Exide Technologies GB4139 User Manual

Operating Instructions and Safety Precautions for the EHF Series Charger

CHARGE STATUS

INDICATION

mode

Auto-balance pulse / refresh

Safety

Only a t rained person should operate this equipment. The input and output voltages used with this equipment may be high enough to endanger life, so insulated, shrouded connectors must be fitted.

Please read this manual completely and convey instructions to all personnel concerned. Keep the manual in a s afe and convenient place.

It is advisable to thoroughly read the information on battery safety supplied with the battery, prior to charging.

Towards the end of charge, lead acid batteries give off hydrogen gas, which is explosive if in sufficient concentration, therefore avoid flames and sparks. Appropriate measures must be taken to ensure adequate ventilation.

Incorrect use of a charger or maladjustment of its controls can damage a battery. The equipment has been factory set and does not require user adjustment.

This product has been designed, manufactured and certified to be in conformance with UL Standards. Testing has ensured that the battery and c harger combination conform as a system for use in Light and Heavy Industrial environments for each respective product variant. The following notes are for the guidance of the person installing and using the product.

The charger must be i solated from the input supply and t he battery, before any of the panels are removed. It is strongly recommended that a Safety Warning Notice is placed at the input supply isolator, to warn against inadvertent reconnection of the mains supply and the isolator is locked in the off position.

DANGER - Risk of electric shock. Do not touch un-insulated portion of output connector or un-insulated battery terminal.

Installation

Installation must only be carried out by suitably qualified personnel and in accordance with current local and national wiring regulations.

The unit should be positioned using lifting equipment, placed under the base.

Battery leads should not be altered without prior consultation with service personnel.

The charger should be sited in a cool, dry, well-ventilated location away from corrosive fumes and humid atmospheres. Ambient temperature range must be maintained between 32°F - 95°F.

charger must have a minimum clearance overhead of eight

The

inches (8”), ensuring ventilation is not obstructed at the rear intake and the front exhaust vents.

The charger is for inside use only.

Before installation, check that:

• The charger has not sustained any transit damage.

• The rating is suitable for the intended input supply and ‘lead

acid’ battery to be charged.

• The connector polarity is correct and matches the polarity of

the battery connector.

Input supply

A hand operated lockable isolator should be used in the installation, to enable the charger to be disconnected from the supply, for maintenance or repair work. The charger does not exhibit high in-rush current, therefore type B or C circuit breakers can be used.

CAUTI

ON - To reduce the risk of fire, use only on circuits provided with branch circuit protection consistent with the current indicated on the rating label and i n accordance with the National Electrical Code, ANSI/NFPA 70 or equivalent.

The circuit breakers rating should be bas ed on the chargers maximum input current, as stated on the rating label.

Careful consideration must be taken when connecting this charger to a generator. The generator must be capable of at least four times the input power requirements of the charger, failure to do so can result in damage to the charger. The generator should have load step immunity to prevent undershoot and overshoot with typical loads. Typically the generator control bandwidth should be less than 7Hz with good gain and phase margins.

Display and Control

Overview

1. Communications Port

2. High Visibility - Charge Status Indicator

3. Soft-keys (The function of the button will be displayed on the LCD Display)

4. LCD Display

5. Pause Button

Charge Status Indicator

INDICATION

LCD Symbols

* Optional extra

*Watering system (Shown when enabled, flashing during operation)

Communications port (Shown when active) Equalise (Shown when enabled, flashing during operation)

Automatic Equalise (Shown when enabled, flashing during operation) Warning (Shown when a warning is active) Battery Recovery Mode (Shown when enabled, flashing during operation)

*Air system enabled (Shown when enabled, flashing during operation)

Cycling red

Cycling yellow Second stage / watering

All green Charge complete

Green with cycling red

All flashing red Critical fault

All off Standby / pause / inhibit

Left hand indicator red Power save mode

MODE

Bulk charge / battery recovery

pulse / equalising / cool down

Operation

Before connecting the battery, check that the battery voltage corresponds to the voltage indicated inside the battery symbol on the LCD Display. The charger should be permanently connected to the mains supply.

Standby

With the input supply connected and no battery, the charger will enter the standby mode. During this mode the charge status

indicator will show indication 6 and the LCD display will show the following:

As a power saving feature the LCD back light will be switched off after 1 minute of inactivity, the backlight can be turned back on by briefly pressing any of the buttons. During this time the charge status indicator will show indication 7.

Charging

When a battery is connected to the charger, charge will start automatically. The charge status indicator will show indication 1 or

indication 2 (The speed of the rotation indicat es t he state of charge of the battery, with fast cycling indicat ing a low charge state) and

the LCD Display will show the following:

The bar graph display gives the user an indication of the batteries present state of charge.

During charge, the user can scroll through the following charge information, by pressing the

• VPC Voltage per cell

• Ah Total Ampere hours delivered to the battery

• Amps The present output current

• Stage The present charge stage

• Charge Time The total charge time

• Rest Time Time elapsed since charge completed

• Warnings Displays any warnings - Only shown when applicable

Charge Complete

When charge is complete the charge status indicator will show indication 3 and the LCD Display will show the following:

or keys.

the cells to the same charge state, this should be performed after the standard charge has completed.

This mode can be enabled by pressing the = key during the charge cycle, a second press will clear this function. The equalize function can not be c leared once it has started and onl y one equalize is allowed per cycle.

In addition to enabling equalize manually, the equalize feature can be set to initiate automatically by configuring the automatic equalize feature in the programming mode. Automatic equalize may be set to occur every 0 to 250 cycles. Once set the A= symbol will be shown in the top right corner of the LCD Display.

Once enabled, the charger will perform the equalize function after the standard charge has been completed.

Battery Recover Mode

If a bat tery is connected to the charger that is below the normal operating voltage an incorrect battery fault (F07) will be displayed. However if the battery voltage is between 1 and 1. 5VPC, battery recover mode is available. This mode employs a special charging technique to recover batteries that have been left unused for a long time or have been over discharged.

This mode can be enabl ed by pressing the BRM key when the fault is displayed. Battery recover mode will then start; once the battery voltage has been r ecovered to a normal level a standard charge will be performed.

Cool Down Mode (Profile Dependant)

Cool down mode is activated after the charge has completed and allows the battery time to ‘cool down’ before its next use. During this time the battery should remain connected to the charger, but can be removed if required.

Delayed Start

Note: This function is only available if the network function is OFF and can only be set without a battery connected.

The delayed start function will delay the start of charge for a s et time up to 48 hour s in 15 minute increments. The timer begins count down upon connection to a battery.

During the delay period the charge status indicator will show indication 6 and the LCD Display will show the following:

If the Auto Balanc e feature is enabled the battery should be left connected to the charger until required; under these c ondit ions the battery will receive periods of refreshing charge to maintai n it in the fully charged condition. During these periods, the charge status indicator will show indication 4.

Removing the battery

The battery can only be disconnected when charging current has stopped flowing. Therefore, the pause button must be pressed before disconnection. A second press of the paus e key

will clear the pause condition and continue charge (Disabled during the first 10 seconds of pause).

When the charger is paused the charge status indicator will show indication 6 and the LCD Display will show the following:

If the pause mode is entered but the battery is not removed within 10 minutes the charge will automatically continue.

Equalize Mode (Profile Dependant)

Periodically, batteries require additional charging to equalize all of

Once the time period has elapsed, charge will start as normal. This can be overridden by pressing the >> button, for this cycle only.

User menu

A user menu can be ac cessed by pressing the MENU key, the following options can then be scrolled through by pressing the

keys and then activated by pressing the SELECT key:

Charger History

Cycle Data Total Charge Ah Cycle Graphs Total Charge Time Total Initiations Total Terminations

Charger Information

Charger Type Software Version Module Part Number Network ID Module Temperature Network Speed Serial Number Date Code Auto Equalisation Watering System

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