User manual for intelligent pulse battery charger AP-3000, 12V 135A, 24V 100A, 36V 75A, 48V 50A

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1 Eyra elektronika d.o.o., Gabrje pri Stični 45,1295 Ivančna Gorica,, User manual for intelligent pulse battery charger AP-3000, 12V 135A, 24V 100A, 36V 75A, 48V 50A Properties: - Charger can "listen" to the chemistry of the battery Fast, gentle and battery friendly charging Battery determines charging current by itself, under supervision of Intelligent microprocessor pulse charging system No warming up effect, which reduces battery life at overcharge Regenerate cells majorly, when they were charged inproperly Long life of battery Battery desulfatization effect Good electrochemical efficiency Safe against short circuit and wrong battery connect on the charger Precise indicator of overcharging (green LED) Temperature compensate charge reference voltage Working temperature range from 0ºC to 35ºC Up to 8 charging programs for diferent type of bateries Continue or pulse charge current Simple green, red, yellow LED signal, acustic buzzer and OLED display Setings by using the selecting button and by prressing a key 1

2 Pulse charge technology Pulse charging sistem is electrode specific charging system; it is new technology of battery charging. It presents a small revolution on this area, because the results in practice are drastically better. With this technology is possible very fast and very precise charging, because only electrochemical position of battery "dictates" the charging phase and charging current, which is momentarily correctly for the battery. Charging with high current is accomplished only in phases, when cells can accept energy, without warming up or giving off gas. When charging with pulse charger AP-3000, does not come to the gasification of the electrolyte and warming ap, that destroys (breaks) cell lead-acid batteries. So as a result, pulse charging extremely extended battery life and shortens the charging time. El. network is the biggest limit to charging with pulse charger. 100Ah battery could be fully charged in one hour, if you have enough strong current source, that is 100A. With 50A current, could be fully charged such a battery in 2 hours. We can say that pulse charging technology works as transformator between battery chemistry and signals that commands the charge. Each battery is "treated" individually. Your experience with this charging method please forward to info@eyraelektronika.si. How to operate a charger AP-3000 On the back site of the charger is connector for 230Vac and the main switch. Insert the plug (Schuko 16A) into a mains socket and turn ON the main switch. On the front side are three LEDs, red, yellow and green. The device responds with a short beep and all three LEDs short blinks and the display show captions. This lets us know that the device is ready for battery charging. Press the red button START/STOP, device shortly beeps 3x, yellow LED starts to blinks, display shows current and voltage values. Battery is charging. Battery is fully charged when the green LED light turns on and the display shows "Float" and the value of 100%. The battery can be used immediately after the green LED blinks and charge is 90%, but it is recommended to at least 1x per month leave the battery on the charger to fully charged. If the charger is not actuated by a yellow LED, then the battery voltage is too low (fully discharged battery-check the display level of the battery voltage). Status on the OLED screen We change the charging status and the settings on the screen by using selection button and by pressing a key on it. 2

3 Status menu Immediately after the device is switched on, the status menu appears: voltage (VOLT) current (AMPS) emitted charge (Ah) charging time (TIME) battery type select (WET ) charger status (Ready, ) battery charge in % ambient temperature Main menu By pressing the button, the system goes into main menu. By turning the button, we set the wanted section and choose it by pressing a key. In menu»batttype«select the wanted type of battery. In menu»disp Contrast«set the best screen visibility. In menu»burst«force the charger to charge when the battery is fully discharged. Battery select menu By turning the button in one and the other side, put the cursor on the appropriate place. By pressing on the button confirm the new selected type of battery. Then It's hear a short beep and the system goes into main menu. Charging programs are: Universal(UNI), GEL, Standard (STA), CaCaWET(WET), LeadCrystal(LC), U-I, AGM, Traction (TRA). The charging program is still selected after switching off the device. Status menu (charge) Picture of display apprears, when the battery is almost fully charged. Following charging phases are: Ready, Bulk charge, abs (absorption), Equal (equalization), Float (maintenance) 3

4 Status menu (float) Picture of display appears, when the battery is fully charged (float), after the battery charger is disconnected from the battery. Value of the charge (CAP) and the charging time (TIME) remain in memory. At the recharging both the value will be cleared. Contrast MENU By using selection button and by pressing a key, selection»menu/contrast«here we can set screen brightness. Reduced brightness levels extends the lifetime of the screen. Menu for forced charging If the battery is fully discharged (when voltage does not reach even 50% of its nominal voltage), the system will not start charging. In that case choose the heading "Burst Charge" to activate forced charging. Current limit MENU By using the selecting button and by pressing a key, you can set limit of the charging current in the range of 20 to 100%, based on the rated charging current. 4

5 Battery Size MENU By using the selecting button and by pressing a key, select battery size within the limit between 50 in 1000Ah. Battery select menu (U-I) If you want to charge with a constant linear current UoIo (non pulsed) in Battery select menu (U-I) select UoIo caption. The wanted voltage U0 and maximum current I0 can be selected in the submenu»uoio Menu«UoIo Menu By using the selecting button and by pressing a key, select wanted voltage Uo (48.0V-68.0V) and Io (1.8A-50A). Finally, confirm with OK to leave the menu. Calibrate Heading: calibration of the reference voltage Uo. The calibration value These section do not change! For servis intervention only. Charging with continue current U-I For special purposes where we need a stable voltage and charging current, a device also provides this option. Charging current is continuous. In menu "Battery Type" select UoIo caption. In the submenu "UoIo Menu", set the wanted voltage and current, and confirm with "OK". The system automatically goes in to "Status menu" On the top right corner of the display you can see the caption "U-I". 5

6 There are technical constraints of the device, which is not possible to set, for example voltage of 62V and current 50A at the same time. An example relates to 48V battery charger. Selected voltage Uo Max selected current Io >66.0V 10.5A 64.0V 12.2A 62.0V 15.8A 60.0V 29.8A 59.2V 40.2A <59.2V 50.0A Too low mains voltage In the case of too low the mains voltage, for this considered all voltages below 210Vac, the charging current step is automatically reduced up to 35% from the nominal value. This happens when the mains voltage 90Vac. The device can therefore also be used in environments where mains voltage varies strongly. Current from the mains will never exceed 16A. The system automatically protects against destruction, as well as the network installation and the mains fuse is 16A. Charge current is reduced in steps, as shown in the table below. Mains voltage is displayed in the status menu, bottom left. If the charger is in standby and is not charging, the display shows the mains voltage with a considerable error. During charging, the measurement error of mains voltage is minimum. Uac[V] 210 Ibat[%] Start / Stop Button (Button MENU) Start / stop button can be used to start charging when the battery and charger are connected. In the menu, the key is activated by selecting "enable". Before disconnected the battery from the charger, when charging has been completed, press the button again. If we want a button will be deactivated, in this case the charging will begin immediately when the battery and charger are connected, then select "disable" in the menu. Potency of the charging current (Current limit MENU) It happens that the line fuse in installation does not allow such a large consumption of energy from the network (example 10A fuse), as it needs Charger AP One of the reasons may be a agregat, which is too weak, or the battery is too small for such a large charging currents. Power of the charging current in this case can be reduced to 20% of nominal. A step of reduction the charging current is 10%. In the case of setting the charging current to 20% of the power consumption of the network more than 650W. 6

7 Choosing the size of the battery (Battery Size MENU) The battery, which is filled can be small (less than 50Ah) or large, over Depending on the size of the battery is the ability to accepting el. energy in absorption phase very different. Charging profile is therefore in the phases of the of absorption, equalizing and maintaining adjusts the the battery size. To make sure that battery charging is really optimal, select the size (capacity) of the battery in the "Batt Size MENU". Charging diagram Legend of LED signals while charging the battery LED LED activity Charge phase Battery tension red, yellow, green short blink all LEDs charger is ready / 7

8 yellow blinks bulk charge < 65% yellow continue on absorbtion I charge (Abso1) % green blinks absorbtion II charge (Abso2) % green 2x fast blink Equalization charge (Equ) % green continue on float charge >100% red continue on temperature off (Error) / Programs for charging batteries (Battery select menu) Universal program - UNI, Universal, used for unrecognized types of batteries Standard Pb battery - STA, Standard, used for older types of Pb batteries Pb Ca / Ca battery CaCaWET, is used for starting, maintenance free batteries Pb with acid swab - AGM, used for hermetic AGM batteries Pb with GEL electrolyte - GEL, used for hermetic GEL batteries Kristal Pb-LC, SiPb, Lead Cristal, used to lead Si crystal battery U-I, continuous charging current, U and I set Pb Traction battery-tra, Traction, used for charging fountain traction batteries Operational Problems Error the charger is connected to the mains, power switch is ON. LED not flashing, the display does not work. Cause - there is no mains voltage 230Vac Solution - ensure mains voltage 230Vac battery is connected, but the charger is - to low voltage on the battery (battery not charging. All LED blinking, is fully discharge) indicates like»no battery applies«. The display shows a low voltage. - select from the menu BURST red LED ligts and inscription Error - devices has overheated because to high ambient temperatures - defect fan (Error) - incorrect polarity of battery -reduce temp. of envoironment -service intervention -clean up fan the battery is connected in but the charger is not charging, all the LEDs are flashing, the display shows the corresponding voltage. - Start / Stop button is on - press Start / Stop button. 8

9 Tehnical data Model Output Input Protect Environment Other THE MAIN CHARGE MAINTENANCE VOLTAGE PULSED CURRENTEFF BATTERY CAPACITY BATTERY TYPE CHARGING MODE CHARGING PHASES MAINS VOLTAGE MAINS FREQUEANCY POVER FACTOR EFFICIENCY INPUT CURRENT INRUSH CURRENT LEAKAGE CURRENT SHORT CIRCUIT START CHARGING AT WRONG POLARITY OVER TEMPERATURE COOLING VORKING TEMPERATURE IP PROTECTION TEMPERATURE COMP. WEIGHT DIMENSIONS SIGNALS USE AREA VERSION AP V 135A AP V 100A AP V 75A AP V 50A 14,6V yellow LED 13,6V green LED 29,2V yellow LED 27,2V greenled 43,8V yellow LED 40,8V green LED 58,4V yellow LED 54,4V green LED 135A 100A 75A 50A 200Ah (min) 150Ah (min) 100Ah (min) 50Ah (min) GEL, AGM, liquid electrolyte CA/CA, traction, univerzal, standard, cristal SiPb, U-I intelligent pulse charging, 20Hz bulk / absorbtion I / absorbtion II / equalization float / maintaining 90Vac-265Vac under 210Vac, the charging current is automatically reduced / show bottom left Hz > 0,97 at all volt. range, Activ PFC 91% 92% 93% 94% 15Aeff at 215Vac 13,5Aeff at 230Vac cold start 23A < 4,5mA / 240Vac, klasa I save, no voltage on ouput, if battery is not conect 6V 12V 18V 24V save, active protect, acustic buzzer active and red LED is on, error on display automatically disconect charge current and red LED is on, error on display active with fan, multi-level operation 0-35 C, shows on the bottom right on the display IP20 +2mV/ C /cel, if temp < 15 C and -2mV/ C/cel, if temp > 25 C, for SiPb battery: +4mV/ C/cel, if temp<15 C in -4mV/ C/cel., if temp >25 C 10 kg 330 x 180 x 245 mm (D x Š x V) red, yellow, green LEDs & buzzer sound, OLED graphic display, selecting button and key electric vehicles, forklifts, river and lake vessels, industry... table and wall mounting Servis: Eyra elektronika d.o.o., Gabrje pri Stični 45, SI-1295 Ivančna Gorica, Slovenija Tel (0) Fax++386 (0) e: info@eyra-elektronika.si w: 9