wear protective goggles and suitable protective clothing In case of direct contact rinse any acid splashes and seek medical advice if necessary During the charge gas and vapor are released that can be harmful and could be highly explosive Only use the charger in well ventilated areas to prevent the accumulation of explosive gases Battery areas with less than 4 hydrogen are deemed not to be at risk of blast A good ventilation provides a safe environment for the charging operation While charging maintain a distance of at least 50 cm between battery and charger Possible sources of ignition must be kept away from the battery The battery connection must not be disconnected while charging Do not inhale any of the gas and vapor released from the battery when charging Make sure that the charger and battery area is well ventilated To prevent short circuit do not place any tools or conductive metals on the battery HOW TO HANDLE THE BATTERY Protect the battery from dirt and mechanical damage Store charged battery in a cool place Self discharge is kept to a minimum at approx 20 C Every week perform an inspection of the battery to ensure that the electrolyte level is correct If any of the
11. k voltage you have to act on the terminal block inside the rectifier It is important to check out these values 10 5 Rated 5 Use a socket that corresponds to the parameter between measured and rated voltage Example Rated voltage 400 Vac Line voltage 420 Vac Ratio 5 Terminal block position 420 Rated voltage 400 Vac Line voltage 380 Vac Ratio 5 Terminal block position 380 Warning Voltage inside the charger may cause injuries Only the personnel qualified can manage this device Single Phase connection To correct the network voltage you have to act on the terminal block inside the rectifier It is important to check out these values 10 5 Rated 5 Use a socket that corresponds to the parameter between measured and rated voltage Example Rated voltage 230 Vac Line voltage 240 Vac Ratio 5 Terminal block position 240 Rated voltage 230 Vac Line voltage 220 Vac Ratio 5 Terminal block position 220 Warning Voltage inside the charger may cause injuries Only the personnel qualified can manage this device CHARGING CURVES Charging curve installed is Wa with decreasing current according to DIN41774 standard To obtain the right charge for the battery the battery charger must be able to supply a charge as exact as possible to that of the standard indeed it allows a starting charging current equal to 16 of the battery capacity and a decreasing trend To choose the right battery charger you
12. n 40 C in your working location Wait at least 24H after opening the charger s package before putting it in operation Avoid pouring water on in the battery charger It has an IP21 protection level Make sure the charger fits the battery check the info plate on the battery charger before use Protect the network with a delayed switch or a charging fuse larger than the greater absorption of the battery charger Respect the battery connector polarity black cables mark negative polarity and red cables mark positive polarity PROTECTION DEVICE A fuse protects c c circuit in case of extended overvoltage or polarity inversion If there is no network charging process will TEMPORARILY interrupt Charge will reactivate AUTOMATICALLY when the electricity network will come back on SECURITY CERTIFICATION Devices with the CE mark satisfy the essential requirements of the low voltage and electromagnetic compatibility standards NETWORK LINKING Our rectifier works with a three phase 380 440 Vac and single phase 220 255 Vac network operation Before connecting make sure the network voltage is close to its normal value If the charging values are not correct in case of anomalies in the supply line or because it is being used in a different time band when the voltage is higher ex Night band it is possible to correct the power of the transformer up to the Measured voltage value Three Phase connection To correct the networ
13. ove it Remove the white front panel by lifting it upwards to have full access to the charger s power transformer PHASE 4 As soon as you take off the top it is possible to test the good condition of the power fuse verify the lock of the bolts on the diode bridge and check the wiring of the power transformer It is also possible to check the conditions of the Auxiliary transformer and contactor and make sure the connection are properly fastened PHASE 5 When the charger is completely open it is possible to test the operational status of the power transformer and adapt the input voltage to the network voltage check the Network Linking section of this manual PHASE 6 It is possible to check the integrity of the motherboard and the proper insertion of its connectors N B When reassembling the Metal Panel make sure that the connectors are properly fastened in their slots Control Card Wiring schematic 1 Blue cables x 2 2 White cables x 2 3 Orange cables x 2 4 Red cable 5 Black cable nzro7is WA a TCE Srl CC FRONT PANEL OPERATIOANAL GUIDE Box M CHARGING S0O CHARGE 100 CHARGE EQUALIZATION ANOMALY S When the battery charger is powered the charger will run a quick test to check the integrity of the LEDs and the LED bar When the battery is connected the yellow LED on top of the On Off button will flash for a few seconds the control card checks the battery conditions and then
14. s powered The first visualization shows the unit model At the same time all the LEDs on the card turns on for a second to test their functionality The charger while turning on is already testing the connection if present with the battery and in case the result is positive and the battery is correct for the charger it will automatically start charging In case there is no battery connected to the charger on the display the NO BATTERY visualization will appear notifying the user of this situation The CHARGING visualization appears after the automatic start of the charge of after the customers manually starts the charge by pressing the button On Off It shows the battery Voltage and the total length of the charge In addition a small battery figure shows the level of the charge of the battery in real time In case of interruption between the battery and the charger unplug of connectors the charge automatically stops The ABS CHARGE visualization appears when the charge is at 80 Push the ENTER button to access the ERROR Visualization it shows the error codes in case of anomalies or malfunctions The error codes descriptions can be seen in the Before calling the Technician section of this manual Push the ENTER button to check the pre set length of the ABS charge and the total length of the charge To change the ABS Charging time check the below instructions IMPORTANT DO NOT DO THE FOLLOW OPERATION WHILE CHARGING OR IF A BATT
15. se extra charging cycles that maintain the battery current in predefined charging values and always full BEFORE CALLING THE TECHNICIAN Before calling the technician make sure to e Read carefully the Mains line connection section Verify that the battery charger is correctly supplied in case of three phase devices check the presence of the three phases Verify on the display if the battery is connected Check the battery current Verify that the available network power is larger than the maximum absorption of the battery charger see data plate Check the integrity of connectors If the problem continues call an authorized technician Error code T Error code V Error code Time exceeded Power transformer overheated Thermal Over Voltage Charging Time Exceeded probe opened due to an over temperature of Solutions If the charging cycle cannot reach the final phase the the power transformer Check if the battery is correct for the safety timer will exceed the 12h limit and this error will Solution charger appear on the main visualization Wait until the transformer cools off Check if the battery is too charged Solutions Check if the 2 orange wires are z Check if the control card is set on the gt Make sure that the input wires on the power properly connected behind the control correct V behind the control card transformer match the network voltage card Check the condition of the battery PROBLEM SOLVING Section reserved for
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