to the LEAD ACID User Manual for the 4kw
Contents
1. Strapping near the charger s output terminal Plug in the connectors before Bar Code Label TC 615 n Ap Label sensor should be fixed on the battery shell Recommend to place it in Mez LED Label T t an middle position between two cells Make sure the DC cord is Bar Code connected to the battery properly charging Place the LED at the conveniently location A thermal Version Label V Appearance Labels Please check carefully the labels on the casing of the charger before using in order to completing the transaction check the label on the charger before using it can provide some help for you to understand the performance and the specification of the charger i Bar Code Label Attaches on the output terminal of the charger For example SN10071001 1007 Production batch number Il 1001 Bar code number SNIOOT71001 48 25 Hardware model 48V 254 48 25 HD VER 1 6 HD VER 1 6 Version number from the manufacturer ii Model Label take the model TCCH 48 25 for example INDUSTRIAL BATTERY CHARGER Inout 100 240VAC 50 60Hz 14 8 1A Output 48V 125A 240VAC 48V 24 5A 115VAC 24 cells TCCH 48 25 Environmental Enclosure IP46 a Input 100 240VAC 50 60Hz 14 8 1A The rated input current is 14A at 115VAC and 8 1A at 220VAC b 48V b5AQ240VAC 48V 24 54 1 15VAC The maximum output current is 25A at input 220VAC and 24 5A at input 115VAC iii LED Label It2. HF PFC 4KW Lead acid Battery Charger Models Boa V out Nominal V out Max A out Max Battery Charger e H 66V TCCH 168 20 168V 233 3V Size mm 367 L x 352 W x 139 H TCCH 180 18 180V 243V Product Summary amp Application Scopes The charger is applicable for various Lead acid batteries like Flooded GEL AGM hemi colloid etc It features light weight small volume stable performance high efficiency and reliable security etc It can be switched automatically between the floating and balancing charging and also has the protection functions of reverse connection output short circuit and overload and so on The charger is widely used for battery charging cycles in electric vehicles such as electric forklift golf cars electric trucks electric tour bus electric yacht cleaning machines or Uninterruptible Power Supply UPS solar energy wind power dynamo and electric communication system on the railway etc Il Technical Target AC Input Voltage Range AC pa roger Full Load Efficiency Mechanical Shock amp Conformance to Vibration Resistance Level SAEJ1378 Standard Environmental Enclosure IP46 Operating Temperature 40 C 455 C 40 F 131 F Storage Temperature 40 C 100 C 40 F 4 212T 10 Charging Curves Charging Mode Available Intelligent temperature compensation Charging Control never to be charge off or charge due lll Protection Features 1 Thermal Self Protection Whe
3. he charger will start the battery protection A Incorrect AC Input Voltage Check that the AC input voltage is in accordance with the requirement A External Thermal Sensor Fault Ensure connect the thermal sensor correctly A Communication Interface Fault Make sure the communication have been correctly connected or if it is damaged A Charger Overheated Check if the ambient temperature is too high or the ventilation is smooth A Charger Relay Fault Repair A Charger Itself failure Repair IX Charging Curve 1 The charging curve is custom build to your battery set a Typical charge curve for flooded 6v Lead Acid Trojan batteries under temperature of 25 C V4 I VA V3 au 1 Pre charge after connecting the charger and battery pack the charger detects the voltage D V DT U0 a5 T of the battery pack It will pre charge the cells or the pack when the voltage is between V1 V2 with constant current of 1 when the battery voltage reaches V2 or the charging time reaches S1 it will enter the next stage of charging 2 Constant current charging charging current is I2 when the charging voltage reaches V3 it will enter the next step of charging 3 Constant voltage limited current charging or constant power charging Charging voltage goes up gradually until the maximum point V4 under constant voltage the charging current goes down to I3 or the charging time reaches S3 it enters the next step 4 Trickle charge charge current
4. is the important symbol to evaluate whether the charger works normally The LED will flash red several times when AC is first connected then the LED will flash green once The number of red flashes denotes the present curve e g If the red flashes three times it means the present curve is curve 3 and so on Hed Green flash Battery Disconnected one second interval Red flash Repair Battery three seconds interval Red flash l lt 80 Charge Indicator one second interval Yellow flash gt 80 Charge Indicator one second interval Green flash 100 Charge Indicator one second interval iv Charging Curves Label Ten charging curves respectively represent different capacities of the Lead acid battery 14 means the equalizing current Algorithms 105 means the procedure code from the manufacturer e g the charger of Lead acid flooded battery 48V for example 48V Flooded Battery 1 5KW Charger Algorithms_105 1 105 126ah 3 36a 6 262 315ah 8 37A_ 3 1se 1e2an aeaa 8 are tsaon 12 060 4 te2 219ah 581A 9 454 5adah 14 478 Charging Curves Setup curve 1 10 1 The LED will flash red several times when AC power is connected and then the LED will flash green once The number of red flashes denotes the present curve E g If the red flashes three times it means the present curve is curve 3 2 To choose another curve please cut off the power supply first then uncover the label pressing the b
5. n the internal temperature of the charger exceeds 75 C the charging current will reduce automatically If it exceeds 85 C the charger will shut down protectively When the internal temperature drops it will resume charging automatically 2 Short circuit Protection When the charger encounters unexpected short circuit it will automatically stop to output When fault removes the charger will re start in 10 seconds 3 Reverse Connection Protection When the battery is polarity reversed the charger will cut off the connection between the internal circuit and the battery and refuses to start It can avoid any destroy 4 Input Low voltage amp Over voltage Protection When the AC input Voltage is lower than 85V or higher than 265V the charger will shut down protectively and automatically resume working with the voltage is normal again IV Main Accessories amp Wiring Diagram Accessories Thermal Sensor TC 615 together with LED TC 618 as per the specific vehicle model or a single Thermal Sensor TC 615 Functions Thermal sensor TC 615 provides the real time detection of the battery s temperature in the charging process to prevent charge off or charge due LED TC 618 shows the state of the charging such as lt 80 or gt 80 or 100 and can be fitted onto the vehicle panels Wiring Diagram Note Thermal sensor and LED share the connector SP1310 P P1310 P Heat strinktube e which pairs up with the charger s communication port SP1312 S
6. turns to 14 Maximum voltage is V5 charging limited time is 94 5 Floating charge charge voltage is V6 charging time is S5 b Temperature compensation curve single cell 4 x 30CWE 0 003V T REY 3 CUT 0 002V 2 54V g Ek V l Zee 2 45V 2V v r ROTER 200 0c 25
7. utton while connecting the power If you want to choose curve 3 release the button after the 3rd LED Flash Now the selected curve e g curve 3 will be recorded in memory If you want the charger to work with the selected curve e g curve 3 cut off the power and reconnect it Note 10 charge curves are only available for volume order instead of sample order Vill Common Faults amp Solutions In case of the charging fails please examine all the outside lines carefully to make sure that they are connected correctly Apart from the circuit s failure please check the failure code of charging LED and handle it according to the following table LED Flashing swamncaorecyso SOMER dT RO eses Wrong Battery Overcharged mE Battery Overheated Es RGRGR____ Incorrect AC Input Voltage RGRGRG___ External Thermal Sensor Fault EJ RGRGRGR Communication Interface Fault 7 Charger Overheated Charger Relay Fault 9 GRGR Charger Itself Fault Note 1 R red G green 2 denotes one second pause 3 Above LED flashing sequence is one cycle the LED will flash repeatedly if the fault has not been removed Solutions A Wrong Battery Verify the battery voltage range matching with charger or inspect the battery for damage A Overcharged Confirm the battery capacity and the selected curve are matched or if the battery is defective A Battery Overheated Check the temperature at the external thermal sensor If overheated t
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