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SERVICE MANUAL - Montreal Chargeur Home

1. Don t open the cabinet of the charger Only qualified personnel can service the unit Allow adequate air flow inside of the unit in order to prevent excessive heat buildup Don t install the unit near materials that may obstruct the air passages near devices that may generate heat under the direct sunlight or in presence of excessive dust or mechanical vibration Page 4 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual CONNECTION OF THE AC INPUT The charger must be connected to the AC input using an adequate cable and plug with disconnect switch and fuses The AC input wires have to be connected to the AC INPUT TERMINAL BLOCK that is located on the internal panel See yellow label electric warning Make sure to tighten the terminal block screws with the proper torque and pull each wire separately in order to verify that they are mounted properly 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 e Read on the data label the AC current value corresponding to the line voltage to which charger is to be connect
2. Capacity Returned Ah The Black Diamond Charger performs an exclusive charge cycle that is composed by stages at constant current and stages at pulsed current with cool down pauses in between The management of the charging curve is totally automatic Depending on the programming of the Full Charge time window Parameter 9 when the battery approaches the gassing voltage the charger may suspend the charge typical opportunity charge cycle In this situation the display visualizes the message DELAYED OVERCH hh mm A gt hh mm B Where hh mm A represents the real time at that moment and hh mm B represents the beginning of the Full Charge Overcharge time window During the cool down pauses that are normally inserted during the gassing phase the display visualizes the message Cooling Cooling x e Page 18 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual EMERGENCY STOP If the battery doesn t reach the gassing voltage within a predetermined time the charger will suspend the charge and it will visualize the message EMERGENCY STOP VGAS NOT REACHED In this case the charge cannot proceed and it s necessary to disconnect the battery It s recommended to control the battery for damaged cells AC INPUT BLACK OUT If there is a black out of the AC input while the charge is in progress the charger will shut down while the charge parameter
3. using the UP DOWN buttons it s possible to edit the battery ID information __ ID Number 8 alphanumeric digits to be confirmed individually by pressing ENTER for 3 seconds Nominal Voltage Capacity Type Once all the parameters are set correctly push the buttons UP DOWN Simultaneously in order to save the data to the ID module The programming sequence may take up to 3 minutes while the charger display will show the message BATT ID MODULE PROGRAMMING When the programming sequence is completed the display will show the message BATT ID MODULE SET OK At this point it s possible to disconnect the battery from the charger If the battery is left connected a charge cycle will be initiated The Battery ID Module will keep the information in memory for an unlimited time In order to erase the memory it s necessary to disconnect the ID module from the battery Page 23 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual PROGRAMMING HARDWARE RULES During installation and programming activity it is necessary to ensure that the position of the battery power cables and charger cables are correct As illustrated below it is important that the cables are not overlapping or entwined in the cables of another battery fig 1 correct position of the cables fig 2 incorrect position of the cables Failure to comply with these instructions may dist
4. Default value Disabled NOTE This parameter sets the operation of the charger with the Wireless Battery Identification module WBM optional Three different operating modes are selectable Enabled When a battery is connected the charger establishes a communication with the WBM and uses the information stored into the WBM to optimize the charge cycle Only batteries with WBM installed and properly configured will be charged Disabled The communication of the charger with WBMs is disabled and any battery with correct voltage will be charged Optional When a battery is connected the charger tries to establish a communication with the WBM If a WBM is found it s used to optimize the charge cycle and to add the battery ID tag on the charge history log If a WBM is not found the battery will be charged anyway Page 14 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual PARAMETER 13 WIRED IP ADDRESS RS 485 Programmable values 1 to 254 Default value 1 NOTE This parameter sets the IP address of the charger when it s connected to a wired DoctorFleet com management network PARAMETER 14 RESET WIRELESS Programmable values Disabled Try Search NET Default value Disabled NOTE This parameter is used during the setup procedure of a wireless DoctorFleet com management network PARAMETER 15 TEST WIRELESS Programmable values Disabled Try Send Test Defa
5. Voltage Volt Nr of Refresh cycles already given to the battery Total Time of Charge hours minutes Total Capacity Returned Ah During cycle Refresh the display shows the same set of information that are visualized during the normal charge cycle Page 21 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual DISCONNECTION OF THE BATTERY DURING THE CHARGE WARNING DON T DISCONNET THE BATTERY DURING THE CHARGE RISK OF EXPLOSION If it s necessary to disconnect the battery while it s being charged press the button UP for five seconds in order to stop the charger manually The charger will suspend the charge and the display will show the message MANUAL STOP At this time it s possible to disconnect the battery Eventually the charge can be restarted by pressing the button UP for 5 seconds Page 22 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual 5 PROGRAMMING BATTERY ID MODULE When a battery ID module is installed on a battery for the first time it must be initialized and programmed by following this procedure Connect the battery to a Black Diamond charger the Battery Recognition mode must be set to BATTERY ID MODULE or OPTIONAL The Black Diamond charger will establish a communication with the New Battery ID module and it will show the message BATT ID MODULE CONNECTED At this point
6. executed because time window Disabled 12 Charge completed successfully Equalize completed successfully GROUP 2 MANUAL STOP 11 Charge stopped manually during a generic cooling state 20 Charge stopped manually before to reach the gassing voltage 21 Charge stopped manually during the finishing charge 22 Charge stopped manually during eq 23 Charge stopped manually during refresh 24 Charge stopped manually during desulphation GROUP 3 BATTERY DISCONNECTED 30 The battery has been disconnected before the begin of the charge while the charger was waiting for the programmed Start Time window 31 The battery has been disconnected during the first part of the charge before to reach the gassing voltage 32 Successful Opportunity charging cycle The battery reached the gassing point the charger entered in stand by mode waiting for the Full Charge Overcharge time window and at that point the battery has been disconnected 33 The battery has been disconnected during the finishing charge while it was cooling between two charging pulses Page 27 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual 34 The battery has been disconnected during the finishing charge while it was receiving a charging pulse 36 Charge never started The battery has been disconnected while the charger was trying to establish a wireless connection with the Battery Identifi
7. 6 10 12 hours I 15 26 of C Wa Finishing Charge Proportional 75 10 12 hours I 15 26 of C ao Default value Usually specified at the order If not specified default value is H NOTES This parameter allows to adjust the finishing rate of the charger depending on the matching Current VS Capacity that has been chosen at the order The proper setting of this parameter is useful to maximize the electrical efficiency of the system and to minimize the temperature rise of the battery during the finishing charge EXAMPLE 1 If the battery capacity is 500 Ah and the time available for charging it is 8 9 hours the recommended Black Diamond charger should have a nominal current of 100A 16 of and the default curve H Wa Finishing Charge Proportional 50 will be correct Page 12 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual PARAMETER 7 EQUALIZE INTENSITY Programmable values from 1 to 8 hours Default value 4 hours NOTES This parameter allows to adjust the duration of the weekly Equalize cycle In most of the cases the default value of 2 hours works well but sometimes it can be useful to modify this setting depending on the status of the battery and on the operating cycle IMPORTANT The battery will be equalized only during the programmed time window See parameters 10 and 11 If the Equalize time window is not set or it s set too short the b
8. BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual BLACK DIAMOND CONTROL FLUX YS GH ral CONTROL FLUX BLACK DIAMOND SERVICE MANUAL V 160 November 2011 www montrealchargeur com www battelec ca www doctorfleet com Page 1 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual 1 SAFETY PRECAUTIONS 1 Before to start using the Black Diamond Charger read these instructions carefully Installation and Service operations can be done by qualified personnel only To prevent the risk of electric shock don t touch uninsulated portions of the Black Diamond Charger and the Battery Manually stop the charger before to disconnect the battery The charger is suitable for indoor installation in ambients with abundant ventilation Don t use the charger near flammable materials Don t obstruct the ventilation slots and leave sufficient free space around the unit Don t expose the charger to liquids or excessive dust 9 Check the conditions of cables and accessories on a regular basis and replace them immediately if they get damaged 10 Don t extend the battery cables Replace them if necessary with cables of the same type length section and insulation as the original ones 11 During the installation of the charger make sure to connect the EARTH conductor properly and respect all the applicable Safety Standards 12 Don t mod
9. MANUFACTURED DATE N SHEATH NON INNER MELT HEAT SHRINK IN WHITE INK PREFERRED l MM YY NI i UL WIRE 18AWG 16 30 UL 1015 PVC WHITE DUAL WALL TFE FEP INNER MELT TEFLON HEAT SHRINK L_ SURE SEAL CONNECTOR 120 1807 000 1 4 0D SHEATH 31655 AV PART NUMBER 09525 001 09525 002 09525 003 SPECIFICATIONS NOMINAL REISISTANCE 100KQ 25 TWO WIRE SINGLE ELEMENT lt NTC THERMISTER VISHAY P N 2381 640 63104 A TEMPERATURE RANGE 50 90 C MMM 100KQN 25 C MENSI ES RACTIONS ANGLES diesel x APPLICATION Eng Asp O Orensalhaus 71 2 08 11306 Mfg Apx M Shapiro 41 308 Page 11 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual PARAMETER 6 FINISHING CHARGE Programmable values A Wa Finishing Charge 2 Hours 10 12 hours I 15 26 of C B Wa Finishing Charge 3 Hours 10 12 hours I 15 26 of C C Wa Finishing Charge 4 Hours 10 12 hours I 15 26 of C D Wa Finishing Charge 5 Hours 10 12 hours I 15 26 of C E Wa Finishing Charge 6 Hours 10 12 hours l 15 26 of C F Wa Finishing Charge Proportional 25 10 12 hours I 15 26 of C G Wa Finishing Charge Proportional 33 10 12 hours I 15 26 of C H Wa Finishing Charge Proportional 50 10 12 hours I 15 26 of C Wa Finishing Charge Proportional 6
10. attery will not receive a sufficient Equalize PARAMETER 8 DATE and TIME Programmable values Day Month Year Hour Minute Default value Eastern Time GMT 5 NOTE It s fundamental to keep the Real Time Clock set to the correct date and time in order to use all the time base functions It s necessary to adjust the Clock manually in Daylight saving time periods The Charger calculates the Day of the Week automatically PARAMETER 9 START TIME WINDOW Programmable values From 00 00 to 23 59 Default value From 00 00 to 23 59 NOTE This parameter sets a time window during the day in which the charger is allowed to start a new charge cycle If a battery is connected outside of this time window the charger will remain in stand by mode until the programmed Start time will be reached Once the charge cycle has begun this time window is not considered anymore Page 13 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual PARAMETER 10 and 11 EQUALIZE TIME WINDOW Programmable values Any day from 00 00 to 23 59 Default value From SATURDAY at 12 00 to SUNDAY at 22 00 NOTE These parameters set a time window during the week in which the charger is allowed to fully charge and Equalize the battery It s recommended to set a minimum Equalize time of 12 hours after the normal completion of the charge cycle PARAMETER 12 WBM ENABLE Programmable values Enabled Disabled Optional
11. battery plug Stop stop the charge cycle Stop Restart by pressing the Stop Restart button Program Desulphate Cod 0203128801 PN PNR PRELIMINARY CONTROLS Before to proceed with the programming sequence and before to connect a battery make sure that the Black Charger has been installed by a qualified electrician according with the instructions reported in this manual Before to use the charger it s necessary to control that the ventilation slots are not obstructed and that all the safety precautions reported in this manual are respected Page 7 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual STARTUP SEQUENCE Turn on the charger by moving the main switch to position 1 The charger will perform an automatic test of the control circuits and will wait for a random delay on start The display will visualize the following messages BLACK DIAMOND SYSTEM CHECK PLEASE WAIT SYSTEM READY xxx VY xxx A SYSTEM READY DATE TIME USER PROGRAMMING MODE Page 8 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual HOW TO ACTIVATE USER PROGRAMMING MODE Press the button DOWN and keep it pressed for 3 seconds The display will show the message EDIT PASSWORD Enter the Password UP DOWN UP DOWN UP The display will show the message MOD USER HOW TO MODIFY A VALUE Scrol
12. cation Module WBM 37 Charge never started The battery has been disconnected while the charger was communicating with the Battery Identification Module WBM 38 Desulphation cycle NOT completed The battery has been immediately disconnected at the beginning of the Desulphation cycle 39 Desulphation cycle NOT completed The battery has been immediately disconnected before to complete the programming of the Desulphation cycle 40 Desulphation cycle NOT completed The battery has been disconnected while the Desulphation cycle was in progress GROUP 4 EMERGENCY STOP 60 Emergency Stop Maximum voltage limit exceeded during first part of the charge before to reach the gassing voltage 61 Emergency Stop Maximum voltage exceeded during the finishing charge 62 Emergency Stop Maximum voltage exceeded during the equalize cycle 63 Emergency Stop Page 28 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual Gassing voltage not reached within the predetermined time limit 64 Charge never started Battery voltage was too LOW 65 Charge never started Battery voltage was too HIGH 66 Emergency Stop Maximum Current Limit Exceeded 67 Emergency Stop Maximum voltage exceeded during the refresh cycle 68 Emergency Stop Maximum temperature exceeded before to reach the gassing voltage 69 Emergency Stop Maximum temperature exceeded during the fini
13. ed Using that current value select the proper fuses disconnect switch and power cable sizes according with any applicable national or local code e Check that the charger is disconnected from AC input and battery e Open the cabinet e Mount the input cable and connect the four power conductors three phase ground to the terminal blocks e Close the cabinet With disconnect switch on AC input power line on position OFF or OPEN connect the power cable coming from the charger to the switch and then install the fuses in the switch Page 5 30 BAT TELEL MONTR AL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual 1 PHASE picture a n picture b Verity that the AC Input is OFF and connect the AC Input cable in INPUT position see picture a In picture b the operator can adapt the charger at the correct input voltage Verity that the AC Input is OFF and connect the AC Input cable in INPUT position see picture c In picture d the operator can adapt the charger at the correct input voltage Page 6 30 BAT TELEL MONTR AL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual 4 PROGRAMMING OPERATING INSTRUCTIONS Connect charger Plug Battery Charger will start Char gin go after short delay 80 Charged RE Complete Up Down Enter ARC HAZARD Fault O Before connecting A or disconnecting the
14. ext paragraph Duration Total charging time Ah Total capacity returned to the battery Page 25 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual CHARGE TERMINATION CODES GROUP 1 CHARGE COMPLETED 00 Battery modules recognized Start charging 01 Charge completed successfully 02 Charge completed successfully Equalize NOT executed because battery was disconnected 03 Charge completed successfully Equalize started but not completed because battery was disconnected during the cool down time before the Equalize cycle 04 Charge completed successfully Equalize started but not completed because battery was disconnected while the Equalize was in progress 05 Charge completed successfully Over range maximum time during pulsed 06 Desulphation cycle completed successfully 07 Charge completed successfully Equalize completed successfully Refresh Cycle NOT executed because battery was disconnected 08 Charge completed successfully Equalize completed successfully Refresh Cycle started but not completed because battery was disconnected while the Refresh was in progress 09 Charge completed successfully Equalize completed successfully Refresh Cycle completed successfully Page 26 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual 10 Gassing voltage reached successfully Full charge NOT
15. functionalities including an automatic algorithm for the compensation of the voltage drop of the charging leads These functionalities are programmable through an Advanced Configuration Menu Please call your service technician for more details The operation is completely automatic and it s managed by a microprocessor based control system composed by a Main Control Board installed inside of the charger and an optional wireless Battery Identification Module WBM that is permanently connected to the battery Page 3 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual 3 INSTALLATION Conditions of use e Temperature operation from 0 C to 50 C e Temperature storage from 20 C to 60 C e Relative Humidity less than 75 ATTENTION The Black Diamond Charger can be installed by qualified personnel only It s recommended to control that the AC input voltage available at the installation site has the right value and that the power available is sufficient The nominal AC input voltages that the charger can accept and maximum input current and power are reported on the nameplate of the unit In order to prevent fires or electrical shock don t expose the Black Diamond Charger to rain or excessive humidity Don t use the Black Diamond Charger near flammable gas because it contains components contactors that may generate sparks during their normal operation
16. harger remains in stand by mode and the display shows the message DELAYED EQUALIZE DAY TIME Where DAY and TIME represent the beginning of the programmed Equalize time window EQUALIZE CYCLE MANUAL During the charging of the battery the operator can scroll the menu of the display and he can force a EQ manual cycle at the end of this cycle FORCE MANAUL EQ ENABLED Page 20 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual DESULFATION The operator can every time interrupt the standard charging and enable with a easy procedure a special desulfation cycle During the charging the operator can press Enter few seconds and the display shows a desulfation menu in this menu the operator can select the time during of desulfation and the type of restart of desulfation infact sometimes it is strategic important to complete a standard charging after a completed desulfation cycle REFRESH MAINTENANCE This function is useful to keep the battery in perfect condition when it s not used for an long period weeks months It is sufficient to leave the battery connected to the charger After a normal termination of the charge and the equalize cycle the control board will activate the charger automatically for 15 minutes of refresh charge every day While the charger waits before to activate a Refresh cycle the display shows the messages R END NR XxX E Battery
17. ify any part of the charger Any modification applied without written authorization of the manufacturer may generate unsafe operating conditions and will void the warranty Page 2 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual 2 DESCRIPTION The Black Diamond Charger is suitable to charge lead acid motive batteries The operation is completely automatic and it s managed by a microprocessor control system composed by a Main Control Board installed inside of the charger and an optional wireless Battery Identification Module WBM that is permanently connected to the battery The power conversion system of the Black Diamond and its optimized charging algorithm help to reduce the charging factor to the minimum value so the duration of the overcharge gassing phase and the average temperature of the battery are minimized The Black Diamond Charger is equipped with a built in Real Time Clock which allows the user to program the desired start time of the day the full charge time window and to schedule the weekly equalize cycles It is possible to connect the charger to the Fleet Management System DoctorFleet com which allows to monitor program and configure the complete fleet through a WEB based interface at any time of the day and from anywhere in the World to send automatic messages by email in case of problems The Black Diamond charger features an extensive set of advanced
18. l between the programmable values using the UP DOWN buttons In order to modify a value press ENTER and keep it pressed for 2 seconds until the cursor will start blinking over the value that can be modified Modify the value using the UP DOWN buttons Confirm the modified value by pressing ENTER for 2 seconds ultil the cursor will disappear At this point the new value will be saved HOW TO RETURN TO NORMAL MODE Press the buttons UP and DOWN simultaneously Page 9 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual PARAMETER 1 NOMINAL OUTPUT VOLTAGE only MANUFACTURER MODE Programmable values 12 24 36 48 72 80 96 120 Volts Default value Nominal voltage of the charger NOTE This parameter should be changed only after replacing the control board of the charger PARAMETER 2 NOMINAL CHARGING CURRENT only MANUFACTURER MODE Programmable values From 10 to 400 Amps Default value Nominal output current of the charger NOTE This parameter should be changed only after replacing the control board of the charger PARAMETER 3 GASSING VOLTAGE Programmable values from 2 35 to 2 50 V Cell Default value 2 40 V cell NOTE This charging algorithm of the Black charger is adaptive so it s capable of adjusting the charging curve even if the gassing voltage of the battery deviates significantly from the programmed value For this reason this parameter should be modified on
19. ly when using non standard batteries or if the operating temperature is extremely low or high When a battery temperature probe optional is connected the charger compensate the gassing voltage VS temperature of the electrolyte PARAMETER 4 MAXIMUM VOLTAGE Programmable values from 2 40 to 2 80 V Cell or DISABLED Default value 2 80 V cell NOTE This parameter sets a maximum limit for the cell voltage If this limit is reached the charge is terminated and a specific error message is given Page 10 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual PARAMETER 5 MAXIMUM TEMPERATURE optional Programmable values from 115 to 160 F or DISABLED Default value DISABLED NOTE This parameter sets a maximum limit for the battery temperature If this limit is reached the charge is terminated and a specific error message is given This parameter works only if it is installed the temperature sensor probe In this case the default settings is 140 F When the charger read the temperature during the charging it applied a temperature compensation voltage 3 COMTAMS CONFIDENTIAL AAD PROPRIETARY OATA ORIGIMATED BY ACROVIRCHMENT PAS ALL COSIGM MANUFACTURING REPROCUCTION Ci APY PIFORMATION Re GARCINNG 1 TO AMY GM ASTHORIESD PERSON OR TO RIDCRPORATS THIS DATA INTO AMY OTHER CSI OR USS T FLOW RITE BUSHING TAG WITH MANUFACTURED DATE oR r THERMISTER POTTED IN MARK
20. ovember 2011 CHARGEUR BLACK Service Manual When the charge begins the display visualizes the message PREPARING TO CHARGE BATTERY VOLTAGE TOO HIGH If the battery voltage is higher than a maximum threshold the charge will not start and the display visualizes the message BATTERY VOLTAGE DORA TROP IE If this message appears it s recommended to verify that the nominal battery voltage matches the nominal voltage of the charger Probably a wrong battery has been connected BATTERY VOLTAGE TOO LOW If the battery voltage is lower than a minimum threshold the charge will not start and the display visualizes the message BATTERY VOLTAGE TOC LOW J If this message appears it s recommended to verify that the nominal battery voltage matches the nominal voltage of the charger Probably a wrong battery has been connected It s also possible that the battery has been deeply discharged bringing the voltage below the minimum value required for the automatic start the charge In this case it s possible to start the charge manually by pushing the button DOWN for 5 seconds Page 17 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual CHARGE CYCLE When the preliminary controls are complete the charge starts automatically and the display visualizes the following information Battery Voltage Volt Charging Current Amps Time of Charge hours minutes
21. s will remain in memory When the AC input will be recovered the charger will restart the charge cycle automatically and the display will show the message RESTART AFTER POWER SUPPLY OFF OVERCURRENT PROTECTION If the AC input voltage is abnormally high and or the AC input adjustments have not been done correctly See Chapter INSTALLATION the charging current may reach an excessive value In this case the charger will suspend the charge and the display will visualize the message CURRENT TOO HIGH The charge will not proceed and it s necessary to disconnect the battery It s recommended to control the AC input connections of the charger as explained in Chapter 3 INSTALLATION It s recommended to verify the condition of the battery as it may have one or more cells in short circuit Page 19 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual AUTOMATIC STOP The charger shuts down automatically when the charge is correctly complete and it will visualize the message CHARGE COMPLETE At this time it s possible to disconnect the battery EQUALIZE CYCLE AUTOMATIC clock mode At the end of the charge if the battery is left connected to the charger for a sufficient time the charger activates the Equalize cycle automatically based upon the programmed schedule If the charge cycle ends outside of the programmed Equalize time window the c
22. shing charge 70 Emergency Stop Maximum temperature exceeded during the equalize cycle 71 Emergency Stop Maximum temperature exceeded during the refresh cycle 72 Emergency Stop When a battery is connected the WBM communicate that the voltage of battery is not compatible with this charger 76 Emergency Stop Maximum temperature exceeded during desulphation Page 29 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual GROUP 5 WARNING MESSAGES 80 Maximum finishing charge time safety timer exceeded Charge termination criteria dV dt not reached 82 The battery has been disconnected while the charge was in progress in a generic state 83 Output fuse blown 85 Communication problem with Wireless Battery Module 99 Black out of the AC input www montrealchargeur com www battelec ca www doctorfleet com End of Manual End of Manual Page 30 30
23. ult value Disabled NOTE This parameter is used during the setup procedure of a wireless DoctorFleet com management network Page 15 30 BAT TELEL MONTR AL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual 5 OPERATION CONNECTION OF THE BATTERY AUTOMATIC START Connect the Battery to the charger using a connector of adequate size When the battery is correctly connected the charger visualizes the following message BATTERY CONNECTED WIRELESS CONNECTION TO BATTERY IDENTIFICATION MODULE OPTIONAL If the Battery Identification Module is enabled a few seconds after the connection of the battery the charger will try to establish a wireless connection And the display will visualize the message BATT ID MODULE SRARCHING When the wireless connection is active the charger is ready to start the charging cycle The display visualizes the message BATT ID MODULE LOIN INT HOM aD At this point the battery information are transferred to the charger and are visualized on the display The charger is now ready to start Depending on the programmed start time window Parameter 8 the charger may enter in stand by mode and the display visualizes the message DELAYED START hh mm A hh mm B Where hh mm A represents the real time at that moment and hh mm B represents the programmed start time Page 16 30 BATTELEC MONTREAL CHARGEUR V 160 m1 N
24. urb the communication signals from the battery module if this occurs the charger will generate the following alarm Page 24 30 BATTELEC MONTREAL CHARGEUR V 160 m1 November 2011 CHARGEUR BLACK Service Manual 6 ENERGY METERING AND HISTORY LOG The internal memory of the BLACK DIAMOND charger contains a log of the last gt 250 charge cycles More than 50 parameters are saved for every charge cycle The most significative parameters of the 50 most recent cycles can be visualized on the display of the charger while the complete history log can be accessed and downloaded through DoctorFleet com management system In order to visualize the 50 most recent cycles it s sufficient to scroll the menu using the UP DOWN buttons and to press ENTER for 3 seconds in order to access the database The results of each charge cycle are represented on two pages Use the UP DOWN buttons to scroll between each record First page No VSTART Valor Date and Time Where No Number of cycle 1 is the most recent Vstart Battery Voltage at the connection Vstop Battery Voltage at the end of the charge Date and Time Date and Time of the BEGINNING of the charge Second page Date and Time ENDCODE Duration Ah Where Date and Time Date and Time of the END of the charge ENDCODE Charge termination code 30 different codes identify all the possible situations that determined the termination of the charging cycle see n

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