Elektron HS 12/24-120, HS 12/24-120B Operating Manual
Made in Germany
Operating Manual
HS 12/24-120
HS 12/24-120B
Charger for 12V und 24 V Lead- and Li-Ion Rechargeable Batteries
Charging Current up to 120 A
Article-No.: 328 xxx GB
Revision: 0.1 – Translation
Date: 01.08.2018
Be sure you have read and understood this operating
manual before starting any work!
Keep operating manual for later use!
2
© BlitzRotary GmbH
Hüfinger Straße 55
D-78199 Bräunlingen
Germany
Phone: +49 (0)771.9233.0
Fax: +49 (0)771.9233.99
E-Mail: vertrieb@elektron-bremen.de
Internet: www.elektron-bremen.de
Issued by:
BlitzRotary GmbH, Bräunlingen
HS 12/24-120
Table of Contents
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Table of Contents
1 General Information 5
1.1 Information concerning this operating manual ............................................................................... 5
1.2 Copyright ........................................................................................................................................ 5
1.3 Symbols .......................................................................................................................................... 5
1.4 Disclaimer ....................................................................................................................................... 7
1.5 Warranty and guarantee ................................................................................................................ 7
1.6 Customer Service ........................................................................................................................... 7
1.7 Health and Safety ........................................................................................................................... 7
1.8 Intended Use .................................................................................................................................. 7
1.9 Responsibilities of the Operating Company ................................................................................... 8
1.9.1 General Obligations ........................................................................................................ 8
1.9.2 Demands on Employees ................................................................................................. 9
1.9.3 Personal protective equipment (PPE) ............................................................................ 9
1.10 Particular Dangers ....................................................................................................................... 10
1.10.1 Dangers due to the equipment ..................................................................................... 10
1.10.2 Dangers due to work environment ................................................................................ 11
1.10.3 Danger to this equipment and other property ............................................................... 11
1.11 Correct behaviour in accidents and dangerous situations ........................................................... 12
1.12 Safety devices .............................................................................................................................. 13
1.13 Safety labels and markings on the unit ........................................................................................ 13
1.13.1 On the top cover ........................................................................................................... 13
1.14 Spare parts ................................................................................................................................... 13
1.15 Waste management and environmental protection ..................................................................... 14
2 Transport, packing, storage 14
2.1 Safety during transport ................................................................................................................. 14
2.2 Unpacking .................................................................................................................................... 14
2.3 Acceptance after shipping ............................................................................................................ 15
2.4 In case of further transport / return of goods ................................................................................ 15
2.5 Storage ......................................................................................................................................... 15
3 Design and functionality 16
3.1 Short description .......................................................................................................................... 16
3.2 Overview front panel .................................................................................................................... 16
3.3 Rear stand .................................................................................................................................... 17
3.4 Connection cables ........................................................................................................................ 17
3.5 Description of the unit .................................................................................................................. 17
4 Operation 18
4.1 Provisions ..................................................................................................................................... 18
4.2 Connect the electrical system ...................................................................................................... 19
4.3 Switching on ................................................................................................................................. 19
4.3.1 Checks before switching on .......................................................................................... 19
4.4 Start-up ......................................................................................................................................... 19
4.5 Charging / Trickle charging / Buffer operation (Charge Mode) .................................................... 19
4.6 External power supply / EPS operation (Support Mode) ............................................................. 20
4.7 Operation ...................................................................................................................................... 21
4.8 Operating modes .......................................................................................................................... 21
4.8.1 Auto-start function ......................................................................................................... 21
HS 12/24-120
Table of Contents
4.8.2 Charging 12V ................................................................................................................22
4.8.3 Selection of battery type / Adjustment of charging parameters ....................................22
4.8.3.1 Selection of battery type ................................................................................22
4.8.3.2 Adjusting charge parameters ........................................................................23
4.8.4 Support Mode (External power supply EPS) ................................................................24
4.8.5 Charging rate test, deep discharged batteries ..............................................................24
4.9 Service-Menu ...............................................................................................................................25
4.9.1 General functions ..........................................................................................................25
4.9.2 Charging parameters ....................................................................................................25
4.9.3 De-sulphating program .................................................................................................26
5 Troubleshooting 27
5.1 Health and safety during troubleshooting.....................................................................................27
5.2 Error messages and troubleshooting tables ................................................................................27
5.2.1 Fault indicator ...............................................................................................................27
5.2.2 LED – Display Table .....................................................................................................28
6 Maintenance 29
6.1 Maintenance schedule .................................................................................................................29
6.2 Maintenance jobs .........................................................................................................................29
6.2.1 Personnel ......................................................................................................................29
6.2.2 Cleaning ........................................................................................................................29
6.3 Measures after maintenance ........................................................................................................29
7 Specifications 30
8 Index 31
9 Appendix 32
9.1 Training report ..............................................................................................................................32
HS 12/24-120
General Information
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1 General Information
1.1 Information concerning this operating manual
This operating manual will enable you to work efficiently and safely with this equipment.
The manual is an essential part of this product and must be stored ready at hand not far from the
equipment, so that people can use it at any time without any problems. Operators must read and
understand the manual before they carry out any work. Compliance with any and all information
contained herein concerning health, safety and safe behaviour and procedures is a prerequisite for
safe work.
Additionally, shall apply any and all local accident prevention regulations, any and all general safety
regulations, that may apply to the scope of application of this equipment.
Pictures, drawings etc. contained in this operating manual are supposed to convey a general
understanding of facts. In details, they may deviate from the reality you encounter.
Besides this operating manual, there may be specific instructions for units, components etc. They shall
apply accordingly.
1.2 Copyright
This operating manual is protected by copyright. It may be used for internal purposes, exclusively.
The manual and / or its contents may not be relinquished to third parties and/or communicated,
processed, used and / or reproduced in any way or form whatsoever (not even in excerpts and / or for
internal purposes) without the prior written consent of the manufacturer.
Contravention shall entail compensation claims.
All other rights reserved.
1.3 Symbols
Safety information
This manual uses symbols to highlight important safety information. In addition, there is always a
signal word heading the information indicating the severity of the danger or hazard that may be
encountered.
Be sure to comply with any and all safety information. Proceed with care and circumspection. Prevent
accidents and damage to people and property.
Warnings
DANGER!
… indicates a situation that is imminently dangerous and will entail the death of people
and severe injuries unless it is properly avoided and prevented.
WARNING!
... indicates a situation that may become dangerous and may entail the death of people
and severe injuries unless it is properly avoided and prevented.
CAUTION!
... indicates a situation that may become dangerous and may entail medium and small
injuries unless it is properly avoided and prevented.
HS 12/24-120
General Information
CAUTION!
… indicates a situation that may become critical and may entail damage to property
unless properly avoided and prevented.
Electric Shock
Danger to life due to electricity
Warning about dangers due to batteries
Danger to persons and property due to incorrect handling.
Danger to life due to corrosive substances!
Battery acid is corrosive.
Danger to life due to explosive gases!
Danger of explosion due to oxyhydrogen during charging of batteries.
Avoid fire, open light and generating sparkles.
Harmful substances
Danger due to toxic, at least harmful vapors.
Stumbling hazards
Danger of injuries due to stumbling and falling.
Personal protective equipment (PPE)
Non-inflammable safety clothing
is a tight-fitting sort of special clothing that is not inflammable, covers arms and legs
completely and tears easily (instead of getting pulled in). Its main purpose is to protect
against burns.
Face screen
protects the face and eyes against splashes, flying sparks and other hot particles.
Safety gloves
protects the hands against splashes, flying sparks and other hot particles.
Never use wet gloves.
Tips and recommendations
NOTE!
... highlights information that may be helpful to maintain efficient and trouble-free
operation.
HS 12/24-120
General Information
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1.4 Disclaimer
Any and all information contained in this operating manual has been written on the basis of pertinent
standards and regulations, the state of the art, and the long-standing insights and experience of our
staff.
The manufacturer cannot be made liable for damage due to:
Non-compliance with this operating manual
Non-compliance with the purpose and intent of this equipment
Deployment of unskilled personnel
Unauthorised constructional changes, alterations etc.
Unauthorised changes, modifications etc. to design and engineering etc.
Use of unauthorised spare and wear parts
The scope of the delivery you actually receive may deviate from explanations and/or representations
in this manual - if and when you ordered special options, your equipment is a special design and/or
technical progress facilitates improvements.
Shall apply: any and all obligations and stipulations of the Delivery Contract, the General Terms of
Business and Terms of Supply and Delivery of the manufacturer as well as any and all legal
stipulations and regulations in force on the day the Contract was concluded.
We constantly strive to further develop and improve our products and their functionality. We, therefore,
reserve the right to implement technical changes without notice.
1.5 Warranty and guarantee
The guarantee conditions shall be as stipulated in the General Terms of Business of the manufacturer.
1.6 Customer Service
Our customer service will be happy to provide technical support. For contact information, see
page 2 of this manual. Please note: Our staff is always eager to learn about new information, insights
and / or experience our customers may derive from the work with our products that may be helpful for
their future improvement.
1.7 Health and Safety
This section contains an overview of the most important health and safety at work aspects in order to
protect employees and to guarantee safe and trouble-free operation.
Non-compliance with any and all of the information, safe behaviour and procedures etc. contained
herein may entail severe health and safety risks.
1.8 Intended Use
This equipment has been designed and built for the following purpose(s), exclusively, and shall be
used accordingly:
HS 12/24-120
General Information
The battery charger HS 12/24-120 is intended for charging of rechargeable 12 or 24 V-wet lead
batteries (Lead-Calcium and EFB as well), as well as maintenance-free AGM-, Gel-, Fleece- and Li-Ion
rechargeable batteries exclusively, and must be operated within the limits of the specification and
operational limits ( refer to chapter 7 “Specifications”). Non-rechargeable batteries or primary
batteries must not be connected!
This charger is intended for use in industrial environments and may cause radio interference in
residential areas.
"Intended use" and "intended purpose" shall include proper compliance with any and all information
contained in this operating manual. Any and all use diverting from and / or going beyond the limits as
set by the equipment's intended purpose and use shall be deemed as misuse and may entail
dangerous situations.
WARNING! Misuse may entail danger
Misuse of this equipment may entail dangerous situations.
Therefore:
Do not operate this equipment unless clearly within its specs and limits of use
( see chapter 7 “Specifications”).
Do not use this equipment in explosive atmospheres.
Do not open, alter, modify and/or manipulate etc. this equipment.
The manufacturer shall not be held liable for any and all damage due to misuse of this equipment.
1.9 Responsibilities of the Operating Company
1.9.1 General Obligations
This equipment has been designed for professional use. The owner/operator or operating company
therefore being a businessman or commercial company, they are subject to any and all legal
obligations concerning health and safety at work. This means, in addition to this operating manual, any
and all accident prevention, health and safety at work and environmental regulations pertaining to this
equipment's scope of application shall apply as well.
This means in particular:
The operating company must be informed about any and all pertinent health and safety at
work regulations and must carry out a risk assessment in order to determine additional
hazards existing under the specific conditions in the specific work environment at the place of
operation. Any and all findings from such a risk assessment must then be used to draw up
additional operating instructions for the operation of this equipment.
During the entire lifetime of this equipment, the operating company must check in regular
intervals whether such additional operating instructions are still up to date and must update
them when necessary.
The operating company must unambiguously determine and communicate responsibilities
concerning the installation, operation, maintenance and cleaning of this equipment.
The operating company must make sure that any person handling this equipment has read
and understood this operating manual. Operating personnel, in addition, must be trained in
regular intervals and must be informed about the dangers existing in connection with this
equipment. (For a draft of a training report form, see "Appendix”
HS 12/24-120
General Information
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The operating company must equip operating personnel with suitable personal protective
equipment (PPE) and check it for proper working condition in regular intervals. Defective PPE
must be replaced with new ones.
The operating company must take appropriate and suitable fire protection measures and make
available fire extinguishers and first aid kits.
The operating company is responsible that the equipment is in proper working order at all times.
Therefore:
The operating company must make sure that any and all maintenance jobs described in this
manual are really carried out.
The operating company must have any and all safety labels, markings etc. on the equipment
checked for integrity and readability in regular intervals.
1.9.2 Demands on Employees
WARNING! People with insufficient skills may suffer injuries.
Inexpert handling may entail severe damage to persons and property.
Therefore:
Make sure that any and all activities are carried out by skilled personnel, only.
This equipment may be operated only by persons who do reliably their work properly.
Persons whose capability of reaction is impaired, e.g. by drugs, alcohol or medication, must
not be allowed to handle this equipment.
When selecting suitable operating personnel, be sure to respect occupational regulations and
legislation concerning skills, age etc.
This operating manual specifically names the following types of personnel who must have the
following skills:
Operator
The operator has been coached / trained by employees of ELEKTRON and / or an authorised
representative / dealer of ELEKTRON concerning his tasks and duties and possible hazards in
connection with inappropriate behaviour and confirms this with his signature (see draft of
training report form, "Appendix").
Service Personnel
refers to manufacturer's own service personnel and/or that of his representative / dealer. Such
service personnel have the professional training, skills and experience as well as knowledge of
pertinent regulations to carry out the jobs they accept and to identify, avoid and prevent
hazards on their own and without additional support.
1.9.3 Personal protective equipment (PPE)
CAUTION! Insufficient protection against injuries
Defective safety clothing may not constitute a proper protection against injuries.
Therefore:
Be sure to check PPE for integrity and good working condition before you start any
works.
Replace defective PPE.
Consider manufacturer's instructions and expiration dates, when and where
applicable.
HS 12/24-120
General Information
Wearing PPE during work is essential to minimise health and safety risks.
Be sure to be always wearing the appropriate PPE for the job at hand.
Be sure to take note of and comply with warning signs concerning PPE that may be installed at
the workplace.
Face screen
protects the face and eyes against splashes, flying sparks and other hot particles.
Non-inflammable safety clothing
is a tight-fitting sort of special clothing that is not inflammable, covers arms and legs
completely and tears easily (instead of getting pulled in). Its main purpose is to protect
against burns.
Safety gloves
protects the hands against splashes, flying sparks and other hot particles.
Never use wet gloves.
Furthermore
Do not wear long hair, rings, necklaces, watches or other jewellery.
Do not carry inflammable items such as matches or lighters.
1.10 Particular Dangers
1.10.1 Dangers due to the equipment Electricity
DANGER! Electricity constitutes a danger to life and limb.
Touching live components can result in a fatal electrical shock.
Therefore:
As soon as you notice any damage to insulation, disconnect the power supply and
have the damage repaired.
Do not open this equipment yourself. Have all repairs carried out by service
personnel, exclusively. Have works on electrical equipment carried out by skilled
electricians, exclusively.
Before any and all electrical works: disconnect power, earth and short. Check
whether equipment is really dead.
Keep live components away from liquids and humidity. They may cause short
circuits.
Protect cables against running over, contact with oils, aggressive substances, tools,
pointed and/or hot objects.
When pulling from a socket: Never pull on the cable. Pull on the plug.
Do not use the cable to trail or drag equipment over the floor. Always grab
equipment by the handles provided for that purpose.
Use strain relief clamps to protect cables.
Make sure protective ground conductors have been connected properly.
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