Battery Charger
Battery Charger
Battery Charger
RE
USER'S MANUAL
(THIS PAGE WAS INTENTIONALLY LEFT BLANK)
Table of Contents
· 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...................................................................... 7
· 3. Description........................................................................................... 7
· 4. Installation........................................................................................... 8
· INTERNAL VIEW OF THE CHARGER, CABINET S.......................................... 9
· INTERNAL VIEW OF THE CHARGER, CABINET A........................................ 10
· INTERNAL VIEW OF THE CHARGER, CABINET B........................................ 10
· INTERNAL VIEW OF THE CHARGER, CABINET C........................................ 11
· AC INPUT VOLTAGE ADJUSTMENT – CABINETS S, A, B............................ 12
· AC INPUT VOLTAGE ADJUSTMENT – CABINET C........................................13
· 5. How to use the charger [Cabinets S, A, B]..................................... 14
· START OF CHARGE........................................................................................ 15
· CHARGE CYCLE.............................................................................................. 15
· 6. How to use the charger [Cabinet C]................................................ 16
· START OF CHARGE........................................................................................ 17
· CHARGE CYCLE.............................................................................................. 17
· 7. Trouble Shooting Guide................................................................... 18
· 8. Spare Parts List................................................................................. 23
· 9. Cabinet table....................................................................................... 24
Battery Charger RE
User's Manual
1. Introduction
This manual contains instructions and suggestions for the users of Energic plus RE 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 RE battery charger will not be responsible for damages and/or
injuries caused by the charger in these situations:
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.
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.
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.
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.
EMERGENCY FIRST AID: Call phisician and ambulance immediately and use First Aid techniques
recommended by the American Red Cross.
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.
In case of acid in the eyes, flush very well with clean water and obtain professional medical attention
immediately.
3. Description
Energic plus RE battery chargers have been designed to charge Pb batteries.
These units convert the AC input voltage to a DC voltage at the correct level, in order to charge the
battery cells.
These battery chargers are fully automatic, and they are controlled by a microprocessor based
electronic board.
The entire charge sequence is monitored by the microprocessor, that is programmed to manage all
the possible operating conditions:
• Automatic start on battery connection, with 5 seconds delay to avoid sparks between the
connectors;
• Automatic shutdown on battery disconnection;
• Adaptive algorithm for charge time calculation;
• Wrong battery detection;
• Automatic weekly equalization charge;
• Two emergency timers for battery protection.
4. Installation
The charger is marked with a technical label, containing the following data:
• Model;
• Serial number (S/N);
• Weight (kg);
• Input voltages (V);
• Maximum input current (A);
• Maximum input power (KVA);
• Input frequency (Hz);
• Battery voltage (V);
• Maximum output current (A).
Conditions of use:
CAUTION !
NOTE
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 !
CAUTION !
NOTE
CAUTION !
PROCEDURE:
CAUTION !
PROCEDURE:
WARNING !
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.
START OF CHARGE
The charger turns on automatically when the battery is correctly connected, with a delay of 5 seconds,
in order to avoid sparks between the connectiors.
If the main supply is not present, all the control LEDs (except the “BATTERY CONNECTION” LED)
blink alternately.
CHARGE CYCLE
The current of charge follows the Wa curve. During the first charge period, while the battery voltage is
below the gassing value, the LED “CHARGE ON” blinks continuously.
After some hours, depending by the conditions of the battery, when the battery’s voltage reaches
gassing value, the LED “FINAL CHARGE” starts to blink and the charge continues.
The electronic control of the charger measures only the time of effective charge so, even after one or
more main supply black-outs, the charge cycle re-starts from the point of interruption. The electronic
control is reset only when the battery is disconnected.
After the finishing charge time (~3 hours) the charge is completed, and the LED “STOP-100%” turns
on. At this point the equalization cycle starts.
If the charge is not normally completed within 12 hours, the electronic control stops the charger, the
LED “EMERGENCY STOP” turns on and the equalization cycle is excluded. If this happens, it’s
recommendend to check the conditions of charger and battery before starting another charge cycle.
EQUALIZATION
When a battery is new, all the cells are virtually in the same condition. After the first cycle of charge-
discharge, it's possible to measure small differences of voltage between the cells. These little
differences between cells, in the next charge-discharge cycles, are more and more emphasized. This
process reduces the performance of the battery and its life.
The EQUALIZATION function, performed by ENERGIC Plus RE chargers, has been developed to keep
all the cells of the battery at the same level, even after years of continuous work.
Equalization is performed by giving extra charge cycles of 30 minutes every 15,5 hours.
During extra charge cycles the LEDs “ FINAL CHARGE” and “STOP-100%” blink alternately.
The equalization function starts with a pause of 15,5 hours, it is then performed when the battery
remains connected to the charger for more than about 24 hours (example: week-ends).
END OF CHARGE
When the battery is completely charged the charger turns off automatically, and the LED “STOP –
100%” continues to blink.
WARNING !
WARNING !
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.
• 0-80% (CHARGE ON): lights on and flashes during the first period of the charge
• 80-99% (FINAL CHARGE): lights on and blinks, together with the LED “CHARGE ON”, during the
second part of the charge (battery voltage above gassing value);
• STOP-100% (EQUALIZING): At the end of the charge, this LED blinks. At the end the equalization, it
remains on.
• EMERGENCY STOP: if the charge continues after the maximum time allowed, the charger turns off
automatically and this LED remains on.
• LED AMMETER: the ammeter gives an indication of the charge current. The indication of the LED
ammeter is in percent of the rated output current (see data label on box).
Normally, the seventh LED (110%) should never light on, except for the first minutes of charge.
START OF CHARGE
When the battery is correctly connected, the first LED “BATTERY CONNECTION” ligths on, then, the
charge cycle starts automatically in 5 seconds and the LED “CHARGE ON” starts to blink.
If the main supply is not present, all the control LEDs (except the “BATTERY CONNECTION” LED)
blink alternately.
CHARGE CYCLE
The current of charge follows the Wa curve. During the first charge period, while the battery voltage is
below the gassing value, the LED “CHARGE ON” blinks continuously.
After some hours, depending by the conditions of the battery, when the battery’s voltage reaches
gassing value, the LED “FINAL CHARGE” starts to blink and the charge continues.
The electronic control of the charger measures only the time of effective charge so, even after one or
more main supply black-outs, the charge cycle re-starts from the point of interruption. The electronic
control is reset only when the battery is disconnected.
After the finishing charge time (~3 hours) the charge is completed, and the LED “STOP-100%” turns
on. At this point the equalization cycle starts.
If the charge is not normally completed within 12 hours, the electronic control stops the charger, the
LED “EMERGENCY STOP” turns on and the equalization cycle is excluded. If this happens, it’s
recommendend to check the conditions of charger and battery before starting another charge cycle.
EQUALIZATION
When a battery is new, all the cells are virtually in the same condition. After the first cycle of charge-
discharge, it's possible to measure small differences of voltage between the cells. These little
differences between cells, in the next charge-discharge cycles, are more and more emphasized. This
process reduces the performance of the battery and its life.
The EQUALIZATION function, performed by ENERGIC Plus RE chargers, has been developed to keep
all the cells of the battery at the same level, even after years of continuous work.
Equalization is performed by giving extra charge cycles of 30 minutes every 15,5 hours.
During extra charge cycles the LEDs “ FINAL CHARGE” and “STOP-100%” blink alternately.
The equalization function starts with a pause of 15,5 hours, it is then performed when the battery
remains connected to the charger for more than about 24 hours (example: week-ends).
END OF CHARGE
When the battery is completely charged the charger turns off automatically, and the LED “STOP –
100%” continues to blink.
POS. DESCR. 12-10 12-15 12-20 12-25 12-30 12-40 24-10 24-15 24-20 24-25
11-S Rectifier 0201902 0201903 0201903 0201911 0201911 0201912 0201902 0201903 0201903 0201911
Printcard
12-S 0202751 0202751 0202751 0202751 0202751 0202751 0202752 0202752 0202752 0202752
539SCE
13-S Output fuse 0201061 0201061 0201061 0201062 0201062 0201063 0201061 0201061 0201061 0201062
POS DESCR. 12-100 24-80 24-100 36-50 36-60 36-80 48-40 48-50 48-60
8-B Rectifier 0201922 0201888 0201889 0201914 0201915 0201888 0201912 0201914 0201915
Printcard
9-B 0202751 0202752 0202752 0202753 0202753 0202753 0202754 0202754 0202754
539SCE
10-B Output fuse 0201067 0201066 0201067 0201064 0201065 0201066 0201063 0201064 0201065
9. Cabinet table
S 12/10 12/15 12/20 12/25 12/30 12/40 24/10 24/15 24/20 24/25 48/10 60/10
A 12/50 12/60 12/80 24/30 24/40 24/50 24/60 36/30 36/40 36/50 48/15 48/30
B 12/100 24/80 24/100 36/60 36/80 40/50 40/60 48/40 48/50 48/60 --- ---
12/120 24/120 24/160 36/100 36/120 40/80 40/100 48/80 48/100 48/120 --- ---
C
72/60 72/80 72/100 80/40 80/60 80/80 --- --- --- --- --- ---