Fiamm Premium HF flex Technical Manual

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Fiamm Motive Power
®
Premium HF flex
Technical manual GB
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Contents
Warning..................................................................... 2
Guarantee...................................................................2
Recommendations.................................................... 2
Electrical safety..........................................................2
Limitations on use.....................................................3
Destruction of the equipment.................................. 3
Improvements and modifications............................3
Receipt - Storage.......................................................3
Replacement parts.................................................... 3
Information plate.......................................................3
Glossary..................................................................... 3
EEC declaration of conformity................................. 3
Introduction............................................................... 4
Introduction............................................................... 4
External components................................................4
Control panel............................................................. 4
Menus.........................................................................5
Menu access.............................................................. 5
Memory......................................................................5
Status......................................................................... 6
Configuration.............................................................6
Contrast......................................................................6
Backlight.....................................................................6
Language................................................................... 6
Use............................................................................. 7
Unpacking.................................................................. 7
Mechanical Installation.............................................7
Electrical Connection................................................ 7
Factory configuration................................................7
Charging the battery................................................. 7
Display of the history per charging operation........9
Display of the charger’s history............................... 9
Fault messages..........................................................9
Technical characteristics......................................... 10
Warning
Aim of this manual
This manual is designed for use by any skilled worker wishing to use Fiamm Motive Power®Premium HF flex 3-phase battery chargers for rechar
ging lead/acid unsealed or gel batteries. This manual provides details of:
• The chargers’ functions.
• Any adjustments required and how to use the chargers.
• The chargers’ technical characteristics. When producing this manual, Fiamm Motive Power has aimed to provide its information in as simple and precise a manner as possible but cannot assume any responsibility for any misinterpretation. The owner of the equipment is required to retain this manual throughout the equipment’s life and to pass it on to any purchaser in the event of its resale.
Guarantee
The manufacturer covers the guarantee in accordance with the local regulations. Please contact your dealer for more detailed information.
Recommendations
This manual contains information and advice that should be followed by the operator to ensure his safety and maintain the equipment’s safe condition.
Recommended use
This manual should be read through carefully before using the equipment and also read by anyone likely to use the equipment. The equipment:
• Presents no obstacles to the free circulation of air
through the air inlet and outlet but, nevertheless, should be cleaned of dust every six months by a qualified person.
• Must be used in conformance with its indicated level of
protection and never come into contact with water.
• Must be used within the temperature limits stated in the
technical characteristics.
• Must not be installed on surfaces subject to vibration
(near to compressors, engines, motors, etc.).
Operator safety
Take all necessary precautions when the equipment will be used in areas where there is the possible risk of an accident occurring. Ensure appropriate ventilation when charging unsealed lead/acid batteries to allow any gases released to escape. Never disconnect the battery while it is being charged.
General checks
Before putting the charger into service, we recommend that you check:
• That it is correctly earthed.
• That the local power supply conforms to the charger’s
operating voltage.
• That the battery voltage conforms to that of the charger.
• That the charger’s output is suitable for the battery’s
capacity.
Electrical safety
The prevailing safety regulations must be observed. The system protection installed on the power supply to the charger must conform to the charger’s electrical characteristics. The installation of a suitable circuit breaker is recommended. It is imperative to ensure that when fuses are being replaced only fuses of the specified type and of the correct calibre are used. It is strictly forbidden to use inappropriate fuses or to short-circuit the fuse holders. This equipment conforms to Class 1 safety standards, which means that the appliance must be earthed and requires to be powered from an earthed supply. Earthing is provided by means of a braid or cable of cross-section in excess of or
ENGLISH
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equal to 6mm2; this cable must be as short as possible. Before opening the equipment for the purposes of adjustment, replacement of components, maintenance or repairs, it must be disconnected from all sources of electri­cal power (including mains and battery power). The battery must only be disconnected after the Start/Stop button has been set to “0”. Any adjustment, maintenance or repairs to the equipment while it is open must only be carried out by an appropriately skilled person who is aware of the risks involved.
Contact one of the company’s trained technicians if any problem is encountered when putting the charger into operation.
Limitations on use
This equipment has been designed for use in a covered environment. It is only designed to recharge lead/acid batteries on industrial premises.
Destruction of the equipment
When the equipment becomes obsolete, the casings and the other internal components can be disposed of by specialist companies. Local legislation takes precedence over any instructions in this document and must be scrupulously observed.
Improvements and modifications
Fiamm Motive Power®reserves the right to make any impro­vements and/or modifications to the product described in this manual at any time and without prior notice and is not obliged under any circumstances whatsoever to update the contents of this manual nor the equipment concerned.
Receipt – Storage
Upon receipt of the package, check for any external or internal damage and, if necessary, notify the haulier at his usual premises, by recorded delivery letter, fax or e-mail, within 24 hours of delivery. If the charger is to be stored before its use, it must be kept carefully sealed in its original packaging. It must be stored in a clean and dry location at a moderate temperature (0°C to +40°C). Equipment stored at a temperature of less than 15°C must be brought progressively to operating temperature (over a period of 24 hours) to avoid any risk of condensation causing electrical faults (particularly short-circuits).
Replacement parts
The equipment’s production number must be supplied when ordering any replacement parts. This number can be found on the information plate.
Information plate
This is located on one side of the charger.
Glossary
The chargers‘ advantages
Fiamm Motive Power chargers are microprocessor­controlled. The processor calculates the battery’s capacity so that the charging profile can be automatically adapted to the battery’s actual state over a wide range of capacities. The charging coefficient is maintained absolutely on all types of batteries. Fiamm Motive Power chargers adapt to the battery’s capacity and its discharge level.
Charging coefficient
The ratio of the number of amp hours restored during charging to the number of amp hours consumed during discharge.
Compensation charging
Compensation charging enables the battery to be maintained at maximum charge all the time that it is connected to the charger.
Desulphation charging
Desulphation charging, effected before normal charging, enables the density of batteries that have been heavily discharged or left a long time without use to be restored.
Equalisation charging
Equalisation charging, effected after normal charging, balances the densities in the battery’s cells.
Fiamm Motive Power energycom
This unit, permanently mounted on the battery, ensures that certain battery parameters can be sent to the charger, with no additional cable required, for the purposes of optimising the charge and monitoring the charging and discharging characteristics.
Gel
A sealed battery with gellified electrolyte.
Charging profile
The charging profile defines the rate of current charge over time. Different charging profiles can be selected, depending on the type of charger. The charger adapts to the battery’s age and level of discharge and prolongs its effective life. Controlling the overcharge coefficient, whatever the battery’s discharge level, reduces the amount of water (except for sealed batteries) and electricity consumed.
“Ionic” profile
Also called “ionic mixing”. This type of charging profile consists of sending short pulses of current to stimulate gas formation in the active material, causing sulphuric acid to be distributed outside the plates. This system of mixing the electrolyte enables more rapid charging of unsealed batteries subject to very high demands and balances out differences in density, homogenising the electrolyte across the surface of the plates.
Gel battery profile
The procedure for charging sealed, maintenance-free batteries has been optimised to ensure that the particular conditions required for recharging them are observed. The main advantages of these batteries are that there is no necessity to add water, thus reducing maintenance costs, and no necessity for special charging rooms with ventilation and water demineralisation units.
Rest function
The Rest function prevents the battery from being dis­connected for a pre-defined period to ensure a period of inactivity after charging.
EC declaration of conformity
EnerSys®hereby declares that the chargers in the Premium HF flex range covered by this declaration conform to the descriptions laid down in European Directives
Directive 2006/95/EC (Low Voltage Directive): EN60950-1
Directive 2004/108/EC (ElectroMagnetic Compatibility): EN61000-6-2, EN61000-6-4:Immunity and emissions limits for industrial electronics (Class A –Industrial Environments)
Directive 2002/95/EC (RoHS).
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Introduction
The Premium HF flex range of chargers enable batteries to be recharged from the 3-phase mains supply. The Premium HF flex chargers can recharge automatically batteries in the following ranges 24-36-48V or 48-72-80V. The microprocessor control automatically recognises the battery’s voltage, capacity, state of charge, etc., providing optimum battery control from highly efficient analyses of its condition. Several charging profiles are available (for free electrolyte “unsealed lead/acid”, sealed, gellified or “gel” battery types), depending on the user’s configuration. Desulphation, equalisation and compensation charging cycles are available.
External components
The general components are shown below:
No. Function
1. Ventilation holes.
2. Controls and monitoring devices (please see the next diagram).
3. Mains power cable.
4. Protective cover retaining screw.
5. Wall mounting bracket.
6. Battery cable.
Figure 1: The charger’s general components.
Control Panel
This contains the display and the control buttons. Please refer to the Chapters on Menus and Use for details of the information shown.
No. Function
1. LCD graphic display.
2. Menu navigation button (Up).
3. OK button.
4. Menu navigation button (Down).
5. Red ‘Fault’ light. Unlit: no fault. Flashing: fault detection in progress. Permanently lit: fault.
6. Yellow ‘Charging in progress’ light. Unlit: charger stopped. Lit: charging in progress.
7. Green ‘Charging completed’ light (battery charged). Unlit: charger stopped or battery not available Flashing: relaxation phase. Permanently lit: battery available.
8. Start-Stop switch.
9. Button for exiting the menu, initiating equalisation and initiating desulphation.
Figure 2: The charger’s controls.
Introduction
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2 3 4
5 6
7
9
8
4
5
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2
3
7
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The menus provide access to the following functions:
• View of the last 100 measurements (Memory Menu).
• View of the fault and alarm statuses, etc. (Status Menu).
• Charger configuration (Configuration Menu).
• Parametering the contrast (Contrast Menu), the display’s back-lighting (Backlight Menu) and the display language (Language Menu).
Menu access
The buttons’ functions
The buttons have the following general functions:
Button Function
▼▲ Menu navigation.
OK Selects the active menu or confirms the
entered value.
Closes the window.
Entering the password
When the charger is in the ‘Waiting’ position (Start-Stop switch on “0”), press OK. Enter the password using the
▼/▲ buttons until the valid number is displayed. The Main
Menu is then displayed.
Each of the six menus available is detailed below. The current menu is automatically exited after one minute of inactivity or can be exited voluntarily by pressing the
button.
Memory
This presents the history of each of the last 100 charging operations.
Access On the Main Menu, select MEMORY and press OK.
Call-up screen
The display shows here that 17 charges have been stored in memory (title line). MEMO 1 is the latest charge memorised. After memorising the one-hundredth charge, the oldest record is deleted and replaced by the next oldest.
Displaying a history
Proceed as follows:
1. Select a record (MEMO x) using the
▼/▲ buttons.
2. Display the first History screen by pressing OK.
3. Display the second History screen by pressing ▼.
4. Return to the Main Menu by pressing .
The information displayed
The history is presented on two screens.
Screen No. 1 (Battery information)
No. Without With
FMP energycom FMP energycom
1. Empty line. Battery’s serial number.
2. Voltage and Voltage, capacity
programmed and temperature operating memorised before temperature. charging.
3. Programmed type. Detected type.
4. Empty line. Alarm symbol (Table A).
Symbol Types of alarms
Alarms present.
Low electrolyte level alarm.
Voltage balance alarm.
Battery temperature alarm.
Equalisation charges missing.
Excessive over-discharges.
Average number of daily cycles too high.
FMP energycom disconnected.
Table A: Symbols for the types of alarms.
Screen No. 2 (Charger information)
No. Without With
FMP energycom FMP energycom
1. Type, percentage of Type, percentage
charge and of charge and parametered temperature temperature. memorised before
charging.
2. Voltage on starting and completing charging and current on completing charging.
3. Capacity restored and charging time (hh:mm).
4. Symbol for condition when charging complete
(Table B) and type of fault, if present (see ‘Fault messages’ section).
5. Coded indication of the charge.
Menus
!
C
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The information on these screens can be reset to zero via the Reset line on the Configuration Menu.
Symbol Condition when charging complete
Normal.
Abnormal (voluntary interruption or interruption following a fault).
Table B: Symbols for condition when charging complete.
Status
This menu displays the status of the charger’s internal counters (number of normal and equalisation charges, faults by type, etc.).
Access On the Main Menu, select STATUS and then press OK.
Call-up screen
An example is presented below.
The information displayed
The information on the screen can be reset to zero via the Reset line on the Configuration Menu.
Message Information
Charge No. of charging operations performed.
This corresponds to the sum of lines 2 and 3.
No. of charging operations terminated abnormally.
No. of charging operations terminated normally.
Equal No. of automatic equalisation operations
performed by the charger.
TH No. of thermal faults*.
DF1, etc. No. of fault of types 1, 2, 3, 4, 5 or 7*.
(*) : See ‘Fault Messages’.
Configuration
This menus provides access to the charger’s 12 configuration menus.
Access On the Main Menu, select Configuration and then press OK.
Profile
This defines the type of battery connected to the charger from among different types (for example Ionic, Gel or PNEU). To change the profile, press OK, select a profile from the list using the ▼/▲ buttons and confirm by pressing OK.
Temperature
This value is adjustable according to the battery technology.
• Without Fiamm Motive Power®energycom: it defines the battery’s average operating temperature before charging.
• With Fiamm Motive Power energycom: the battery’s operating temperature is defined automatically. It is advisable to enter the average temperature recorded, particularly in cold areas.
Equal time
Only valid for unsealed lead/acid batteries. This defines the length of the equalisation operation (1 to 8 hours).
Delayed equal
Only valid for unsealed lead/acid batteries. This defines the delay before equalisation (1 to 8 hours).
Auto equal
Only valid for unsealed lead/acid batteries. This defines the initiation method: manual or automatic. Select:
• ON for equalisation to start automatically on completion of charging.
• OFF to prevent automatic equalisation on completion of charging.
Delayed charge
This defines the delay (1 to 8 hours) between the time charging is initiated and the time that charging effectively starts. This time delay enables you to take advantage of ‘ Off-Peak’ tariff times.
Battery rest
This defines the waiting time (1 to 8 hours) after charging has finished to allow the battery to stabilise.
Electrovalve
This defines the opening time (15 to 120 seconds – Ionic and Pneumatic profiles only) of the electro-valve for filling the batteries automatically. When the OK button is pressed, a function test is immediately initiated for ten seconds. The operator can therefore check that the electro-valve is opening correctly.
Range
Only accessible for chargers of the Premium HF flex 48-72-80V type. This defines the battery charging voltage (48/72V or 48/80V).
Cable length
This defines the length of the cable battery-charger (1.0 to 10.0m).
Cable section
This defines the cross-section of the cable (battery-charger). Select a cross-section from the values offered (10, 16, 25, 35, 50 or 70mm
2
).
Reset
This reinitialises the Status and Memory counters after entry of the password.
Config version
This shows the charger’s configuration version.
Contrast
This modifies the display’s contrast. A zero value shows a white screen; a value of 100 shows a black screen. The optimum value depends on the ambient lighting conditions. If the messages on the display are unreadable (black or white screen):
1. Hold down and ▲ simultaneously.
2. When the LEDs flash (Fig. 2), adjust the contrast via the
▼/▲ buttons.
3. Confirm by pressing OK.
Backlight
This activates (ON) or deactivates (OFF) the display’s backlighting.
Language
This selects the language displayed in the menus.
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Unpacking
The charger is supplied with the following components:
• A 2m-long mains cable.
• A 3m-long battery cable.
• The present instruction manual.
Mechanical Installation
The charger must be mounted on the wall in a vertical position. The lower part of the charger must be at least
0.60m from the floor and/or the charger below and the upper part 1.0m from the ceiling. The minimum distance between two chargers must be 0.30m. You must avoid areas
where the chargers may be splashed with water.
The charger is held by 4 M8 screws suitable for the type of support. The drilling pattern varies according to the model of charger. Follow the illustration below.
Electrical Connection
To the three-phase supply
You may only connect to the 3-phase 400V AC mains supply via a standard socket and an appropriate circuit breaker (not supplied). The current consumption is shown on the charger’s information plate.
To the battery
Polarity must be observed. Any reversal of polarity will blow the output fuse, prevent charging and cause DF2 to be displayed. Please refer to the Fault Messages section. The charger must be connected to the battery by the cables supplied:
• The RED cable: to the battery’s POSITIVE terminal.
• The BLACK cable: to the battery’s NEGATIVE terminal.
Factory Configuration
The charger is supplied with the following factory configuration:
Profile: As per the order
Output cable length: 4 m
Configuration: As per the order
Automatic equalisation No selected:
Deferred charging activated: No
• If no modification to the above is desired, please proceed directly to the section on ‘Charging the battery’.
• If modification is required, go to the Configuration section.
Charging the battery
When the charger has been configured in accordance with the Configuration section, it can only be started when a technically compliant battery is connected to it (type, capacity, voltage).
Display when not charging
When the charger is in the waiting position (Start/Stop switch on “0”) and the OK has not been pressed, the display shows the information regarding the charger (top and bottom lines):
1. Type of charger.
2. Charger’s characteristics.
3. ‘Waiting’ status message.
4. Previously selected charging profile.
5. Software version.
6. Selected operating temperature.
Initiating delayed charging
If the charger has been programmed in this way (Configuration Menu / Delayed Start), charging starts after the time delay set. The display shows the time remaining before charging starts.
Use
394
H
H (mm)
Type 1 540
Type 2 540
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Initiating desulphation before charging
Desulphation of an unsealed lead/acid battery:
• Either starts automatically when the battery is heavily discharged; the length of the desulphating operation is defined by the charger’s electronics. The charging process is initiated automatically at the end of the desulphation period.
• Or is initiated manually, as shown below.
To initiate desulphation manually:
1. Set the Start/Stop switch to “0”.
2. Hold down the button.
3. Set the Start/Stop switch to “1”. Release .
Desulphation is initiated for the programmed period (“Equal time“ menu). The charging initiation process must be started manually on completion of the desulphation period.
Initiating charging
1. Set the Start/Stop switch to “ I “.
The display shows the information on the battery connected and counts down the time remaining before effective charging starts.
No. Without With
FMP energycom FMP energycom
1. Type of charger, software version.
2. Countdown for Countdown for 2 2 minutes before minutes maximum charging effectively before charging starts. effectively starts.
3. Programmed charging Detected charging profile – flashing profile – flashing during this phase. during this phase (*).
4. Empty line. Alternating display of
the voltage, capacity and the serial number detected, as the information is received and alarms if present (*).
5. Programmed Detected operating operating T°. temperature (*).
6. Equalisation symbol requested on completion of charging (see § Completion of charging with equalisation).
(*) As the information is received.
Once the two-minute countdown is complete, the display shows the information regarding the charging operation. Proceed to the section on Effective Charging. Faults DF1, DF2 and DF3 prevent charging. Please refer to the section on Fault Messages.
Effective charging
A few moments after charging starts, the display shows the various charging details in alternation.
No. Without With
FMP energycom FMP energycom
1. Type of charger, software version.
2. Charging symbol. Priority alarm if present.
3. Equalisation requested on completion of charging.
4. Programmed Detected operating operating T°. temperature.
5. Programmed charging Detected charging profile. profile.
6. Empty line. Alternation between
the voltage, capacity, the serial number detected and alarms if present.
7. Charging indicator.
8. Information updated and displayed cyclically. Please refer to Table C.
9. Percentage of charge.
Information displayed
Sign Type of measurement Example
U Battery voltage (V). 26.1
u Voltage per cell (V). 2.18
I Instantaneous charging current (A). 55
C Capacity restored (Ah). 71
t Charging time spent (hh:mm). 03:36
H Estimated remaining charging time 05
(hours).
DF No. of any fault occurring. See § Fault DF5
Messages.
Table C: Symbols for the information displayed during charging.
Completion of charging without equalisation
1. The green light (Fig. 2, No. 7) illuminates when charging has been completed correctly.
The green ‘charging complete’ light (Fig.2, No. 7) is illuminated and the message AVAIL is displayed (1). The display shows, in alternation (2):
• The charging time taken.
• The number of amp hours restored.
Please refer to the sections on Memory or Status for details of the information on completion of charging. Any other visual indication from any of the three lights indicates a problem during charging. Please refer to the Control Panel section.
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If the battery remains connected, in order to keep it charged, compensation and subsequent equalisation charging operations will be initiated automatically, depending on the type of battery.
2. If an equalisation charging operation has been programmed (unsealed lead/acid battery), this is initiated automatically.
If this is not the case, equalisation charging can be
initiated manually: please refer to the section on
Completion of charging with equalisation.
3. If the green light is flashing, the battery is in its resting phase.
Wait until the light stops flashing.
4. Set the Start/Stop switch to “0”.
5. Disconnect the battery, which is now ready for use.
Completion of charging with equalisation
Equalisation only concerns unsealed lead/acid batteries. It can be initiated either manually or automatically.
Manual initiation
1. As soon as charging is complete (the green light is permanently lit or is flashing - Fig.2, No. 7), press the button.
The messages EQUAL I = (equalisation current) and EQUAL H = (remaining equalisation time) (Nos. 1 and 2
below) indicate that equalisation has been initiated.
2. The battery is ready for use as soon as the green light
(Fig. 2, No. 7) illuminates.
Automatic initiation
If equalisation has been programmed (Configuration Menu / Equal time, Delayed equal and Auto equal set to ON), equalisation charging is initiated automatically.
Furthermore, if the battery remains connected, in order to keep it charged, maintenance charges (compensation and subsequent equalisation charging operations) will be initia­ted automatically, depending on the type of battery. The same information as for manual initiation is displayed (see above).
Display of the history per charging operation
To display the memorised information and to reset it to zero, please refer to the Memory section.
Display of the charger’s history
To display the history and to reset it to zero, please refer to the Status section.
Fault messages
Fault Cause Remedial action
DC Appears before a DF1
fault is displayed.
DF1* Charger fault. Check the power supply
voltage.
DF2* Output fault. Check that the battery is
correctly connected (that the cables are not reversed) and the output fuse.
DF3* Unsuitable battery. Battery voltage too high
or too low. Connect the correct charger for the battery
DF4 The battery has been Charging continues.
discharged more than 80% of its capacity.
DF5 Battery requires Check the charging
inspection. cables (cross-section too
small), the terminals (oxidisation, not tight) and the battery (defective elements).
DF7 Pneumatic mixing air Check the air
circuit fault (the red circuit (pump, tubing). light flashes).
TH* Thermal fault Check that the fan(s)
resulting in is (are) working interruption of correctly and/or charging. that the ambient
temperature is not too high or whether there is poor natural ventilation to the charger.
STOP* Critical electrolyte level in the battery.
Fill the battery.
(*): A blocking fault preventing charging from continuing.
Technical characteristics of Premium HF flex
Units 2004 2006 2008 2010
Power supply voltage V 400 ±10% tri 400 ±10% tri 400 ±10% tri 400 ±10% tri
Frequency Hz 50/60 50/60 50/60 50/60
Current absorbed A 7 10 13 17
Power supply cable mm
2
4 x 2.5 4 x 2.5 4 x 4 4 x 4
Power supply fuse A Protistor 20A Protistor 20A Protistor 30A Protistor 30A
Battery cable (1) mm
2
25 25 50 50
Battery cable length m 1 to 10 1 to 10 1 to 10 1 to 10
IP protection level IP20 IP20 IP20 IP20
Operating temp. °C 0 to +40 0 to +40 0 to +40 0 to +40
Display LCD LCD LCD LCD
Weight kg 30 30 30 55
Dimensions (Hx W x D) mm 750x410x317 750x410x317 750x410x317 940x410x317
(1) Take the electrical installation into account when determining the actual cable cross-section.
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12.2011 / Subject to revisions without prior notice
European Headquarters:
EnerSys EMEA
EH Europe GmbH Löwenstrasse 32 8001 Zürich Switzerland Phone: +41 44 215 74 10 Fax: +41 44 215 74 11
EnerSys Ltd
Oak Court Clifton Business Park Wynne Avenue Swinton Manchester M27 8FF Phone: 0161 794 4611 Fax: 0161 727 3809
Please refer to the website address for details of your nearest EnerSys office: www.enersys-emea.com
© 2011. All rights reserved. All trademarks and logos are the property of or licensed to EnerSys and its affiliates unless otherwise noted.
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