Zivan NG1 Installation And User Manual

BATTERY CHARGER

BATTERY CHARGER

NG1

Installation and User Manual

Battery charger NG1

ATTENTION: To reduce the risk of
electric shock, do not remove cover.
Refer servicing to qualified service personnel.
Disconnect the mains supply before connecting
or disconnecting the links to the battery.

Read the Instruction Manual carefully
before use. Verify that the selected
charge curve is suitable for the type
of battery You have to re-charge.

Explanation of Graphical Symbols

The lightning flash with arrowhead symbol, within an equilateral triangle, is intended to alert
the user to the presence of uninsulated “dangerous voltage” within the equipment’s
enclosure; that may be of sufficient magnitude to constitute a risk of electric shock to
persons.

The exclamation point within an equilateral triangle is intended to alert the user to the
presence of important operating and maintenance (servicing) instructions in the literature
accompanying the equipment.

This product is covered by warranty.
The relative warranty certificate is attached to the Instructions Manual.
If the Manual is not provided with this certificate, please ask your retailer for a copy.
For further references, please write the serial number in the proper space:

Serial No._____________________

Information contained in this Manual relates to ZIVAN S.r.l. property which reserves
the right to supply for the exclusive use of customers.
No other use is allowed without a written authorization supplied by ZIVAN S.r.l.

ZIVAN S.r.l. will be not responsible for inaccuracies contained in this manual due to
print or translation errors. ZIVAN S.r.l. has the right to make changes or
improvements, also for the user interest, without prejudicing the essential
characteristic of operation and safety.

Copyright © 2003 by ZIVAN S.r.l.

First Edition

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Battery charger NG1

Installation and safety instructions

Battery charger NG1 has been designed to provide safety and reliable. It is necessary to observe the
following precautions in order to avoid damage to persons and to the battery charger:

• Read the installation instructions contained in this Manual carefully. For further information put the
Manual in a proper place.

• Fix the battery charger to a stable surface through the appropriate holes inserted on the fixing
flanges. In case of installation on a vehicle it is advisable to use antivibration supports.

• Preferably the charger should be installed in the vertical position with fans facing up. The horizontal
installation is allowed. Never install in the vertical position with fans facing down.

• Ensure all ventilation ports are not obstructed, to avoid the overheating. Do not put the battery
charger near heat sources. Make sure that free space around the battery charger is sufficient to
provide adequate ventilation and an easy access to cables sockets.

• Protect the battery charger from ingress of water. Do not pour liquids inside the case.

• Verify that the available supply voltage corresponds to the voltage that is stated on the battery

charger name plate. In case of doubt, consult a retailer or local Electric Supply Authority.

• For safety and electromagnetic compatibility, the battery charger has a 3-prong plug as a safety
feature, and it will only fit into an earthed outlet. If you can not plug it in, chances are you have an
older, non-earthed outlet; contact an electrician to have the outlet replaced. Do not use an adapter to
defeat the earthing.

• To avoid damaging the power cord, do not put anything on it or place it where it will be walked on. If
the cord becomes damaged or frayed, replace it immediately.

• If you are using an extension cord or power strip, make sure that the total of the amperes required by
all the equipment on the extension is less than the extension’s rating.

• Disconnect the mains supply before connecting or disconnecting the links to the battery.

• To recharge Lead Acid batteries: WARNING: Explosive Gas – Avoid flames and sparks. The battery

must be positioned in a correctly cooled place.

• Do not use to charge batteries installed on board of thermal engine cars.

• Avoid recharging of non-rechargeable batteries.

• Verify that the nominal voltage of the battery to be re-charged corresponds to the voltage stated on

the battery charger name plate.

• Verify that the selected charging curve is suitable for the type of battery to be re-charged. In case of
doubt, consult Your retailer. ZIVAN S.r.l. will not accept any responsibility in case of mistaken choice
of the charging curve that may cause irreversible damage to the battery.

• In order to avoid voltage drop, thereby assuring 100% charge at the battery, the output cables must
be as short as possible, and the diameter must be adequate for the output current.

• In the case of thermal compensation of the battery voltage, it is necessary to place the thermal
sensor in the area of highest battery temperature.

• Do not try to service the battery charger yourself. Opening the cover may expose you to shocks or
other hazards.

• If the battery charger does not work correctly or if it has been damaged, unplugged it immediately
from the supply socket and from the battery socket and contact a retailer.

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Battery charger NG1

A

Operating principle

The battery charger considerably affects battery life and performances, which is the main part of every
electric vehicle.

A non controlled traditional battery charger (rectifier) provides a simple direct AC/DC conversion.

i

v

AC

Battery

DC

In modern battery chargers these disadvantages are solved with an indirect AC/DC conversion, by
passing through an intermediate DC/DC conversion.

i

v

C

DC

The main advantages of this solution are:

• High efficiency

• Reduced dimensions

• Short charge times

• Charge independent from the changes of the mains supply

• Electronic control that provides the desired charge curve

The advent of electrical problems (due to commutation) has imposed the introduction of adequate filtering
to satisfy requirements of EMC 89/336/EEC directive for electromagnetic compatibility.

DC

DC

Disadvantages of this solution are:

• Low efficiency

• Large physical size

• Long charge times

• Charge depends on changes in the mains supply (with

overcharge danger in the final charge phase)

This is the usual method of operation for the
SMPS (Switching Mode Power Supply) at
high power. This solution gives a good

Battery

performance for minimum costs and physical
dimensions using switches more faster and
powerful (modern technology).

Block Diagram

F1 F2

L

E

N

EMI

FILTER FILTER

RECTIFIER

AND

FILTER

RECTIFIER

AND

FILTER

POWER

STAGE

CONTROL

LOGIC

RECTIFIER

AND

FILTER

EMI

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Battery charger NG1

LED Indicator

100%

80%80%

START

RED LED shows that the battery is in the initial charging phase.
YELLOW LED shows that the battery charger has reached 80% of charge.
GREEN LED shows that the battery has reached 100% of charge.

Further information can be found in the description of the Charging Curve.

Alarms (Two-tone audible message)

An two-tone audible message and the flashing LED shows that an Alarm situation has occurred:

Condition Alarm Type Description (Action)

Audible message +

RED flash

Audible message +

YELLOW flash

Audible message +

GREEN flash

Audible message +

RED-YELLOW flash

Audible message +
RED-GREEN flash
Audible message +

YELLOW -GREEN flash

Audible message +

RED-YELLOW-GREEN

flash

Battery Presence Battery disconnected or not in conformity. (Verify the

connection and the nominal voltage).

Thermal Sensor The thermal sensor is disconnected during the re-

charge or it is out working range. (Verify the
connection of the sensor and measure the
temperature of the battery).

Timeout Phase 1 and/or Phase 2 have a duration in excess of

the maximal allowed. (Verify the battery capacity).

Battery Current Loss of output Current control. (Failure of the control

logic).

Battery Voltage Loss of output Voltage control. (Battery disconnected

or failure of the control logic).

Selection An unavailable configuration has been selected

(Verify the selector’s position)

Thermal Overheating of semiconductors. (Verify the fan

operation).

When there is an alarm the battery charger stops supplying current.

Thermal Sensor and/or External Indicator

Thermal Sensor and External Indicator are Options that have to be connected to the 5 pole socket 180°.

Unless otherwise stated, the compensation of the Battery Voltage in
function of the temperature of the Thermal Sensor is of -5mV/°C for
battery cell.
The control range of the Thermal Sensor goes from -20°C to +50°C.

The External Indicator reflects exactly the LED Indicator which is placed
on the equipment.
Further information can be found in the description of the Charging
Curve.

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A

A

Auxiliary Contacts

UX1

NC

C

Unless otherwise stated, the auxiliary contacts provide the following functions:

Section Function Description

UX2

NOCNCNO

Technical Features: changeovers contacts
0,3A 125VAC
0,3A 110VDC
1A 30VDC

Connector: faston 6,3 × 0,8 mm

AUX1 Mains Presence When the equipment is switched on, the contact

AUX2 End of charge or

Trickle Phase

Normally Open (NO) CLOSES and instead the contact
Normally Closed (NC) OPENS.

When the Stop Phase or the No Stop Phase is reached,
the contact Normally Open (NO) CLOSES and instead
the contact Normally Closed (NC) OPENS.

Battery

A battery is characterised by two sizes: tension and capacity.

Tension:

Each element has a nominal tension, which depends on the type of battery (no
matter what size).
In order to reach higher tension, many elements are connected in series, so
creating a “BATTERY” of elements.
The number of elements is calculated by dividing the nominal tension of the
battery for the tension of each single element in the table:

Capacity:

It is the quantity of electric charge that the batteries can supply to an external circuit before the tension
decreases under the final limit value and it is obtained by multiplying the intensity of the discharging
current I, expressed in ampere (A), for the discharging time t expressed in hours (h): C = I x t.
The traction battery capacity is normally referred to the discharging system of 5h: C5 = I x 5h.
The capacity values that can be recharged by the battery chargers can be found in the description of the
Charging Curve (this value is not present in the curves able to charge any capacity).

Type

Pb 2 V/cell
NiCd 1,2 V/cell
NiMH 1,2 V/cell
NiZn 1,714 V/cell

Nominal
Tension

:

This device is in conformity with the Low Voltage directive 73/23/EEC

and EMC directive 89/336/EEC and their further modifications.

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Battery charger NG1

Mechanical dimensions

160

78

N.B. All dimensions are expressed in mm.

Drilling details

155

= =

Ø6

245

3

300

9

UP



300

275

==

80

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16

Advised Installation

N.B. All dimensions are expressed in mm.

Battery charger NG1

TECHNICAL FEATURES

Ta=25°C unless otherwise specified

Mains side

Description Symbol Test Condition Value and/or

Range

Supply Voltage Vin - 230 ± 10% Veff
Frequency f - 50 ÷ 60 Hz
Absorbed Maximum Current Iin

P = P

max

6,8 Aeff

max

Inrush Current - Vin = 230Veff < 2,7 A
Power Factor

cosϕ
Absorbed Minimum Power Pin
Absorbed Maximum Power Pin

P = P

0,68 -

max

End of charge < 5 W

min

P = P

max

1 kW

max

Battery side

Description Symbol Test Condition Value and/or

Output current I - See curve ­Maximum output current I1 Phase 1 See curve A
Output current ripple - I = I1 < 5% ­Absorbed current Ia Equipment turned off < 0.2 mA
Output voltage U - See curve ­Constant output voltage U1 Phase 2 See curve V
Thermal compensation of output

dU1/dT Phase 2 -5

voltage
Operating range of Temperature

Sensor

∆T

- from -20 to +50 °C

Output voltage ripple - U = U1 < 1% ­Maximum power supplied P

U = U1, I = I1 864 W

max

Output capacity C -

Range

(°C·cell)

Depend on the

model (>0,3)

Unit

Unit

mV /

mF

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Battery charger NG1

General

Description Symbol Test Condition Value and/or

Operating range of temperature

Maximum relative humidity RH - 90% ­Switching frequency fc - 50 ± 5% kHz
Efficiency

Maximum size a×b×c Without connecting cable 300×160×80 mm
Weight - Without connecting cable 2,2 kg
Enclosure class - - IP20 -

∆T

η

At each operation
condition

- from -20 to

Range

+50

> 85% -

Unit

°C

Protection and Safety

Description Symbol Test Condition Value and/or

Insulation - Mains to Battery side 1250 VAC
Insulation - Mains side to Earth 500 VDC
Insulation - Battery side to Earth 500 VDC
Leakage current IL Supplied equipment < 3 mA
Input fuse F1 Inside the equipment 10 A
Output fuse F2 Inside the equipment
Minimum output voltage of operation

(Battery Detector)
Maximum output voltage Um Phase 3 (IUIa - IUIUo) See curve V
Reverse output polarity - At the connection to the

Thermal protection of semiconductors
(Temperature of Thermal Alarm)

Safety Requirements (Rules) ­EMC Requirements (Rules) -

- Equipment turn on 1,5 V/cell

Battery

- Ta=55°C 100 °C

EN60335-1, EN60335-2-29
EN55014-1, EN61000-3-3

EN55014-2, EN61000-4-2
EN61000-4-4, EN61000-4-5
EN61000-4-6, EN61000-4-11

Range

about 1,2×I1

Protection

provided by

fuse F2

- -

- -

Unit

A

-

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Battery charger NG1

Design, production and sales:

ZIVAN SRL

Via della Costituzione, 36
42028 Poviglio (RE) ITALIA
Tel. [phone]
Fax [phone]
[e-mail]

SALES OFFICES

ITALY FRANCE SWITZERLAND

ZAPI SPA URMA SARL ASMO ENGINEERING AG
Via Parma, 59 30, Rue de Morvan Silic 503 Glashütte, 58
42028 Poviglio (RE) 94623 Rungis Cedex CH 4229 Beinwil (SO)
Tel. [phone] Tel. [phone] Tel. [phone]
Fax [phone] Fax [phone] Fax [phone]
[e-mail] [e-mail] [e-mail]

SLOVENIA/CROATIA HOLLAND UNITED KINGDOM

PROTEUS ELECTRIC SRL SPI Special Product for Industry EZ ELECTROFIT ZAPI LTD
Via di Noghere, 94/1 Vlijtseweg 232 Unit 2 - Halesfield 17 - Telford
34147 Muggia Aquilina (TS) 7317 AN Apeldoorn Shropshire TF7 4PW
Tel. [phone]-232388 Tel. [phone] Tel. [phone]
Fax [phone] Fax [phone] Fax [phone]

U.S.A. GERMANY SPAIN

ELECTRIC CONVERSIONS ATECH Antriebstechnik GmbH VARELEC SCCL
215, 14th Sreet Gewerbepark Lindach D7 c / Lope de Vega 10-12 Bajos
95814 Sacramento CA 84489 Burghausen 08005 Barcelona
Tel. [phone] Tel. [phone] Tel. [phone]
Fax [phone] Fax [phone] Fax [phone]
[e-mail] [e-mail] [e-mail]

SPAIN SWEDEN BELGIUM

JZ RECIELCA S.L. ETP KRAFTELEKTRONIK AB BATTERY SUPPLIES n.v.
C / Progrés, 2-A. Gavà Järningen, 15 Lindestraat, 89A
08850 Barcelona 43323 Partille 8790 Waregem
Tel. [phone] Tel. [phone] Tel. [phone]
Fax [phone] Fax [phone] Fax [phone]
[e-mail] [e-mail] [e-mail]

GREECE CHINA

START Industrial Batteries CNEEC
7-9 Agiou Filippou Street N° 1 Lianhuahe Hutong
18540 Piraeus Beijing 100036
Tel. [phone] Tel. [phone]
Fax [phone] Fax [phone]
[e-mail] [e-mail]

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Battery charger NG1

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Electric Conversions

Distributor of ZIVAN Battery Chargers

215 14th Street, Sacramento CA 95814
Tel. [phone]

Fax [phone]
E-mail: [e-mail]
Web: www.zivanusa.com

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