Lifetech® Modular - EnerSys
Contents
1. 4 Completion of charging with equalization Manual equalization only concerns vented lead acid batteries It will be initiated manually or automatically through the menu All other technologies will have an automatic preset equalization time A programmed equalization will start automatically after the end of the charge The launch of the equalization and its duration can be adjusted throug the menu The display indicates the date or remaining time to start the equlization nn ALT Jl Equalization mode auto Days of the week the symbol below indicates when the equailzation is programed e g Saturday and Sunday To start manually an equalisation charge at the end of the charge AVAIL display press the equaliza tion button To force manual equalization when the charger is Switched off keep pressed the equalization button right button and contemporary click the On Off only charging profiles for flooded During equalization the following message Is displayed Em zs Li E E LM T mem During equalization Line 1 mode equal current total voltage remaining time 5 Completion of charging with float If the Float function has been selected the screen will show the message floating During floating Line 1 current voltage per cell Lifetech Modular LCD FAULT MESSAGES No display and Blue No mains supply Check the power supply and the input2. OFF O6HOO NEVER OFF Zz Delay Start of charge is delayed for the amount of time stored in value O to 24 hours Time of day charge will not start until the time of day stored in value 24 hour format Daily charge On Off Sets daily charge on or off Daily Chg Start Sets daily charge start time Daily Chg End Sets daily charge end time Floating On Off Sets float mode on or off Current Sets float current Voltage Sets float voltage Lifetech Modular This feature can be turned ON or OFF depen ding on the application A float charge at the end of standard charge is intended to compensate for consumption by the truck electronics that are left on when truck is not used typically AGV The parameter Voltage is in mVpc millivolts per cell determines the maximum float voltage parameter Current defines the current output during float the current will automatically decrease to keep the battery voltage at the maximum defined by the Voltage parameter Battery rest oet battery rest time in hours Conditional charge oet conditional charge The charger will only commence the charge if the battery has reached the limit of depth of discharge DoD of more than x For example if the user wants to charge the battery only if it is discharged more than 30 the parameter 30 has to be entered in the conditional charge The O value disables the function Ref
3. matching with continuous current loops Default CF 1 15 no need to set CF but available if required Used to charge batteries gt 1 charging rate between 0 13 and 0 09 profile O 17 to 0 22 C Auto battery capacity by loops final current 176 CF 2 1 06 Can manually set battery capacity if required IUI profile 0 2 C Auto battery capacity by loops final current 2 2 finish time limitation Can manually set battery capacity if required Standard Water Less profile IUI profile 0 2 C finish CF 1 10 final current 5 C Auto battery capacity matching with phase 1 loop Can manually set battery capacity if required Pneumatic Airmix profile Must have Air kit fitted to use this profile profile 0 22 C Auto battery capacity by loops final current 5 finish CF 2 1 07 Can manually set battery capacity if required For XFC Block product Only visible after setting XFCBLC menu item to ON all other profiles invisible Do NOT use for XFC2V product Profile IUI 0 5 C finish time limitation with refresh IMPORTANT SAFETY INSTRUCTIONS 1 This manual contains important safety operating instructions Before using the battery charger read all instructions cautions and warnings on the battery charger the battery and the product using the battery This charger has been designed to only charge flooded lead acid batteries Read and understand all setup and operating instructions before using th
4. HAWKER MODULAR CHARGERS KEEP ON GUI EVEN WHEN PART OF THE TEAM IS MISSING Modular Lifetech Modular Lifetech Modular The modular range is based on the modular concept made of universal power bricks allocated into different cabinet sizes in order to achieve the required output power For 1 phase the module is a 1kW power AC DC converter 1 l phase 230 Vac The modules are installed into 3 bay cabinet up to 3KW 1 bay cabinet stand alone 1kW charger 6 bay cabinet up to 6kW future development Stand alone 1kW charger 3 bay cabinet for chargers up to 3kW 12V 6LA20650 1kW module 24V 6LA20629 1kW module 36 48 6LA20635 1kW module Lifetech Modular For 3 phase the module is 3 5kW Power DC converter with the following outputs 3 phase 400 Vac 24 36 48 0 65 60A 72 80 40 36A 24 36 48V 3 5kW module 72 80 3 5kW module CHARGE PROFILE CODES The following table describes the codes to be used in new charger part numbers to indicate the charging profile of the charger Pz5 PzB PZM Slow charge LOWCHG PROFILESLOW PzS PzM PzQ Heavy duty HDUTY PzS PzB PzM Normal Duty std flooded STDWL XFC AFG Blocs KFCBLG Not available on the 1 phase stand alone charger Specific part number for charger must be used Lifetech Modular PROFILE DESCRIPTION Heavy Duty Profile IONIC Auto battery capacity
5. ar PASSWORD This is where the password is entered to gain access to service level menus by authorized EnerSys service personal The default password is 0099 CONFIGURATION This menu allows for configuration of the charger Password is required to view this menu Access On the main menu select password and then press ENTER Use the four ESC EQ W and A pads to select the numbers corresponding to your pass word Then select configuration Required setup the following parameters must set including date and time Parameters daylight savings Parameters display screen saver Parameters display time Parameters serial number Configuration charge charge delay type Configuration charge charge delay value hour delay Configuration battery cap manu auto Configuration equalization time Configuration equalization delay Configuration equalization frequency Configuration equalization refresh on off default factory ship configurations CHARGE Profile Function to select right charging profile for the application LOWCHARGE HDUTY STDWL GEL VRLA XFC BLOC PNEU AUTO START ON Charger will start when the battery is connected OFF Need to press the start button to start the charging process Charge delay Type sets OFF Delay or Time of day Value hour delay sets the amount or time of day for the delay 00 00 to 24 00 EUROPE 00 15 PER ORDER
6. d osos Eurus al oom be mem Power Full Solutions EnerSys EMEA EH Europe GmbH L wenstrasse 32 8001 Z rich Switzerland Phone 41 44 215 74 10 Fax 41 44 215 74 11 WWW enersys emea com Enersys Ltd Oak Court Clifton Business Park Wynne Avenue Swinton Manchester M27 8FF Phone 0161 794 4611 Fax 0161 727 3809 Please refer to the website address for details of your nearest EnerSys office www enersys emea com 2015 EnerSys All rights reserved All trademarks and logos the property of or licensed to EnerSys and its affiliates unless otherwise noted 03 2015 Subject to revisions without prior notice E amp OE
7. e battery charger to prevent damage to the battery and to the charger Do not touch non insulated parts of the output connector or the battery terminals to prevent electrical shock During charge batteries produce hydrogen gas which can explode if ignited Never smoke use an open flame or create sparks in the vicinity of the battery Ventilate well when the battery is in an enclosed space Do not connect or disconnect the battery plug while the charger is on Doing so will 10 LI cause arcing and burning of the connector resulting in charger damage or battery explosion Lead acid batteries contain sulfuric acid which causes burns Do not get in eyes on skin or on clothing In cases of contact with eyes flush immediately with clean water for 15 minutes Seek medical attention immediately Only factory qualified personnel service this equipment De energize all AC and DC power connections before servicing the charger The charger is not for outdoor use Do not expose the charger to moisture Operating conditions should be O to 45 O to 70 relative humidity Do not operate the charger if it has been dropped received a sharp hit or otherwise damaged in any way For continued protection to reduce the risk of fire install chargers on a floor of non combustible material such as Stone brick or grounded metal WARNING The shipping pallet must be removed for proper and safe operation Life
8. ed led flashing Check power supply If all modules in fault a DF1 error will follow blocking fault MOD DFC Blocking fault one or more module are not compatible with the charger configurati on for example 24V charger with one 48V module This can happen if the user replaces one module with another one with a different voltage setting DEF ID Use correct module I x A hlocking fault preventing charging from continuing Refer to the Technical Characteristics sheet joined to the charger Lifetech Modular MAINTENANCE amp SERVICE The charger requires a minimum of maintenance Connections and terminals should be kept clean CAUTION and tight The unit especially the module heatsink There are dagerous voltages within and fan should be periodically cleaned with low the battery charger cabinet Only pressure air to prevent any excessive dirt build up me on components Care should be taken not to bump qualified personnel should service or move any adjustments during cleaning Make this battery charger sure that both the AC lines and the battery are disconnected before cleaning frequency of this type of maintenance depends on the environment in which this unit 15 installed TESTING OF COMPONENTS SINGLE PHASE Only qualified personnel should service this battery charger IMPORTANT Disconnect battery and turn AC power OFF before servicing 1 DC Output fuse Disconnect the AC p
9. fuse s LED off DF CUR DF1 Charger fault Check the power supply voltage Check that the battery is correctly connected DF2 Charger fault that the cables are not reversed and check the output fuse Battery voltage too high too low Connect are the correct battery to the charger The battery has been discharged more than 80 of its capacity Charging continues Check the charging cables cross section too Bigs Battery requires inspection Small the terminals oxidization not tight and the battery defective cells Pneumatic mixing air circuit fault the red 2220 DF light flashes Check the air circuit pump tubing Check that the fan s is are working correctly Thermal fault resulting in interruption of and or that the ambient temperature is not too charging high or whether there is poor natural ventilation to the charger Check that the fan s is are working correctly and or that the ambient temperature is not too high or whether there is poor natural ventilation to the charger all modules are in thermal fault then a TH fault will follow Alternating with charge parameters one or more module in thermal fault the charge process continues the faulty module s is are displayed red led flashing MOD TH Alternating with charge parameters one or more module DF1 fault the charge process continues the faulty module s is are displayed r
10. harges have been stored in memory title line Memo is the latest charge memorized After memorizing the two hundredth charge the oldest record is deleted and replaced by the next oldest Displaying a charge cycle Proceed as follows Select a record Memo x using the A V buttons Display the first history screen by pressing Enter 2 Display the second history screen by pressing W 4 Return to the main menu by pressing Esc The charge history is displayed use the A W to scroll through the parameters Profile Selected profile U end Battery voltage at end of charge Vpc Capacity Current at end of charge Time of the charge cycle U batt Rated battery voltage V Chg time dam Battery temperature at AH Amp hours returned p start of charge F during charge cycle otate of charge at start of 7o init charge tart of charge date and Time U start Battery voltage at start of pp Battery disconnect date charge Vpc and time STATUS This menu displays the status of the charger s internal counters number of normal and partial charges faults by type etc Lifetech Modular STATUS SCREEN Total number of charges Corresponds to the total of normally terminated charges and charges Charge terminated with or by faults Number of charges normally terminated Number of charges terminated abnormally TH Number of charger temperature faults DF1 etc Nu
11. inet chargers The charger must be mounted on a wall or Stand in a vertical position The lower part of the charger must be at least 60 cm from the ground and or the charger below and the upper part 90 cm from the ceiling The minimum distance between two chargers must be 30 cm The charger will be installed with the bracket supplied See the Wall Mounting Dimensions section at the end of this manual for proper bolt pattern NOTE Ambient temperature at all levels cannot exceed AO Electrical connections To prevent failure of the charger be sure it is connected to the correct line voltage Connecting Input Power WARNING Make sure the power to the charger is OFF and the battery is disconnected before connecting the input power to the terminals of the charger Connect the input power to the appropriate terminals including ground Follow your local electrical or National Electric Code in making these connections AC connection The user must provide suitable branch circul protection and a disconnect method from the AC power supply to the charger to allow for safe servicing Plug polarity The charging cable is connected to the DC output of the charger with the positive lead marked RED The output polarity of the charger must be strictly observed when connecting to the battery read warning above Improper connection will open the DC fuse Grounding the charger DANGER Failure to ground the charger c
12. lt setting autostart ON then the charge will start automatically else press the start stop button The display will show 3 different screens alternating CHARGE PZM T p o Es TN SrA 24 57 HAF 0 Line 1 charge mode charging profile equal symbol if selected or no blocking fault Line 2 charging current total voltage CHARGE 2 BRA em Line 1 charge mode charging profile equal symbol if selected or no blocking fault Line 2 charging current voltage cell charging time CHARGE __ Lo Fa i n mM Line 1 charge mode charging profile equal symbol if selected or no blocking fault Line 2 charging current state of charge estimated remaining time COMPLETION OF CHARGING 1 The LCD screen will give you the message of availability AVAIL The battery is charged and ready to use 2 STOP the charge and disconnect the battery To stop the charge press the Stop Start button Never disconnect the battery during charge without stopping the charging process This could lead to dangerous sparks or to charger damage 3 Completion of charging without equalization The green charging complete light is illuminated and the message AVAIL is displayed The display shows in alternation e The charging time taken e The number of Ah recharged Non blocking faults if present Ex
13. mber of faults recorded by the charger see Fault codes USB This menu provides access to the USB function The charger can store charging data in a USB memory and update software Record memo This function enables the storage of charge memorizations and the status data The file in CSV format useable with Memoreport or Excel will be stored in the USB stick under the name MDDDHHMM CSV with M for Memorization DDD Day of the year HH Hour of file creation MM Minute of file creation Update software Update chargers internal software The software is provided by EnerSys PARAMETERS Date time oets date and time of the charger The clock has a battery backup which will preserve the time when power to the charger is off Daylight savings Enable or disable automatic clock adjustment for daylight savings time When enabled seasonal time change 15 adjusted automatically The charger must be powered up at the time of the change for it to take effect Language oelects the language displayed in the menus Region select the format for date metric EU or imperial US units for temperature length and cable gauge Display oet screen saver function Contrast Modifies the display contrast level 20 to 39 Screen saver Enable or disable the screen saver function Delay oet the time the screen stays illuminated The delay time is ad justable in minutes up to 1hour and 59 minutes Lifetech Modul
14. ould lead to fatal electric shock Follow national electric code for ground wire sizing DESCRIPTION OF OPERATION General EnerSys Lifetech Modular chargers can easily be set to charge flooded and sealed lead acid batteries including XFC blocs within the appropriate range of the cell and ampere hour rating Beginning the charge When battery is connected to the charger the control board senses voltage and after a 15 second delay the charger starts Charging Charging current is determined by the battery voltage and interaction of the charger As the battery charges the LCD display will output various charge parameters including the percentage of battery capacity AC power fail If the AC power fails with a battery connected to the charger during a charge cycle the charger will reset and start a new charge cycle when power is restored All charger settings as well as the time and date are preserved Series charging In series charging the voltages of both batteries add up and must match charger s nameplate rating The chargers ampere hour rating must be equal to each of the batteries ampere hour rating Charge cycle will not start unless both batteries are connected GLOSSARY Charging profile The charging profile defines the rate of Current charge over time charger adapts to the battery s age and level of discharge OPERATING INSTRUCTIONS Control panel 10 Lifetech Modula
15. ower and the battery before _ opening the door Check of output fuse Is carried 0 22 fuse Ok out with the multimeter in Q position Infinity replace the fuse Part number 6LA10465 DC fuse DC output fuse amp DC cables Torque M6 to Nm and M4 to 1 5Nm 7 Nm 1 5 Nm Lifetech Modular 2 Display board and door Display and control board CAUTION Use an anti static wrist strap when removing and replacing circuit board assemblies If a fault on the display control board or external door occurred replace the full door with kit REMOVAL Please follow these steps to remove a display board 1 2 Touch your finger to a ground to remove any static charge Unplug connectors from the display board Some connectors maybe secured by screws Unscrew the hinges on the side Remove the door REPLACEMENT 1 Align the door kit to the in proper position 2 Reallocate screws in on the side hinge torque to 1 Nm 3 Reconnect the ribbon cable s ENSURE TO PROGRAM THE CHARGER CORRECTLY FOR THE APPLICATION THE CHARGER SERIAL NUMBER HAS TO BE SET UP IN THE MENU Lifetech Modular 3 Module test and replacement Rolling green red alternatively for 6 seconds Red ON or flashing refer to charger display 12V 6LA20650 1kW module 24V 6LA20629 1kW module 36 48V 6LA20635 1kW module Unplug AC plug DC from battery D Pull the module out from its guide 2 Watt till bl
16. r Controlling the overcharge coefficient whatever the battery s discharge level reduces the amount of electricity consumed Equalization charging Equalization charging performed after normal charging balances the electrolyte densities in the battery s cells Refresh charging Refresh or maintenance charging enables the battery to be maintained at maximum charge all the time that it is connected to the charger oelect active menu Return to top of list press for 2 sec ra Access a sub menu Lifetech Modular MENU ACCESS When the charger is idle press and hold ESC the main menu is then displayed main menu is automatically exited after 60 seconds of inactivity or can be exited voluntarily by pressing the lt 5 gt button Main menu Al menus are accessed from main menu a detailed description of each menu is included in the next sections of this manual The menus that require a password are not displayed until the correct password has been entered The menus provide access to the following functions View last 200 charging cycles memorizations menu View of faults alarms etc status menu USB functions USB menu Setting of date language and others parameters menu Management of password password menu Memorization data MEMO Memorizations display screen The charger can display the details of the last 200 charge cycles he display shows here that c
17. r OFF or charger idle mode ON or Yellow OFF module in fault Module in stand by ohort green pulses 24 36 48V 3 5kW module 72 80 3 5kW module Unplug AC plug and DC from battery 6 Pull the module out from its guide 2 Wall till blue light on the screen off 2 Place the new one in ensure to use an 3 Touch your finger to a ground to remove appropriate module any static charge 8 screw the top and bottom screw back 4 Open the charger door oP Unscrew the module Lifetech Modular TECHNICAL SPECIFICATION SINGLE PHASE Specifications 1 bay stand alone Specifications 2 and 4 bay cabinet Stand Alone 1kW EE 230V 10 1ph 21 0 C to 45 C lt 10 2 line LCD 344 x 250 x 182 no brackets 435 x 286 x 185 no brackets L __tbaystencaone _____ _______ 3 bay cabinet LL 8 400V 10 3ph oa rome 21 0 C to 45 C 0 95 lt 10 2 line LCD 2baytrmoauiy rare modules bay 3 modules bay bay 6 modules 6 bay modles 6 bay cabinet Lifetech Modular GENERAL ELECTRIC DIAGRAM 3 PHASE Modular 3 5kW ne epus GENERAL ELECTRIC DIAGRAM 3 PHASE Power Module 3 5kW 400 480V MAPLE LL m
18. resh On Off Sets refresh mode on or off Imax oets charger maximum output current BATTERY Cap Manu Auto When in lonic mode the charger can estimate the capacity of the connected battery automatically Auto or the charger will use the capacity entered manually Manu in the Capacity menu Capacity Battery AH capacity used by the charger must be set to Manu for lonic profile to determine start and finish rates Battery temperature This parameter adjusts the regulation voltages on the charging profile values between 15 C 65 149 F Cell size oets number of battery cells 6 12 18 24 36 and AO cells according to the charger CABLE Length Select the length of DC cables from the charger to the battery terminals in 1m to 15m Section Sets the DC cable gauge from 6 to 70 mm EQUALIZATION Current This defines the equalization or desulphation current for a manual start Manual equalization is disabled during opportunity cycles Time Sets the equalization time from 1 to 48 hrs Delayed start delay sets the delay between the normal charge and the equalization charge from O hr to 23 hrs Frequency selects one or several periods for carrying out the equalization charge The user can select one or several days per week Lifetech Modular CHARGING THE BATTERY Initiating charging The display in idle will show the WAIT message Connect the battery If defau
19. tech Modular TECHNICAL INFORMATION The nameplate located on the outside of the charger should be used to check this application before installation Model Serial number Operating input voltage Output Range Vac Voltage V Mains amp frequency Hz Current A Max input power W PART NUMBER UK or standard European input plug can be selected by using different part numbers 12 1 1 12 1 24 98PMGMLT2B24 128PMGMLT2B24UK IBPMGMLT3B24 128 240 36 N 28 1 TC1 LTM 36 48V 2kW l2BPMSMLT2B4B 128PM3MLT2BASUK TC1 LTM 36 48V 3kW l 1i28PM3MLT3BAB 128PM3MLT3EABUK _ I28XMIMCTIBI2 128XMTMLTIBIZUK TO LIM 24V 1KW y T28XMTMLTIB2Z4 128XMTML TC1 LTM 24V 2kW 128XM3MLT2B24 198XM3MLT2B24UK TC1 LTM 24V 3kW 128XM3MLTSB24 128XM3MLT3B24UK XFC 12 1 48 128XM1MLT184BUK TC1 LTM 36 48V 2kW 128XM3MLT2B48 128XM3MLT2BABUK TC1LTM36 48V 3KW 3 T2BXM3MLT3B48 128XM3MLT3BABUK Lifetech Modular INSTALLATION WARNING The shipping pallet must be removed for proper and safe operation Location For maximum trouble free service choose a location which is free of excess moisture dust and corrosive fumes Also avoid locations where temperatures are high or where liquids will drip on the charger Do not obstruct the ventilating openings or the space under the charger Mounting wall cab
20. the MOV with a multimeter diode position DL Tw 0 N Replace the faulty fuses located as in picture Replace the top lid Replace the module Test the charger 0 7V gt replace the faulty fuse s 0 0 to 0 55V gt replace the module Lifetech Modular 3 DC Fuse DC fuse Bussmann 125LET 24 36 48V module 3953635 DC fuse Bussmann 8O0LET 72 80V module 3553043 Every module has its own output fuse If one module fails due to a burned fuse refer to internal LEDs meaning above Replace the metal cover and screw it back Replace the module in the charger Test the charger Open the front door of the charger Unscrew the faulty module and extract it Remove the metal cover on the side Replace the DC output fuse torque to Nm pq p EC 4 Display board and door Kit display 2 4 bay IQ 055092579 Kit display 6 bay IQ 3554201 1 Remove the top lid of the charger by unscrewing the two main top screws and slide of Ps Disconnect the ribbon cable Lifetech Modular Remove bottom screws of the display panel Remove the front panel Reconnect the new panel by screwing back all the screws and reconnecting the ribbon cable Pg oM ENSURE TO PROGRAM THE CHARGER CORRECTLY FOR THE APPLICATION THE CHARGER SERIAL NUMBER HAS TO BE SET UP IN THE MENU 9 Module test and replacement Initialization sequence Rolling yellow green red alternatively for 6 seconds AC powe
21. ue light on the screen is off o Place the new in 3 Touch your finger to a ground to remove 7 ocrew the top and bottom screw back any static charge 4 Remove top and bottom screw Module bottom and fan Module heatsinks COMPONENT LOCATIONS 1 phase AC cable DC Cables Lifetech Modular S N NB 148507065 Product Type z4vwersion C alibration Test Firmmveare 148 20140828 12 38 Verification Test Firrnware 1 20140526 1848 Passed Every module has a unique serial number to be used for eventual claims Aux supply fuse control board 2 Module Module 2 Slot 3 Slot DC Fuse Lifetech Modular TESTING OF COMPONENTS 3 phase Only qualified personnel should service this battery charger IMPORTANT Disconnect battery and turn AC power OFF before servicing 1 AC input cabinet fuse 1 Disconnect both mains and battery from the charger 2 Remove the top cover of the charger 2 and 4 bay cabinets 30A time delayed fuses 10x38 6 bay cabinet 40A time delayed fuses 14x51 Euge po Replace the faulty fuses Replace the top cover Test the charger Refer to Spare Part hub for part numbers 2 AC input module fuse DC fuse Bussmann FWH O1LOA6F 3393091 l Disconnect both mains and battery from the charger Open the charger door Unscrew and extract the faulty module Remove the top lid of the module Test the voltage across
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