SERVICE MANUAL
Contents
1. connected we should launch the rege neration mode for the purpose of desulphation during the waiting period before the automatic start of the main charging process The desulphation is suitable to be performed regularly at least every two months 4 5093 00 3 19 7 Charger maintenance In order to secure reliable operation a regular service inspection as well as cleaning are necessary to be car ried out every six months of device operation The inspection should focus on test of indicator lamps by means of connection of the charger to the power mains battery is not connec ted for the type of AXlgo 24 30 12 30 which is in the stand by mode and the indicator lamps do not shine connect a battery to the charger both the indicator lamps will flash a visual check of insulation of the supply cable as well as of the outgoing cables blowing out of the dust inside the charger by means of compressed air if the charger is operated in the environment with a high level of dust it is necessary to pay great attention to cleaning of the charger and as need may be to shorten the interval between the service inspections the layer of dust decreases the efficiency of cooling of power parts and there is a risk of power element overheating the charger test of the insulation conditions by means of high voltage is forbidden semiconductor devices may be damaged The charger is necessary to be disconnected from power mains before this wiring te2. from the voltage of 2 0V cell the current in the Charging Ichar phase agrees with the set value of the charger output current from the moment when the voltage of 2 4 V cell is reached the so called gassing voltage charging current dropping occurs at the constant voltage to the value of 33 Ichar the Post charging phase starts when the mentioned values have been reached at the voltage of 2 40 V cell and continues as long as the calculated amount of ampere hours is not fulfilled 20 of the number of Ampere hours supplied to the start of Post charging Minimal number of ampere hours supplied in the phase of Post charging is numerically 15 Ichar e g Ichar 30 A in the phase of Post Charging 4 5 Ah will be supplied the current in the Post charging phase is kept at the value of 33 Ichar Characteristics lUla 100 Output current 9 ua vy wo oo 6 1 L 1 fi D So fi w 36 1 charging ao N e fi slz charged oo 1 o T T T 1 6 1 7 1 8 1 9 2 2 1 2 2 2 3 2 4 2 5 26 sas 275 cell voltage V 4 5093 00 3 D fm 5 2 5 2 Ula gel Characteristic The inserting process of the parameters of the characteristics is similar to the preceding one After voltage 2 35V cell is reached the postcharging starts with 9 of the IcHar The charging is finished as the value of 2 65V cell 2 8V cell is reached or after 4 hrs of postcharging Characteristics lUla gel ou
3. max current value is set to 20 A after another press of the button the green indicator lamp flashes five times the max current value is set to 15 A You can set the output current even for the types with a wider current range up to 6 flashes in the same way The required value of the output current should be selected by repeated pressing of the pushbutton Having selected the output current proceed with a long press of the pushbutton to the stage of the char ging characteristic selection This phase is indicated by a red indicator lamp the red indicator lamp is flashing the IUla characteristic has been set default setting ex factory after a short press of the pushbutton the red indicator lamp starts shining continuously the IUla gel cha racteristic has been selected the mode can be finished by a long pressing of the pushbutton and the charger is ready for operation lUla gel charging curve setting Having selected lUla gel characteristics proceed with a long press of the pushbutton to the stage of the end voltage selection This phase is indicated by flashing of b oth green and red indicator lamps 2 flashs 2 65V cell end voltage 3 flashs 2 80V cell end voltage the mode can be finished by a long pressing of the pushbutton and the charger is ready for operation 3 2 How to find out the current setting The current setting of the charger can be found out by pressing of the pushbutton for approxim
4. of guarantee means breach of the conditions of guarantee and therefore the device will not be subject to the guarantee repair The charger is equipped with a three conductor lead 3 PE in a one phase design with a three conductor lead 1 N PE ex factory It should be connected to the power mains by means of the respective four pin five pin or three pin plug The socket for the connection must be protected with a suitable circuit breaker Cables for battery connection are conducted from the charger outlet The positive outlet is indicated by red colour whereas the negative outlet is coloured blue or it does not have any colouring Voltage dropping in these cables is taken into consideration during the process of charging In order to avoid the change in char ging parameters it is forbidden to adjust the length of the outgoing cables Further it is necessary to provide the operational staff with the access to the charger during operation and service 4 5093 00 3 D i i 2 3 Description of charger control and signalling Figure 1 shows the description of control and signalling elements of the charger JH Green indicator lamp Red indicator lamp STOP pushbutton Fig 1 Front Panel of the Charger Standard charging will be automatically started after the battery has been connected see chapt 5 The charging process in progr
5. range of c 50 100 Inom The AXIgo chargers use the principles of high frequency technology They are based on power units operating in a high switching frequency with the efficiency of up to 94 The charging is either a one phase one or a three phase one The charging process is controlled by a microprocessor control system Important statuses are indicated by indicator lamps According to their dimensions the AXIgo chargers are installed into three types of boxes S M L see chapt 2 1 1 2 Usage The chargers are designed to be used in interiors with standard conditions humidity temperature dusti ness When operated in a place with a higher level of dustiness the interval of service inspections must be shortened They should be connected to one phase or three phase power mains with a standard moveable lead cable with a three pole or a four pole connector The suitable protection must be carried out in the installation of the charging station They are intended for cycle charging of traction batteries and they can be continuously operated Cooling is provided by fans placed inside the charger 1 3 The marking system of the AXlgo type chargers AXIgo aa7bb aa rated output voltage types 24 36 48 72 80 96V bb rated output current 25 200A Examples of the marking AXIgo 24 30 voltage 24V current 30A box S AXIgo 48 50 voltage 48V current 50A box M AXIgo 80 55 voltage 80V current 55A box L 1 4 Standards The AX
6. to be supplied with the respective settings Otherwise the setting is carried out by service or distribution organizations before the installation of the charger at the customer s premises The already operated charger can also be set again by means of service intervention e g for a different battery type All the output current setting possibilities for the respective types are mentioned in the chart Nr 1 The pro cedure of charger setting is the same for all the types The only exception is the type of AXIgo 24 30 12 30 see the note 4 5093 00 3 ee ie i The setting is described in the following example for the type of AXlgo 48 30 The configuration mode should be set as follows pressing the STOP pushbutton connect the charger to the power mains If you press the pushbutton for about 5 seconds a green indicator lamp will switch on Having released the pushbutton it will start flashing The number of flashes indicates the value of the set output current and after a rather long pause it will be repeated According to the chart Nr 1 the relation between the setting and its signalling is as follows the green indicator lamp flashes twice and then there is a rather long pause the max current value is set to 30A having pressed the button for a short time the green indicator lamp flashes three times the max current value is set to 25 A after another press of the button the green indicator lamp flashes four times the
7. Igo chargers meets the requirements of the following standards EN 60950 1 Information Technology Equipment Safety EN 61000 6 2 EMC Immunity for Industrial Environments EN 61000 6 4 EMC Emission Standard for Industrial Environments CSN 33 2000 4 41 Electrical Devices Safety 1 5 Operational safety The following requirements must be met during the operation of the chargers during the charging process the chargers must be placed in well ventilated rooms the chargers must be connected only to the standard power mains it is necessary to avoid sparking and making a fire near the battery explosion hazard during the process of charging 4 5093 00 3 ee ie i the chargers must not be operated without a cover an electric shock hazard only batteries intended for charging with the parameters voltage capacity ranges suitable for the speci fied type of charger can be charged during charging it is dangerous to touch the supply leads to the battery poles the transport of the charger during the charging process is prohibited the supply leads to the battery must not be disconnected during the process of charging the charger can be operated only by a respectively qualified person any changes in parameters can be made only by an authorized technical engineer 1 6 Supplies and storage The charger is supplied in a completed condition with Operating Instructions Normally it is supplied without connect
8. SERVICE MANUAL 4 5093 00 3 Te E AXIgo TRACTION BATTERY CHARGER Content 1 Basic Data sxcicsce Scacchi dea cnc ce cere Seana eee eee eee 2 1 1 Device Characteristics cceinccsacmassestnesvecives sauaaatantion svepevestataaataes quatayedaaaaadeasiesn ude 2 T2 Usage tanned tana ean an nadine aati 2 1 3 The Marking System of the AXIgo type Chargers cccececceeeeeeeeeeeeeeetteeeeeteeennees 2 T4 Standards arse act cme dn alco aE aca nin cinta E A REEN E AARRE ad 2 1 5 Operational Safety isc ciascicc sat aarcsssecdaasivanives siesaaadaqaces wacuusisantbandiorgataumausdnaniataacns 2 1 6 S pplies and Storage senesi we nee ne Ca 3 1 7 S NV CE Spee eee ee eer rm nT een Ee een ee ee ee EE 3 1 8 Abbreviations used cand dey se etcetera dete ed rittt t eed ce ca atteeedrvatjen A ddanamenad aides 3 2 Technical Characteristics xiicc cscs cto ca cesses creed eunea naiaiaee naeia 4 2 1 Technical Specifications sass iisceee ciuansentraesv cy at nints dancundy lt 6 aia aidanwntnad tise sedaumaanaies ees 4 2 2 Installation of the Charger scsuceancussiansaaacven sucdieiinda ud tain anieerdydisaataanmnnaanadon tle Duaaa tans avenclte 5 2 3 Description of Charger Control and Signalling ceceeeeeeeteeeeeereeeeenteeeesenteeeeeees 6 3 Setting of the Charger cciecbecccccceceseeeeccetctecce cece cecscentrencremdettcandensittecenccetenmetcands 6 3 1 Setting of the Output Current and the Selection of the Charging Characteristics 6 3 2 How to F
9. ately 3 seconds the charger is connected to the power mains the battery is not connected After this period the indicator lamps signal the charger setting the output current value by flashing of the green indicator lamp in accordance with the chart Nr 1 and the selected charging characteristic by lighting or flashing of the red indicator lamp 4 Charger Functions Charging Procedure In addition to the main charging the charger makes it possible to maintain the battery by means of the regeneration mode see below During the process of charging either in a standard mode or in a regeneration one it is necessary to keep the following sequence of operations connect the charger to the power mains it is indicated by single flashing of both the indicator lamps AXIgo 24 30 12 30 see below 4 5093 00 3 ee ie i connect the battery to the charger after the waiting period of 15 seconds the battery charging will automatically start during the waiting period start the regeneration mode by pushing the button for approximately 3 se conds both the indicator lamps will start flashing after the battery has been charged the green indicator lamp is continuously shining disconnect the battery the green indicator lamp will switch off if it is necessary to disconnect the battery during the process of charging the green indicator lamp is flas hing stop charging by means of the STOP pushbutton and subsequently disconnec
10. d out regularly on a two week basis The most suitable way is to perform the equalization after the standard charging of the battery After the end of the main charging the green indicator lamp is continuously shining the regeneration mode can be launched see above in order to fulfil this purpose In this case it is not necessary to disconnect the battery because of the setting of the battery default status Application for removal of lead II sulphate crystals from the cell boards desulphation The so called cell sulphation occurs when the battery is not regularly charged until the final signs of the char ging process or if it has been left flat for a rather long period or when the battery is overcharged During the process of sulphation a layer of lead II sulphate crystals occurs on cell boards As a result of this process the active surface of the boards as well as battery capacity is reduced a low density of electrolyte even after a long charging process and an increased temperature of the cells during the charging process occur The desulphation is suitable to be carried out instead of common battery charging best till the final signs of the charging process min 2 5 V cell 2 29 g cm3 As the total charging of the battery in a regeneration mode is a time consuming process it may take even several days it is necessary to launch the regeneration process repeatedly 2x 6x with no need to disconnect the battery Having the battery
11. disrupted and the red indicator lamp signals a failure the battery with high impedance The charging process is automatically finished after the battery has been charged The finished charging process is signalled by the continuously shining green indicator lamp When the charging process is finished the battery can be disconnected from the charger The disconnection of the battery returns the charger to the default status and thus the charger is ready for another cycle The charging in progress can be disrupted by pressing of the STOP pushbutton It is forbidden to disconnect the battery during the process of charging If power outage occurs during the charging process it is not necessary to disconnect the battery As soon as the voltage is restored the charging process continues in the selected mode The shining red indicator lamp signals the failure during the charging process The main charging process runs according to one of the two default programmed characteristics 5 1 Ula characteristic This characteristic is the basic one and it is used for normal traction batteries with liquid electrolyte If it is not agreed differently it is normally set ex factory It has the following parameters set current in the Precharge phase voltage 1 73 V cell is set to the value of 50 Ichar A low charging current is very gentle to such a deeply flat battery From the mentioned voltage the current rises up to Ichar the Charging phase starts
12. ess is indicated by a flashing green indicator lamp When the charging process has been automatically finished the green indicator lamp will shine continuously It is possible to stop the charging process in an arbitrary stage by means of the STOP pushbutton The regeneration mode see chapt 6 can be launched by a long press of the STOP pushbutton The regeneration charging process is indicated by flashing of both the indicator lamps both the green one and the red one When the process is finished the indicator lamps stop flashing and the green lamp shines continuously The continuously shining red indicator lamp signals a failure in charging and its disruption By means of the STOP pushbutton and the signalling by the indicator lamps you can also find out the cur rent setting of the charger output current charging characteristic see chapt 3 2 or the charger can be set to a different values according to your requirements see chapt 3 1 3 Setting of the charger 3 1 Setting of the output current and the selection of the charging characteristics All the AXIgo chargers are standardly set to the rated maximal output current Inom ex factory However they make it possible to set the output current in a step way in the range of ca 50 100 Inom to the value which is optimal for the specific battery If clearly specified in the order specified battery parameters or already selected setting of the chosen charger the charger is possible
13. ind Out the Current Setting eceeeeeeeeeeeeeeeeeeeteeeeeeneeeeneeeesteeeesieentteeeens 7 4 Charger Functions Charging Procedure ccsssseecccssseeeeeesseeeeeseeeeeeeseneneeeseeeees 8 5 Standard Charging sissies a cess di a ed reedetcreeatsccnet EE aama aaa asenada Eaa iea 9 5 1 IUla Characteristic acta rina reteene dete deo este eter ala ae sheet can ate Mee aa tammae rect lay saa toeapna amelie 9 5 2 IUa Characteristic cg ace teh a tesco irae cept esau aw ay a pean tetera en ats aes gels 10 6 Battery Regeneration Mode aiceniccnccecsc cece cccceteestenstecivedecencectcwees eteeeassieeeenenesnnienceced 10 7 Charger Maintenance ie ae eee cde re nee cece ecnted ntti edteaewecicersesateeeeeteienentecete 11 8 Alarm signalling cts cece ee ce eee hs clearence ewes ina nesne 11 4 5093 00 3 l D D 1 Basic data 1 1 Device characteristics The AXlgo type chargers are intended for industrial applications mainly for charging traction batteries for electric high lift trucks and manipulation and cleaning technology devices With regard to the perfect electric parameters they are suitable even for different types of batteries e g maintenance free batteries gel batte ries AGM etc The whole model range is shown in the Chart 1 The rated maximum charging current is in the range of 25 200A The standard output voltage is 12 96V a different one on request The respective types enable to set the output current in a step operation in the
14. llution Class 2 Working environment 10 to 40 C max rel humidity 95 non condensing Standards EMC LVD CSN EN 61000 6 4 CSN EN 61000 6 2 CSN EN 60950 1 4 2 kV I O 4 5093 00 3 D i i forced ventilation Dimensions of chargers Case Dimensions mm Width Height Depth Mounting by 4 screws 5 110x265mm_ 110x375 mm 110 x 410 mm 110 x 465 mm X x Y Colour of the box is standard black or arbitrary at customer s request 2 2 Installation of the charger The box of the AXIgo chargers is intended to be hung on the wall on a stand or on a bracket in the vertical working position Fastening should be carried out by means of wood screws with the diameter of 5 8mm However the char ger may be operated in the horizontal position laid on its rear side on a table or a base etc To secure the correct functioning of the charger it is necessary to keep the distance of at least 100 mm on both the sides of the charger as well as on the front side from other devices in order to provide sufficient ventilation The slots for air suction must not be covered With regard to the possibility of dust suction the placement of the device on the floor or in a low position above the floor is not suitable If the charger is operated in the environment with a high dust level the interval between service inspections and cleaning procedures must be shortened Possible damage or destruction of the charger due to heavy dusting during the duration
15. ors except for the 1 phase power supply with the 2m long outgoing cables A functional test is carried out with every charger The charger must be transported in the original package the position during the transport can be arbitrary It is permitted to store the chargers in roofed dry rooms with the temperature from 25 C to 80 C rela tive humidity up to 95 non condensing 1 7 Service If a fault of the charger occurs contact your retailer On no account should the charger be repaired on your own The service of the chargers is provided by AXIMA spol s r o V de sk 125 619 00 Brno Czech Re public 1 8 Abbreviations used Ah ampere hour Cnom rated battery capacity Inom rated current of the charger Ichar set current at the top of the charging characteristics in the range of 2 00 2 4V cell Unom rated charging voltage 4 5093 00 3 ee ie i 2 Technical characteristics 2 1 Technical specifications Table of types AXIgo type Nom input Max out voltage V put current eoar so 0 55 so 20 80 so 96 25 o6 esso o 96 75 o 30 60 30 60 10 2 200 30 30 10 3 3 3 3 100 2 2 2 27 80 27 80 UW _ ul N 3 5 4 33 12 3 2 3 6 7 3 10 8 4 12 l UI N D N 7 2 4 External protection circuit breaker char C nebo D Mains tolerance 15 10 1phase chargers 15 Charasterictic Protection class Po
16. st is carried out 8 Alarm signalling If a failure during the charging process occurs a red control lamp will start shining and the charging process will be disrupted The failure indication includes unsatisfactory test at the beginning of the charging process high internal source impedance of the batte ry a too sharp increase in voltage high charging current gt 120 of the set value low charging current lt 50 of the set value high voltage on the battery during the charging process gt 3V cell disconnection of the battery during the process of charging without stopping by means of the STOP pus hbutton high temperature of the charger gt 900C only for the AXlgo 24 30 12 30 type A red indicator lamp is continuously shining After the disconnection of the battery it will switch off in 10 seconds www axima cz v AXIMA spol s r o V de sk 125 Brno CZ 619 00 AX i MA tel 420 547 424011 e fax 420 547 424 030 e mail acdc axima cz 11 4 5093 00 3
17. t the battery disconnect the charger from the power mains it is suitable for a rather long operational break when employed regularly it is not necessary AXIgo charger Setting of the output current A Flash number of green indicator lamp i SEEE R A E a E a a neo es s o o l o M e a S a a a E a a os o 2s Table 1 Setting of output current 4 5093 00 3 D D i 5 Standard Charging The charger is set for the specific battery ex factory or in a service organization according to the customer s request output voltage charging current and selected characteristics After connecting of the battery the control unit measures the battery voltage If the battery voltage is in the range of 1 3 to 2 3V cell analysed as correct connection of the battery the actual charging process will start after the waiting period of 15 s since the battery was connected without pressing of the pushbutton If the voltage is out of the menti oned range the charging process will not be launched If the battery voltage is within the range of 1 3 to 2 1V cell the battery test is performed at the beginning of the charging cycle The test is carried out at low current 15 Ichar for the period of 15 seconds If there is no battery voltage increase above 2 37 V cell the charging process continues The charging pro cess is indicated by the flashing green indicator lamp If the voltage exceeds 2 37 V cell during the test the charging process is
18. tput current 30 charging 20 4 Nis i charged ZS T T 1 1 6 1 7 1 8 1 9 2 2 1 2 2 2 3 2 4 2 5 2 6 2 7 cell voltage V 6 Battery regeneration mode The regeneration mode is used to improve the battery condition and to restore the parameters impaired due to non standard operating conditions temperature an unsuitable operating mode and wrong charging process staff external interventions As need may be equalization in order to equal voltage in the respecti ve cells or desulphation to remove any deposits of lead Il sulphate crystals from the battery boards can be applied The regular employment of regeneration positively influences the operating lifetime of the battery but on condition of the correct operation of the battery The regeneration mode shall be started manually by a long press of the STOP button for ca 3 seconds ac cording to the selected purpose of the application see below Both the indicator lamps green and red start flashing and subsequently as soon as the pushbutton has been released the charging process begins The charging process in the regeneration mode runs with a constant current of 10 of the set output current and it lasts 20 hrs It will be finished after the end of this period The indicator lamps will stop flashing and the green one will be shining continuously Application for the equalization of the voltage on the cells equalization The equalization is recommended to be carrie
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