Operating
Instructions
Li-Charger
5 - 18 kW
EN-US
Operating instructions
42,0426,0390,EA 006-11082022
Table of contents
Li-Charger power categories 5
General 5
Safety Instructions 6
General 6
Intended Use 6
Environmental conditions 6
Grid connection 7
Dangers due to Grid and Charging Current 7
Dangers due to the battery 7
General information on working with lithium batteries 8
Personal protection and protection of others 9
Safety Measures in Normal Operation 9
EMC device classifications 9
EMC Measures 10
Data backup 10
Maintenance 10
Repair 10
Obligations of the operating company 10
Safety Inspection 10
Markings on the device 11
Disposal 11
Copyright 11
General information 12
Explanation of Safety Instructions 12
Device concept 12
Customer-specific information 12
Correct battery configuration 12
Grid connection 13
Correct routing of the mains/charging cables 14
Warning notices on the device 15
Warning notices inside the device 16
Setup regulations 16
Wall bracket 18
External start/stop 21
Operating controls and connections 22
Operating controls and connections 22
Option plug 23
Charging plug pin assignment 24
Control panel 25
Charging the battery 27
Starting for the first time 27
Charging process 28
Displays during charging 29
Pausing/resuming the charging process 30
Ending the charging process 31
Display 32
Overview of display modes 32
Menu selection 32
Standard mode 33
Statistics mode 33
History mode 34
Configuration mode 35
Charging settings 37
Additional functions 40
General options 42
Reset settings 44
USB mode 44
Status codes 45
Options 50
Safety 50
EN-US
3
Charging lights 50
Wall and floor bracket 51
LED strip 51
IP 23 51
Air filter 51
"Mobile" set 52
Remote control system 52
Relay board 52
Charging 53
Charge 50 % 53
Charge 80 % 53
Charge not complete 53
Charge Finish 53
Cumulative Error 53
Cumulative error + warning 53
Signal Lamp 53
Immobiliser 54
Blue LED 54
Technical data 55
Li-Charger D1 5 kW 400 V 9 kW 400 V 55
Li-Charger E1 8 kW 220 V 57
Li-Charger E1 17 kW 400 V 59
Li-Charger F1 8 kW 400 V 18 kW 400 V 61
4
Li-Charger power categories
General The kW specification for the power categories refers to the housing design and is
not directly related to the actual device power.
EN-US
Battery voltage Device type Max. charging
current
24 V
48 V
80 V
5 kW 24 V 200 A D1
8 kW 24 V 350 A F1
8 kW 48 V 160 A E1 3~ 220 V
9 kW 48 V
185 A D1
18 kW 48 V 325 A F1
9 kW 80 V
110 A D1
A 9 kW 80 V
17 kW 80 V 210 A E1
Housing Mains voltage
3~ 400 V
3~ 400 VA 9 kW 48 V
3~ 400 V
5
Safety Instructions
General The device has been manufactured using state-of-the-art technology and ac-
cording to recognized 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 equipment
-
All persons involved in the commissioning, operation, maintenance, and servicing
of the device must
be suitably qualified
-
have completely read and followed these operating instructions
-
The operating instructions must always be at hand wherever the device is being
used. In addition to the operating instructions, all applicable local rules and regulations regarding accident prevention and environmental protection must also
be followed.
All safety and danger notices on the device
must be kept in a legible state,
-
must not be damaged/marked,
-
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, eliminate any faults that could compromise
safety.
Your personal safety is at stake!
Intended Use The device is to be used exclusively for its intended purpose. Utilization for any
other purpose, or in any other manner, shall be deemed to be not in accordance
with the intended purpose. The manufacturer shall not be liable for damage resulting from this nor for faulty or incorrect work results.
Proper use also means:
Completely reading and obeying the operating instructions and all safety in-
-
structions and danger notices,
Carrying out all the specified inspection and servicing work,
-
Complying with all instructions from the battery and vehicle manufacturers.
-
The device must be handled correctly in order for it to work. Never pull on the
cable when handling the device.
Environmental
conditions
6
Operation or storage of the device outside the stipulated area will be deemed as
not in accordance with the intended purpose. The manufacturer accepts no liability for any damage resulting from improper use.
For exact information on permitted environmental conditions, please refer to the
"Technical data" chapter.
Grid connection Devices with a high output can influence the energy quality of the grid due to
their current consumption.
This may affect a number of device types in terms of:
Connection restrictions, requirements regarding maximum permissible grid
-
impedance *) or
-
criteria regarding the minimum required short circuit power
*)
both at the interface with the public grid
*)
See technical data
In this case, the operator or the person using the device should check whether or
not the device is allowed to be connected, where appropriate through discussion
with the grid operator.
IMPORTANT! Ensure secure grounding of the grid connection.
EN-US
Dangers due to
Grid and Charging Current
Dangers due to
the battery
Work with battery charging systems poses a number of dangers, such as:
electrical hazard due to grid and charging current.
-
hazardous electromagnetic fields that may pose a risk of death for individu-
-
als with pacemakers.
An electric shock can be fatal. Every electric shock poses a risk of death. To prevent electric shock during operation:
do not touch any voltage-carrying parts inside or outside of the device.
-
never touch the battery poles.
-
do not short-circuit the charging cable or charging terminals.
-
All cables and leads must be secured, undamaged, insulated, and adequately dimensioned. Loose connections, scorched, damaged, or under-dimensioned
cables and leads must be repaired immediately by an authorized specialist.
The substances inside the battery to be charged can have a dangerous impact on
the environment and the health of humans and animals.
If the battery is damaged, observe the following points:
Ensure that escaping liquids cannot penetrate into the soil or groundwater
-
If contamination has already occurred, take corrective steps as prescribed by
-
applicable national regulations
There is a risk of fire if the battery overheats. Protect the battery from heat.
(e.g., from the permanent effects of heat and fire)
Toxic vapors which can irritate the airways may escape from the battery if it is
damaged or used improperly.
If this occurs:
Get fresh air
-
Consult a physician if irritation continues
-
If the battery is defective, liquid may leak out.
Avoid contact with the liquid
-
Hand over the battery to the authorized service body for repair
-
Clean and inspect parts that have come into contact with the liquid
-
Operation or storage in potentially explosive atmospheres is prohibited.
Special regulations apply in rooms subject to fire and explosion hazards
- Observe the relevant national and international regulations.
7
To comply with European Directive 2006/66/EC on batteries and its implementation in national law, used batteries must be collected separately and returned to
an approved recycling facility. Any battery that you no longer require must be returned to your distributor or else taken to the approved collection or recycling
facilities in your area. Ignoring this European directive may have potentially adverse effects on the environment and your health.
As soon as it can be assumed that the battery has been mechanically damaged,
the battery must be disposed of at the nearest recycling collection point in accordance with national laws and guidelines.
In case of any uncertainties or questions regarding disposal, contact the authorized service body.
General information on working
with lithium batteries
Lithium batteries are sealed, gas-tight units and harmless, provided that the
-
manufacturer's instructions are observed during use and handling
Never use battery chargers that are not suitable for the type of battery
-
Do not short circuit
-
Do not damage mechanically (pierce, deform, disassemble, etc.)
-
Do not heat or burn above the permissible temperature
-
Always store batteries in a dry and cool place
-
Lithium batteries, when handled properly under the parameters specified by
-
the manufacturer, are safe during use
Incorrect handling or circumstances leading to improper operation may
-
cause leakage of battery contents and decomposition products, resulting in
violent reactions that endanger health and the environment
Since a wide variety of chemical substances are used inside batteries, the
-
manufacturer's instructions for immediate action and first-aid measures
must always be followed in the event of an accident
Lithium batteries must be handled in accordance with the manufacturer's in-
-
structions under all circumstances
This applies in particular to compliance with the limits for maximum current
-
load, charging and discharging cutoff voltages, as well as mechanical and
thermal loads
The battery charger and battery are matched to each other and must not be
-
modified or tampered with under any circumstances, as this may result in
considerable safety risks
Lithium batteries should preferably be stored at room temperature and in a
-
dry place (for details, refer to the manufacturer's instructions on the storage
temperature range)
Avoid large temperature fluctuations (e.g., do not store near heaters, do not
-
expose to continuous sunlight)
8
In case of leakage of substances due to damage or improper handling, the
-
manufacturer's instructions must be followed without fail
This includes in particular the use of personal protective equipment
-
When storing larger quantities of lithium batteries, the local authorities
-
should be consulted
Training of employees in the proper handling of lithium batteries (analogous
-
to hazardous materials)
EN-US
Personal protection and protection of others
Safety Measures
in Normal Operation
Keep persons, especially children, away from the device and working area during
operation. However, if persons are in the vicinity:
Inform them of any dangers (hazardous electrolytes and gases, risk due to
-
grid and charging current, etc.)
Provide suitable protective equipment
-
Before leaving the working area, ensure that no personal injury or property damage can occur in your absence.
Operate devices with ground conductors only on a grid with a ground conductor
and a socket with a ground conductor contact. Operating the device on a grid
without a ground conductor or on a socket without a ground conductor contact is
considered gross negligence. The manufacturer is not responsible for any damage resulting from improper use.
Only operate the device in accordance with the degree of protection shown on
the rating plate.
Never commission the device if it is damaged.
Have the grid and device supply lead regularly inspected by an electrician to ensure that the ground conductor is functioning properly.
EMC device classifications
Safety devices that are not fully functional and components with defects must
be repaired by an authorized specialist before the device is turned on.
Never bypass or disable protection devices.
A freely accessible mains plug is required after installation.
Devices in emission class A:
Are only designed for use in industrial areas
-
Can cause wiring-related or 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 lowvoltage grid.
EMC device classification as per the rating plate or technical data.
9
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 backup The user is responsible for backing up any changes made to the factory settings.
The manufacturer accepts no liability for any deleted personal settings.
Maintenance Check the mains plug, mains cable, charging lead, and charging terminals for
damage before each commissioning.
If dirt accumulates on the device, clean the surface of the device housing with a
soft cloth and only with solvent-free cleaning agents.
Repair Repair work must only be carried out by authorized personnel. Use only original
spare and wearing parts (also applies to standard parts). It is impossible to guarantee that third-party parts are designed and manufactured to meet the demands made on them, or that they satisfy safety requirements.
Obligations of
the operating
company
Safety Inspection
Do not carry out any alterations, installations, or modifications to the device
without first obtaining the manufacturer’s permission.
The operating company must only allow persons to work with the device if they
are familiar with the basic occupational safety and accident prevention regu-
-
lations and are trained in handling the device
have read and understood these Operating Instructions, especially the
-
"Safety rules" section, and have confirmed this with their signature
are trained according to the requirements for the work results.
-
The safety-conscious work of the personnel must be checked regularly.
The manufacturer recommends that a safety inspection of the device be performed at least every 12 months.
A safety inspection by a certified electrician is recommended
after changes,
-
after alterations,
-
after repair, service and maintenance,
-
at least every 12 months.
-
10
For the safety inspection, follow the appropriate national and international
standards and guidelines.
You can obtain more information about the safety inspection from your service
center. The service center will provide the necessary documents upon request.
Markings on the
device
Disposal To comply with European directives and national law, waste electrical and elec-
Copyright Copyright of these Operating Instructions remains with the manufacturer.
Devices bearing the CE label satisfy the essential requirements of applicable directives.
Devices bearing the EAC mark of conformity satisfy the requirements of the relevant standards for Russia, Belarus, Kazakhstan, Armenia, and Kyrgyzstan.
tronic equipment must be collected separately and sent for environmentallyfriendly recycling. Used devices must be returned to a distributor or an approved
collection and recycling facility in your area. Proper disposal of used devices promotes the sustainable recycling of material resources. Ignoring this may have potentially adverse effects on the environment and your health.
Packaging materials
Materials collected separately. Check the regulations in your area. Reduce the
volume of cardboard.
Text and illustrations were accurate at the time of printing. Fronius reserves 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 Operating Instructions, we will be most grateful for your comments.
EN-US
11
General information
Explanation of
Safety Instructions
DANGER!
Indicates an immediate danger.
Death or serious injury may result if appropriate precautions are not taken.
▶
WARNING!
Indicates a possibly dangerous situation.
Death or serious injury may result if appropriate precautions are not taken.
▶
CAUTION!
Indicates a situation where damage or injury could occur.
Minor injury or damage to property may result if appropriate precautions are
▶
not taken.
NOTE!
Indicates the possibility of flawed results and damage to the equipment.
Device concept The technology is enclosed in a robust industry-standard housing. The extremely
compact design meets all requirements for safety standards, reduces space requirements, and protects the components for a long service life.
Featuring a graphic display, an integrated datalogger, new interfaces, and additional options, the device is perfectly equipped for the future.
Customer-specific information
Correct battery
configuration
If customer-specific information exists for the supplied device, this is provided
with the device.
WARNING!
Danger due to unsuitable batteries connected to the battery charger.
Serious personal injury and property damage as a result of escaping gases, ignition, or explosion may result.
Only connect batteries to the battery charger which are suitable for the
▶
charger in terms of their type and voltage, and which correspond to the settings on the charger.
The battery charger must only be used with lithium-ion batteries approved
▶
by Fronius.
12
WARNING!
Grid connection
Danger due to charging cables lying around.
Injuries due to getting caught or tripping on loose cables can be the result.
Lay the charging cables so that no one can trip over them or get caught on
▶
them.
WARNING!
Danger when disconnecting the charging plug while charging is in progress.
This can result in severe personal injury and damage to property.
Before disconnecting the charging plug, end the charging process by press-
▶
ing the Stop / Start key.
When charging is complete, wind up the charging cables or place them on
▶
the cable holder, if available.
WARNING!
Danger from electrical current.
This may result in serious injuries or death.
Before starting work, switch off all devices and components involved, and
▶
disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back
▶
on.
If necessary, only use a type B residual current circuit breaker for the grid
▶
connection of the device.
EN-US
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in severe personal injury and damage to property.
All the work and functions described in this document must only be carried
▶
out by trained and qualified personnel.
Read and understand this document.
▶
Read and understand all the Operating Instructions for the system compon-
▶
ents, especially the safety rules.
WARNING!
Danger due to faulty or insufficient grid power supply.
This can result in severe personal injury and damage to property.
The requirements for the grid power supply according to the "Technical data"
▶
chapter must be fulfilled.
13
Correct routing
of the mains/
charging cables
CAUTION!
Danger due to overheating as a result of incorrectly laid mains/charging cables.
Risk of damage to the components.
Lay the mains/charging cable without a loop.
▶
Do not cover the mains/charging cable.
▶
Charging cables longer than 5 m (16 ft. 4.85 in.) must be laid individually (no
▶
bundling).
Charging cables longer than 5 m (16 ft. 4.85 in.) can have an increased sur-
▶
face temperature (be aware of hot surfaces).
In the following cases, pay special attention that the surface temperature of
▶
the charging cables does not exceed 80 °C (176 °F):
- Ambient temperature is 30 °C (86 °F) or more
- Cross-section of the charging cable is 95 mm2 or more
- Length of the charging cable is 5 m (16 ft. 4.85 in.) or more
The mains/charging cable may only be replaced by a qualified electrician.
▶
14
Warning notices
xxxxxxxx
xxxxxxxx
xxxxxxxx
Gerätebezeichnung
xxxx
OVC III
HIGH LEAKAGE CURRENT! Ensure proper grounding
4,001,xxx Setup xxxx xxxx xxxx
Fronius International GmbH
Froniusstraße 1
A-4643 Pettenbach
Austria
Ser. No.:
Part No.:
UDC nom.
IDC max.
I
AC max.
U
AC nom.
P
AC max.
Production Date Code
80V
375A
54.0A
3~ NPE 400V 50/60Hz
32290W
Platform G1IP20
Protective class I
Ladevorgang immer stoppen bevor das Ladekabel abgezogen wird!
Nur mit zugelassener Lithium Ionen Batterie verwenden!
Always stop charging before you disconnect the charging cable!
Use only with approved lithium ion battery!
Toujours arrêter la charge avant de déconnecter le câble de charge!
Utiliser uniquement avec des batteries lithium-ion agréées!
¡Detener siempre la carga antes de desconectar el cable de carga!
¡Utilizar exclusivamente baterías de iones de litio homologadas!
Interrompere sempre la carica prima di scollegare il cavo di carica!
Utilizzare solo con la batteria agli ioni di litio approvata!
Li
WARNUNG - WARNING - ATTENTION
ADVERTENCIA - AVVISO
42,0409,0420
on the device
The battery charger is equipped with safety symbols on the rating plate. The
safety symbols must not be removed or painted over.
On the rating plate there is a 4-digit number which allows you to calculate the
production date. If you subtract the value 11 from the first two digits, you get the
year of production. The last two digits represent the calendar week in which the
device was produced.
Example: Value on rating plate = 3205
32 - 11 = 21: Production year 2021
05: Calendar week 05
EN-US
An electric shock can be fatal. The housing may only be opened by service technicians trained by the manufacturer. Before working with the
housing open, the device must be disconnected from the mains. A suitable measuring device must be used to ensure that electrically
charged components (e.g., capacitors) are completely discharged. Ensure that the device remains disconnected from the grid until all work
is complete.
Use functions only after reading the operating instructions in full.
Keep potential sources of ignition such as fire, sparks, and open flames
away from the battery.
The device can cause DC residual currents in the ground conductor. If
a residual current device (RCD) is used on the grid side to protect
against electric shock, this must be a type B RCD.
Do not dispose of the product with domestic waste, but in accordance
with the disposal regulations for waste electrical and electronic equipment applicable at the place of installation.
15
Warning notices
WARNING
Hazardous Voltage
Kondensator Entladezeit < 3 min.
Capacitor discharge time < 3 min.
Décharge de condensateur < 3 min.
Condensador tiempo de descarga < 3 min.
Condensatore tempo di scaricamento < 3 min.
inside the device
WARNING!
Danger from electrical current.
This may result in serious injuries or death.
The housing may only be opened by service technicians trained by the manu-
▶
facturer.
Before starting work, switch off all devices and components involved, and
▶
disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back
▶
on.
After opening the device, use a suitable measuring instrument to check that
▶
electrically charged components (such as capacitors) have been discharged.
With the aid of a clearly legible, understandable warning sign, ensure that
▶
the device remains disconnected from the mains until all work has been
completed.
Setup regulations
16
WARNING!
Danger from devices falling or toppling over.
This can result in severe personal injury and damage to property.
Set up all system components in a stable position.
▶
When using a floor bracket or wall bracket, always ensure that all fastening
▶
elements are firmly seated.
Devices weighing more than 25 kg (55.12 lb.) must be carried by at least 2
▶
persons.
When mounted on a shelf, the load capacity of the shelf must at least cor-
▶
respond to the weight of the device.
The device has been tested according to degree of protection IP20. This means:
Protection against the penetration of solid foreign bodies with a diameter of
-
more than 12.5 mm (0.49 in.).
No protection against water.
-
The device can be set up and operated in dry, closed rooms in accordance with
degree of protection IP20. Avoid exposure to moisture.
The permissible operating position of
(a)
(b)
the device is horizontal.
Cooling air
The device must be set up so that cooling air can flow through the housing openings provided unhindered. A minimum distance of 0.2 m (7.874 in.) must always
be observed from the air inlet and outlet openings. The ambient air must be free
from:
Excessive dust exposure
-
Electrically conductive particles (carbon black or metal chips)
-
Heat sources
-
The cooling air flows in and out as indicated by the arrow symbols in the following illustrations.
EN-US
NOTE!
Danger due to partially or completely covered air intake and outlet openings.
This can result in damage to property.
The setup of several devices one behind the other should be staggered.
▶
If the devices are arranged in a line one behind the other without being
staggered, the distance between the devices must be as follows:
D1: Minimum distance 30 cm (11.81 in.)
a)
E1+F1: Minimum distance 60 cm (1 ft. 11.62 in.)
b)
17
Wall bracket
312
32
62
62
WARNING!
Danger from incorrectly performed work and falling equipment.
This can result in severe personal injury and damage to property.
The mounting may only be carried out by trained and qualified personnel.
▶
Follow the safety rules in the battery charger's Operating Instructions.
▶
Depending on the substrate, different dowels and screws are required.
▶
Therefore, dowels and screws are not part of the scope of supply for the ser-
▶
vice station.
The system installer is responsible for selecting the proper dowels and
▶
screws.
WARNING!
Danger from devices falling or toppling over.
This can result in severe personal injury and damage to property.
Check that all screw connections are tightly fastened.
▶
Only use with a Fronius Li-Charger 5-18 kW battery charger.
▶
Mount the device horizontally.
▶
1
2
18
633 (24.92)
mm (in.)
13
(.51)
180 (7.09)
193 (7.6)
595,5 (23.44)
179 (7.05)
453 (17.83)
344 (13.54)
109
(4.29)
D1
E1
392 (15.43)
502 (19.76)
647 (25.47)
267 (10.51)
247 (9.72)
241 (9.49)
585 (23.03)
20
(.79)
110
(4.33)
mm (in.)
EN-US
19
342 (13.46)
418 (16.46)
494 (19.45)
500 (19.69)
492 (19.37)
450 (17.72)
400 (15.75)
300 (11.81)
200 (7.87)
20 (.79)
8.3
(.79)
6
(.24)
7 (.28)
8.5
(.33)
6
(.24)
25
(.98)
76 (2.99)
60
(2.36)
mm (in.)
D1 / E1
Hole pattern
F1
392 (15.43)
516 (20.31)
mm (in.)
785 (30.91)
500 (19.69)
570 (22.44)
241 (9.49)
646 (25.43)
723 (28.46)
267 (10.51)
247 (9.72
(.79)
20
76
(2.99)
9
(.35)
24
(.94)
124
(4.88)
Weight of the wall bracket:
D1 1.80 kg (3.97 lbs.)
E1 3.15 kg (6.49 lbs.)
F1 4.30 kg (9.48 lbs.)
20
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