three phase hf evolution charger maintenance and user manual
Contents
1. WN oe WN E Wy WNW WM Wh TH A i Mil nu WI oy lt mw i THREE PHASE HF EVOLUTION CHARGER MAINTENANCE AND USER MANUAL WARRANTY TERMS This battery charger is manufactured according to basic standards that assure its good quality and every assembling phase is checked by our skilled technicians The warranty is recognized only in case of anomalies caused by manufacturing or components Complaints recognized in warranty terms cause the restoration or the replacement with an identical product without expense provide that the device is brought to our site in Saletto Pd Anything else that is not mentioned above won t be considered ex material or moral damages stop of devices Warranty duration is 12 months after the first use of the product or after 12 months of the date of the VAT invoice 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 malfunctions caused by natural events corrosive or damaging environment for electric circuits unusual impact delivery damage and misuse Shipment cost is not refunded unless the anomaly or malfunction of the device is caused by bad manufacture or problem related to the components T C E can modify and update2. If the following error appears on the display E02 TEMPERATURE CHARGING ABORTED The charging cycle has been terminated following the engaging of the thermostat Turn off the battery charger and wait for it to cool down before starting a new charging cycle If the problem persist contact TCE If the following error appears on the display E031 timer T1 CHARGING ABORTED The charging cycle has been terminated following the engaging of the safety timer in the first phase Turn off the battery charger Check the charge current is correctly set Check that the batteries are in good condition If the following error appears on the display E032 timer T2 CHARGING ABORTED The charging cycle has been terminated following the engaging of the safety timer in the second phase Turn off the battery charger Check the charge current is correctly set Check that the batteries are in good condition If the following error appears on the display E03 timer Tx CHARGING ABORTED The charging cycle has been terminated following the engaging of the safety timer in phase x Turn off the battery charger Check the charge current is correctly set Check that the batteries are in good condition SECURITY CERTIFICATION C Devices with the CE mark satisfy the essential requirements of the low voltage and electromagnetic compatibility standards
3. A U 51 8V C 0125h 01 15 If during start up the battery is not detected because it is missing or because it is connected with polarity reversal an output short circuiti s detected or battery voltage WAITING xxV BATT measured is 5V higher than the programmed nominal battery voltage the display will VBATTERY xx xV read as shown to the right and the battery charger will not proceed to power module testing If the power module test which occurs during start up does not return a positive result the error shown to the right will appear on the display where x indicates the module giving problems CHECK MODULE X CHARGER ABORTED If however all controls return positive result the battery charger will start supplying current to the batteries Current will be brought to the maximum nominal value set by programming in soft start mode in other words slowly in order to protect the batteries themselves During normal operation of the battery charger in addition there are various controls which may interrupt the charge cycle If current supplied to the batteries IB is higher than current Ibmax 160A the error Srt IB gt IBmax message shown to the right will appear CHARGING ABORTED Each charging curve can be provided with a safety timer on reaching which the SCt CHARGING TIME charge will be interrupted with the warning shown to the right CHARGING ABORTED In the event that the charging cycle is interrupted
4. rates 14 Working in the vicinity of a lead acid is dangerous as batteries generate explosives gases during charging Therefore smoking and or generating open flames and or sparks must be avoided 15 Never charge a frozen battery 16 Battery must be charging in specific well ventilated areas 17 In order to reduce risk of injury only charge Lead Acid GEL or AGM type Lithium Polymer or Lithium lon batteries Do not charge other types of rechargeable or non rechargeable batteries as they could explode causing damage or injury FURTHER SPECIFICATIONS FOR LITHIUM BATTERIES 18 In order to charge Lithium Polymer and Lithium lon batteries a BMS battery Management System must always be used comprising an active and passive safety system in compliance with safety regulations in force 19 The possibility of the BMS acting directly on the battery charger operation during cell balancing phase rules out for any reason whatsoever that the battery charger is held directly responsible should damage caused to the battery or even a fire or an explosion be due to an error in the BMS software 20 The faculty offered by the materials produced by TCE to select different levels of voltage for charging is entrusted to the control and supervision of the end user and TCE is not liable for any consequences resulting from the selection of the incorrect level voltage If in doubt the user should ask a qualified professional for clarification 21 The battery c
5. charged 32 We recommend fitting a fuse between battery charge and battery The fuse must be installed along the connection to the positive terminal of the battery The rating of the fuse must be proportionate to the nominal output current of the battery charger the diameter of the cable used and the environment in which it is be installed 33 We recommend unplugging it from the mains supply before connecting and disconneting batteries 34 During normal operation of the battery charger the external surface may become hot and may remain so for a certain period of time after it has been switched off 35 The battery charger needs no special maintenance only regular cleaning procedures to be carried out according to the type of working environment Cleaning procedures should only be carried out on the external surface of the battery charger Before starting any cleaning procedures the mains supply cable and battery cables must be unplugged Do NOT use water and detergents in general and pressure washes of any kind when carrying out cleaning LACK OF USE 36 If safe operation of the battery charger can no longer be ensured stop the device and ensure that it cannot be put back into operation 37 The specifications set out in this manual are subject to change without any notice This publication replaces any previously supplied information USER MANUAL HF EVO EVOLUTION SERIES TECHNICAL CHARACTERISTICS 1 Mains supply voltage 400V three phase A spe
6. cial version of HF EVO for 480Vac three phase mains supply for NON European countries is available on request 2 Charge parameters immune to variations in mains supply voltage in the interval 10 3 High frequency modular switching technology 4 85 increased efficiency 5 Charge profile can be programmed for all types of battery on sale 6 Versatility of use of battery charger due to smartcard programming eS aS YH wa 7 Viewing on backlit display of charger current battery voltage amp hours absorbed by the battery and charge cycle durations 8 Viewing on the display alphanumerically of any error messages 9 Compensation of voltage drop on battery cables 10 Charger process start in Soft star mode and automatic reset on insertion of a new battery 11 Charge cycle start also with 4V batteries 12 Protection against output short circuit 13 Protection against polarity reversal with output fuse which cannot be automatically reset and polarized battery connector 14 Battery charger manufactured compliance with directive 89 336 EEC regarding ELECTROMAGNETIC COMPATIBILITY HF EVO SERIES OPERATION Turn the general switch into the OFF position and plug the mains supply cable into a three phase socket with adequate power Connect the battery paying attention to polarity When turned on the following information will appear as shown below in sequence Information about the manufacturer Contro
7. due to the opening of the output E01 OPEN CIRCUIT circuit the error message shown to the right will appear The display will flash for 60 WAIT 1 MIN seconds The battery charger is fitted with a temperature sensor which engaging on the maximum allowed temperature being exceeded interrupts the charging cycle and display the error message shown to the right E02 TEMPERATURE CHARGING ABORTED In the event that the timer set on the first phase of the charge cycle is exceeded the E031 timer T1 error message shown to the right will be appear CHARGING ABORTED In the event that the timer set on the second phase of the charge cycle is exceeded E032 timer T2 the error message shown to the right will appear CHARGING ABORTED In the event that the timer set on phase X of the charger cycle is exceeded the error message shown to the right will be appear error valid whenever the charge cycle is E032 TIMER Tx made up more than one phase and each phase is set with a safety timer CHARGING ABORTED Should an error occur for safety reasons the power remote control switch for the three phase circuit will open thus interrupting the charge cycle and cutting supply to the power modules TROUBLESHOOTING FOR EVO HV THREE PHASE POBLEMS SOLUTIONS The battery charger won t turn on Check that there is adequate mains supply voltage at the mains socket and that the fuse is working The charge cycle won t start and
8. edge unless they are properly supervised by a person responsible for their safety WHERE TO INSTALL 5 Never place the battery charger in the immediate vicinity of the battery in order to prevent gases produced or emitted by the actual battery during charging corroding or damaging the battery charger Place the battery charger as far away from the battery as the length of cables permits 6 Do not install the battery charger in a closed space or in such a way as to somehow prevent ventilation For units equipped with fans at least 30mm clearance must be left around the vents In order to facilitate the heat exchange of the battery charger it must be positioned vertically exploiting the fixture holes where provided 7 Do not use the battery charger outdoors 8 Do not expose the battery charger to rain water splashes or steam 9 Do not install the battery charger in caravans and similar vehicles 10 Do not install the battery charger near any heat sources or in areas with high concentrations of dust 11 Do not install the battery charger near any potential sources of flammable material for example methane gas pipes or fuel depot 12 Do not place and or fit the battery charger onto surfaces manufactured out of combustible material like wooden shelves or walls BATTERIES 13 Follow the specific safety instructions provided by the battery manufactured carefully for example whether or not remove cell caps during charging and recommended charge
9. electrical system If one of this things occurs the plant operator or the person using the device should check whether the device may be connected asking for a confirmation to a skilled technician Connect the battery charger to a mains 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 undamaged 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 charging gas and vapor are released that can be harmful and could be highly explosive Only use the charger in well ventilated areas to preve
10. harger tolerance thresholds as far as levels of over voltage and overcharging are concerned are used only for the safeguarding of the system of the same and have no safety functions for the battery itself The safety or which depends solely on BMS even when the battery charger is connected to the battery whether the latter is being charged or not 22 Should the client want to use the battery charger on a specific on board system and in general in any cases of special usage it is the client s responsibility to inform TCE so that the latter an draw up any necessary recommendations In this case the client must provide TCE with all designs diagrams and descriptive material necessary TCE cannot be held responsible for any damage resulting from the use of the battery charger after opening it and modifying it and inserting it into other systems 23 Under no circumstances can TCE be held responsible for the malfunctioning of the batteries or the incineration explosion of these in so much as the safety of the battery is the task of the BMS and not of the battery charger CHECKING CABLES GRID EARTHING 24 Do not transport the battery charger by pulling on the cables as they could be damaged Use the handles if provided 25 Before using the battery charger check the the sleeving on the mains cable and battery cables is in good conditions Should one of the cables be damaged have it replaced by TCE qualified technician 26 Chec
11. its devices without noticing to the customers but guaranteeing replacement parts Restorations of replaced parts are guaranteed for 6 six months The buyer agrees with the terms of warranty Relating to the manufacturer s responsibility T C E 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 SPee Fs Dear Customer Thank you for your trust and for buying this high quality T C E 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 different features offered by this T C E product Please note the safety standards to ensure greater safety when using the product Careful handling of the product will repay you with years of safe and reliable operation Safety rules CAUTION Indicates a possible dangerous situation that if not avoided can provoke mild injuries or material damage WARNING Indicates a dangerous situation that if not avoided can provoke serious injuries or death DANGER Indicates a direct and imminent threat that if not avoided will provoke death or serious injuries IMPORTANT Indicate the correct use of the machine and other useful information This sign doesn t stand for a
12. k the compatibility of the mains plug supplied with the battery charger the use of adaptors is not recommended 27 Check that the input voltage of the battery charger given on the data plate is in line with the voltage available 28 The battery charger must be plugged into a socket fitted with an earth wire Should the socket not be equipped with an earth connection do not use the device before having a suitable socket installed by a qualified technician 29 The power socket to which the battery charger is to be connected must be protected by an electrical device by law fuse and automatic cut out capable of absorbing an electrical current equal the absorption of current stated on the matriculation number of the battery charger increased by 10 30 Do not open the battery charger as there are no parts which can be serviced and replaced by user Only specialized personnel authorized by TCE may carry out servicing which involves opening the actual device Electrical components inside may cause electric shocks even if the device is not plugged in CHECKING BATTERY CHARGEE OPERATION AND CURVE 31 Before charging make sure that the battery charger is in line with the voltage of the battery that the charging current suits the capacity of the battery and that the selected charging curve for lead acid batteries and the batteries or for airtight GEL or AGM type batteries Lithium Polymer or Lithium lon batteries is correct for the type of battery to be
13. l circuit board model and firmware version inside the micro controller these parameters may be subject to change without any notice Voltage current and charging curve programming In the example to the right configuration for 48V 100A with charging curve IUla WET Number of modules detected inside the battery charger In the example to the right 3 power modules are detected Viewing of full scale voltage and length of cables used in order to calculate compensation of voltage drop on the latter In the example to the right a full scale of 100V and cable length of 3 5m is shown Battery detected In the example to the right programming for 48V battery is shown whilst 49 2V identifies the voltage measured Closure of the power remote control switch for the three phase circuit Test to check if power module X is supplying current The test is carried out for all the modules Display during normal operation of the battery charger In the example to the right the values given are solely identificatory Time is always given in the hh mm format During battery charger strat up various controls are carried out which if not returning a positive result may prevent the battery charger from working TCE ELETTRONICA INDUSTRIALE UBRICK FLASH V 1 01 C000 CBHF 48V 100A CURVE IUla WET POWER MODULES 03 FULL SCALE 100V OUT CABLE 03 5M WAITING 48V BATT VBATTERY 49 2V MAIN SWITCH ON POWERMODULE X PWM xx IM xx xA I 100
14. n 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 IP32 instructions Never operate the charger if there is any evidence of damage Any safety devices or parts that are not functioning properly or are in a condition that won t assure its proper functioning must be repaired before switching the charger on Never bypass or disable protection or safety devices Important safety instruction Keep these instructions This manual contains important instructions for the safety of the user and operation of the device GENERAL WARNINGS 1 Before each use of the battery charger the instructions set out below must be carefully read and abided by 2 The failure to follow these instruction and or errors in installing or using the battery charger could lead to endangering the operator and or damaging the device voiding the manufacturer s guarantee 3 The battery charger cannot be used as a component in system which provide life support and or medical device without explicit written authorization from TCE 4 The battery charger must not be used by person with reduced physical sensory and mental capacities or with lack of experience and knowl
15. nt the accumulation of explosive gases Battery areas with less than 4 hydrogen are deemed not to be at risk of blast This environment situation is provided by a good ventilation 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 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 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 following occurs do not start the battery charger and have the battery checked Uneven electrolyte levels or high water consumption in individual cells 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 in the vicinity 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 s safe eve
16. ny 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 a to third party damage to the device itself and other material or assets belonging to the company inefficient operations All personnel involved in commissioning operating maintaining and servicing the device must have suitable qualification read and follow these operating manual carefully 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 over Before switching on the battery charger rectify any faults that could compromise its safety The device is to be used exclusively for its intended purpose Any use above and beyond is deemed improper The manufacturer is not responsible for any damage unexpected or incorrect results caused by such misuse The use includes reading and obeying all operating instructions and safety and danger warnings performing all inspection and maintenance work following all instructions on the battery and vehicle manufacturers Mains line connection Devices with a higher rating may affect the energy quality of the mains due to their voltage input This may affect a number of battery chargers and cause connection restrictions like insufficient network capacity insufficient dimensioning of the
17. the display reads WAITING xxV BATT VBATTERY xx xV Check battery connection and correct polarity Check the battery fuse Check that the battery voltage does not exceed by more than 5V the battery charger programming nominal voltage The yellow led won t come on even 15 hours after the start of the charge cycle Check the battery it could have faulty cells If during start up this error appears on the display CHECK MODULE x CHARGING ABORTED Module x is in short circuit Turn off the battery charger Unplug the mains cable from socket Contact TCE for replacement of the power module If the following error appears on the display Srt IB gt lbmax CHARGING ABORTED Current supplied to the batteries IB is higher than current Ibmax 160A Turn off the battery charger Unplug the mains cable from socket and contact TCE If the following error appears on the display Sct CHARGING TIME CHARGING ABORTED The safety timer has interrupted charging Check the charge current is correctly set Check that the batteries are in good condition If the following error appears on the display E01 OPEN CIRCUIT WAIT 1 MIN The charging cycle has been interrupted following the opening of the output circuit The display will flash for 60 seconds At the end of the 60 second reconnect the batteries The charge cycle will start again from the beginning
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