Installation Manual

Professionalprogrammablebatterychargers
omnichargeOC
omnichargeOC
omnichargeOC
omnichargeOC
12-40(12V-40A)
12-60(12V-60A)
24-20(24V-20A)
24-30(24V-30A)
Owner’smanual
Thankyouforpurchasinga TBSElectronics
professionalprogrammablebatterycharger.
Pleasereadthisowner’smanualforinformation
aboutusingtheproductcorrectlyandsafely.
Keepthisowner’smanualclosetothechargerfor
futurereference.
TBSELECTRONICSBV
DeMarowijne3,1689AR,Zwaag, TheNetherlands
http://www.tbs-electronics.com
1.Omnichargedisplayandcontroloverview
2.Dipswitchsettings
Duringstep3oftheinstallationsequence,youcanalterthefactorysettingsofthe
dipswitchestochangethecharger’sfunctionalityonafewpoints. Thefollowingsettings
canbemade:
Beforeproceedingwiththisowner’smanual,pleasemake
sureyouhavecarefullyreadtheenclosedsafetyflyerand
theinstallationguideonthebacksideofthispaper!
EN
8.Warrantyconditions
outputcurrentbar
“chargeron”or“error”indicator
indicatormode: description:
continuousgreen poweron,normaloperation
flashingred(1flashpersec.) batteryerror
flashingred(2flashespersec.) chargeroverload
flashingred(3flashespersec.) highchargertemperature
2)
3)
flashingred(4flashespersec.) chargererror(returnforservice)
“poweron,off,forced
float”switch
Wheninposition“O”the
chargerisoff .
Whenswitchedto“I”the
chargerswitchesonin
normalchargingmode.
Whenswitchedto“II”the
chargeroperatesin
forcedfloatmode.See
chapter5formoredetails
ontheforcedfloatmode.
1)
indicatesthepercen-
tageofdelivered
outputcurrent.
note1: Whentheswitchisinposition“O”,itdoesnotinterruptanyinternal ACorDCsources.
Thismeansthattherearestilllethalvoltagespresentinsidethecharger!Inposition“O”,
thechargerwillstillconsumeasmallamountof ACcurrent.
note2: A batteryerrorcanappearforseveralreasons.Theseare:batteryvoltageistoo
low(toodeeplydischarged)ortoohighandbatterytemperatureistoolowortoohigh
(onlyavailablewhenbatterytemperaturesensorisconnected).Thechargerwillnot
restartautomaticallyinbatteryerrormode,exceptwhenthiserrorwasgeneratedduetoa
toolowbatteryvoltageora
note3: Thechargerautomaticallyrestartswhenthetemperatureisbelowanacceptablelevel.
toolowbatterytemperature.
1.LOC./EXT. Choosetoconfigurethebatterytypelocally(usingdipswitch2and
3),oroverridethesesettingsandsetupthechargerexternallyusing
the TBSDashboardforWindowssoftware.
1
on
1
on
SettingON
SettingOFF
Thelocaldipswitchsettingsofdipswitch2and3areignoredand
configurationmustbedoneexternally.
Thelocaldipswitchsettingsareused(factorydefault).
:
:
:
2&3.BATTERY
TYPE
Selectthetypeoflead-acidbatterythatyouwishtocharge.Each
settingrepresentsthebestchargingvoltagesforthegivenbattery
typelistedbelow.Iftherearestillothervoltagelevelsordifferent
chargingprogramsneededforyourbattery,pleaseusethe TBS
DashboardsoftwaretocreateyourownandstorethisasCustom
settinginsidethecharger.
3
on
2
on
Flooded(factorydefault)
absorptionvoltage14.4V/28.8V,floatvoltage13.5V/27.0V
GEL
absorptionvoltage14.2V/28.4V,floatvoltage13.5V/27.0V
:
4.BYPASSREMOTE
SW.
Bypassestheremoteswitchconnectionwhennoremoteswitchis
connected.
4
on
4
on
SettingON
SettingOFF
remoteswitchconnectionterminalsarebypassed(factorydefault).
remoteswitchconnectionterminalsareopen. A remoteswitch
mustbeconnectedandswitchedONinordertoactivatethe
charger. Thelocalon/offswitchonthefrontpanelalwaysoverrides
theremoteswitch.Soinordertousetheremoteswitch,thelocal
on/offswitchmustbeinthe'poweron'or'forcedfloat’ position.
:
:
:
Thefourthstagecalled“Pulse”,willperformashortrefreshchargeofapproximately1hour
each7dayswhilethechargeroperatesintheFloatstage. Thiswillkeepthebatteryin
optimalconditionwhileprolongingit'slifetime. Thebatterycanremainconnectedtothe
activatedchargercontinuously,withoutriskofovercharging.
Whenthebatterytemperaturesensorisinstalled,thechargerautomaticallycompensates
thechargevoltagesagainstbatterytemperature. Thismeansthatthechargevoltagesare
slightlyincreasedatlowertemperaturesanddecreasedathighertemperatures(-30mV/°C
at12Vchargersand-60mV/°Cat24Vchargers). Thisway,overchargingisprevented
whichprolongsyourbattery'slifetime. A connectedbatterytemperaturesensoralso
enablesthebatterytemperatureprotection,whichstopsthechargingprocesswhenthe
battery'stemperatureisbelow-20°Corabove+50°C.
Whenthestandardselectablechargingprogramsdonotsatisfyyourrequirements,or
whendifferentvoltage-andcurrentlevelsareneeded,youcanusetheoptional TBSLink
communicationkitandcreateyourownchargeprogramsusing TBSDashboard.Upto8
differentstagescanbelinkedtogetherandallindividualstagescanbeconfigured
extensively.Pleasecontactyour TBSequipmentsupplierforfurtherinformationonthe
TBSLinkcommunicationkit.
The AuxiliarybatteryoutputalwaysfollowsthechargeprocessoftheMainbattery
automatically. Youcanusethisoutputtochargeasecond(smaller)battery,likeastarter
battery.ItisnotpossibletousethisoutputwhentheMainbatteryisnotconnected!
TBSElectronics(TBS)warrantsthischargertobefreefromdefectsinworkmanshipor
materialsfor24monthsfromthedateofpurchase.Duringthisperiod TBSwillrepairthe
defectivechargerfreeofcharge. TBSisnotresponsibleforanycostsofthetransportof
thischarger.
Thiswarrantyisvoidifthechargerhassufferedanyphysicaldamageoralteration,either
internallyorexternally,anddoesnotcoverdamagearisingfromimproperuse ,orfrom
useinanunsuitableenvironment.
Thiswarrantywillnotapplywheretheproducthasbeenmisused,neglected,improperly
installedorrepairedbyanyoneotherthan TBS. TBSisnotresponsibleforanyloss,
damageorcostsarisingfromimproperuse,useinanunsuitableenvironment,improper
installingofthechargerandchargermalfunctioning.
Since TBScannotcontroltheuseandinstallation(accordingtolocalregulations)oftheir
products,thecustomerisalwaysresponsiblefortheactualuseoftheseproducts. TBS
productsarenotdesignedforuseascricitalcomponentsinlifesupportdevicesor
systems,thatcanpotentiallyharmhumansand/ortheenvironment. Thecustomeris
alwaysresponsiblewhenimplementing TBSproductsinthesekindofapplications. TBS
doesnotacceptanyresponsibilityforanyviolationofpatentsorotherrightsofthird
parties,resultingfromtheuseofthe TBSproduct. TBSkeepstherighttochangeproduct
specificationswithoutpreviousnotice.
Examplesofimproperuseare:
- Toohigh ACinputvoltageapplied
-Connectingwrongbatteries(toohighbatteryvoltages)
-Mechanicalstressedenclosureorinternalsduetoharshhandlingand/orincorrect
packaging
-Contactwithanyliquidsoroxidationcausedbycondensation
1)
1)
Chargestatusbar
A roughindicationofthe
chargingprogress.
100%full(ready)
80%full
50%full
empty
3
on
2
on
3
on
2
on
AGM
absorptionvoltage14.3V/28.6V,floatvoltage13.3V/26.6V
Custom
notavailablewhendipswitch1issettoOFF(LOC.)
3
on
2
on
DS2 DS3 BATTERY TYPE(12V/24V)
Invalidbatterytypesettingscancauseseriousdamagetoyourbatteriesand/or
connectedbatteryloads. Alwaysconsultyourbattery’sdocumentationforthe
correctchargevoltagesettings.
3.Chargeprograms
Allstandardselectablechargeprograms(usingdipswitches2and3),performafourstage
IUoUoP chargingprocesscomprisingofa“Bulk”,an“Absorption”,a“Float”anda“Pulse”
stage. Theimagebelowvisualizesthefourstagechargingprocess:
Pulse
V(12V)
t
14.4V
13.5V
12.5V
Bulk Absorption Float Float Bulk
absorptiontime-out
max.4hrs
globalchargetime-out
max.8hrs
floattime-out
7days
pulse
1hr
batteryload
turnedon
(Iload>Imax)
restartthreestage
chargingprocess
V(24V)
28.8V
27.0V
25.0V
t
Ich
Imax
10%Imax
IntheBulkstage,thechargerdeliversfulloutputcurrentandtypicallyreturns
approximately80%ofchargebackintothebatteryoncetheabsorptionvoltageisreached.
Duringthisstage,indicatorsandwillbelitdependingontheBulkchargeprogress.
Whentheabsorptionvoltagehasbeenreached,the Absorptionstagewillbeenteredand
indicatorwillbelit. Thisstagewillreturnthefinal20%ofchargetothebattery. The
outputvoltageiskeptataconstantlevelandthechargecurrentdecreasesasafunctionof
thebattery'sstateofcharge.Whenthechargecurrenthasdroppedbelowacertainvalue
orwhenthemaximumabsorptiontimerhasbeenexpired,theFloatstagewillbeentered.
Indicatorwillbelitandanacousticalmessagewillsound,indicatingthatthebatteryis
full.Inthisstagethebatteryvoltagewillbeheldconstantatasafelevelforthebattery.It
willmaintainthebatteryinoptimalconditionforaslongasthebatteryremainsconnected
totheactivatedcharger.Connectedbatteryloadswillbedirectlypoweredbythecharger
uptothecharger'smaximumoutputcurrentlevel.Whenevenmorecurrentisdrawn,the
batterymustsupplythiswhichresultsinadecliningbatteryvoltage. Atacertainbattery
voltagelevel,thechargerjumpsbacktotheBulkstageandwillfinalizeacompletethree
stagechargingprocessagain,oncethebatteryloadconsumptionhasdroppedbelowthe
charger'smaximumoutputcurrentlevel.
4.Chargingbatteries
Beforeyoustarttochargebatteries,
.
Thelistbelowgloballydescribesthestepstofollowforchargingbatteries:
1.Pushthechargerswitchinthe“O”(Off)positionanddisconnectthe ACsupplytothe
charger
2.Ifpossibledisconnectorswitchoffallloadsfromthebattery
3.Connectthebatterytothecharger
4.Switchonthe ACsupplyandactivatethechargerbypushingthechargerswitchinthe
“I”(poweron)position. Afteratwotonebeep,thechargerwillstartthechargingproces.
5. Afterchargingiscompleted,pushthechargerswitchinposition“O”andswitchoffthe
ACsupplyagain,beforedisconnectingthebattery.Or,keepallconnectionsandthe
chargerswitchpositionuntouchedandjustre-connectallbatteryloads.
readallenclosedsafetyinstructionsandwarnings
whilefollowingallsafetyprecautionsaboutworkingwithbatteries
5.Forcedfloatmode
Theforcedfloatmodecanbeactivatedbypushingthemainswitchintoposition“II”.Inthis
mode,theoutputvoltageofthechargerissetconstantlytothefloatvoltage(valueis
dependingonselectedbatterytype)whilebeingabletodeliverfullratedoutputcurrent.
Sincenoautomaticchargingprogramsareactivatedinthismode,itcanbeusedfor
constantvoltagechargingoroperatingthechargerasabatterybufferedpowersupply.
6.Equalizingafloodedbattery
Ifyouareusingafloodedleadacidbattery,anoccasionalequalizationchargecyclemay
berecommendedbythemanufacturer. Thismightalsobetruewhenthefloodedbattery
hasbeenverydeeplydischargedoroftenchargedinadequately.Duringequalization,the
batterywillbechargedupto15.5V(or31Vfor24Vmodels)atareducedoutputcurrent
level.Beforestartinganequalizationchargecycle,thefollowingcautionstatementsmust
bereadcarefully:
Equalizationshouldonlybeperformedonaflooded(wet)leadacidbattery.
ThereforetheOmnichargechargersonlyallowequalizationwhenthebattery
typedipswitchesaresettoFlooded.OtherbatterytypeslikeGEL or AGMwillbe
damagedbythisprocess.
Alwaysfollowthebatterymanufacturer'sinstructionswhenequalizingflooded
batteries.
Duringequalization,thebatterygeneratesexplosivegasses.Followallthebattery
safetyprecautionsenclosedwithyourcharger.Ventilatetheareaaroundthe
batterysufficientlyandensurethattherearenosourcesofflamesorsparksinthe
vicinity.
Disconnectallloadsconnectedtothebatteryduringequalization. Thevoltage
appliedtothebatteryduringthisprocessmaybeabovesafelevelsforsomeloads.
TheOmnichargechargerscannotautomaticallydeterminewhentostopthe
equalizationofabattery. Theusermustmonitorthebattery’sspecificgravity
throughoutthisprocesstodeterminetheendoftheequalizationcycle. Theinternal
2hourstime-outtimerofyourchargerisonlyintendedasasafetyfeature,butmaynotbe
sufficientlyshorttopreventbatterydamage. Therefore,equalizingabatteryisalwaysa
processthatmustcontinuouslybesupervisedbytheuser.
Whenequalizingthemainbattery,thesmallerbatteryconnectedtotheauxiliary
batteryoutputwillbeequalizedaswell.Whenthisisnotdesirable,please
disconnectthisbatterybeforestartingtheequalizationcycle.
Sinceequalizationisonlyallowedforflooded(wet-)leadacidbatteries,theOmnicharge
chargerswillonlyallowthisfunctiontobeavailablewhenthe“Flooded”chargingprogram
isselected(seechapter2).Besidesthis,thechargeralsoneedstohaveafullchargecycle
completedandisoperatingintheFloatmode.Whenthesetwoconditionsaremet,the
equalizationchargemodecanbeactivatedbypressingtherecessedpushbuttononthe
bottomsideofthecharger(seeinstallationguidestep4)for3secondsuntilallcharge
statusindicatorsstartflashing. Thechargerwillallowamaximumequalizationtimeof2
hoursbeforeitautomaticallyjumpsbacktoFloatmode.Ifthespecificgravityofeachcell
doesnotmatchthebatterymanufacturer'sspecificationsyet,youcaninitiateanew2hours
equalizationcyclebypressingthepushbuttonfor3secondsagain. Alwayskeepon
checkingthespecificgravityofeachcellrepeatedlyduringtheequalizationprocess.When
thesevaluesarecorrect,youcanmanuallyexittheequalizationprocessbypressingthe
recessedpushbuttononce. ThechargerwillthenreturntotheFloatmode.
Thischargerisequippedwithapotentialfreealarmrelay. Thisrelaywillbeactivatedwhen
thechargershutsdownandjumpstoanerrormodeasdescribedinchapter1. Thealarm
relayde-activatesagainwhentheerrormodehasbeenclearedandthechargerisrunning
innormaloperatingmodeagain.Onpins1,2and3ofthe5pinsscrewterminallocatedin
theconnectioncompartment,bothnormallyclosedandnormallyopencontactsare
available.Pleasemakesurenottoexceedthemaximumrelaycontactratingof60Vand
1A toavoiddamagingtherelay.
7. Alarmrelay
CAUTION
!
CAUTION
!
CAUTION
!
CAUTION
!
CAUTION
!
CAUTION
!
CAUTION
!
9.Declarationofconformity
MANUFACTURER : TBSElectronicsBV
ADDRESS : DeMarowijne3
1689 ARZwaag
TheNetherlands
Declaresthatthefollowingproducts:
PRODUCT TYPE : Professionalprogrammablebatterycharger
MODELS : OC12-40,OC12-60,OC24-20,OC24-30
ConformstotherequirementsofthefollowingDirectivesoftheEuropeanUnion:
EMCDirective2004/108/EC
Theaboveproductisinconformitywiththefollowingharmonizedstandards:
LowVoltageDirective2006/95/EC
EN61000-6-3:2001 EMC-GenericEmissionsStandard
EN61000-6-2:2005 EMC-GenericImmunityStandard
EN60335-1:1999 Genericsafetystandard
EN60335-2-29:2004 Safetyrequirementsforbatterychargers