BAT 490 New standards for battery chargers Toni Scheschko AA-SEU2 AA/SEU2 Toni Scheschko 13/10/2010 Robert Bosch GmbH 2010. All rights reserved, also regarding any disposal, exploitation, 1 reproduction, editing,
Content General overview BAT 490 Features 1-3 Standard-Mode in detail Expert-Mode in detail Technical data Important information Scope of delivery Accessories Key Buying Factors AA/SEU2 Toni Scheschko 13/10/2010 Robert Bosch GmbH 2010. All rights reserved, also regarding any disposal, exploitation, 2 reproduction, editing,
General overview BAT 490 Portable - Weight: 10.5 kg Single-colour display - Background lighting with changeable contrast - 128x64 Pix. / 8 lines x 21 figures Keys - Up/Down - Enter - Backwards Cable 3m (5m Special accessories kit) - High quality cable for 90A - High flexibility - All-insulated - Removable and easy to connect - Diameter: 16mm 2 for 3m and 25mm 2 for 5m LED s AA/SEU2 Toni Scheschko 13/10/2010 Robert Bosch GmbH 2010. All rights reserved, also regarding any disposal, exploitation, 3 reproduction, editing, - 3 LED s to show the battery charge level
Features (1) 12V / 24V charger (Car/Truck) possible for all lead batteries (standard, maintenance free, gel-, fleece-, AGM-Batteries). Highlight 2 Main modes*: Standard modus For quick and easy charging Expert modus Flexible charging parameter Floating-mode operation BAT 490 keeps the state of charge and stabilizes the vehicle electrical system during diagnosis and reprogramming of control units (when the engine is switched off) Backup mode Maintains a current supply in order to preserve the data (e.g. car stereos, supply and control units, etc.) during the battery replacement. 12V 24V *See slide 8-10 for more details AA/SEU2 Toni Scheschko 13/10/2010 Robert Bosch GmbH 2010. All rights reserved, also regarding any disposal, exploitation, 4 reproduction, editing,
Features (2) Ingenious electronic protection management system Protects against: reverse polarity; overcharge; overheating; short circuit; voltage peaks; malfunction; damage of car components Communication interface USB interface Highlight Firmware updateable Charging current is variable, up to 90A 0 to 90A in 5A steps Selectable via menu Device detects breakage of battery terminal If the battery terminals are disconnected during charging process, the battery charger switches itself into standby mode in order to avoid short circuits AA/SEU2 Toni Scheschko 13/10/2010 Robert Bosch GmbH 2010. All rights reserved, also regarding any disposal, exploitation, 5 reproduction, editing,
Features (3) Detection of malfunction Malfunctions will be shown on the display e.g. intern temperature sensor is outside the tolerance range, etc. Automatic detection of 12V / 24V systems The device detects automatically if a 12V or a 24V system is connected. AA/SEU2 Toni Scheschko 13/10/2010 Robert Bosch GmbH 2010. All rights reserved, also regarding any disposal, exploitation, 6 reproduction, editing,
Standard mode in detail Fig. 4: "Standard" charging characteristic I 1 = 20 % of set battery capacity I 2 = 2 % of set battery capacity U 1 = 14.0 V 14.4 V (12 V) 28.0 V 28.8 V (24 V) U 2 = 14.4 V 14.8 V (12 V) 28.8 V 29.6 V (24 V) U 3 = 12.8 V / 25.6 V Phase 1: Main charging, green LED flashes rapidly The charging current I 1 is approx. 20 % of the set battery capacity. Once the battery has attained the charging cut-off voltage U 1, the charging current I 1 starts to de-crease approx. 65% of the battery capacity has then been attained. The battery is ready for use as a starter battery. Phase 1 is over when the charging current I 1 drops below approx. 2% of the battery capacity. The battery is then approx. 97% charged. Phase 2: Secondary charging, green LED flashes slowly The charging current I 2 is approx. 2% of the set battery capacity. Phase 2 is time-controlled with a duration corresponding to 65 % of the phase 1 time. The charging voltage is restricted to U 2. Phase 3: Trickle charging, green LED lights The charging current is always activated when the battery voltage drops below U 3. The charging current remains active until the charging voltage U 1 is attained again. 7
Expert mode in detail (1) Fig. 6: "Expert" charging characteristic I, U 1, U 2 and "o" : Governed by the set value Phase 1: Main charging, green LED flashes rapidly The battery is charged at a constant charging current I until the voltage U 1 is attained. Phase 2: Main charging, green LED flashes rapidly or slowly The charging voltage U 1 is kept constant and the charging current decreases with increasing battery charge. The green LED flashes rapidly until the current limit value "o" is attained. In rare cases the limit value "o" is attained in less than 30 minutes and the green LED flashes slowly until the end of the 30 minute period. Phase 3: Trickle charging, green LED lights Trickle charging commences on completion of the minimum 30 minute period and when the current limit value "o" is attained or undershot. The BAT 490 sets the battery voltage U 2. The charging current I is governed by the capacity of the battery to be charged and the time profile. 8
Expert mode in detail (2) Variables in the expert mode: I : 12 Volt 3A I 90A 24 Volt 3A I 45A U1: 12 Volt 14V U1 15.6V 24 Volt 28V U1 31.2V U2: 12 Volt 12.8V U2 14V 24 Volt 25.6V U2 28V o: 12 Volt 0.2A o 5A 24 Volt 0.2A o 5A Wrong parameters (exorbitant high values for I or U1 and a defective value for o ) could destroy the battery. 9
Technical data BAT 490 Charging current max. 90 A Length of charging cable 3 m Length of charging cable (USA) 9.8 ft Charging cable cross-section 16 mm² Power input 1,600 W Weight 10.5 kg Standard charging characteristic IUIaIaI Expert charging characteristic IUoU Standard charging cut-off voltage (temperature-regulated) 12V 14 V - 14.4 V 24V 28 V - 28.8 V Backup mode 10.0 V / 26.0 V max. 10 A Floating mode 13.5 V / 27.0 V V max. 90 A / 45 A Operating temperature 0 C - 40 C Mains voltage/frequency 230 V, 50/60 Hz Rated battery voltage 12 V / 24 V Degree of protection (DIN 40530) 20 D Safety class (DIN 40530) I Dimensions (W x H x D) 300x200x390 mm Conducted interference level DIN 40839 Conducted interface level I 10
Scope of delivery BAT 490 Charging cable 3m Power cable Operating instruction in 13 Languages (Individual manual for JP) Safety instructions 11
Accessories 5 meter cable kit (in black and red) 1 687 011 520 Trolley 1 687 012 102 12
Product information Information BAT 490 Key buying factors Suitable for all kinds of vehicles cars, heavy duty, etc Variable charging current, up to 90A simple and rapid charging Standard and expert charging modes; programmable floating mode Suitable for majority of OES and IAM workshops worldwide Back up mode, up to 5A data protection during battery replacement Communication interface via USB Various safety features are present Maximum safety to end user 13