Description and Operating Instructions
MultiCharger 1500
12V/100A...24V/50A
Read instructions carefully before use!
All rights reserved in relation to legislation on copyright and unfair competition. This product description and these operating instructions
may not be copied, reproduced or made accessible to third parties without our prior written consent.
Page 1
Imprint
MultiCha
EVD .:
c-No.:
Do
ID-code:
rger 1500
811-0206-0
2068264.01
0109
Page 2
IMPORTANT SAFETY INSTRUCTIONS
1. SAVE THESE INSTRUCTIONS
This manual contains
MultiCharger 1500.
2. Do not expose charger to rain or snow.
3. Use of an attachment not recommended or sold by the battery charger manufacturer may result
in a risk o
f fire, electric shock, or injury to persons
important safety and operating instructions for battery charger model
4. To reduce risk of da
disconnecting charger.
5. An extension cord sho
cord could r
6. Do not operate charg
7. Do not operate charg
any wa
8. Do not disassemble charger; take
Incorrect re
9. To reduce risk of e
or cleaning.
10. WARNING - RISK OF EXPLOSIVE GASES.
esult in a risk of fire and electric shock. If extension cord must be used, make sure:
a) That pins on plug of extension cord are the same number, size, and shape as those
of plug on charger;
b) That extension cord is properly wired and in good electrical condition; and
c) That wire size is large enough for ac ampere rating of char
y; take it to a qualified serviceman.
assembly may result in a risk of electric shock or fire.
Turning off controls will not reduce this risk.
a) WORKING IN VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTE
GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR
THIS REASON, IT IS OF UTMOST
R CHARGER, YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIO
YOU
EXACTLY.
b) To reduce risk of batt
battery man
battery. Review cautiona
mage to electric plug and cord, pull by plug rather than cord
uld not be used unless absolutely n
er with damaged cord or plug - replace the cord
er if it has received a sh
it to a qualified serviceman when service or repair is require
lectric shock, unplug charger from outlet before att
IMPORTANCE THAT EACH TIME BEFORE U
ery explosion, follow these instructions and those published
ufacturer and manufacturer of any equipment you intend to use in vicinity
ry marking on these products and on
when
ecessary. Use of improper extension
ger.
or plug immediately.
arp blow, been dropped, or otherwise damaged in
d.
empting any maintenance
RIES
SING
NS
by
of
engine.
11. PERS
a) Someone
b) Have plenty of fresh water and soap nearby in case batte
c) Wear co
d) If battery acid conta
e) NEVER smoke or allow a spark or flame in vicinity of battery or engine.
ONAL PREC
you work near a lead-acid battery.
or eyes.
near battery.
enters eye, immediately flood eye with running cold water for at least 10 minutes and get
medical atte
AUTIONS
should be within range of your voice or close enough to come to your ai
mplete eye protection and clothing protection.
cts skin or clothing, wash immediately with soap a
ntion immedi
ately.
Page 3
ry acid cont
Avoid touching eyes while working
acts skin, clothing,
nd water. If acid
d when
f) Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or
short-circuit battery or other electrical part that may cause explosion.
g) Remove personal metal items such as rings, bracelets, necklaces, and watches when
working with a lead-acid battery. A lead-acid battery can produce a short-circuit current
high enough to weld a ring or the like to metal, causing a severe burn.
h) Use charger for charging a LEAD-ACID battery only. It is not intended to supply power to
a low voltage electrical system other than in a starter-motor application. Do not use
battery charger for charging dry-cell batteries that are commonly used with home
appliances. These batteries may burst and cause injury to persons and damage to
property.
i) NEVER charge a frozen battery.
12. PREPARING TO CHARGE
a) If necessary to remove battery from vehicle to charge, always remove grounded terminal
from battery first. Make sure all accessories in the vehicle are off, so as not to cause an
arc.
b) Be sure area around battery is well ventilated while battery is being charged. Gas can be
forcefully blown away by using a piece of cardboard or other non metallic material as a
fan.
c) Clean battery terminals. Be careful to keep corrosion from coming in contact with eyes.
d) Add distilled water in each cell until battery acid reaches level specified by battery
manufacturer. This helps purge excessive gas from cells. Do not overfill. For a battery
without cell caps, carefully follow manufacturer’s recharging instructions.
e) Study all battery manufacturers’ specific precautions such as removing or not removing
cell caps while charging and recommended rates of charge.
f) Determine voltage of battery by referring to car owner’s manual and make sure that
output voltage selector switch is set at correct voltage. If charger has adjustable charge
rate, charge battery initially at lowest rate.
13. CHARGER LOCATION
a) Locate charger as far away from battery as dc cables permit.
b) Never place charger directly above battery being charged; gases from battery will
corrode and damage charger.
c) Never allow battery acid to drip on charger when reading gravity or filling battery.
d) Do not operate charger in a closed-in area or restrict ventilation in any way.
e) Do not set a battery on top of charger
14. DC CONNECTION PRECAUTIONS
a) Connect and disconnect dc output clips only after setting any charger switches to off
position and removing ac cord from electric outlet. Never allow clips to touch each other.
b) Attach clips to battery and chassis as indicated in 15(e), 15(f), 16(b), and 16(d).
15. FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VEHICLE. A SPARK NEAR
BATTERY MAY CAUSE BATTERY EXPLOSION. TO REDUCE RISK OF A SPARK NEAR
BATTERY:
a) Position AC and DC cords to reduce risk of damage by hood, door, or moving engine
part.
b) Stay clear of fan blades, belts, pulleys, and other parts that can cause injury to persons.
c) Check polarity of battery posts. POSITIVE (POS, P, +) battery post usually has larger
diameter than NEGATIVE (NEG, N,-) post.
d) Determine which post of battery is grounded (connected) to the chassis. If negative post
is grounded to chassis (as in most vehicles), see (e). If positive post is grounded to the
chassis, see (f).
Page 4
e) For negative-grounded vehicle, connect POSITIVE (RED) clip from battery charger to
POSITIVE (POS, P, +) ungrounded post of battery. Connect NEGATIVE (BLACK) clip to
vehicle chassis or engine block away from battery. Do not connect clip to carburettor,
fuel lines, or sheet-metal body parts. Connect to a heavy gage metal part of the frame or
engine block.
f) For positive-grounded vehicle, connect NEGATIVE (BLACK) clip from battery charger to
NEGATIVE (NEG, N, -) ungrounded post of battery. Connect POSITIVE (RED) clip to
vehicle chassis or engine block away from battery. Do not connect clip to carburettor,
fuel lines, or sheet-metal body parts. Connect to a heavy gage metal part of the frame or
engine block.
g) When disconnecting charger, turn switches to off, disconnect AC cord, remove clip from
vehicle chassis, and then remove clip from battery terminal.
h) See operating instructions for length of charge information.
16. FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE. A SPARK NEAR THE
BATTERY MAY CAUSE BATTERY EXPLOSION. TO REDUCE RISK OF A SPARK NEAR
BATTERY:
a) Check polarity of battery posts. POSITIVE (POS, P, +) battery post usually has a larger
diameter than NEGATIVE (NEG, N, -) post.
b) Attach at least a 24-inch-long 6-gauge (AWG) insulated battery cable to NEGATIVE
(NEG, N, -) battery post.
c) Connect POSITIVE (RED) charger clip to POSITIVE (POS, P, +) post of battery.
d) Position yourself and free end of cable as far away from battery as possible –then
connect NEGATIVE (BLACK) charger clip to free end of cable.
e) Do not face battery when making final connection.
f) When disconnecting charger, always do so in reverse sequence of connecting procedure
and break first connection while as far away from battery as practical.
g) A marine (boat) battery must be removed and charged on shore. To charge it on board
requires equipment specially designed for marine use.
17. GROUNDING AND AC POWER CORD CONNECTION INSTRUCTIONS –
Charger should :
be grounded to reduce risk of electric shock. Charger is equipped with an electric cord
having an equipment-grounding conductor and a grounding plug. The plug must be
plugged into an outlet that is properly installed and grounded in accordance with all local
codes and ordinances.
DANGER - Never alter AC cord or plug provided - if it will not fit outlet, have proper outlet
installed by a qualified electrician. Improper connection can result in a risk of an electric
shock
18. Connect only to lead-acid batteries with rated voltage of 12V and 24V.
19. WARNING - Connect rechargeable batteries only.
20. Do not use the charger in moving vehicles.
21. Warning - Do not undertake any constructional alterations to the device, as this could cause
damage to the device.
END OF SAFETY INFORMATION
Page 5
Contents
Page
Description 8
1
1.1 General mode of operation 8
1.2 Connections 9
1.2.1 9-pole SUB-D socket 9
1.2.2 15-pole SUB-D socket 10
1.2.3 USB interface 10
1.3
Displays and operating controls 11
1.3.1 Button 1 (On/Off) 11
1.3.2 Button 2 (Start/Stop) 11
1.3.3 Button 3 (Enter) 11
1.3.4 Button 4 (Up) 11
1.3.5 Button 5 (Down) 11
1.3.6 LED, green, yellow, red 12
1.3.7 LC Display 12
2
Operating modes 13
2.1 Setting operating mode 13
2.2 Battery charging mode (CHRG) 13
2.2.1 Output current in battery charging mode 14
2.3
External power supply (EPS) mode 15
2.4 EPS autostart mode 15
2.5 Charging AGM batteries 15
2.6 Charging Gel batteries 16
2.7 Charging motorcycle batteries 16
3 Internal monitoring 17
3.1 Mains power monitoring 17
3.2 Monitoring intermediate circuit voltage 17
3.3 Output overvoltage protection 17
3.4 Output undervoltage protection 17
3.5 Excessive output current 17
3.6 Temperature monitoring 18
3.7 Relay monitoring 18
4 External monitoring 19
4.1 Short circuit 19
4.2 Reverse polarity 19
4.3 Faulty battery 19
4.4 Clamp contact 19
4.5 Return voltage 19
4.6 Reverse polarity return voltage 20
5 Service menu 21
5.1 Operating modes 25
5.1.1 Charging (CHRG) mode 25
5.1.2 EPS 12V mode 25
5.1.3 EPS 24V mode 25
5.1.4 EPS autostart mode 25
Page 6
Page
5.2 Activate 24V mode 26
5.2.1 24V mode on / off 26
5.3
Set voltage 26
5.3.1 Set 12V trickle voltage 26
5.3.2 Set 24V trickle voltage 26
5.3.3 Set 12V charging voltage 26
5.3.4 Set 24V charging voltage 27
5.3.5 Set 12V EPS voltage 27
5.3.6 Set 24V EPS voltage 27
5.4
Set voltage limit 28
5.4.1 Set Ua max 12V 28
5.4.2 Set Ua min 12V 28
5.4.3 Set Ua max 24V 28
5.4.4 Set Ua min 24V 28
5.5
Output current limits 29
5.5.1 Set I-limit CHRG 12V 29
5.5.2 Set I-limit CHRG 24V 29
5.5.3 Set I-limit EPS 12V 29
5.5.4 Set I-limit EPS 24V 29
5.6
Process times 30
5.6.1 Set switch back time 30
5.6.2 Set maximum charging time 30
5.6.3 Set current limit 2 30
5.7
Autostart 31
5.7.1 Turn on/off autostart 31
5.8
Error log 31
5.8.1 Error 0 - 9 31
6
Derating 32
7 Default settings 33
8 Select language 33
9 Technical data 34
10 Appendix A: Status and error descriptions 36
Page 7
1 Description
1.1 General mode of operation
The MultiCharger 1500 is used for charging motor vehicle batteries and can also be used as an
external supply of electric power to a vehicle. The MultiCharger 1500 is equally suited for use in
12V and 24V systems. Power output is 1500W, sufficient to charge all popular vehicle batteries.
The MultiCharger 1500 is fed from the mains supply and transforms the connected alternating
current voltage into direct current voltage. The power element is fitted with an isolating transformer
that ensures that the output voltage is electrically isolated from the mains supply.
For protection, input and output cut-outs are built into the MultiCharger 1500. If it becomes
overloaded, a current limiter also kicks in to stop the MultiCharger 1500 getting damaged.
The MultiCharger 1500 is designed as a bench unit, which is cooled by the free flow of air from the
base to the top. You should therefore make sure that your MultiCharger 1500 remains uncovered.
All connections, displays and operating controls are located on the front of the MultiCharger 1500.
Page 8
1.2 Connections
All connections of the MultiCharger 1500 are at the front.
Mains power is connected to the MultiCharger 1500 through a plug for non-heating devices.
3 potential-free relay contacts, which signal various states of the MultiCharger 1500, and also a
hardware contact "Remote On/Off", can be connected through a 15-pole SUB-D socket.
To connect a signal light, a 9-pole SUB-D socket is used.
The signal light (green/yellow/red) signals various states of the MultiCharger 1500. Optionally, a
WLAN box can be connected for configuration, signalling and remote On/Off via PC network.
A sensor cable can be connected to an M8 plugged connector (three-pole socket).
A Mini-USB socket is used for configuration via PC and the software WinCharge. Software
updates can also be carried out through this interface.
The charging cable is connected with a plugged bayonet connection.
Mains power 15-pole 9-pole Sensor Mini-USB L- L+
SUB-D SUB-D socket socket Battery
socket socket connections
1.2.1 9-pole SUB-D socket
A 9-pole SUB-D socket on the front side of the device is used to connect a signal light. The signal
lights (green/yellow/red) signal the following states of the MultiCharger:
State Signal light
MultiCharger off, Standby all LEDs off
MultiCharger on and trickle charging,
Battery fully charged or second current limit
reached
MultiCharger on and charging yellow LED on, green LED off, red LED off
MultiCharger not connected yellow LED blinking, green LED off, red LED off
Device defect, poles reversed or flat battery red LED on, green LED off, yellow LED off
Optionally, a WLAN box can be connected for configuration, signalling and remote On/Off via PC
network. Detailed information about this can be found in the description of the WLAN box.
green LED on, yellow LED off, red LED off
Page 9
1.2.2 15-pole SUB-D socket
A 15-pole SUB-D socket provides 3 potential-free relay contacts, which signal the following states
of the MultiCharger:
State Relay 1 Relay 2 Relay 3
MultiCharger off, Standby 0 0 0
MultiCharger on and trickle charging,
0 0 1
Battery fully charged or second current limit
reached
MultiCharger on and charging 0 1 0
MultiCharger not connected 0 1 1
----- 1 0 0
Device defect 1 0 1
Poles reversed or flat battery 1 1 0
----- 1 1 1
1: relay pulled in 2: Relay released
1.2.3 USB interface
A Mini-USB socket is fitted on the right front side of the MultiCharger 1500, which can be used to
connect a laptop or PC.
The MultiCharger 1500 can be configured through this interface and software updates can be
carried out. For configuration or to alter the device software (Firmware Update) the software
WinCharge is required. Detailed information about this can be found in the description of the PC
Software WinCharge.
The configuration of the interface is shown below:
- data rate 9600 Baud
- 8 Data bits
- 1 Start bit, 1 Stop bit
- no parity
- no protocol
Page 10
1.3 Displays and operating controls
1.3.1 Button 1 (On/Off)
Button 1 is used to switch the MultiCharger 1500 on and off. If the connected mains power voltage
is over 90V, pressing button 1 switches the MultiCharger 1500 on and makes it ready for use.
You will also need to use button 1 to re-enable the system if a fault makes the unit shut down.
1.3.2 Button 2 (Start/Stop)
Button 2 is used to start or stop the charging process or the supply of external power.
1.3.3 Button 3 (Enter)
Button 3 is used as a button to confirm entries and for system navigation.
1.3.4 Button 4 (Up)
Button 4 is a navigation button.
1.3.5 Button 5 (Down)
Button 5 is also a navigation button.
Page 11
1.3.6 LED, green, yellow, red
The LEDs (green/yellow/red) on the display signal the following states of the MultiCharger:
State LED
MultiCharger off, Standby all LEDs off
MultiCharger on and trickle charging,
battery fully charged or second current limit
reached
MultiCharger on and charging yellow LED on, green LED off, red LED off
MultiCharger not contacted yellow LED blinking, green LED off, red LED off
Device defect, poles reversed or flat battery red LED on, green LED off, yellow LED off
green LED on, yellow LED off, red LED off
1.3.7 LC Display
The MultiCharger 1500’s LCD has two lines and can show 16 characters per line.
The current output voltage and current output are displayed on the top line. The bottom line acts as
a status display, showing in plain text the operating state and details of any faults that occur (see
Appendix A).
The LCD is illuminated and can therefore be easily read both in the dark and in direct sunlight.
Page 12
2 Operating modes
2.1 Setting operating mode
You can only set the operating mode if the MultiCharger 1500 is ready for use, i.e. if it has been
switched on via button 1 (On/Off). However, the unit does not have to be charging a battery and no
battery needs to be connected to the charger output.
When you press button 3 (Enter) a prompt to enter a password appears on the LCD display. The
password is made up of four numerical characters and is explained in more detail in section 5.
After correctly entering the password, you get to the MultiCharger 1500’s service menu. You
navigate this menu by using buttons 3, 4 and 5 (see section 5).
The mode is set through the menu item "set operating mode". This can be used to select the
operating modes described below: "Battery operation", "EPS operation 12", "EPS operation 24 V"
and "EPS autostart".
The operating mode for 24 V can only be activated after it has been approved separately under the
menu item "Approve operating mode 24 V".
The MultiCharger 1500 is supplied from the factory set to battery charging mode.
2.2 Battery charging mode (CHRG)
This is the mode used to charge vehicle batteries. The MultiCharger 1500 is ready for use as soon
as you have switched it on by pressing button 1 (On/Off). Ready for use means that the
MultiCharger 1500’s output voltage will remain at zero volts until a battery is attached to the output
connector.
When a battery is connected, the charger first measures the voltage. This determines the battery’s
rated voltage (12V/24V). The output voltage is then set accordingly and the battery starts to be
charged.
The followin
If the voltage of the batt
MultiCharger 1500 does not switch on, the output voltage remains at 0V and a ‘Faulty battery’ error
message appears on the LCD display.
If the battery voltage is in one of the valid ranges, the MultiCharger 1500 sets the output voltage
accordingly and charges the battery. "Charging active" appears on the LCD display. Charging
continues until the charge current drops below the 2.5A limit. Thereafter the MultiCharger 1500
stays on charge for a preset period (the Default setting is 120 minutes), after which it goes to trickle
charge.
If the current rises back above 2.5A during this secondary charging period or while on trickle
charge, the MultiCharger 1500 switches back to full charging and begins the charge cycle again.
If the charge current fails to drop below 2.5A within a preset period (default setting is 10 hours), the
MultiCharger 1500 switches to trickle charge and the display shows "Charging time max.".
g table gives an overview of valid voltage ranges:
Voltage range MultiCharg
1500
Ready for use
0V - 5V x
5V - 7V x
7V - 15V x
15V - 17V x
17V - 30V x
> 30V x
ery that is connected is outside of one of the permitted ranges, the
er
Error
message
MultiCharger
1500
At 14.8V
MultiCharger
1500
At 28.8V
Page 13
The following table gives an overview of the MultiCharger 1500’s default voltage levels:
Charging 12V Trickle
charging 12V
14.8V 13.4V 28.8V 26.8V
The charging process can be stopped by pressing button 2 (Start/Stop). If the battery remains
connected, the charging process can then be restarted by pressing button 2 (Start/Stop) again. If
the battery is unclamped, the charging process is over and will be restarted automatically if the
battery is connected again.
If the battery is unclamped during the charging process without pressing button 2 (Start/Stop), the
process will likewise be stopped. It will be restarted again automatically if the battery is
reconnected.
Warning:
Unclamping the battery without first properly ending the charging process can briefly create sparks.
The charging process can also be stopped at any time by pressing button 1 (On/Off). When the
MultiCharger 1500 is switched back on the charging process would then begin again from the start.
Charging 24V Trickle
charging 24V
2.2.1 Output current in battery charging mode
In battery charging mode the MultiCharger 1500 can be briefly (max. 1 minute) subjected to an
output current increased by 25%.
The following table gives an overview of maximum levels of output current for the MultiCharger
1500:
Inom at
12V CHRG
80.0A 100.0A 40.0A 50.0A
If the MultiCharger 1500 rated current is exceeded during use, the unit internally measures how
long this situation lasts. After a maximum of one minute the current limit is reset to the rated value.
To avoid the MultiCharger 1500 overheating the unit allows a period for the charger recover five
times as long as the length of time for which the rated current was exceeded. For example, if the
rated current is exceeded for 30 seconds, the MultiCharger 1500 current limit is held at the level of
the rated current for 2 minutes 30 seconds. After that time, the rated current can again be
exceeded.
Imax at
12V CHRG
Inom at
24V CHRG
Imax at
24V CHRG
Page 14
2.3 External power supply (EPS) mode
This operating mode enables power to be supplied to vehicles that have no battery. Once the
MultiCharger 1500 has been switched on by pressing button 1 (On/Off), it is ready for use. That
means that the MultiCharger 1500’s output voltage will stay at zero volts until button 2 (Start/Stop)
is pressed.
The MultiCharger 1500 then goes on to charge at the relevant voltage.
The following table gives an overview of the factory-set voltage levels for the EPS mode:
EPS 12V mode EPS 24V mode
14.0V 28.0V
The output voltage on the MultiCharger 1500 remains switched on until button 2 (Start/Stop) is
pressed again. When you press this button, the MultiCharger 1500 switches output voltage to 0V
until button 2 (Start/Stop) is pressed once again. Then output voltage is switched back on again.
Output voltage can also be switched off by pressing button 1 (On/Off).
Connecting a battery (with a voltage of >1V) to the MultiCharger 1500 before the output voltage is
switched on is not allowed. If this is done, a ‘Return voltage’ error message will appear.
The output voltage on the MultiCharger 1500 can then not be switched on until the battery is once
again removed.
Warning:
Connecting a battery to the MultiCharger 1500 while it is in EPS mode is not allowed.
2.4 EPS autostart mode
This mode works in a similar way to EPS mode. The difference between the two operating modes
is that in EPS autostart mode a battery has to be connected to the MultiCharger 1500.
The MultiCharger 1500 then sets the output voltage automatically to match the battery that is
attached.
2.5 Charging AGM batteries
It is possible that the batteries used in some vehicles may be so-called AGM (Absorbent Glass
Mat) batteries, i.e. batteries containing an absorbent glass-fibre mat.
With these batteries, you should make particularly sure that in no event does the charging voltage
exceed 14.8V (or 29.6V in the case of 24V batteries).
When AGM batteries are used, adjustments to the MultiCharger 1500’s output voltage (see section
5.4) must therefore be made with particular care.
Warning: Any AGM battery will be permanently damaged if the charging voltage exceeds
14.8V (or 29.6V in the case of 24V batteries).
The MultiCharger 1500 is supplied with the output voltage set below the allowable limit for AGM
batteries.
Page 15
2.6 Charging Gel batteries
Gel batteries are used in some vehicles.
With these batteries, you should make particularly sure that the charging voltage is between 14.1V
and 14.8V (or 28.2 - 28.8V in the case of 24V batteries).
The trickle charge voltage should not exceed 13.8V (or 27.6V in the case of 24V batteries).
When Gel batteries are used, adjustments to the MultiCharger 1500 output voltage (see section
5.4) must therefore be made with particular care.
The charging current should be between 15 - 40A for every 100Ah of battery capacity. Refer to the
technical specifications of the relevant Gel battery for the maximum permitted current.
Warning:
If a Gel battery’s charging voltage or trickle charge voltage exceeds the levels shown
above, battery life will be shortened. If these levels are regularly exceeded, the battery will
be permanently damaged.
2.7 Charging motorcycle batteries
Motorcycle batteries generally have a significantly smaller capacity than car batteries. This can
lead to the MultiCharger 1500 maximum charging current (100A for 12V batteries) being too high
for some types of battery.
Should this be the case, the MultiCharger 1500 output current limit should therefore be set lower
(see section 5.6).
For the maximum permitted charging current, refer to the technical specifications of the relevant
motorcycle battery.
Page 16
3 Internal monitoring
The MultiCharger 1500 has several internal monitoring functions that ensure that the charger
works reliably. These are individually described in the following sub-sections.
3.1 Mains power monitoring
If the mains voltage drops below 85V, the MultiCharger 1500 signals a fault and switches off. The
message ‘Mains error’ appears on the LCD display.
If the mains voltage rises above 90V, the MultiCharger 1500 can be made ready for use by
pressing button 1 (On/Off).
3.2 Monitoring intermediate circuit voltage
Intermediate circuit voltage is monitored both against dropping too low and rising too high. If either
limit (350V and 430V respectively) is passed, the MultiCharger 1500 signals a fault and switches
itself off to the unlocked position. The message ‘PFC error’ appears on the LCD display and the
red LED comes on. If either of the limits is exceeded again after restarting the MultiCharger 1500
switches itself off to the locked position.
3.3 Output overvoltage protection
For safety reasons output voltage is monitored for excessive levels in two totally independent
ways.
The controller-independent hardware monitoring threshold for overvoltage output is fixed at 16V or
32V respectively. This monitors internal output voltage. If internal voltage goes over this threshold,
the MultiCharger 1500 signals a fault and switches itself off to the locked position. The message
‘OVP error’ appears in the LCD display and the red LED comes on.
The digital monitoring threshold for overvoltage output is adjustable, while the default setting for
this is also 16V or 32V respectively. If output voltage goes over this threshold, the MultiCharger
1500 signals a fault and switches itself off to the locked position. The message ‘Overvoltage’
appears in the LCD display and the red LED comes on.
3.4 Output undervoltage protection
The monitoring threshold for output undervoltage is 7V or 14V respectively.
If output voltage drops below this threshold, the MultiCharger 1500 signals a fault and switches
itself off to the locked position. The message ‘Voltage too low’ appears on the LCD display and the
red LED comes on.
3.5 Excessive output current
If, due to an internal fault in the appliance, output current exceeds the prevailing current limit level
by more than 25%, the MultiCharger 1500 signals a fault and switches itself off to the locked
position. The message ‘Overcurrent’ appears in the LCD display and the red LED comes on.
Page 17
3.6 Temperature monitoring
This monitoring function measures the temperature inside the MultiCharger 1500. If this rises
above the maximum limit of 90°C, the MultiCharger 1500 signals a fault and is switched off, but not
locked. The message ‘Temperature err.’ appears on the LCD display and the red LED comes on.
The MultiCharger 1500 remains ready for use.
If the temperature drops back below the maximum level, the error message is automatically
cancelled.
3.7 Relay monitoring
This function monitors the internal relay switches in the MultiCharger 1500’s main circuit. If there is
a problem with any of these, the MultiCharger 1500 signals a fault and switches itself off to the
locked position. The message ‘Internal error’ appears on the LCD display and the red LED comes
on.
Page 18
4 External monitoring
The MultiCharger 1500 also has a number of external monitoring functions that keep a constant
check on connected power consumers. These are individually described in the following subsections.
4.1 Short circuit
The MultiCharger 1500 can tell that it has an output short circuit if this occurs in the current limiter
and output voltage drops below the set lower limit (default setting 7V or 14V respectively). In this
case, the MultiCharger 1500 signals a fault and switches itself off to the locked position. The
message ‘Short circuit’ appears on the LCD display and the red LED comes on.
4.2 Reverse polarity
If a battery is connected the wrong way round, the MultiCharger 1500 signals a fault but remains
ready for use. This does not do the MultiCharger 1500 any harm. No charging or trickle charging
process will be started. ‘Reverse polarity’ appears on the LCD display and the red LED comes on.
4.3 Faulty battery
If the battery connected to the charger has an output voltage outside of the permitted limits (see
section 2.2), the MultiCharger 1500 signals a fault and the charging process des not start. The
message ‘Faulty battery’ appears on the LCD display and the red LED comes on.
4.4 Clamp contact
This monitoring function is active in all operational modes; Battery charging mode (see section 2.2)
EPS operation (see section 2.3) and in EPS autostart mode (see section 2.4).
If the MultiCharger 1500’s output current drops below 10mA during the charging or trickle charging
process, the MultiCharger 1500 recognises this as meaning that the clamps have been removed
from the battery posts. The charger then briefly signals a fault, the message ‘Clamp contact’
appears on the LCD display and the red LED comes on. However, the MultiCharger 1500 remains
ready for use.
4.5 Return voltage
This monitoring function is only active in EPS mode (see section 2.3).
You are not permitted to connect a battery to the MultiCharger 1500 in this operating mode. If you
do nevertheless connect a battery ahead of trying to start to charge it, the MultiCharger 1500
signals a fault. The message ‘Return voltage’ appears on the LCD display and the red LED comes
on. The MultiCharger 1500 remains ready for use.
Page 19
4.6 Reverse polarity return voltage
This monitoring function is only active in EPS mode (see section 2.3).
You are not permitted to connect a battery to the MultiCharger 1500 in this operating mode. If you
do nevertheless connect a battery before trying to start charging, and connect it the wrong way
round, the MultiCharger 1500 signals a fault. This will not harm the MultiCharger 1500, but the
message ‘EPS reverse pole’ appears on the LCD display and the red LED comes on. The
MultiCharger 1500 remains ready for use.
Page 20
5 Service menu
The service menu is used to make basic system settings on your MultiCharger 1500. The structure
of this menu is set out below. To avoid mistakes these settings are protected by two different
codes. You should give access to these only to properly trained individuals.
The general code for using the service menu is: 0109.
Changes to parameters such as charging voltage, current limits, monitoring limits and process
times must be made sensibly. Inappropriate changes can detrimentally impact the way the charger
works.
None of the settings can be changed unless the MultiCharger 1500 is ready for use, i.e. unless it
has been switched on via button 1 (On/Off). However, the unit should not be charging a battery
and no battery should to be connected.
When you press button 3 (Enter) a prompt appears on the LCD display for you to enter a
password. This consists of four numeric characters and can be entered by using button 3 (Enter),
button 4 (Up) and button 5 (Down). Each of the four characters is selected using button 4 (Up) and
button 5 (Down) and then confirmed with button 3 (Enter).
After correctly entering the password, you get to the MultiCharger 1500’s service menu. This menu
is also navigated by using buttons 3, 4 and 5.
All of the setting options are described below:
Page 21
Service menu:
ID code: 0000
Service menu structure
0 1
Set mode
Present mode
charging
Present mode
EPS 12V
Present mode
EPS 24V
Present mode
EPS autostart
Activate
24V mode
24V mode off
24V mode on
Set voltage Set voltage limit
Set 12V
trickle voltage
Set 24V
trickle voltage
Set 12V
charging voltage
Set 24V
charging voltage
Set 12 V
EPS voltage
Set 24V
EPS voltage
Exit menu
Trickle 12V
Now at: 13.4V
Trickle 24V
Now at: 26.8V
Charging 12V
Now at: 14.8V
Charging 24V
Now at: 28.8V
EPS 12V
Now at: 14.0V
EPS 24V
Now at: 28.0V
Set Ua max. 12V Ua m ax. 12V
Set Ua min. 12V
Set Ua max. 24V Ua max. 24V
Set Ua min. 24V Ua min. 24V
Exit menu
Now at: 16.0V
Ua min. 12V
Now at: 7.0V
Now at: 32.0V
Now at: 14.0V
Page 22
Service menu structure
1
Set current limit
Set process times
Turn on/off
autostart
2
Set I-limit CHRG
12V
Set I-limit CHRG
24V
Set I-limit EPS 12V I-limit EPS 12V
Set I-limit EPS 24V I-limit EPS 24V
Exit menu
I-limit CHRG 12V
Now at: 80A/100A
I-limit CHRG 24V
Now at: 40A/50A
Now at: 80A
Now at: 40A
Set switch back
time
Set maximum
charging time
Set current limit 2
Exit menu
Switch back time
Now at: 120Min
Max. CHRG time
Now at: 10Std
Current limit 2
Now at: 8A
Autostart now
enabled
Autostart now
disabled
Page 23
Error log
Service menu structure
Factory settings
Software version
MC05Dxx
Select Language
Save entries
Exit menu
02
Display error?
Num. Errors = x
Clear error log?
Exit menu
Error 9:
xxxxxx
Error 8…1:
xxxxxx
Error 0:
xxxxxx
Error log cleared
Load factory
settings?
Factory settings
loaded
Sprache aktuell
Deutsch
Current language
English
Langue active
Francais
Taal actueel
Nederlands
Lingua corrente
Italiano
Idioma actual
Espanol
Valittu kieli
Suomi
Page 24
5.1 Operating modes
The ‘Set mode’ menu enables the different operating modes of the MultiCharger 1500 to be set up
and activated.
These settings should be made very carefully to avoid any potential damage to the vehicle connected
to the charger (e.g. connecting a charger in EPS 24V mode to a vehicle with a 12V electrical system
will cause harm to the vehicle).
5.1.1 Charging (CHRG) mode
This is a sub-item of the ‘Set mode’ menu and can be used to set the MultiCharger 1500 to battery
charging mode. The functioning of this operating mode is described in more detail in section 2.2.
5.1.2 EPS 12V mode
This is a sub-item of the ‘Set mode’ menu and can be used to set the MultiCharger 1500 to external
power supply mode. The functioning of this mode is described in more detail in section 2.3.
5.1.3 EPS 24V mode
This is a sub-item of the ‘Set mode’ menu and can be used to set the MultiCharger 1500 to 24V
external power supply mode. The functioning of this mode is described in more detail in section 2.3.
The charger can only be set to ‘EPS 24V mode’ if this has already been activated (see section 5.2).
5.1.4 EPS autostart mode
This is a sub-item of the ‘Set mode’ menu and can be used to set the MultiCharger 1500 to external
power supply mode with automatic battery voltage recognition. The functioning of this operating mode
is described in more detail in section 2.4.
Page 25
5.2 Activate 24V mode
The ‘Activate 24V mode’ menu lets you activate or deactivate all operating modes with 24V rated
voltage. These settings should be made with extreme care to ensure that unauthorised use of the
charger with 24V rated voltage is not possible. Such use could cause damage to any vehicle that
might be connected to the charger.
5.2.1 24V mode on / off
This is a sub-item of the ‘Activate 24V mode’ menu. This is where 24V modes are activated (turned
on) or deactivated (turned off). If the MultiCharger 1500 is in a 24V operating mode and this is
deactivated, a 12V mode will be automatically activated as a result.
As soon as the 24V operating modes are deactivated, it is no longer possible to activate these from
the ‘Set mode’ menu.
If a 24V battery is connected to the MultiCharger 1500 in this state, the unit will display a battery error
message.
5.3 Set voltage
The ‘Set voltage’ menu enables the level of the MultiCharger 1500 output voltage to be set.
5.3.1 Set 12V trickle voltage
This is a sub-item of the ‘Set voltage’ menu and is used to set the trickle charge voltage for the 12V
battery-charging mode.
Default setting: 13.4V Setting range: 13.0V – 14.0V
5.3.2 Set 24V trickle voltage
This is a sub-item of the ‘Set voltage’ menu and is used to set the trickle charge voltage for the 24V
battery-charging mode.
Default setting: 26.8V Setting range: 26.0V – 28.0V
5.3.3 Set 12V charging voltage
This is a sub-item of the ‘Set voltage’ menu and is used to set the charge voltage for the 12V battery-
charging mode.
Default setting: 14.8V Setting range: 13.0V – 15.0V
Page 26
5.3.4 Set 24V charging voltage
This is a sub-item of the ‘Set voltage’ menu and is used to set the charge voltage for the 24V battery-
charging mode.
Default setting: 28.8V Setting range: 27.0V – 30.0V
5.3.5 Set 12V EPS voltage
This is a sub-item of the ‘Set voltage’ menu and is used to set the output charge voltage for the 12V
external power supply mode.
Default setting: 14.0V Setting range: 13.0V – 15.0V
5.3.6 Set 24V EPS voltage
This is a sub-item of the ‘Set voltage’ menu and is used to set the output charge voltage for the 24V
external power supply mode.
Default setting: 28.0V Setting range: 27.0V – 30.0V
Page 27
5.4 Set voltage limit
The ‘Set voltage limit’ menu is used to set monitoring limits for overvoltage and undervoltage.
5.4.1 Set Ua max 12V
This is a sub-item of the ‘Set voltage limit’ menu and is used to set the monitoring limit for
overvoltage where output voltage is 12V.
Default setting: 16.0V Setting range: 15.0V – 16.0V
5.4.2 Set Ua min 12V
This is a sub-item of the ‘Set voltage limit’ menu and is used to set the monitoring limit for
undervoltage with output voltage at 12V.
Default setting: 7.0V Setting range: 7.0V – 10.0V
5.4.3 Set Ua max 24V
This is a sub-item of the ‘Set voltage limit’ menu and is used to set the monitoring limit for
overvoltage with output voltage at 24V.
Default setting: 32.0V Setting range: 30.0V – 32.0V
5.4.4 Set Ua min 24V
This is a sub-item of the ‘Set voltage limit’ menu and is used to set the monitoring limit for
undervoltage with output voltage at 24V.
Default setting: 14.0V Setting range: 14.0V – 20.0V
Page 28
5.5 Output current limits
The ‘Set current limit’ menu is used to set the level of the MultiCharger 1500 maximum rated
current. The MultiCharger 1500 can constantly deliver whatever current level is entered here. In
battery charging mode, this level can also be exceeded by 25% for a maximum period of 1 minute.
5.5.1 Set I-limit CHRG 12V
This is a sub-item of the ‘Set current limit’ menu and is used to set the MultiCharger 1500 maximum
rated current in 12V battery charging mode.
Default setting: 80.0A/100 A Setting range: 0.0A – 80.0A/100A
5.5.2 Set I-limit CHRG 24V
This is a sub-item of the ‘Set current limit’ menu and is used to set the MultiCharger 1500 maximum
rated current in 24V battery charging mode.
Default setting: 40.0A/50A Setting range: 0.0A – 40.0A/50A
5.5.3 Set I-limit EPS 12V
This is a sub-item of the ‘Set current limit’ menu and is used to set the MultiCharger 1500 maximum
rated current in 12V external power supply mode.
Default setting: 80.0A Setting range: 0.0A – 80.0A
5.5.4 Set I-limit EPS 24V
This is a sub-item of the ‘Set current limit’ menu and is used to set the MultiCharger 1500 maximum
rated current in 24V external power supply mode.
Default setting: 40.0A Setting range: 0.0A – 40.0A
Page 29
5.6 Process times
The ‘Set process times’ menu is used to set relevant times for the battery-charging mode.
5.6.1 Set switch back time
This is a sub-item of the ‘Set process times’ menu and is used to set the length of time for
secondary battery charging. This time begins as soon as the battery’s charging current drops below
2.5A. After this, the MultiCharger 1500 stays on charge until the expiry of the switch back delay set
here. It then switches to trickle charge.
Default setting: 120 minutes Setting range: 0 – 999 minutes
5.6.2 Set maximum charging time
This is a sub-item of the ‘Set process times’ menu and is used to set maximum time for battery
charging. If the battery’s charging current does not drop below 2.5A, charging then stops at the end of
the maximum charging period that you have entered here.
Default setting: 10 hours Setting range: 0 – 24 hours
5.6.3 Set current limit 2
This is a sub-item of the "Set process times" menu. If the charging current of the battery sinks under
current limit 2, the signals (LEDs on the display or signal lamps) change from yellow to green.
The charging process is not interrupted and the LC display continues to signal the current charging
status.
Default setting: 8.0A Setting range: 0…20A
Page 30
5.7 Autostart
The ‘Autostart’ menu lets you enable or disable the automatic starting function for battery charging in
battery charging mode.
5.7.1 Turn on/off autostart
This is a sub-item of the ‘Autostart’ menu and is used to enable or disable the autostart function.
Enabling autostart means that the MultiCharger 1500 (if switched on and in battery charging mode)
will begin the charging process as soon as a battery is connected, with no need for any other
instructions to be entered.
Disabling autostart means that the MultiCharger 1500 (switched on and in battery charging mode) will
only begin the charging process after a battery has been connected and button 2 (Start/Stop) has
been pressed.
Default setting: Autostart enabled
5.8 Error log
The last 10 internal and external errors to occur are stored in the ‘Error log’, which you are able to
access if necessary.
5.8.1 Error 0 - 9
This is a sub-item of the ‘Error log’ menu. This lets you call up any of the last 10 internal or external
errors to occur.
Error 9 is the most recent error to have occurred, while error 0 is the oldest one in the memory. If over
the course of time more than 10 errors occur, the oldest one is always deleted from the memory.
This menu item also gives you the option to clear all of the errors out of the log.
Page 31
6 Derating
The output power is regulated according to the mains input voltage (see diagram).
This prevents the mains input current from exceeding the maximum value.
Output power curve:
Page 32
7 Default settings
Selecting the ‘Default settings’ menu and pressing the ‘Enter’ key restores the following parameters
to their default settings.
12V charging voltage : 14.8V
24V charging voltage : 28.8V
12V trickle charge voltage : 13.4V
24V trickle charge voltage : 26.8V
12V EPS voltage : 14.0V
24V EPS voltage : 28.0V
12V charging current limit : 80.0A/100,0A
24V charging current limit : 40.0A/50,0A
12V EPS current limit : 80.0A
24V EPS current limit : 40.0A
12V Ua max : 16.0V
24V Ua max : 32.0V
12V Ua min : 7.0V
24V Ua min : 14.0V
Switch back delay : 120 mins.
Maximum charging time : 10 hours
Current limit 2 : 8.0 A
Operating mode : 12V charging mode
Autostart : enabled
24V operating modes : deactivated
The MultiCharger 1500 provides the facility to make permanent changes to the default settings
through external software. In this event, the charger’s settings may vary from those shown above.
If the default settings are changed, this should be marked in the accompanying documentation.
8 Select language
The ‘Select language’ menu can be used to select one of the following languages:
- German
- English
- French
- Dutch
- Italian
- Spanish
- Finnish
Each language is shown on the selection menu in that particular language.
Page 33
9 Technical data
Model:
Nominal output:
Maximum output: 1500W
DC output:
Rated voltage: 12V/24V
Max. output current: 80A at 12V (100A for max. 1 min. in Battery charging mode)
Controls: Output voltage static tolerance: 1%
Short circuit protection: Current limiting. Permanently short-circuit proof.
Short circuit response: IV characteristic as per DIN 41772/73
Mains input:
Operating v
Operating voltage range: 90V - 264V
Rated frequency: 50Hz
Frequency range: 47Hz – 63Hz
Displacement factor
(cosϕ): 1
Power factor (λ): 0.99
Input current
"Worst case": 10A
oltage: Single phase
12V/100A - 24V/50A battery charger
1200W
40A at 24V (50A for max. 1 min. in Battery charging mode)
Type of control for sudden changes of load: 10% for
t
a<10 ms, ΔU
<0.6V ( ta = response time; max. deviation = Ua )
a
Efficienc
nominal conditions:
Signalling: LCD display (2 x 16 characters)
y factor under
0.88
5 buttons (display and operation)
Page 34
Electromagnetic compatibility: Emissions comply with EN 61000-6-3
EN 61000-3-2
EN 61000-3-3
Interference
immunity acc. EN 61000-6-2
Protection ty
Protection class:
Operating temperature
T
ype of cooling: Natural convection, without fan
MTBF: >250,000 hours
Required air condition:
Safety
CE certifica
Weight: 6.5kg
Dimensions (HxWxD): 110 x 260 x 370 mm (incl. handles)
Connection ty
Direct current:
Interfaces:
Sensor
specifications: EN 60335
Mains: Inlet connector for non-heating appliances
pe:
: -20°C to 60°C, with lower current from 40°C ambient temp.
tion as per: EMVG
pes:
52
IP
I as per EN 60335
Max. 95% humidity, no condensation
Bayonet
15-pin
9-pin Sub-D connector
Mini-USB socket
M8
plugs
Sub-D connector
plugged connection, 3 poles
Page 35
10 Appendix A: Status and error descriptions
Error messages and operating status details are shown as plain text on the LCD display.
These messages are described below:
Status displays:
System test
CHRG 12V on Mode prior to start of charging process (section 2.2)
CHRG 24V on Mode prior to start of charging process (section 2.2)
No CHRG contact No battery connected (section 2.2)
Start CHRG mode? Prompt to start charging mode if auto start is
12V CHRG on 12V battery charging in progress (section 2.2)
24V CHRG on 24V battery charging in progress (section 2.2)
CHRG 12V standby 12V battery charging on standby (section 2.2)
CHRG 24V standby 24V battery charging on standby (section 2.2)
Battery full Battery fully charged before end of max. loading time (section 2.2)
Max. CHRG time Maximum charging time over, battery not fully charged (section 2.2)
Start EPS 12V? Prompt to start 12V EPS mode (section 2.3)
Start EPS 24V? Prompt to start 24V EPS mode (section 2.3)
Stop EPS 12V? Prompt to end 12V EPS mode (section 2.3)
Stop EPS 24V? Prompt to end 24V EPS mode (section 2.3)
Auto. start EPS EPS auto start mode (section 2.4)
No EPS contact No battery connected in EPS auto start mode (section 2.4)
Internal test routines in progress
disabled (section 5.8)
Error messages:
Mains error No mains voltage or voltage is under 90V (section 3.1)
PFC error Intermediate circuit voltage is wrong (section 3.2)
Overvoltage Output voltage too high (section 3.3)
OVP error Output voltage too high (section 3.3)
Voltage too low Output voltage too low (section 3.4)
Over current Output current too high (section 3.5)
Temperature err. Internal temperature too high (section 3.6)
Internal error Internal defect in the appliance (section 3.7)
Short circuit Short circuit at the output point (section 4.1)
Reversed polarity Battery connected wrong way round (section 4.2)
Faulty battery Voltage of connected battery not allowed (section 4.3)
Clamp contact Connection broken between battery and MultiCharger 1500 (section 4.4)
Return voltage Battery connected in EPS mode (section 4.5)
EPS reverse pole Battery connected wrong way round in EPS mode (section 4.6)
Page 36
Loading...