Jungheinrich SLT 100 Operating Instructions Manual



SLT 100





SLT 100



Operating instructions

50451882

SLT 100

G

10.04 -

11.15

V1

11.15.GB

Foreword

The safe operation of the charger requires
the application of expertise contained in the
present ORIGINAL OPERATING
INSTRUCTIONS. The information is
presented in a precise and clear manner.
The chapters are arranged by letter.

Our equipment is subject to ongoing
development. We reserve the right to alter
the design, features and technical aspects
of the equipment. No guarantee of
particular features of the truck should
therefore be assumed from the present
operating instructions.

Safety instructions and important
explanations are indicated by the following
graphics:

F

Used before safety instructions which must
be observed to avoid danger to personnel.

M

Used before notices which must be
observed to avoid material damage.

Z

Used before notices and explanations.

t Used to indicate standard equipment.

o Used to indicate optional equipment.

Copyright

Copyright of these operating instructions
remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Friedrich-Ebert-Damm 129
D-22047 Hamburg - Germany

Tel: [phone]

www.jungheinrich.com

I1

0709.GB

Table of contents

A Correct use and

application 1

B Description of battery

charger 2

1 Technical description 2
2 Charging electronics 4
3 Protection / Ambient conditions 4
4 Identification label, 4

C Transportation and

Commissioning 5

1 Transporting the charger 5
2 Charger Assembly 5
3 Starting up the charger 5

D Battery - Servicing,

recharging, replacement 6

1 Safety regulations governing

the handling of lead-acid
batteries 6

E Operation 7

1 Safety regulations relating to

the operation of battery chargers 7

2 Description of the operating

controls and indicating elements 8

3 Commissioning the battery

charger 9

3.1 Connecting the charger 9

3.2 Starting the charging operation 9

3.3 Battery charging sequence 9

3.4 Mains supply 9

3.5 Fault indication (safety cut-out) 9

3.6 Manual charging interruption 10

3.7 Boosting charge 10

3.8 Manual Compensation Charge 10

3.9 Automatic equilising charge
function 10

4 Charging state indicator 10

F Charger Maintenance 11

1 Operational safety and

environmental protection 11

2 Safety instructions to

be observed during servicing 11
3 Cleaning operations 11
4 Working on the SLT 100

charger 11
5 Fuses 11

5.1 Small battery charger 11

5.2 Large battery charger 12

G Internal electrolyte stirrer

(EUW) 13

1 Correct use and application 13
2 Charger Assembly 13
3 Electrolyte circulation (EUW) 13
4 Description of the device 13
5 Commissioning 15

5.1 Air volume flow presetting 15
6 Maintenance of the filter 15
7 Aid for malfunctions 16

7.1 Malfunction: Pump does not

react during charging. 16

7.2 Malfunction: Charging time is

not reduced 16

7.3 Malfunction: Loud pump noises 16

H “LIS” charge information

system (

o) 17

I Sample data plate 18

I2

0709.GB

17

1115.GB

H “LIS” charge information system (o)

Chargers with the charge information
system (LIS) store the data from the last
200 charges.

The curves for the individual charges can
be viewed on a PC. The necessary
software is supplied on a CD with the
charge information system.

Z

For information on operating the charge
information system, software installation
instructions and PC connection to the
charger, see “Charge information system”
operating instructions.

1

1115.GB

A Correct use and application

The SLT 100 battery charger is designed
for the fully automatic charging of lead
batteries and may only be operated for this
purpose. The charger operates in
accordance with the Wa characteristic
specified in DIN 41774. This characteristic
is optimized by current pulses at the end of
the charge. This current characteristic
curve, which slopes downwards as the
battery charge level rises, allows for optimal
charging. Safe functioning of the battery
charger is ensured by the reliable charging
electronics monitoring the battery charging
operation.
The technical data and specifications
regarding the connection requirements can
be found on the identification plate and in
the operating instructions. These
specifications must always be heeded.
Operation of the battery chargers is subject
to the provisions contained in the relevant
legislation and regulations, from industry
association guidelines (VDE), from the
EMC directive (2004/108/EC) and
directives issued by local authorities.
Excerpts of such provisions are given in
chapter E1.

The battery charger must only be used for
charging batteries which are of the type
stipulated by the manufacturer.

The battery charger must always be
operated with the housing closed. It is
forbidden to loosen and remove parts of the
housing or any type of suppressor
elements.
Do not place any objects on the charger or
climb onto it.

Additional components may only be
installed after a written approval by the
manufacturer has been obtained.

User obligations:

User within the meaning of these operating
instructions is any natural person or legal
person who either uses the battery charger
himself, or on whose behalf it is used.

In special cases (e.g. leasing or renting),
the user is deemed to be the person, who,
in accordance with existing contractual
agreements between the owner and the
user of the SLT 100 battery charger, is
charged with the observance of the
operating duties.

The user is responsible for choosing the
assembly location. He must check whether
the battery charger will affect any devices
that are sensitive to electromagnetic
interference.
The assembly location of the charger must
be chosen so that operation (high DC
currents generate magnetic interference
fields) does not affect the functioning of
sensitive electromagnetic devices and
magnetic data media, such as
pacemakers, monitors, disks, magnetic
tapes, magnetic cards, watches, see
“Charger Assembly” on page 5.

The user must ensure that the SLT 100
battery charger is used only within its
design limits and that all danger to life and
limb of the operator and third parties is
avoided.

Furthermore, applicable accident
prevention and other health and safety
regulations, along with the operating and
maintenance guidelines, must be observed
at all times.

M

The battery charger must only be operated
when stationary.

The user must also ensure that all persons
operating the battery chargers have read
and understood these operating
instructions.

2

1115.GB

B Description of battery charger

1 Technical description

The SLT 100 battery charger is designed
for the fully automatic charging and
recharging of lead batteries and is
equipped with a special electronic charging
system (1, 2). The rated charging current
specified flows at a charging voltage of

2.0 volts per cell. The battery must be
assigned so that the initial charging current
is approx. 16 Amperes per 100 Ah of
battery capacity.

The difference lies in the initial charging
current – see data plate (3).

Initial charging voltage: 24, 48, 80 volt

depending on type

Initial charging current: 20 A-160 A,

depending on type

The battery charger is protected on the
secondary side by a fuse (5) acting as
a short circuit protection and by a sensor to
limit the transformer temperature.

To ensure the operational safety of the
system, only self-cooled stacked silicon
rectifier elements (4) are used.

Stray field transformers (6) are used to
comply with the specified charging
characteristic.
The stray field transformers are equipped
with additional primary tapping to
DIN 41 774, corresponding to +10 %,
+5 %, 0 % and -5 % to allow for mains
voltage deviations.

Z

Modifications should only be carried out by
the manufacturer’s service department.

2

3

1

4

5

6



SLT 100





SLT 100



15

1115.GB

5 Commissioning

Z

For transport and assembly see chapter C
on page 5.
For chargers with electrolyte circulation the
air volume flow must also be adapted to the
battery, see "Air volume flow presetting” on
page 15.

5.1 Air volume flow presetting

Switch (3) has the following factory settings
for all SLT 100 large battery chargers:

6 Maintenance of the filter

The blue suction filter (5) on the bottom of
the pump must be checked for soiling at
regular intervals.

In strongly dusty areas, it is to be replaced
every 3 months, otherwise at least every 6
months.
To replace the suction filter (5) tip the blue
insertion sleeve to the side and replace the
polishing cotton.

Figure: Large battery charger

Figure: Small battery charger

Voltage class

in V

Volume in l/min

24 4

48 8

80 12

Item Description

4 Cable to the charging switch

5 Filter

6 Air hose

4

5

6

6

54

3

1115.GB

Charging electronics extra option
(Aquamatic)

Z

The Aquamatic serves to control an
external solenoid valve of an automatic
water refilling system.

When a cell voltage of 2.4 V/cell is reached,
a relay contact (normally open contact,
contact rating 5 A) is triggered by the
following pulse train:

- 6-7 pulses with a duration of 3 sec., then
maintained contact for 7 min.

The contact is potential-free, a 230 V power
connection of the battery charger is
available.

Electrolyte circulation:

Z

The charger has an option for controlling an
electrolyte circulation pump.

M

Observe the respective manufacturer’s
guidelines! It should only be connected by
the manufacturer’s service department.

The Aquamatic and electrolyte circuluation
systems are monitored. Any faults are
displayed on the front panel.

M

The connection of external additional
equipment may only be carried out by
skilled electricians.

Z

To attach additional external equipment,
contact the manufacturer’s service
department.

Charging curve / pulse charging:

-T1 = Battery gassing phase reached.

Start of the recharging phase

-T2 = Start of the pulse charging phase

(1-5 pulses depending on the main
charging time)

-T3 = End of battery charge.

Z

If the battery remains attached to the
charger at the end of the charging time
(T3), there will follow an 8 minute trickle
charge every 8 hours and after 24 hours a
one-off compensation charge lasting
2 hours.

Characteristic curve:

Wa Charging characteristic

Uz Cell voltage (V/cell)

ILCharging current

(in % of rated current)

IdN Rated battery current

The curve of the Wa characteristic is
determined by points 1), 2) and 3):

1) 100 % I
dN

at V = 2.0V/cell

2) 50 % I
dN

at V = 2,4V/cell

3) 25 % I
dN

at V = 2,65V/cell

Z

A controlled thorough acid mixing by means
of current pulses is carried out at the end of
the recharging phase.

T

U, I

T1

T2 T3

2,8V

2,6

2,4

2,2

2,0

1,8

2,65

0 25 50 75 100%

1)

2)

3)

IL / I

dN

U

Z

4

1115.GB

2 Charging electronics

The SLT 100 charging electronics monitor
and control the charging operation.
Progress of the charging operation is
shown by the light-emitting diodes (7).
An electronic monitoring unit detects the
gassing time and determines the optimum
recharging time from the charged capacity
(Ah balancing).

Charging starts automatically with a time
delay (approx. 10 sec. to protect the plug
contacts) after the battery has been
connected to the charger.
The control key (12) can be used to cancel
operation at any time.

The standby (13), charging (7), charging
completed (9), and compensation
charge (8) conditions are indicated by the
LEDs (13,7,9,8).

An automatic safety cut-out is provided,
when the gassing voltage has not been
reached within an initial charging phase of
12 hours.

Z

The automatic safety cutout is displayed by
the yellow warning display LED (11)
(flashing code): 3x / interval / 3x.
If the transformer overheats, a warning
is indicated (11) (flashing code: 4x /
interval / 4x). As soon as the transformer
temperature is in the permissible range
again, charging will be continued and the
LED goes off.

Optimum battery charging requires
adaptation to the mains supply. The
charging electronics are zero-voltage proof,
i.e. no malfunctions are possible as a result
of mains failures, as all times are stored
and charging will recommence at the point
the failure had occurred.

3 Protection / Ambient conditions

Protection: IP 22

Ambient conditions:

The charger is self-cooled and is designed
for a max. ambient temperature of
40 °C and a max. relative humidity of 80 %.

Minimum ambient temperatures:

- for storage -20 °C

- for operation 0 °C

If the charger thaws due to sudden
temperature changes, leave the charger for
a least 3 hours before switching it on again.

M

The charger must only be stored in
enclosed areas. Operation of the battery
charger is only permitted in spaces
specially provided for this purpose.

4 Identification label,

e.g. E230 G24/50 SLT 100
(see “Sample Data Plate” on page 18)

Z

The identification label is located on the
rear wall of the unit.

13 12 11 10 9

87

D = 3-phase curr
E = Alternating curr
Mains voltage (V)
Charging rectifier
Initial charging voltage (V)
Initial charging current (A)
Battery load

E 230 G 24 / 50 B SLT 10

0

13

1115.GB

G Internal electrolyte stirrer (EUW)

1 Correct use and application

Z

See also Chapter A ,“Correct use and
application”.

The battery charging device with a built-in
pump and hose system is suitable only for
batteries with electrolyte stirring.

User obligations:

The user must make sure that only
batteries with electrolyte stirring or with a
hose system are permitted to be charged.

M

The pump must not be operated without
counterpressure.

2 Charger Assembly

F

The battery charger must not be operated
outdoors.

Choose the assembly location so that:

- There is sufficient ventilation.

- The flow of cooling air through the
charger is not restricted. It must not be
installed close to radiators or similar heat
sources.

- No flammable gases or dust mixtures
can penetrate inside the charger.

- The charger is placed only on a solid and
secure surface. The surface must not
consist of flammable material.

- The bottom of the charger is approx.

0.5 m above the battery to be charged.

F

It is forbidden to store food in the vicinity of
battery chargers.

Z

The VDE 0510 safety regulations must be
observed.

3 Electrolyte circulation (EUW)

During charging the electrolyte circulation
pump is switched on for approx. 2.5 min.
and off for approx. 7 min.

Charging is recognised by the charge
switch insofar as it:

- Detects the connected battery.

- Detects a charge current.

During the pulse charge phase there is no
electrolyte circulation. The pump is
switched off.

4 Description of the device

During the main charging phase, batteries
without electrolyte circulation generate acid
layers. The charging factor is set according
to the charging device.

Internal electrolyte circulation:

Internal electrolyte stirring is automatically
switched on at the beginning of the
charging procedure. Electrolyte stirring
mixes the acid before the gassing phase.

Z

In the main charging phase, the battery’s
energy consumption increases so that the
recharging phase can be shortened.

The internal charging electronics detect via
the sensor that the pump is switched on
and reduce the recharging time. This
shortens the total charging time at the same
battery charge level.