EVO Series APPLICATIONS BATTERY TYPE CHARGING TIME TECHNICAL FEATURES SAFETY FEATURES GENERAL FEATURES ACCESSORIES. PzS Wet (Lead Acid)

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2 EVO Series BATTERY TYPE PzS Wet (Lead Acid) CHARGING TIME WoWa 8-10H / Wa 10-12H APPLICATIONS Power Supply: Single Phase Vac / 50-60Hz Three Phase V / Hz Microchip Microcontroller PIC16 TM /PIC18 TM Maintenance charge to prevent battery self-discharge Cabinet protection IP21 Current Value reading with SHUNT Power transformer with ventilation Channels (20% cooler) ABS front and back panels to increase efficiency by 5-7% Short circuit and reverse polarity protection with fuse Double safety timer Safe battery disconnection during charge Buzzer noise in case of error or malfunction Protection against overcurrent and overvoltage Backlit 16x2 characters alphanumeric display Charging parameters visualized on display TECHNICAL FEATURES SAFETY FEATURES GENERAL FEATURES Tropicalized stray-flux transformer impregnated with nontoxic resins and kiln dried Automatic equalization charge to prevent sulphation Automatic restart after overheat anomaly or power supply interruption WA or WoWa Charging curve 100 charging cycles log (Duration of the charge, AH delivered) Visualization of estimated charging cycle s length Low output noise while charging Overheat protection with thermal probes and control card Error codes visualization on display Battery health check before charge begins Anomalies management trough microcontroller Protection over every charging phase of the cycle High luminescence LED on the front panel Adjustable final charging stage (from 1 to 10H), standard is 4h Cable Hook PRO Control Card (Box S-C Kit Update Software Battery temperature probe connected to the charger ACCESSORIES Easy Wire System (only Box S ) Modular accessories related to PRO Control Card Cable s plugs Cabinet Stand 1

3 Nominal Vdc V CHARGER SIZES Vac Output Current A Output Current A AH RECHARGE CHART WoWa AH (C5) Wa 8H 10H 12H From To 20A / V 1x 230 Vac A / A / x 230 Vac A / V 3x 400 Vac A A x 230 Vac A V 3x 400 Vac A A x 230 Vac A V 3x 400 Vac A A x 230 Vac A V 80V 3x 400 Vac x 230 Vac x 400 Vac To request other V/A, please contact us through our website WORKING CONDITION Values referred to a 80% discharged PzS Wet (Lead Acid) traction battery. Operating Temperature From -20 C to +45 C Maximum Humidity 90% without condensation Storage Temperature From 0 C to +60 C Environment Not Alkaline In case of environments with different values from the above, please contact us to evaluate further options CHARGING CURVES BOX GUIDE E P DIMENSIONS Box H L D P E COLORS Front Panel White RAL 9010 Gray RAL 7004 Box Orange RAL 2002 Black RAL 9011 Green RAL 6017 The box is based on the size of the power transformer to optimize the charger s operation. 2

4 SE Series BATTERY TYPE PzS Wet (Lead Acid) CHARGING TIME 0-12H APPLICATIONS Power Supply: Single Phase Vac / 50-60Hz Three Phase V / Hz Microchip Microcontroller PIC16 TM /PIC18 TM Maintenance charge to prevent battery self-discharge Cabinet protection IP21 Short circuit and reverse polarity protection with fuse Double safety timer Safe battery disconnection during charge Buzzer noise in case of error or malfunction Protection against overcurrent and overvoltage Backlit 16x2 characters alphanumeric display Charging parameters visualized on display TECHNICAL FEATURES SAFETY FEATURES GENERAL FEATURES Tropicalized stray-flux transformer impregnated with nontoxic resins and kiln dried Automatic equalization charge to prevent sulphation Automatic restart after overheat anomaly or power supply interruption WA Charging curve Overheat protection with thermal probes and control card Error codes visualization on display Battery health check before charge begins Anomalies management trough microcontroller Protection over every charging phase of the cycle High luminescence LED on the front panel Adjustable final charging stage (from 1 to 10H), standard is 4h Cable Hook PRO Control Card (Box S-C Kit Update Software Battery temperature probe connected to the charger ACCESSORIES Easy Wire System (only Box S ) Modular accessories related to PRO Control Card Cable s plugs Cabinet Stand 3

5 Nominal Vdc V CHARGER SIZES Vac Output Current A Output Current A AH RECHARGE CHART 10H AH (C5) From To 20A V 1x 230 Vac A A x 230 Vac A V 3x 400 Vac A A x 230 Vac A V 3x 400 Vac A A x 230 Vac A V 3x 400 Vac A A x 230 Vac A V 3x 400 Vac Values referred to a 80% discharged PzS Wet (Lead Acid) 1x 230 Vac traction battery. 80V 3x 400 Vac To request other V/A, please contact us through our website 12H WA CHARGING CURVE BOX GUIDE S C M WORKING CONDITION DIMENSIONS Box H L D Operating Temperature From -20 C to 35 C M Storage Temperature From 0 C to 60 C C Maximum Humidity 90% without condensation S Environment Not Alkaline COLORS In case of environments with different values from the above, please contact us to evaluate further options Front Panel White RAL 9010 Yellow RAL 1028 Box Orange RAL 2002 Black RAL 9011 Green RAL 6017 The box is based on the size of the power transformer to optimize the charger s operation. 4

6 PRO Control Card SERIES CABINETS APPLICATIONS SE Series: C-S EVO Series: E IMPORTANT: For EVO Series is only required to change the control card, for SE Series the PRO Control Card MUST be installed in our factory. Fleet & Battery Management System Rentals DATA Analysis TFT Graphic display with 2.8 inches Visualization of basic information on the main visual: Temperature inside the charger Date and time Humidity inside the charger Company logo Charger s size (V, A, phase) Integrated touchbuttons (no physical buttons on the card) Storage of 1000 charging cycles with possibility to visualize directly on display or download with Data BOX accessory Language selection: IT, EN, DE, ES Buzzer to notify the user in case of errors/anomalis Data BOX accessory to download the data log from the PRO Card to a PC. Automatic Watering System to automatically water the battery following the parameters set on the display FEATURES ACCESSORIES AND MODULAR FEATURES Color display for fast and simple visualization of the charging cycles and charger s functions RGB Led under touchbuttons with different colors and flashing patterns assigned to the many functions and charging phases Protection against dust, water or other object to enter the card housing slot Error visualization with detailed description of the error. Date and time are also shown. Possibility to increase the ABS Time (from 80% to 100% charge) from 1h to 5h, standard set is 4h Possibility to control the charge by using the modules and accessory Wi-Fi Module accessory adds the possibility to download the data with Wi-Fi connection to any device with a Wi-Fi receiver (phone, tablet, PC) Access point to download the data log on a local server or a remote server. Can be used with Wi-Fi Module to avoid Ethernet cables. CAN/BUS Battery Module to give an ID to the battery and monitor battery temperature and water level. It can stop the charge in case of overheat of the battery (with automatic re-start once cooled off) and don t let the charge start if the water level is too low. Possibility to analyze the downloaded data on PC with the utility tool or with the TCE Cloud found on our website with any PC. Through the TCE Cloud is possible to monitor many batteries and chargers sorted by customers. 5

7 MENU VISUALIZATIONS Main Display The main display is shown when the charger is in idle. After 5 minutes of inactivity, the screen will turn off. In case of modules attached, additional icons will appear on this visual Data Log Menu The Data Log menu offers the possibility to visualize the stored charging cycles. The result of the selected charge is shown in different colors together with other important information Settings Menus Through the settings menus is possible to change the visualization and storage of the parameters read. It is also possible to change the language of the charger s software (IT-EN-DE-ES) Password and Special Menus By doing a combination with the touchbuttons, it s possible to access to the Password visualization. Different password unlocks different level of access to change important settings of the charger CHARGING VISUALIZATIONS During the charging cycle, on the display is shown a battery with different colors based on the battery charge status. The touchbuttons also change colors based on the charge status or the function the charger is performing. Once the charge is complete, the additional integrated functions (Equalization and Maintenance) will automatically start 6

8 CAN-BUS BMS REQUIREMENTS APPLICATIONS PRO Control Card OPTIONALS Water Level Sensor Temperature Probe IMPORTANT: The Battery Module requires a 24V power supply (12 Cells) Fleet & Battery Management System Rentals DATA Analysis DESCRIPTION AND SCHEMATIC Schematic IDxxx IDyyy ID123 Charger PC Utility Tool IDzzz Batteris with BMS Module installed Battery Charger with BMS Module installed OPTIONAL TCE Cloud Data Analysis Description The CAN-BUS Bms Module allows the charger to gather more information regarding the battery connected to it and to give further control over the charging cycle. If the optionals Water Level Sensor and Temperature Probe are installed, the PRO Control card can stop the charging cycle if the temperature rises above 60 C and automatically re-start it if it lowers below 45 C. It can also prevent the charge from starting if the water level measured from the Water Level Sensor is too low. By Giving an ID to the Battery and Charger, is possible to keep an accurate track of the battery life. Combining with each other, the IDs can give full control over big fleets and rentals units. This helps to keep the warranty of the controlled units under check and have accurate data of the customer usage. The tools provided by TCE Srl to do it are the PC Utility Tool Software, a simple executable program that doesn t require any installation, and the TCE Cloud service found on our website. FEATURES Through the ID, is possible to monitor the battery life and Possibility to give a customized ID to the battery have a full report using the Utility Tool on a PC Battery IDs and Charger IDs can combine with each other to Possibility to control many big fleets sorted by customer give a detailed history of both the battery and the charger using the TCE Cloud directly on our website. In case of optionals installed, the charge can be further controlled to prevent any damage to the battery 7

9 Wi-Fi Charger Module REQUIREMENTS PRO Control Card APPLICATIONS Wi-Fi RANGE 150 Mt COMPATIBLE OS Fleet & Battery Management System Rentals DATA Analysis DESCRPITION AND CONNECTION SCHEMATIC Schematic Devices with Wi-Fi Receiver (phone, tablet, PC, etc etc) Devices with Wi-Fi Receiver (phone, tablet, PC, etc etc) Local Server or Access point Wi-Fi Module with Ethernet and USB Port OPTIONAL: 3G/4G Dongle for internet connection in isolated areas Wi-Fi Module with Ethernet and USB Port Description When a device is connected to the Wi-Fi Charger Module, through a web interface it will be possible to visualize in real time what the charger is doing (charging cycle and functions), download the stored data inside the PRO Control card and analyze it. The Module can be connected to a local server to automatically and periodically upload all the stored data. By using the TCE Cloud service directly on our website, analyze all the stored data from all the chargers connected to the local server is simple and intuitive. In case of Access Point (or 3G/4G Dongle), the upload of the files can be to an external server. In this case it will be possible to remotely view the data of the Chargers on a webinterface. The connection between the Local Server and the Access Point can be wireless or via a normal Ethernet Cable. The USB Port, installed on the Module, allows the automatic download of the data on a storage device (Ex. USB PenDrive) and update the software of the system installed (Wi-Fi Module, PRO Control card and Can/Bus module if installed). FEATURES Create an hotspot of the charger with unique name to wireless Can connect to any device with Wi-Fi Receiver (phone, tablet, download the stored data inside the PRO Control card PC, etc.) USB Port to automatically download data directly on a Ethernet port integrated to physically connect the charger to a Storage unit (ex. USB Pendrive) or to update the PC, router or modem Firmware/Software of the system Can connect to a local or remote server to automatically and periodically upload the stored data. Through our TCE Cloud is possible to thoroughly analyze the data uploaded 8

10 Accessories CABLE MANAGEMENT SYSTEMS Easy Wire System The Easy Wire System is an automatic winding system of the charging cables. It preserves the quality of the cables, preventing any damage and guaranteeing their flexibility over time. This system also preserve the integrity of the connector that, when the cables are inside the cabinet, will hang just outside the exiting hole of the cabinet. This system cannot be installed after sale. Can be installed in the S and E cabinets. CASE STAND The case stand is a handy accessory to preserve the integrity of the cabinet. Made with galvanized metal and then treated to withstand harsh working environments and bad weather, it offers a simple solutions to prevent damage caused by accidental bumps and hits. When the charger is on the stand, is possible to move it with a stacker or a fork truck. AUTOMATIC WATERING SYSTEM A feature that can be integrated within the PRO Control Card is the Automatic Watering System. This function allows the automatic watering of the battery with a system supplied by TCE. It is possible, through the display, to change the watering settings based on the battery brand and specifics, to guarantee its optimal topping. Cable Hook A rally simple but efficient and economical solution to prevent the damaging of the charging cables. This accessory can be integrated on the charger after sale, offers a solution to the common problem of the damaging of the charging cables. Made with galvanized metal to prevent the formation of rust, colored with Anti-UV powder paint to prevent the fade of the color in case of direct sunlight for an extended period of time CONNECTORS It is possible to attach to the charger the battery plug and power plug to make the charger ready to use once received. We only high quality connectors from the main brands (REMA, Power Anderson, Ravioli, etc. etc.) to guarantee to the customer a correct execution of the charging cycle. SIDE HANDLES The handles help the user to move the charger without any problems. They are simply installed through the side slits. Simple but yet useful, this accessory is avoids damage to the charger while moving it. For other accessories, please visit the Accessories section in our website 9

11 FAQ What is the length of the cable? The standard length of the cables supplied with T.C.E. chargers is 2 meters for the power cable and 2,8 meters for the exciting cable (red and black). Why the charger is not turning on? The most common reasons why the charger is not turning on are: Anomalies Power supply is missing Charger is not connected or not properly connected to the battery. Wrong battery voltage Battery is already fully charged Fuse is blown The most common reasons why the anomalies are shown on the display or notified through the red LEDs on the front panel are: The maximum charging time has been exceeded Battery has been overly charged Charging current is too high because of the wrong network voltage Network is missing one phase Defective battery or completely exhausted Lack of a network connection during the charging cycle (Blackout) Overheating (thermal-probe intervened) SOLUTION: repeat the standard charging cycle, if the problem persists contact a technician. Choose the correct charger for your fork truck To choose the most suitable charger for your battery check our website and follow the guide Choose in 3 steps or follow the following advices: Based on the battery voltage, having the Ah capacity of the battery is possible to calculate the best charger for this battery Example: battery 48V 600Ah the charger must be the 16% of the battery capacity so 600Ah x 16% = 96Amp, adapt with the model that is closer to the result so the in this case the best model would be a 48V 100Amp Based on the time available to complete the charge: Fast charge in 8-9h with the model WoWa Standard charge in 10-12h with the model Wa Considering the use of the fork truck Example: if a battery is a 680 Ah x 16% = 109 Amp, the closest model would be a 120 Amp for a frequent use (daily charge) or choose a 100Amp for an occasional use (a couple of times a week). What is the equalization charge? The equalization charge is a supplementary charge that improves the energy performance of the battery. Its purpose is to balance the charging level of the battery elements. The charge starts automatically when the pre-set parameters on the control card match the parameters recorded directly from the battery. This phase is handled by the microprocessor that decides both the length of the small charges and the length of the pauses based on the bat tery capacity. How does the Maintenance Charge work? The maintenance charge is used to avoid the inevitable natural loss of the battery charge. The T.C.E. chargers keep the voltage next to 2,3 V/el (Example: 26,76 for 24V batteries), and gives the current requested by the battery. When it starts, the charger at first gives the maximum current and then it starts to decrease with the increasing of the battery voltage until it reaches the maintenance level. The advantage is that the charger can remain connected to the battery for long periods of time and keep the battery always fully charge without provoking any damage. How to optimize the performances and the lifespan of your battery Batteries only require a low maintenance to be preserved in an optimal state: Avoid to discharge the battery over 1,7V/el (Example 20,4 for 24V batteries). Plates are submitted to an excessive mechanical stress because of the variations of the volume of the active matter, they can be seriously damaged. Avoid to overly charge or not charge enough the battery. The over charge of the battery can cause o overheat of the elements causing the active mater to emerge from the positive plates. Never leave the battery unused for long periods, this causes sulfation phenomenon Periodically check the electrolyte level. Make sure that the level is a centimeter above the upper side of the grids (if left uncovered by the electrolyte the part above the level will rapidly sulfate) 10

12 About Us TCE was founded in 1960 and is one of the oldest Italian producers of battery chargers for traction batteries. Through the many years of experience, studies and researches we developed new cutting edge technologies to guarantee the best charge for the battery and optimize its performances. The solutions we offer: Battery Chargers Service Chargers Dischargers (Battery Capacity Testers) Battery Regeneration Products Accessories to preserve the battery and the charger good conditions Fleet Management System Access point (for remote control and data download, live streaming of the charge and real time battery status, can be implemented with only the Wi-Fi Module) Data Analysis Solutions (TCE Cloud ) Our Mission is to create long lasting partnership with our distributors, grow together and create a worldwide network to distribute a product able to optimize and extend the battery life and performances over the years. TCE Srl Via G. di Vittorio, 5 Web: Saletto (PADOVA) Mail: info@tce-italy.it ITALIA Tel: P.IVA IT