Fronius 35A User Manual

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Acctiva Professional 35 A

Acctiva Professional 35 A UCN

Operating Instructions

Battery charging system

42,0426,0093,EN 018-29122014

Dear reader,
	EN
Introduction	Thank you for the trust you have placed in our company and congratulations on buying this
	high-quality Fronius product. These instructions will help you familiarise yourself with the
	product. Reading the instructions carefully will enable you to learn about the many different
	features it has to offer. This will allow you to make full use of its advantages.

Please also note the safety rules to ensure greater safety when using the product. Careful handling of the product will repay you with years of safe and reliable operation. These are essential prerequisites for excellent results.

Contents
	EN
Safety rules ................................................................................................................................................	5
Explanation of safety symbols ..............................................................................................................	5
General .................................................................................................................................................	5
Proper use ............................................................................................................................................	6
Environmental conditions......................................................................................................................	6
Mains connection ..................................................................................................................................	6
Dangers from mains current and charging current ...............................................................................	6
Dangers from acid, gases and vapours ................................................................................................	7
General information regarding the handling of batteries.......................................................................	7
Protecting yourself and others ..............................................................................................................	7
Safety measures in normal operation ...................................................................................................	8
EMC Device Classifications ..................................................................................................................	8
EMC measures .....................................................................................................................................	8
Data protection......................................................................................................................................	8
Maintenance and repair ........................................................................................................................	9
Warranty and liability.............................................................................................................................	9
Safety inspection...................................................................................................................................	9
Safety symbols......................................................................................................................................	9
Disposal ................................................................................................................................................	10
Copyright...............................................................................................................................................	10
Safety rules - required for USA, Canada and Australia .............................................................................	11
General and electrical risks...................................................................................................................	11
Warning - Risk of Explosive Gases.......................................................................................................	11
Personal safety precautions..................................................................................................................	11
Preparing for charging ..........................................................................................................................	12
Charger set-up location.........................................................................................................................	12
Precautions for DC connection .............................................................................................................	12
Steps to follow with battery installed in vehicle .....................................................................................	13
Steps to follow with battery outside the vehicle ....................................................................................	13
Instructions for connecting the mains cable including earthing.............................................................	13
30A + 50A battery chargers in USA......................................................................................................	14
General information ...................................................................................................................................	15
Principle ................................................................................................................................................	15
Device concept .....................................................................................................................................	15
Warning notices on the device..............................................................................................................	15
Start-up ......................................................................................................................................................	16
Safety....................................................................................................................................................	16
Proper use ............................................................................................................................................	16
Mains connection ..................................................................................................................................	16
Safety features - standard protective equipment ..................................................................................	16
Control elements and connections.............................................................................................................	17
General remarks ...................................................................................................................................	17
Control panel.........................................................................................................................................	17
Plugging in options................................................................................................................................	17
Connections ..........................................................................................................................................	18
Removing covers for connections and options .....................................................................................	19
USB update option................................................................................................................................	19
Fitting the optional bracket and strain relief device for the charger lead...............................................	19
Edge guard option.................................................................................................................................	19
Wall bracket option ...............................................................................................................................	20
Preparations for security lock................................................................................................................	20
Installation.............................................................................................................................................	20
Operating modes .......................................................................................................................................	22
General information ..............................................................................................................................	22
Available operating modes....................................................................................................................	22
Selecting the operating mode ...............................................................................................................	22
Charging mode .....................................................................................................................................	22
Buffering (Trickle) mode........................................................................................................................	22
Refresh mode .......................................................................................................................................	23
Battery changing mode .........................................................................................................................	23

Power Supply mode..............................................................................................................................	23
Device options ......................................................................................................................................	23
Charging mode ..........................................................................................................................................	24
General information ..............................................................................................................................	24
Charging the battery .............................................................................................................................	24
Interrupting charging .............................................................................................................................	25
Restarting charging...............................................................................................................................	26
Buffering (Trickle) mode.............................................................................................................................	27
General information ..............................................................................................................................	27
Buffering the battery..............................................................................................................................	27
Interrupting Buffering (Trickle) mode ....................................................................................................	28
Resuming buffering...............................................................................................................................	28
Refresh mode ............................................................................................................................................	29
General information ..............................................................................................................................	29
Reactivating batteries ...........................................................................................................................	29
Interrupting refresh charging.................................................................................................................	31
Resuming refresh charging...................................................................................................................	31
Battery changing mode ..............................................................................................................................	32
General information ..............................................................................................................................	32
Battery changing ...................................................................................................................................	32
Power supply mode ...................................................................................................................................	34
Requirements........................................................................................................................................	34
Power Supply mode..............................................................................................................................	34
Device options ...........................................................................................................................................	35
General information ..............................................................................................................................	35
Selecting device options .......................................................................................................................	35
Configuration.........................................................................................................................................	35
Synergic lines.............................................................................................................................................	37
Safety....................................................................................................................................................	37
Available characteristics .......................................................................................................................	37
Troubleshooting .........................................................................................................................................	39
Safety....................................................................................................................................................	39
Protective equipment ............................................................................................................................	39
Charging errors .....................................................................................................................................	40
Technical data............................................................................................................................................	42
Electrical data input 230V .....................................................................................................................	42
Standards 230V ....................................................................................................................................	42
Electrical data input 120 V ....................................................................................................................	42
Standards 120V ....................................................................................................................................	42
Electrical data output ............................................................................................................................	43
Battery data...........................................................................................................................................	43
Technical data.......................................................................................................................................	43
Environmental conditions......................................................................................................................	43

	Safety rules	EN
		EN
	Explanation of	DANGER! Indicates immediate and real danger. If it is not avoided, death or se-
	safety symbols
	safety symbols	rious injury will result.
		rious injury will result.
		WARNING! Indicates a potentially dangerous situation. Death or serious injury
		may result if appropriate precautions are not taken.
		CAUTION! Indicates a situation where damage or injury could occur. If it is not
		avoided, minor injury and/or damage to property may result.

NOTE! Indicates a risk of flawed results and possible damage to the equipment.

IMPORTANT! Indicates tips for correct operation and other particularly useful information.

It does not indicate a potentially damaging or dangerous situation.

If you see any of the symbols depicted in the "Safety rules" chapter, special care is required.

General		The device is manufactured using state-of-the-art technology and according

		to recognised safety standards. If used incorrectly or misused, however, it can
		cause:

-injury or death to the operator or a third party,

-damage to the device and other material assets belonging to the operating company,

-inefficient operation of the device.

All persons involved in commissioning, operating, maintaining and servicing the device must:

-be suitably qualified,

-read and follow these operating instructions carefully.

The operating instructions must always be at hand wherever the device is being used. In addition to the operating instructions, attention must also be paid to any generally applicable and local regulations regarding accident prevention and environmental protection.

All safety and danger notices on the device

-must be in a legible state,

-must not be damaged,

-must not be removed,

-must not be covered, pasted or painted over.

For the location of the safety and danger notices on the device, refer to the section headed "General information" in the operating instructions for the device.

Before switching on the device, rectify any faults that could compromise safety.

This is for your personal safety!

Proper use			The device is to be used exclusively for its intended purpose. Any use above

			and beyond this purpose is deemed improper. The manufacturer is not liable
			for any damage, or unexpected or incorrect results arising out of such misuse.

Proper use includes:

-carefully reading and obeying all operating instructions and safety and danger notices

-performing all stipulated inspection and maintenance work

-following all instructions from the battery and vehicle manufacturers

Proper handling of the device is essential for it to function correctly. The device must never be pulled around by the cable.

Environmental conditions

Operation or storage of the device outside the stipulated area will be deemed as "not in accordance with the intended purpose". The manufacturer shall not be liable for any damage resulting from such improper use.

For exact information on permitted environmental conditions, please refer to the "Technical data" in the leaflet.

Mains connection	Devices with a higher rating may affect the energy quality of the mains due to

	their current input.

This may affect a number of device types in terms of:

-connection restrictions

-criteria with regard to the maximum permissible mains impedance *)

-criteria with regard to the minimum short-circuit power requirement *)

*) at the interface with the public grid see "Technical data"

In this case, the plant operator or the person using the device should check whether the device may be connected, where appropriate by discussing the matter with the power supply company.

NOTE! Ensure that the mains connection is earthed properly

Dangers from mains current and charging current

Anyone working with chargers exposes themselves to numerous dangers e.g.:

-risk of electrocution from mains current and charging current

-hazardous electromagnetic fields, which can risk the lives of those using cardiac pacemakers

An electric shock can be fatal. Every electric shock is potentially life threatening. To avoid electric shocks while using the charger:

-do not touch any live parts inside or on the outside of the charger.

-under no circumstances touch the battery poles

-do not short-circuit the charger lead or charging terminals

All cables and leads must be secured, undamaged, insulated and adequately dimensioned. Loose connections, scorched, damaged or inadequately dimensioned cables and leads must be immediately repaired by authorised personnel.

Dangers from acid, gases and vapours

Batteries contain acid which is harmful to the eyes and skin. During charging,	EN

gases and vapours are released that can harm health and are highly explosive
in certain circumstances.

Only use the chargers in well ventilated areas to prevent the accumulation of explosive gases. Battery areas are not deemed to be hazardous areas provided that a concentration of hydrogen of less than 4 % can be guaranteed by the use of natural or forced ventilation.

Maintain a distance of at least 0.5 m (19.69 in.) between battery and charger during the charging procedure. Possible sources of ignition, such as fire and naked lights, must be kept away from the battery

The battery connection (e.g. charging terminals) must not be disconnected for any reason during charging

On no account inhale any of the gases and vapours released Make sure the area is well ventilated.

To prevent short circuits, do not place any tools or conductive metals on the battery

Battery acid must not get into the eyes, onto the skin or clothes. Wear protective goggles and suitable protective clothing. Rinse any acid splashes thoroughly with clean water, and seek medical advice if necessary.

General information regarding the handling of batteries

-Protect batteries from dirt and mechanical damage.

-Store charged batteries in a cool place. Self discharge is kept to a minimum at approx. +2 °C (35.6 °F).

-Every week, perform a visual inspection to ensure that the acid (electrolyte) level in the battery is at the Max. mark.

-If any of the following occurs, do not start the device (or stop immediately if already in use) and have the battery checked by an authorised workshop:

-uneven acid levels and/or high water consumption in individual cells caused by a possible fault.

-heating of the battery over 55 °C (131 °F).

Protecting yourself and others

While the charger is in operation, keep all persons, especially children, out of the working area. If, however, there are people in the vicinity,

-warn them about all the dangers (hazardous acids and gases, danger from mains and charging current, etc.),

-provide suitable protective equipment.

Before leaving the work area, ensure that people or property cannot come to any harm in your absence.

Safety measures	-	Chargers with a ground conductor must only be operated on a mains supply
in normal opera-	-
in normal opera-		with a ground conductor and a socket with a ground conductor contact. If the
tion
tion		charger is operated on a mains supply without a ground conductor or in a

		socket without a ground conductor contact, this will be deemed gross negli-
		gence. The manufacturer shall not be held liable for any damage arising
		from such usage.

-Only operate the charger in accordance with the degree of protection shown on the rating plate.

-Never operate the charger if there is any evidence of damage.

-Arrange for the mains cable to be checked regularly by a qualified electrician to ensure the ground conductor is functioning properly.

-Any safety devices and parts that are not functioning properly or are in imperfect condition must be repaired by a qualified technician before switching on the charger.

-Never bypass or disable protection devices.

-After installation, an accessible mains plug is required.

EMC Device Classifications

Devices in emission class A:

-Are only designed for use in industrial settings

-Can cause line-bound and radiated interference in other areas

Devices in emission class B:

-Satisfy the emissions criteria for residential and industrial areas. This is also true for residential areas in which the energy is supplied from the public low-voltage mains.

EMC device classification as per the rating plate or technical data.

EMC measures		In certain cases, even though a device complies with the standard limit values

		for emissions, it may affect the application area for which it was designed (e.g.
		when there is sensitive equipment at the same location, or if the site where the
		device is installed is close to either radio or television receivers).
		If this is the case, then the operating company is obliged to take appropriate
		action to rectify the situation.

Data protection		The user is responsible for the safekeeping of any changes made to the fac-

		tory settings. The manufacturer accepts no liability for any deleted personal
		settings.

Maintenance and repair

Under normal operating conditions, the device requires only a minimum of	EN

care and maintenance. However, it is vital to observe some important points
to ensure it remains in a usable condition for many years.

-Before switching on, always check the mains plug and cable as well as charger leads and charging terminals for any signs of damage.

-If the surface of the device housing is dirty, clean with a soft cloth and sol- vent-free cleaning agent only

Maintenance and repair work must only be carried out by authorised personnel. Use only original replacement and wearing parts (also applies to standard parts). It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made on them, or that they satisfy safety requirements.

Do not carry out any modifications, alterations, etc. to the device without the manufacturer's consent.

Warranty and liability

The warranty period for the charger is 2 years from the date of invoice. However, the manufacturer will not accept any liability if the damage was caused by one or more of the following:

-Use of the charger "not in accordance with the intended purpose"

-Improper installation and operation

-Operating the charger with faulty protection devices

-Non-compliance with the operating instructions

-Unauthorised modifications to the charger

-Catastrophes caused by the activities of third parties and force majeure

Safety inspection	The manufacturer recommends that a safety inspection of the device is per-

	formed at least once every 12 months.

	A safety inspection should be carried out by a qualified electrician
	-	after any changes are made
	-	after any changes are made
	-	after any additional parts are installed, or after any conversions
	-	after repair, care and maintenance has been carried out
	-	at least every twelve months.

For safety inspections, follow the appropriate national and international standards and directives.

Further details on safety inspections can be obtained from your service centre.

They will provide you on request with any documents you may require.

Safety symbols		Devices with the CE mark satisfy the essential requirements of the low-voltage

		and electromagnetic compatibility directives.
		Devices displaying this TÜV test mark satisfy the requirements of the relevant

		standards in Canada and USA.

Disposal

Devices displaying this TÜV test mark satisfy the requirements of the relevant standards in Japan.

Devices displaying this TÜV test mark and the mark on the rating plate satisfy the requirements of the relevant standards in Australia.

Do not dispose of this device with normal domestic waste! To comply with the European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its implementation as national law, electrical equipment that has reached the end of its life must be collected separately and returned to an approved recycling facility. Any device that you no longer require must either be returned to your dealer or given to one of the approved collection and recycling facilities in your area. Ignoring this European Directive may have potentially adverse affects on the environment and your health!

The text and illustrations are all technically correct at the time of printing. We reserve the right to make changes. The contents of the operating instructions shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for improvement, or can point out any mistakes that you have found in the instructions, we will be most grateful for your comments.

Safety rules - required for USA, Canada and Australia

General and elec-	1	KEEP THESE INSTRUCTIONS CAREFULLY - This guide contains important safety
trical risks		and operating instructions for these charger types (for model, see first page of this
		document)
	2	Do not expose the charger to rain or snow
	3	The use of accessories not sold or recommended by the charger manufacturer can
		lead to fire, electric shock or personal injury

	Minimum AWG size of an extension cable
	25 ft (7.6 m)		50 ft (15.2 m)	100 ft (30.5 m)	150 ft (45.6 m)

	AWG 16		AWG 12	AWG 10	AWG 8

	4	To reduce the risk of damage to plugs and cables, always unplug the charger by pull-
		ing at the plug rather than the cable
	5	Only use an extension cable if it is absolutely necessary. The use of an incorrect ex-
		tension cable can lead to fire and electric shock. If an extension cable must be used,
		make sure that
		- the pins of the extension cable plug are of the same number, size and shape as
		those of the charger plug
		- the extension cable is correctly wired and in good electrical condition
		- the cable size is large enough for the AC amperage of the charger, as indicated
		above
	6	Do not use the charger with a damaged cable or plug - replace the cable or plug im-
		mediately
	7	Do not use the charger if it has been subjected to heavy impact, dropped or otherwise
		damaged; hand it over to a qualified service technician
	8	Do not dismantle the charger; hand it over to a qualified service technician if mainte-
		nance or repair is required. Incorrect reassembly can result in fire and electric shock
	9	To reduce the risk of an electric shock, unplug the charger from the socket before car-
		rying out any maintenance or cleaning. This risk cannot be reduced by setting controls

to the "Off" position

Warning - Risk of It is dangerous to work in close proximity to a lead acid battery. Batteries generate explo- Explosive Gases sive gases during normal battery operation. For this reason it is extremely important to read

this guide before using the charger and to follow the instructions precisely.

1To reduce the risk of battery explosion, follow these instructions, the battery manufacturer's instructions and those of the manufacturers of any accessories that you plan to use in the vicinity of the battery. Observe warning signs on these products and on the engine.

Personal safety	There must be another person within hearing range of you or close enough to come to your
precautions	assistance when you are working in the vicinity of a lead acid battery.

1Make sure there is sufficient fresh water and soap nearby in case battery acid comes into contact with the skin, clothing or eyes

2Complete eye protection and protective clothing must be worn. Do not touch your eyes when working in the vicinity of a lead acid battery

3If skin or clothing comes into contact with battery acid, wash the acid immediately with soap and water. If acid gets into the eye, rinse the eye immediately with running cold water for at least 10 minutes and seek immediate medical assistance.

4NEVER smoke or allow sparks or naked flames close to the battery or engine

5Be especially careful to avoid the risk of a metal tool falling onto the battery. This might create sparks or short-circuit the battery or other electrical components, thereby causing an explosion.

6Remove personal metal objects such as rings, bracelets, necklaces and watches before working with a lead acid battery. A lead acid battery can cause a short-circuit current high enough to melt a ring or similar, thereby leading to a fire.

7Use the charger only to charge a LEAD ACID battery. It is not suitable for transferring power to an electrical low-voltage system other than a starter motor application. Do not use the charger to charge dry cell batteries, which are used mainly for home appliances. Such batteries can burst, causing injury to people and damage to property

8NEVER charge a frozen battery

Preparing for charging

1If it is necessary to remove the battery before charging, always detach the earth connection first. Make sure all vehicle equipment is switched off to prevent arcing

2Ensure that the area around the battery is well-ventilated while the battery is being charged. The released gas can be effectively dispersed using a piece of cardboard or other non-metallic object such as a fan

3Clean the battery terminals. Be careful to ensure that corrosion residues do not come into contact with the eyes

4Top up each cell with distilled water until the battery acid reaches the level specified by the manufacturer. This helps to purge surplus gas out of the cells. Do not overfill. In the case of a battery without cell caps, follow the manufacturer's charging instructions carefully

5Study all battery-manufacturer-specific safety precautions, such as the removal or non-removal of cells caps during charging and the recommended charging parameters

6With the help of the vehicle manual, determine the battery voltage and ensure that it matches the output of the charger

Charger set-up location

1Place the charger as far away from the battery as the cables will allow

2Never place the charger directly above the battery being charged; battery gases may corrode and ruin the charger

3When measuring acid density or topping up the battery, never allow battery acid to drip onto the charger

4Do not operate the charger in an enclosed area or where there is limited ventilation

5Do not place the battery on the charger

Precautions for	1	Only connect or disconnect the DC terminals when all controls on the charger are set
DC connection		to the "Off" position and the mains cable has been unplugged from the mains. Never
		allow the terminals to touch one another
	2	Attach the terminals to the battery and chassis as indicated in points 5 and 6 of the
		next section and points 2 and 4 of the section after that
	3	Attach the terminals to the battery poles and turn them to and fro several times to en-
		sure a good connection. This will prevent the terminals from slipping off the battery

poles and reduces the risk of sparks.

Steps to follow with battery installed in vehicle

Follow these steps if the battery is installed in the vehicle. A spark near to the battery can		EN
cause the battery to explode. To reduce the risk of sparks near the battery:		EN

1	Arrange AC and DC cables in such a way that they cannot be damaged by bonnets,
	doors or moving parts of engines

2Keep clear of fan blades, belts, rollers and other parts that pose a risk of personal injury

3Check the polarity of the battery terminals. The POSITIVE (POS, P, +) battery pole usually has a larger diameter than the NEGATIVE (NEG, N, -) pole

4Determine which battery pole is connected to the chassis (earthed). If the negative pole is connected to the chassis (as on most vehicles), go to point 5. If the positive pole is connected to the chassis, go to point 6

5On a negatively earthed vehicle, connect the POSITIVE (RED) charging terminal to the POSITIVE (POS, P, +) unearthed pole of the battery. Clip the NEGATIVE (BLACK) charging terminal to the chassis or engine block far away from the battery. Do not attach the terminal to the carburettor, fuel pipes or body panels, but rather to a solid metal part of the chassis or engine block

6On a positively earthed vehicle, connect the NEGATIVE (BLACK) charging terminal to the NEGATIVE (NEG, N, -) unearthed pole of the battery. Clip the POSITIVE (RED) charging terminal to the chassis or engine block far away from the battery. Do not attach the terminal to the carburettor, fuel pipes or body panels, but rather to a solid metal part of the chassis or engine block

7When disconnecting the charger, switch the controls to the "Off" position, unplug the mains cable, remove the charging terminal from the chassis and then remove the charging terminal from the battery

8For information about the required charging period, refer to the operating instructions

Steps to follow with battery outside the vehicle

Follow these steps if the battery is located outside the vehicle. A spark near to the battery can cause the battery to explode. To reduce the risk of sparks near the battery:

1Check the polarity of the battery terminals. The POSITIVE (POS, P, +) battery pole usually has a larger diameter than the NEGATIVE (NEG, N, -) pole

2Connect an insulated 6-gauge (AWG) battery cable, not less than 24 inches (609.5 mm) long, to the NEGATIVE (NEG, N, -) battery pole

3Connect the POSITIVE (RED) charging terminal to the POSITIVE (POS, P, +) pole of the battery

4Move yourself and the free end of the cable as far away as possible from the battery, then connect the NEGATIVE (BLACK) charging terminal to the free end of the cable

5Do not face the battery when making the last connection

6Disconnect the charger in reverse order to the connection process, making the first disconnection as far away as possible from the battery

7A (marine) boat battery must be taken out and charged on dry land. Charging the battery on board requires special equipment designed for use at sea

Instructions for connecting the mains cable including earthing

The charger must be earthed to reduce the risk of electric shock. The charger has a mains cable with integrated earth conductor and an earthed plug.

1Connect the plug to a socket that has been installed and earthed in accordance with all local rules and regulations

DANGER - Never change the supplied mains cable or its plug - if it does not fit the socket, have a proper socket installed by a qualified electrician. An improper connection may create the risk of electric shock.

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