ARD - Energic plus
Contents
1. 19 Natansons nn nn ds 20 MAINTENANCE eco ss indi dm is t PH 21 s nus 22 Battery Charger RLD User s Manual introduction This manual contains instructions and suggestions for the users of Energic plus RLD 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 Aa Gives important information regarding possible personal injury CAUTION Gives important information regarding va 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 RLD battery charger will not be responsible 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 th2. BATTERY CHARGER AR D USER S MANUAL THIS PAGE WAS INTENTIONALLY LEFT BLANK TABLE OF CONTENTS gi nj 3 ee en i S NE I E S 3 3 a n A cm H A RR RO D 3 n X 3 R 3 3 1 ee E 4 RESPONSIBILITY DISGL ER o a E Rue ee tu 4 2 Safety instructions and 5 2 11221 5 GENERAL seen cm 5 SOG PREVENTION 5 BURN AND BODILY INJURY PREVENTION 6 FIRE AND EXPLOSION PREVENTIOD Ldissie taie epus d dnia 6 MEDICAL AND FIRST AID TREATIMEN Lenss s tms deca rM i EM S 6 EQUIPMENT WARNING LABELS ir rh e i e n eR FX a o eR us 6 or sis sons is n i 7 4 INSt ll fl0fi ss sand sens 9 INTERNAL VIEW OF THE CHARGER CABINET 2 2 11 9 EE S 15 PISECIMINAE Y GONIEROLS asas 15 BATTERY CONNECTION VOLTAGE CHECK AND 16 GHARGE OPERATION cerrara daina 16 AUTOMA TICDATA SAVING croi smit On OE EOE EEO 19 AUTOMATIC AND MANUAL CHARGE
3. Time Wa charge curve FAST CHARGERS WITH WoWa CHARGE CURVE The current of charge follows the WoWa curve as described in the DIN 41773 Standard while the LED CHARGE ON continuously flashes The current value when the charge starts is 20 40 higher than the standard Wa value to reduce the time of charge When the gassing voltage 2 4 Volt per cell is reached the current value is reduced to avoid overheats in the battery and the charge continues in the same way of standard Wa models Current Tension Initial Current Between 20 40 of battery capacity Tension 2 40 vicell Switch ta 2nd lower charge current Tension 2 00 vicell Time WoWa charge curve When the battery reaches the gassing voltage the charge continues for one half of the time needed to reach the gassing voltage with a minimum total time of 30 minutes OWM AR D Page 18 of 23 Battery Charger RLD User s Manual SAFETY TIMER EMERGENCY STOP If the battery doesn t reach the gassing voltage within 12 hours the charge is terminated by the Emergency timer The display will show the error message Time Error If this error message appear it s recommended to call the service for a complete check of the system The cause if this problem may be a wrong setting of the input voltage if the input is set to a certain value for example 610 V but the real voltage is lower for example 575 V the charging cur
4. board The charger process aborts itself and the Replace output fuse and adjust AC input message Output fuse blown secun appear When battery is Check AC input voltage on each phase connected 1 AC input is absent Check AC input connections message C Check AC disconnect switch and fuses 2 Bad contactor Replace contactor appear Output current D 1 Wrong AC input settings Adjust AC input settings to higher voltage is too high 2 Oneor more cells are shorted Repair battery 1 Wrong AC input settings Adjust AC input settings to lower voltage Output current 2 One phase is absent Check AC input voltage on each phase is too low 3 One or more diodes blown Replace rectifier 4 Bad contactor Replace contactor 1 Bad location Install the charger in proper location D Ventilation slots obstructed Remove objects which may obstruct slots Charger A F3 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 OWM AR D Page 22 of 23 Battery Charger RLD User s Manual POSSIBLE CAUSES ACTION Charger 1 Bad contactor Replace contactor and freewheeling diode too noisy 2 One or more diodes shorted Replace rectifier Battery has low 1 Wrong AC input settings Adjust AC input settings to lower voltage S G and or H doesn t 2 Battery capacity too
5. near flammable materials 4 WARNING To reduce the risk of fire the charger must be installed on a floor of non combustible material If this is not possible a floor plate of at least 1 6mm steel extended at least 150mm beyond the charger on all sides must be installed CAUTION Allow adequate air circulation 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 e CAUTION The operations and settings described in this chapter are fundamental for the good functionality of the charger Improper settings can cause severe damage to the charger and the battery Before to install the charger Check that the charger input voltage V is identical to your AC power supply voltage Check that the charger max input power KVA is available from your AC power supply OWM AR D Page 10 of 23 gt Battery Charger RLD User s Manual INTERNAL VIEW OF THE CHARGER m Control board ul In GF 4 m Contactor Board for input voltage selection Plugs for input voltage adjustment N Outp fuse NOTE The BOARD FOR INPUT VOLTAGE SELECTION is present only in charger
6. an 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 OWM AR D Page 6 of 23 Battery Charger RLD User s Manual Description Energic plus RLD battery chargers have been designed to charge lead acid batteries These units can convert the AC input voltage to a DC voltage at the correct level in order to charge the battery cells The digital electronic control is used to monitor the state of the charge to automatically turn off the charger when the charge is complete and to visualize all the necessary information All the features of the digital control will be explained in the next chapters These are the principal devices included in the charger available to the user External box Control panel with digital display STOP pushbutton 0 1 No 2 Cables for battery connection No 1 Cable for main supply connection External box Control panel with digital display Stop pushbutton 0 1 N 2Cablefor N 1 Cable for main battery connection supply connection OWM AR D Page 7 of 23 sa m Battery Charger RLD XS User s Manual Inside of the charger there are the following devices not available to the user Power contactor Power transformer Rectifier Microprocessor contr
7. attery from the charger while it is being charged ARCING AND BURNING OF CONNECTORS OR BATTERY EXPLOSION MAY RESULT PRELIMINARY CONTROLS Inspect the charger completey 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 OWM AR D Page 15 of 23 E Battery Charger RLD ee ts User s Manual BATTERY CONNECTION VOLTAGE CHECK AND AUTOSTART W CAUTION ENERGIC Plus RLD chargers are programmed to do a complete cycle of charge automatically however it s always recommended to survey the operations especially when the battery is connected to the charger for more than 12 hours Connect the battery to the charger using an adequate connector When the battery is correctly connected the display will show the battery voltage If the battery voltage is below the minimum threshold of 1 62 V cell the charger will not start and the display will show the error message Voltage Low ENT If the battery voltage is higher than the maximum threshold of 2 60 V cell the charger will not start and the display will show the flashing error message Voltage High gt If the battery voltage is between the minimum and maximum thresholds the charger will turn on aut
8. d Capacity charged remain stored in memory If the red STOP pushbutton is pressed the display will show these values in sequence If the charge has been terminated manually equalization and maintenance functions are automatically disabled EQUALIZATION The EQUALIZATION function is useful to keep all the cells of the battery at the same voltage level even after years of continuous work When a battery is charged discharged everyday it s suggested to equalize it weekly The charger after a normally completed charge cycle will add 4 extra charges of 30 minutes with 15 hours interval between each charge During the interval between each equalization charge the display will show the scrolling message End When the equalization chargers are in progress the display will show the message F1 followed by the current value OWM AR D Page 20 of 23 Battery Charger RLD RRR User s Manual MAINTENANCE The MAINTENANCE function is useful to keep the battery in perfect condition when it s not used for an indefined time weeks months It is sufficient to leave the battery connected to the charger the control board will keep the battery voltage under control and will activate the charger automatically when the voltage falls below a predefined minimum theshold While the charger is off and the battery voltage is being monitored this message is displayed If the voltage falls below the mi
9. e 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
10. is 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 OWM AR D Page 4 of 23 lt ss Battery Charger RLD User s Manual 2 Safety instructions and warnings Battery chargers can cause injury or death or damage to other eguipment 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 Electrica equipment must be installed and mantained in accordanc
11. low Replace battery last full shift 1 Wrong AC input settings Adjust AC input settings to higher voltage Battery 2 Battery power demand too high Consider purchasing bigger Ah battery temperature I Increase cool down time before after too high 3 Insufficient cool down time l i charging 4 Automatic stop doesn t work Check and replace board and or contactor OWM AR D Page 23 of 23
12. nimum threshold the charger will give a refresh charge to pull up the voltage to a programmed maximum threshold and the display will show the message F2 T NOTES E With this voltage controlled maintenance refresh system the battery will be kept in perfect condition for an undefined time without any risk of undercharge or overcharge If the battery is in ideal condition no self discharge the refresh charge will never be activated If the battery is in bad condition self discharge is significant the refresh charge will be often activated and the battery will be kept charged without problems OWM AR D Page 21 of 23 6 Trouble shootinc Battery Charger RLD User s Manual dk WARNING The charger can be repaired by qualified personnel only To avoid the risk of electrical injuries the user is not allowed to open the cabinet POSSIBLE CAUSES SYMPTOM ACTION 1 Battery not connected properly Check battery connectors harness En nc 9 Charger has been connected to Disconnect forkift motor and 5 forklift motor connector connect battery react to battery being connected A Check charger connectors and battery and display 3 a CADES TVETEN polarities Output fuse is probably blown remains OET 4 Bad control board connection Check board connectors green 5 Bad control board Replace control
13. olled electronic board Output fuse Plugs for input voltage selection Plugs for input voltage adjustment Output fuse Rectifier Power contactor LT il T APR JM F v m7 LA 2 EL A Plugs for input voltage selection Microprocessor controlled electronic board Plugs for input Power transformer V voltage adjustment OWM AR D Page 8 of 23 Battery Charger RLD User s Manual Installation The charger is marked with a technical label containing the following data Model Serial number S N Weight kg and Ibs Input voltages V Maximum input current A Maximum input power KVA Input frequency Hz Battery voltage V Maximum output current A Conditions of use Operating temperature 5 C to 45 C Storage temperature 20 C to 60 C Relative humidity less than 75 4 WARNING The charger can be installed by qualified personnel only To avoid the risk of injuries the user is not allowed to open the cabinet Always refer to qualified electricians for installation and service operations OWM AR D Page 9 of 23 zzl L Battery Charger RLD REA User s Manual 4 WARNING To prevent fire or shock hazard do not expose the charger to rain or moisture Do not use the e charger in presence of flammable gas because it can generate sparks Do not install the charger
14. omatically after 5 seconds If during the charge the battery voltage exceeds the maximum threshold of 2 80 V cell the charger will shut down automatically and the errore message Voltage High will appear on the display CHARGE PROCESS While the charge is in progress the following parameters are continuously displayed in sequence Battery Voltage cell Output voltage U Volt Charge current Output current A Ampere Effective time of charge h Hours Capacity charged C Ah The letter after the value U A h C indicates which parameter being is displayed To display the time the charger uses this format OWM AR D Page 16 of 23 MIPS PNE Battery Charger RLD User s Manual HOURS MINUTE DECADES h Examples Time of charge 3h 30minutes Displayed 3 3h Time of charge 7h 50minutes Displayed 7 5h gu 44 4 amp OWM AR D Page 17 of 23 Battery Charger RLD User s Manual STANDARD CHARGERS WITH Wa CHARGE CURVE The current of charge follows the Wa charge curve as described in the DIN 41774 Standard After some hours depending by the conditions of the battery when the battery s voltage reaches the value of gassing 2 4 Volt per cell the LED FINAL CHARGE starts to flash and the charge continues Current Tension Tension Initial Current about 16 of battery capacity Tension 2 40 vicell Current 50 af Initial current Tension 2 00 vicell
15. rent will be significantly lower than the nominal value therefore it will take more time to reach the gassing voltage AUTOMATIC DATA SAVING If while the charge or the equalization are in progress a black out of the AC input occurs the charger saves automatically all the relevant information about the state of the charge While the input power is absent the message Black Out is displayed When the power supply will be available again the charger will re start automatically from the exact point of interruption and the charge will be normally completed AUTOMATIC AND MANUAL CHARGE TERMINA TION Aa WARNING DON T disconnect the battery from the charger while it is being charged ARCING AND BURNING OF CONNECTORS OR BATTERY EXPLOSION MAY RESULT AUTOMATIC CHARGE TERMINATION When the charge has been normally completed the charger turns off automatically The display shows the flashing message End At this point it s possible to disconnect the battery OWM AR D Page 19 of 23 gt Battery Charger RLD User s Manual MANUAL CHARGE TERMINATION The charge can be manually terminated in any moment by pressing the red STOP pushbutton The display will show the message Stop At this point it S possible to disconnect the battery o o vo After the charge termination while the battery remains connected the final values of Voltage cell Time an
16. s with 3x 220 380 Vac input and it s NOT present in chargers with 3x440 Vac input The PLUGS FOR INPUT VOLTAGE ADJUSTMENT are present in all the chargers OWM AR D Page 11 of 23 Battery Charger RLD User s Manual AC VOLTAGE SELECTION 3 x 220 380 V The BOARD FOR INPUT VOLTAGE SELECTION is composed by six terminal blocks to be connected in one of the two configurations represented on the picture inside the charger PROCEDURE Check that the charger is disconnected from AC input and battery Open the cabinet and move the three wires WHITE in position 220V or 380V Close the cabinet Lu ur M an Loon c ceoo coo GOGae OWM AR D Page 12 of 23 Battery Charger RLD User s Manual AC INPUT VOLTAGE ADJUSTMENT The local AC input voltage must be measured with an adequate voltmeter then the charger input must be adjusted by moving the three wires marked with the letters A B C on the PLUGS FOR INPUT VOLTAGE ADJUSTMENT PROCEDURE Check that the charger is disconnected from AC input and battery Open the cabinet and move the wires A B C to the desired position Close the cabinet OWM AR D Page 13 of 23 M 55 Battery Charger RLD User s Manual GROUNDING AND LINE CONNECTION A WARNING The cabinet of the battery charger must be properly grounded to protect personnel against hazard of electrical shock in case of fa
17. 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 OWM AR D Page 5 of 23 Battery Charger RLD RRR 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 ofthe 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
18. 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 First aid facilities and a qualified first aid person should be available for each shift for immediate treatment of electrical shock victims DANGER ELECTRICAL SHOCK CAN 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 EMERGENCY FIRST AID Call phisician and ambulance immediately and use First Aid techniques recommended by the Americ
19. ult on the charger The grounding conductor must have a current carrying capacity equal or higher than the current carrying capacity of the AC input wires 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 Read on the data label the AC current value corresponding to the line voltage to which charger is to be connected Using that current value select the proper fuses disconnect switch and power cable sizes according with any applicable national or local code Check that the charger is disconnected from AC input and battery Open the cabinet Mount the input cable and connect the four power conductors three phase ground to the terminal blocks 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 OWM AR D Page 14 of 23 Battery Charger RLD User s Manual Operation Aa WARNING DON T connect the battery to the charger if the digital display is ON DON T disconnect the b
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