Energic Plus TST-D Operating Instructions Manual

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SHOCK PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 BURN AND BODILY INJURY PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . 4 FIRE AND EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ARCING AND BURNING OF CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . 4 MEDICAL AND FIRST AID TREATMENT 4 DESCRIPTION OF THE CHARGER 5 INSTALLATION OF THE CHARGER 6 INTERNAL VIEW OF THE CHARGER, CABINET A . . . . . . . . . . . . . . . . . . . . . . 7 INTERNAL VIEW OF THE CHARGER, CABINET B . . . . . . . . . . . . . . . . . . . . . . 8 AC VOLTAGE SELECTION 3 x 240/480 V (not for 600V input models) . . . . . . . . . . . . 9 AC INPUT VOLTAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 GROUNDING AND LINE CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . 10 HOW TO USE THE CHARGER 11 PRELIMINARY CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 BATTERY CONNECTION, VOLTAGE CHECK AND AUTOSTART . . . . . . . . . . . . . . 12 CHARGE PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 AUTOMATIC DATA SAVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 AUTOMATIC AND MANUAL CHARGE TERMINATION . . . . . . . . . . . . . . . . . . 14 EQUALIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 TROUBLE SHOOTING 17 INDEX 2

Before you start using your Energic Plus battery charger, please take the time to read these instructions carefully . The owner’s manual is an important part of the charger . It’s recommended to keep it in good condition for the lifetime of the charger . It should be kept in a dry and clean place, always available to the users . To indicate important instructions, the following blocks are used throughout this manual . CAUTION! This operation can be dangerous for the user. ATTENTION! This operation is important for the functionality and reliability of the charger. GENERAL Battery charging products can cause serious injury or death, or damage to other equipment or property, if the operator 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 equipment . SHOCK PREVENTION Bare conductors, or terminals in the output circuit, or ungrounded, electrically-live equipment 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 - 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 sin- gle-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 ground- ing conductor must be of a size equal to or larger than the size of the line conductors . 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 . Don’t replace the original cables with longer cables . Don’t use additional cables to lenghten the original connections . 3

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 . 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 . 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 of the battery . Battery acid is very corrosive . Always 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 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 . ARCING AND BURNING OF CONNECTOR To prevent arcing and burning of the connector contacts, be sure the charger is OFF before connecting or disconnecting the battery . The ammeter should NOT indicate current flow . 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 . EMERGENCY FIRST AID: Call physician and ambulance immediately and use First Aid techniques recommended by the American Red Cross . DANGER: ELECTRICAL SHOCK CAN BE 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. In case of acid in the eyes, flush very well with clean water and obtain professional medical attention immediately . 4

Energic Plus TST-D battery chargers have been designed to charge Pb batteries . These units convert the AC main supply in a DC output at the correct voltage, in order to charge the battery cells . The microprocessor controlled electronic card is used to monitor the state of the charge, and automatically turn the charger off when the battery is fully charged . The charge current follows the Wa curve, and the operation is fully automatic . Current Voltage Initial Current (about 16% of battery capacity) Voltage = 2.40 V/cell Current = 50% of Initial current Voltage = 2.00 V/cell Voltage Current Time 5

Conditions of use: • Operating temperature: 5°C to 45°C • Storage temperature: -20°C to 60°C • Relative humidity: less than 75% CAUTION! Risk of electrical shock! The charger must be installed by qualified personnel only. To prevent fire or shock hazard, do not expose the unit to rain or moisture. Don’t use the unit in presence of flammable gas, because it can generate sparks. ATTENTION! Make sure that the unit’s maximum input power (reported on the data label) is available from your power supply, and verify that the unit’s operating voltage is correct. Allow adequate air circulation to prevent internal heat buildup. Don’t place 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. ATTENTION! The proper setting of the power transformer taps is fundamental for the correct operation of the charger. If the real AC input voltage is different than the AC nominal voltage to which the charger is set, the charging current of the charger may be significantly different than the nominal current 6

NOTE The BOARD FOR INPUT VOLTAGE SELECTION is present only in chargers with 3x 208 / 240 / 480 Vac input, and is not NOT present in chargers with 3x600 Vac input. The PLUGS FOR INPUT VOLTAGE ADJUSTMENT are present in all the chargers. 7 CONTROL BOARD BOARD FOR INPUT VOLTAGE SELECTION TERMINAL BLOCKS FOR AC INPUT CORD PLUGS FOR INPUT VOLTAGE ADJUSTMENT OUTPUT FUSE POWER TRANSFORMER CONTACTOR

NOTE The BOARD FOR INPUT VOLTAGE SELECTION is present only in chargers with 3x 208 / 240 / 480 Vac input, and is NOT present in chargers with 3x600 Vac input. The PLUGS FOR INPUT VOLTAGE ADJUSTMENT are present in all the chargers. 8 CONTROL BOARD CONTACTOR OUTPUT FUSE POWER TRANSFORMER TERMINAL BLOCKS FOR AC INPUT CORD PLUGS FOR INPUT VOLTAGE ADJUSTMENT BOARD FOR INPUT VOLTAGE SELECTION

The input voltage setting of the charger is made using two devices: 1) BOARD FOR INPUT VOLTAGE SELECTION (BVS) (two selectable ranges: 200-250V or 440-524V) 2) PLUGS FOR INPUT VOLTAGE ADJUSTMENT (five taps within the selected range, see next chapter) The BOARD FOR INPUT VOLTAGE SELECTION has three metal bars, 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 remove the plastic protection over the BVS • Remove the metal bars and position them in the correct configuration • Fix the nuts carefully • Mount the plastic protection over the BVS • Close the cabinet Metal bars in position 200-250 Vac Metal bars in position 440-524 Vac 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 • Disconnect the wires A, B, C from the original position • Connect the wire A, B, C to the desired position • Close the cabinet MODELS WITH INPUT VOLTAGE 3x600V POSITION 5 4 3 2 1 VOLTAGE 550V 575V 600V 610V 620V MODELS WITH INPUT VOLTAGE 3x208/240/480V POSITION 5 4 3 2 1 BVS AT 240 Vac 200V 208V 224V 240V 250V BVS AT 480 Vac 440V 450V 480V 508V 524V 9

CAUTION! Risk of electrical shock! The cabinet of the battery charger must be properly grounded to protect personnel against hazard of electrical shock in case of fault 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 sep- arate 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 10

CAUTION! DON’T connect the battery to the charger if the digital display is ON. DON’T disconnect the battery from the charger while it is being charged. ARCING AND BURNING OF CONNECTORS OR BATTERY EXPLOSION MAY RESULT! PRELIMINARY CHECKS • 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 code . 11

CAUTION ! ENERGIC Plus 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”: 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”: If the battery voltage is between the minimum and maximum thresholds the charger will turn on automatically 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 . 12

continuously displayed in sequence: • Battery voltage/cell (Output voltage) (U) (Volt); • Charge current (Output current) (A) (Ampere); • Capacity charged (C) (Ah); • Effective time of charge (h) (Hours); The letter after the value (U-A-C-h) indicates which parameter being is displayed . To display the time the charger uses this format: (HOURS) . (MINUTE DECADES) h Examples: Time of charge 3h 30minutes: Displayed 3 .3h Time of charge 7h 50minutes: Displayed 7 .5h • The charge current follows the Wa curve as described in the norm DIN 41774. Current Voltage Initial Current (about 16% of battery capacity) Voltage = 2.40 V/cell Current = 50% of Initial current Voltage = 2.00 V/cell Voltage Current Time 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 . 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”: 13

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 current 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 is 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 TERMINATION CAUTION! NEVER disconnect the battery while it’s being charged. Disconnecting the battery while it’s being charged is hazardous for the user and voids the charger warranty. • 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 . • 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 . 14

[Voltage/cell], [Time] and [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 CAUTION! NEVER disconnect the battery while it’s being charged. Disconnecting the battery while it’s being charged is hazardous for the user and voids the charger warranty. 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: 15

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 threshold . While the charger is off and the battery voltage is being monitored, this message is displayed: If the voltage falls below the minimum 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” . NOTE With this “voltage controlled” maintenance/refresh system, the battery will be kept in perfect con- dition 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 acti- vated and the battery will be kept charged without problems. 16

react to battery be- ing connected, and display remains OFF . 1 Battery not connected properly . Check battery connectors/harness . 2 Charger has been connected to forklift motor connector . Disconnect forkift motor and connect battery . 3 Output fuse blown . Replace output fuse and adjust AC input settings . 4 Output cables reversed . Check charger, connectors and battery polarities . Output fuse is probably blown . 5 Bad control board connection . Check board connectors (green) . 6 Bad control board . Replace control board . When battery is connected, message appears . 1 AC input is absent . Check AC input voltage on each phase . Check AC input connections . Check AC disconnect switch and fuses . 2 Bad contactor . Replace contactor and freewheeling diode . Output current is too high 1 Wrong AC input settings . Adjust AC input settings to higher voltage . 2 One or more cells are shorted . Repair battery . Output current is too low 1 Wrong AC input settings . Adjust AC input settings to lower voltage . 2 One AC phase is absent . Check AC input voltage on each phase . 3 One or more diodes blown . Replace rectifier . 4 Bad contactor . Replace contactor . Charger smells hot 1 Bad location . Install the charger in proper location . 2 Ventilation slots obstructed . Remove objects which may obstruct slots . 3 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 . Charger too noisy 1 Bad contactor . Replace contactor and freewheeling diode . 2 One or more diodes shorted . Replace rectifier . Battery has low S .G . and/or doesn't last full shift 1 Wrong AC input settings . Adjust AC input settings to lower voltage . 2 Battery capacity too low . Replace battery . Battery temperature too high . 1 Wrong AC input settings . Adjust AC input settings to higher voltage . 2 Battery power demand too high . Consider purchasing bigger Ah battery . 3 Insufficient cool down time . Increase cool down time before/after charging . 4 Automatic stop doesn't work . Check and replace board and/or contactor . TROUBLE SHOOTING 17