Jungheinrich SLH 200 Service Manual

4156 EN

SLH 200

10.04 -

Operating Instructions 50452174

01.08

Contents

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Jungheinrich Aktiengesellschaft

Am Stadtrand 35 D-22047 Hamburg-Germany

Tel.: +49 (0) 40/6948-0

www.jungheinrich.com

Contents

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Index

General ...........................................................................................................................4

1.1

Purpose of Operating Instructions...........................................................................................4

Safety..............................................................................................................................4

2.1

General ......................................................................................................................................4

2.2

Decal and Symbol Notices........................................................................................................4

2.3

Personnel Qualification.............................................................................................................5

2.3.1 Commercial Use................................................................................................................5

2.4

Correct use and application......................................................................................................5

2.5

Assembly and Installation Safety Instructions ........................................................................6

2.6

Operating Safety Instructions...................................................................................................7

2.7

Troubleshooting and Repairs Safety Instructions...................................................................7

Product Specifications ..................................................................................................7

3.1

Product Functional Description................................................................................................7

3.2

Model Description.....................................................................................................................8

3.3

Accessory Functional Description...........................................................................................8

3.3.1 Charger.............................................................................................................................8

3.4

Residual Risk.............................................................................................................................8

3.5

Protective Mechanisms.............................................................................................................9

3.6

Charger Labelling and Decals.................................................................................................10

Transport, Handling and Storage................................................................................10

Assembly / Installation / Commissioning...................................................................10

5.1

Delivery scope.........................................................................................................................10

5.2

Site Requirements...................................................................................................................11

5.3

Mains Connection and Mains Fuses.......................................................................................11

5.4

Assembly and Installation.......................................................................................................12

5.5

Commissioning the charger for the first time and operational testing.................................12

Operation......................................................................................................................12

6.1

Operating and Display Function.............................................................................................13

6.1.1 Charge Status Light.........................................................................................................14

6.1.2 Soft keys.........................................................................................................................15

6.1.3 Graphic display and menu structure.................................................................................16

6.1.4 Adjustable parameters.....................................................................................................17

6.1.5 Function – Battery Maintenance.......................................................................................17

6.1.6 Function – Measured values............................................................................................18

6.1.7 Graphic Display Information.............................................................................................18

6.1.8 Parameters – Consumption data......................................................................................18

6.1.9 Parameters - Statistics.....................................................................................................19

6.2

Charger Mains Connection.....................................................................................................19

6.3

Battery Connection.................................................................................................................19

6.4

Charging automatic start........................................................................................................20

6.5

Interrupting a charge...............................................................................................................21

6.6

Charging automatic end..........................................................................................................21

6.7

Readings..................................................................................................................................22

6.8

Status messages.....................................................................................................................23

6.9

Faults and Error Messages.....................................................................................................24

6.10 Switching off the charger........................................................................................................25

Maintenance.................................................................................................................25

7.1

Cleaning, Inspection and Maintenance..................................................................................25

7.2

Changing the charging program.............................................................................................26

7.3

Spare parts..............................................................................................................................26

Disposal........................................................................................................................26

Appendix.......................................................................................................................27

9.1

Dimension and Projection Drawings (not to scale) ...............................................................27

9.2

Specifications..........................................................................................................................28

9.3

Model table..............................................................................................................................28

9.4

Charging programs.................................................................................................................29

9.5

Spare parts catalog.................................................................................................................30

General

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1 General

1.1 Purpose of Operating Instructions

The aim of the present operating instructions is to ensure the correct and safe operation of the SLH 200 charger. The SLH 200 will hereafter be referred to as the charger.

The operating instructions must always be available and stored in the vicinity of the charger. The operating instructions must be read and applied by anyone involved in operating the charger, including shipping, assembly and installation, operation, maintenance and disassembly work.

For commercial use, the relevant work safety guidelines, standards and regulations of the place or country of operation must be observed alongside the present operating instructions.

For further information beyond the scope of the operating instructions, please consult with the manufacturer's specialist technicians.

All documentation is copyright protected. The transfer or reproduction of documentation, including excerpts, as well as the assessment and dissemination of its content are prohibited unless expressly permitted.

2 Safety

2.1 General

The operating instructions are a major component of the charger. The owner shall ensure that the operating instructions are permanently in the vicinity of

the charger, and that operating personnel shall be notified of these guidelines. The owner shall add further instructions regarding national accident prevention and

environmental protection regulations to the operating instructions, including information on supervisory and reporting obligations, taking into account particular company practices e.g. in terms of work organization, work processes and the personnel employed.

Apart from the operating instructions and the current accident prevention regulations in force in the country and place of use, generally recognised technical regulations for safe and proper use shall be observed.

2.2 Decal and Symbol Notices

This charger has been produced in accordance with generally accepted principles and state-of-the-art technology. To ensure sufficient levels of safety for personnel, additional safety instructions are issued. Sufficient safety when handling the charger is only provided when these instructions are observed.

From time to time it is necessary to emphasize specific instructions. These sections have different meanings:

Safety

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Note

Notes contain additional information to ensure safe and efficient handling of the charger.

Attention

This warning indicates possible damage that could be caused by failing to take precautionary measures or improper use. Observe all warnings and measures needed to prevent damage from occuring to the charger and other articles. Be particularly vigilant.

Danger

This warning indicates possible damage that could be caused to persons, by failing to take precautionary measures or improper use. Observe all warnings and measures required to prevent injuring yourself or other people. Be particularly vigilant.

2.3 Personnel Qualification

Only qualified technicians should operate the charger. The levels of responsibility for personnel operating and installing/repairing the charger should be clearly separated.

Qualified technicians in the sense of these basic instructions are people responsible for assembly, installation, commissioning, operation, maintenance, de-commissioning and disassembly, and who are suitably qualified to carry out their role.

The charger may only be installed, commissioned for the first time, repaired and disassembled by qualified and authorized electrical engineers.

With trained electrical engineers it is assumed that they will observe and comply with current regulations of the local energy supply company as well as the industry work safety guidelines (e.g. BGV A2) an d all regulations governing the safe and proper use of the charger (e.g. DIN VDE 0100 and IEC 60664 or DIN VDE 0110).

The manufacturer does not accept liability for any damage or loss of business arising from the failure to comply with these operating instructions.

2.3.1 Commercial Use

If the charger is used in a commercial environment, the following also applies:

− The operator must undergo special instruction or training on how to charge lead acid

accumulators and how to operate them.

− Only authorised personnel may operate the charger.

2.4 Correct use and application

The SLH 200 charger is designed to charge lead acid accumulators. Depending on the preset charging program, only wet cell batteries designed for the charger program or suitably sealed, maintenance-free traction batteries should be charged. The charger is unsuitable for all other accumulators and non-rechargeable batteries.

If required by the owner, the charger can be fitted with a range of different connectors. The owner is therefore obliged,

− only to use connectors with the suitable fuse rating for the charger,

− to avoid connecting unsuitable battery types.

Safety

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The latter could be achieved for example by colour-coding or mechanically coding the connector.

Always observe and comply with the battery manufacturer’s instructions. If the charger has a charging program which has been modified, the owner is obliged to

permanently advise of the suitable battery type on the housing exterior. To ensure proper use, observe and comply with the details on the location site (see

sections 2.5 and 5.2), the data plate and the specifications (see Appendix).

Risk of injury

Serious damage to personnel and property could arise from:

improper use or incorrect operation,

unauthorised opening of the charger,

incorrect installation or improper service or repair work.

All instructions regarding the correct use, residual risk, installation, operation and maintenance contained in these operating instructions must therefore be noted and observed.

The charger must only be used for the purposes foreseen in the present operating instructions and the technical description and only with the accessories or components recommended and approved by the manufacturer.

Any other use beyond the scope of the above is not appropriate. The owner or user of the charger shall be liable for any damage arising from the above.

The charger shall only be commissioned in accordance with electromagnetic compatibility guidelines (89/336/EC).

2.5 Assembly and Installation Safety Instructions

Before installing the charger, check that all the components have been supplied against the delivery notes. If anything is missing, immediately contact the manufacturer.

The place of operation must be weather-proof and dry. The ambient temperature at the site must not fall below 0°C or exceed 40°C. Avoid the

build-up of heat within the charger, e.g. through heat sources or by blocking the air vents.

The location site must be sufficiently ventilated to distribute (reduce) charging gases which may arise (acid fog, electrolytic gas) and prevent the build-up of explosive gas mixtures.

The site must not contain excessive dust. Avoid the occurrence of conductive dust (soot, metal).

No liquid must enter the inside of the charger. The distance between the charger and inflammable materials must be at least 2.5m

horizontally. It is forbidden to store inflammable materials, e.g. in shelves, or to use inflammable materials above the charger. There must be at least a 5.00m gap between fire and explosive-hazardous areas.

The charger must be protected against overload or stress. In particular, no components must be damaged during transport and when being handled. Avoid contact with electronic components.

The charger contains electrostatic endangered components which can easily be damaged through improper handling. Electrical components must not be physically damaged or destroyed.

Product Specifications

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Electrical installation (wire cross sections, fuses, earth leads) must be performed in accordance with current regulations.

Prior to electrical installation, the performance data on the data plate must be checked against the performance data of the supply connections. The charger must be protected against excessive shock-hazard voltages through a mains fuse connected in series. Observe the mains connection values indicated on the data plate (voltage and frequency).

2.6 Operating Safety Instructions

The charger must only be used when in technically good working order and when used in accordance with the present operating instructions with attention paid to the safety and hazard risks. Any faults that could affect safety must be removed immediately.

The data plate specifications regarding the appropriate battery voltage must be checked and complied with prior to connecting the charger cable. The charger leads must be connected to the correct battery terminals.

When connecting the battery, route the charging leads so that they cannot be tripped over and that charging cannot be interrupted by unplugging the charging lead. If an ongoing charge is interrupted by removing the charging lead, this may produce sparks which could result in fire or explosions.

If the charger or the operating pattern of the charger is changed in a way that could affect safety, shut down the charger and notify the relevant department of the fault.

2.7 Troubleshooting and Repairs Safety Instructions

Contact the manufacturer prior to opening the housing for maintenance and repair purposes.

Prior to carrying out maintenance or repair work, always disconnect the charger from the mains.

After switching off the charger, wait for at least five minutes before opening the panels and housing.

No changes or modifications may be made to the charger which could affect safety without obtaining the manufacturer’s approval. This also applies to the assembly and setting of safety mechanisms. In particular make sure that no safety, leakage or air distances are reduced.

Spare parts used must meet the technical requirements specified by the manufacturer. This requirement is always met by original manufacturer’s spare parts.

3 Product Specifications

3.1 Product Functional Description

The SLH 200 charger is designed to charge lead acid accumulators. Depending on the preset charging program, wet cell batteries or sealed, maintenance-free traction batteries can be charged.

The charger has an adjustable, high-frequency power part, a micro-processor controlled charging electronics system and a control/display panel with buttons and a charge status light, as well as a graphic enhanced LCD display. The charging program for the respective battery type is factory-set to the customer’s requirements.

Product Specifications

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The various charger assemblies are installed in a secure steel sheet housing with a plastic front panel. The charger is equipped with a mains cable and connector (optional for threephase models) for connection to the mains.

3.2 Model Description

The SLH 200 charger is available in different options. The following is a typical model description (e.g. for a 24 volt, 120 amp charger).

Type E 230 G 24/120 B-SLH200

Model description – SLH 200 Output rated current Output rated voltage Output current type ‘G’ – DC Input rated voltage Input current type ‘E’ – Single phase AC current

For the exact technical specifications refer to the data plate on the charger and the technical specifications attached.

3.3 Accessory Functional Description

3.3.1 Charger

Various battery connectors can be used depending on the battery type. The charger can therefore be supplied with or without a charging lead, as required. Refer to the attached delivery notes.

3.4 Residual Risk

Warning: Hazardous Electrical Voltage!

The charger is an electric component conducting voltages and currents that are hazardous to people. The charger must therefore only be operated by trained technicians. The charger must therefore only be opened, repaired and disassembled where necessary by qualified electrical engineers. The mains supply and a battery contact where necessary must be disconnected before carrying out any work on the charger.

Explosion hazard

When a battery is charged, potentially explosive gases can escape. The charger must therefore only be operated in well ventilated rooms. Never remove the battery connection while charging. This could produce sparks which could ignite the charging gases (electrolytic gas).

Danger of getting caught on charging leads

A removed charging lead could cause people to trip over it and run the risk of interrupting a charge. People can get caught on removed, loose cables, trip over them and pull the charging lead out of the battery during charging. The sparks this produces could ignite the charging gases and as a result cause a fire or trigger an explosion.

When connecting the battery always route the charging lead so that nobody can trip over it. After charging, place the charging lead carefully on its bracket.

Product Specifications

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Attention

Connecting an incorrect battery to the charger can result in damage to the charger and battery: The battery could gas, decoct or even explode. Always check that the charger is set for your battery type. If in doubt, contact the relevant experts.

Attention

Corrosive acid gases can be produced when a battery is being charged. Acid gases can cause short circuits in electrical equipment (risk of burning) and can corrode components.

Therefore always position batteries next to charging stations in such a way that any acid gases arising can be freely distributed (reduced) on site and can dissipate.

3.5 Protective Mechanisms

The charger has been designed and constructed in accordance with state-of-the-art technology. If used properly, it therefore poses no danger to the health and safety of those operating it or third parties.

All live assemblies are fitted with housings and panels that can only be undone with tools. All cables and connectors are appropriately screened / earthed. The charger has an IP 21 protection class.

All electric and electronic components bear the CE mark; all necessary isolating distances have been observed. All circuits are fitted with primary and secondary fuses with defined current rating and activation characteristics.

All metallic components are earthed via an earth lead system. The charger is fitted with an automatic cutout function as soon as the preset maximum

charge status of the battery is reached. This avoids overloading and excessive release of explosive gases.

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