Battery Charger

Transcript

BATTERY CHARGER RX USER'S MANUAL (THIS PAGE WAS INTENTIONALLY LEFT BLANK) INDEX · 1. Introduction.........................................................................................4 · RESPONSIBILITY DISCLAIMER.............................................................................4 · 2. Safety instructions and warnings......................................................5 · GENERAL.................................................................................................................5 · SHOCK PREVENTION.............................................................................................5 · BURN AND BODILY INJURY PREVENTION..........................................................6 · FIRE AND EXPLOSION PREVENTION...................................................................6 · MEDICAL AND FIRST AID TREATMENT................................................................6 · EQUIPMENT WARNING LABELS...........................................................................6 · 3. Description...........................................................................................7 · 4. Installation of the charger..................................................................9 · INTERNAL VIEW OF THE CHARGER..................................................................10 · ELECTRICAL INSTALLATION OF THE CHARGER.............................................11 · AC VOLTAGE ADJUSTMENT – SINGLE PHASE – Box S-A-B............................11 · AC VOLTAGE ADJUSTMENT – SINGLE PHASE – Box B-C...............................12 · AC VOLTAGE ADJUSTMENT – THREE PHASES – Box B-C-D-E.....................12 · 5. Operation...........................................................................................14 · CHARGING CYCLES.............................................................................................14 · PRELIMINARY CONTROLS...................................................................................14 · RX SINGLEPHASE – BOX S-A-B..........................................................................16 · 567SCE Control Board – CHARGE OPERATION.............................................16 · RX THEEPHASES – BOX B...................................................................................20 · MRG4-3 Control Board – CHARGE OPERATION.............................................20 · MRG4-3 Control Board – ALARMS....................................................................24 · RX SINGLEPHASE and THREEPHASES – BOX C(RL) – BOX D(RTC) – BOX E (MAXI).....................................................................................................................27 · 6. · MRG5-7 Control Board – CHARGE OPERATION.............................................27 · MRG5-7 Control Board – ALARMS....................................................................31 TROUBLE SHOOTING GUIDE..........................................................34 Battery Charger RX User's Manual 1. Introduction This manual contains instructions and suggestions for the users of Energic plus RX 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 NOTE Gives additional information and tips concerning important procedures and features of the charger RESPONSIBILITY DISCLAIMER The manufacturer of the Energic plus RX battery charger will not be responsable 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 label 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. Page 4 of 36 Battery Charger RX 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 data 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. Never extend the charging leads without prior approval of the manufacturer. Extending the charging leads without prior approval of the manufacturer may cause wrong operation of the charger and voids the warranty. 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 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. Page 5 of 36 Battery Charger RX User's Manual BURN 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 prevent 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 DANGER: ELECTRICAL SHOCK CAN BE FATAL. If person is unconscious and electric shock is suspected, do not touch person if he or she is in contact with charging equipment, battery, charging leads, or other live electrical parts. Disconnect power at wall switch and then use First Aid. Dry wood, wooden broom, and other insulating material can be used to move cables, if necessary, away from person. IF BREATHING IS DIFFICULT, give oxygen. IF NOT BREATHING, BEGIN ARTIFICIAL BREATHING, such as mouth-to-mouth. IF PULSE IS ABSENT, BEGIN ARTIFICIAL CIRCULATION, such as external heart massage. 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 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. Page 6 of 36 Battery Charger RX User's Manual 3. Description Energic Plus RX battery chargers have been designed to charge Pb batteries. These units can convert the AC input voltage to a DC voltage at the correct level, in order to charge the battery cells. These are the principal devices included in the charger, available to the user: • • • • • External box; Led control panel; Main switch (0-1); No.2 Cables for battery connection; No.1 Cable for main supply connection; Page 7 of 36 Battery Charger RX User's Manual Page 8 of 36 Battery Charger RX User's Manual 4. Installation of the charger Conditions of use: • • • Operating temperature: Storage temperature: Relative humidity: 5°C to 45°C -20°C to 60°C less than 75% CAUTION ! The charger can be installed by qualified personnel only. NOTE Check that the unit's operating voltage is identical to your local power supply. Check that the unit's maximum input power is available from your power supply. CAUTION ! To prevent fire or shock hazard, do not expose the unit to rain or moisture. Do not use the unit in presence of flammable gas, because it can be generate sparks. CAUTION ! To avoid electrical shock, do not open the cabinet. Refer servicing to qualified personnel only. CAUTION ! Allow adeguate air circolation to prevent internal heat buildup. Do not place the unit near materials that may block the ventilation slots. Do not install 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. Page 9 of 36 Battery Charger RX User's Manual INTERNAL VIEW OF THE CHARGER Box S/A/B internal view Box C(RL)/D(RTC)/E(MAXI) internal view Page 10 of 36 Battery Charger RX User's Manual ELECTRICAL INSTALLATION OF THE CHARGER • • • Check the efficiency of earth circuitry (yellow/green wire); Connect the charger to the mains using an adeguate plugs, with pushbutton and fuses; Use an adeguate plug to connect the charger to the battery; CAUTION ! These settings can be done by qualified personnel only. For more information please contact the manifacturer. AC VOLTAGE ADJUSTMENT – SINGLE PHASE – Box S-A-B • • • • • • • Disconnect the charger from main supply and battery; Open the cabinet; Locate the terminal block for AC input voltage setting; Disconnect the wire A from the original terminal block (position 2); Connect the wire A to the desired position. [Check the table to find the correct position]; Close the cabinet; Connect the charger to main supply. Page 11 of 36 Battery Charger RX User's Manual AC VOLTAGE ADJUSTMENT – SINGLE PHASE – Box B-C • • • • • • Disconnect the charger from main supply and from the battery; Open the cabinet; Find the terminal blocks for AC input voltage setting; Connect the wires A and B to the desired position. [Check the table to find the correct position]; Close the cabinet; Connect the charger to main supply. AC VOLTAGE ADJUSTMENT – THREE PHASES – Box B-C-D-E • • • • • • • Disconnect the charger from main supply and battery; Open the cabinet and identify the terminal blocks (transformer taps) for AC input voltage adjustment; Disconnect the wires A, B, C from their original positions; Connect the wires A, B, C to the desired position, according with the voltages reported on the yellow label. Check the table to find the correct position; Close the cabinet; Connect the charger to main supply. Page 12 of 36 Battery Charger RX User's Manual AC Voltage Setting – Three Phase Box B AC Voltage Setting – Three Phase Box C-D-E Page 13 of 36 Battery Charger RX User's Manual 5. Operation CHARGING CYCLES The standard model of the RX chargers follows the Wa charging curve as described in the DIN 41774 norm. On the Wa charge curve, the relationship between the battery voltage and the output current of the charger can be described in 3 points: ● 100% of the rated current at the beginning of the charge (when the battery voltage is at 2,10 V/cell), ● 50% of the rated current at 80% of the charge (when the battery voltage reaches the “gasing point” that corresponds to 2,40 V/cell), ● 25% of the rated current at the end of the charge (when the battery voltage reaches its maximum value, that may vary depending on the battery type and manufacturer). PRELIMINARY CONTROLS • • • • Inspect the charger completely 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 norm. Connect the charger to the battery; Page 14 of 36 Battery Charger RX User's Manual WARNING ! When the charge is started, check that the LED “CHARGE ON” is flashing at frequency of about 1 second. This control is useful to be sure that the electronic control is working correctly. WARNING ! ENERGIC Plus RX chargers are programmed to do a complete cycle of charge, however it’s recommended to survey the operations when the battery must remain connected to the charger for more than 12 hours (example: week-ends) NOTE The operations described in these chapters are done by ENERGIC Plus RX chargers automatically. WARNING ! Before disconnecting the battery, check it is not being charged. If it is charging turn off the charger using the main switch or the stop pushbutton, to avoid sparks between connectors. Page 15 of 36 Battery Charger RX User's Manual RX SINGLEPHASE – BOX S-A-B The RX SINGLEPHASE Chargers made on the Box S,A,B mount the 567SCE Control Board. The Front Panel of the 567SCE Control Board is composed by 4 Status Leds that indicate the state of charge. After the connection of the battery, the Control Board turns on. If the battery and the AC Input are properly connected and the main switch is in position 1 the charger cycle starts automatically. If, after the connection of the battery, the main switch is in position 0, all the leds start to blink and the charge cycle doesn't start. To begin the charge cycle, move the main switch in position 1. 567SCE Control Board – CHARGE OPERATION The charge current follows the Wa charge curve as described in the DIN 41774 norm. During the first phase of charge, since the beginning of the charge cycle until the reaching of the gasing point, the led 'CHARGE ON' blinks. If the gassing point , equal to 2,4V/cell, isn't reached within 12 hours since the beginning of the charge process, the charge process stops and the led 'Emergency Stop' blinks. Page 16 of 36 Battery Charger RX User's Manual First Phase of Charge Emergency Stop – Safety Time reached When the gasing point is reached the Final Phase of Charger begins. The Final Phase of charge lasts for 3 hours. During the Final Phase of charge the leds 'CHARGE ON' and 'FINAL CHARGER' blink alternately. Page 17 of 36 Battery Charger RX User's Manual Final Phase of Charge When the three hours of Final Charge are completed the Control Board 567SCE stops the charge process. The led STOP blinks; the charge process is succesfully completed. End of the charge process If, during the charge process, the AC Input fails the 567SCE Control Board stores in memory the status of the charge process. When the AC Input comes back the charge process starts from the point of interruption. While the AC Input fails all the 4 Status Leds blink alternately. Page 18 of 36 Battery Charger RX User's Manual AC Input Fails After the end of the charge process, if the battery remains connected to the charger for more than 15 hours the 567SCE Control Board executes the Equalizations cycles. The equalization cycles consist of 4 extra charge cycles of 30 minutes executed every 15 hours. During extra charge cycles the LEDs “ FINAL CHARGE” and “STOP” flash alternately. Equalization Cycle The EQUALIZATION function, performed by ENERGIC Plus RX chargers, has been developed to keep all the cells of the battery at the same level, even after years of continuous work. Page 19 of 36 Battery Charger RX User's Manual RX THEEPHASES – BOX B The RX THREEPHASES Chargers made on the Box B mounts the MRG4-3 Control Board. The Front Panel of the MRG4-3 Control Board is composed by 4 Status Led that indicate the state of charge and 3 Leds that indicate the charge current level. After the connection of the battery, the Control Board turns on. If the battery and the AC Input are properly connected the charger cycle starts automatically. MRG4-3 Control Board – CHARGE OPERATION The charge current follows the Wa charge curve as described in the DIN 41774 norm. During the first phase of charge, since the beginning of the charge cycle until the reaching of the gassing point, the led 'CHARGE ON' blinks. If the gassing point , equal to 2,4V/cell, isn't reached within 12 hours since the beginning of the charge process, the charge process stops. See the next paragraph for the details of the alarm situations. Page 20 of 36 Battery Charger RX User's Manual First Phase of Charge When the gasing point is reached the Final Phase of Charger begins. The Final Phase of charge lasts for 4 hours. During the Final Phase of charge the leds 'CHARGE ON' and 'FINAL CHARGER' blink alternately. Final Phase of Charge When the four hours of Final Charge are completed the Control Board MRG4-3 stops the charge process. The led STOP blinks; the charge process is succesfully completed. Page 21 of 36 Battery Charger RX User's Manual End of the charge process If, during the charge process, the AC Input fails the MRG4-3 Control Board stores in memory the status of the charge process. When the AC Input comes back the charge process starts from the point of interruption. While the AC Input fails all the 4 Status Leds blink alternately. AC Input Fails After the end of the charge process, if the battery remains connected to the charger for more than 15 hours the MRG4-3 Control Board executes the Equalizations cycles. The equalization cycles consist of 4 extra charge cycles of 30 minutes executed every 15 hours. During extra charge cycles the LEDs “ FINAL CHARGE” and “STOP” flash alternately. Page 22 of 36 Battery Charger RX User's Manual Equalization Cycle The EQUALIZATION function, performed by ENERGIC Plus RX chargers, has been developed to keep all the cells of the battery at the same level, even after years of continuous work. After the End of 4 Equalization Cycles the Led' STOP ' is fixed ON to indicate that also the equalization cycles have been succesfully completed. End of the charge process and equalization cycles Page 23 of 36 Battery Charger RX User's Manual MRG4-3 Control Board – ALARMS If the Led 'Emergency Stop' blinks means that the charge cycle or an Equalization cycle has been interrupted because an alarm has occurred. The MRG4-3, lighting the current leds on the left, can indicate the cause of the allarm. Stop Pushbutton pressed during the charge cycle or during an equalization cycle. The battery voltage read after the connection of the battery is too low (under 1,60V/cell) The charge cycle doesn't begin. Page 24 of 36 Battery Charger RX User's Manual The battery voltage read after the connection of the battery is too high (over 2,50V/cell) The charge cycle doesn't begin. The battery voltage reached during the charging cycle or during an equalization cycle is too high (over 2,80V/cell). The charge cycle stops. Page 25 of 36 Battery Charger RX User's Manual The charge current reached during the charge cycle is too high (over the 140% of the nominal value). The battery voltage hasn't reached the gassing point within 12 hours of charge. Page 26 of 36 Battery Charger RX User's Manual RX SINGLEPHASE and THREEPHASES – BOX C(RL) – BOX D(RTC) – BOX E (MAXI) The RX Chargers made on the Box C(RL),D(RTC) and E(MAXI) mounts the MRG5-7 Control Board. The Front Panel of the MRG5-7 Control Board is composed by 5 Status Led that indicate the state of charge and 7 Leds that indicate the charge current level. After the connection of the battery, the Control Board turns on. The Led 'BATTERY CONNECTION' is on to indicate the right connection of the battery. If the battery and the AC Input are properly connected the charger cycle starts automatically. MRG5-7 Control Board – CHARGE OPERATION The charge current follows the Wa charge curve as described in the DIN 41774 norm. During the first phase of charge, since the beginning of the charge cycle until the reaching of the gassing point, the led 'CHARGE ON' blinks. If the gasing point , equal to 2,4V/cell, isn't reached within 12 hours since the beginning of the charge process, the charge process stops. See the next paragraph for the details of the alarm situations. Page 27 of 36 Battery Charger RX User's Manual First Phase of Charge When the gasing point is reached the Final Phase of Charger begins. The Final Phase of charge lasts for 4 hours. During the Final Phase of charge the leds 'CHARGE ON' and 'FINAL CHARGER' blink alternately. Final Phase of Charge When the four hours of Final Charge are completed the Control Board MRG5-7 stops the charge process. The led STOP blinks; the charge process is succesfully completed. Page 28 of 36 Battery Charger RX User's Manual End of the charge process If, during the charge process, the AC Input fails the MRG5-7 Control Board stores in memory the status of the charge process. When the AC Input comes back the charge process starts from the point of interruption. While the AC Input fails all the 4 Status Leds blink alternately. AC Input Fails After the end of the charge process, if the battery remains connected to the charger for more than 15 hours the MRg5-7 Control Board executes the Equalizations cycles. Page 29 of 36 Battery Charger RX User's Manual The equalization cycles consists of 4 extra charge cycles of 30 minutes executed every 15 hours. During extra charge cycles the LEDs “ FINAL CHARGE” and “STOP” flash alternately. Equalization Cycle The EQUALIZATION function, performed by ENERGIC Plus RX chargers, has been developed to keep all the cells of the battery at the same level, even after years of continuous work. After the End of 4 Equalization Cycles the Led' STOP ' is fixed ON to indicate that also the equalization cycles have been succesfully completed. End of the charge process and equalization cycles Page 30 of 36 Battery Charger RX User's Manual MRG5-7 Control Board – ALARMS If the Led 'Emergency Stop' blinks means that the charge cycle or an Equalization cycle has been interrupted because an alarm has occurred. The MRG5-7, lighting the current leds on the left, can indicate the cause of the allarm. Stop Pushbutton pressed during the charge cycle or during an equalization cycle. The battery voltage read after the connection of the battery is too low (under 1,60V/cell) The charge cycle doesn't begin. Page 31 of 36 Battery Charger RX User's Manual The battery voltage read after the connection of the battery is too high (over 2,50V/cell) The charge cycle doesn't begin. The battery voltage reached during the charging cycle or during an equalization cycle is too high (over 2,80V/cell). The charge cycle stops. Page 32 of 36 Battery Charger RX User's Manual The charge current reached during the charge cycle is too high (over the 140% of the nominal value). The battery voltage hasn't reached the gassing point within 12 hours of charge. Page 33 of 36 Battery Charger RX User's Manual 6. TROUBLE SHOOTING GUIDE SYMPTOM POSSIBLE CAUSES ACTION 1 Battery not connected properly. Check battery connectors/harness. Charger does not 2 react to battery being connected, A and LED control 3 panel remains 4 OFF. Charger has been connected to forklift motor connector. Disconnect forkift motor and connect battery. Output cables reversed. Check charger, connectors and battery polarities. Output fuse is probably blown. Bad control board connection. Check board connectors (green). Bad control board. Replace control board. Output fuse blown. Replace output fuse and adjust AC input setting. 1 AC input is absent. Check AC input voltage on each phase. Check AC input connections. Check AC disconnect switch and fuses. 2 Bad contactor. Replace contactor. Wrong AC input settings. Adjust AC input settings to higher voltage. One or more cells are shorted. Repair battery. 1 Wrong AC input settings. Adjust AC input settings to lower voltage. 2 One AC phase is absent. Check AC input voltage on each phase. 3 One or more diodes blown. Replace rectifier. 4 Bad contactor. Replace contactor. 1 Bad location. Install the charger in proper location. 2 Ventilation slots obstructed. Remove objects which may obstruct slots. Wrong AC input settings. Adjust AC input settings to higher voltage. 4 Bad or loose power wirings. Check and thighten all power wirings. 5 Transformer burned. Replace transformer. 1 Bad contactor. Replace contactor and freewheeling diode. 2 One or more diodes shorted. Replace rectifier. 1 Wrong AC input settings. Adjust AC input settings to lower voltage. 2 Battery capacity too low. Replace battery. 1 Wrong AC input settings. Adjust AC input settings to higher voltage. 5 Output current is B absent. All the control LEDs flash alternately. C 1 Output current is D too high. 2 Output current is too low. Charger smells hot. Charger too noisy Battery has low S.G. and/or doesn't last full shift . Battery temperature too high. E F 3 G H 2 Battery power demand too high. I Consider purchasing bigger Ah battery. 3 Insufficient cool down time. Increase cool down time before/after charging. 4 Automatic stop doesn't work. Check and replace board and/or contactor. Page 34 of 36 Battery Charger RX User's Manual Page 35 of 36 Battery Charger RX User's Manual Page 36 of 36