Via Luigi Barchi 9/B – Reggio Emilia 42124 – Italy
Tel. +39 0522 345518 – Fax +39 0522 345551 – mail: [email protected]
www.adelsystem.com
Instruction Manual CB12245A r8.doc
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CB1224xA: Smart Battery Charger
Thank you for having chosen one of our products for your work.
We are certain that it will give the utmost satisfaction and be a notable help on the job.
General Description
The CB series is a “Switching technology” and “Battery Care philosophy” since many years parts of
the know-how ADEL system, led to the development of this advanced multi-stage battery charging ,
completely automatic and suited to meet the most advanced requirements of battery manufacturers.
The Battery Care concept is based on algorithms that implement rapid and automatic cycle of
battery charging, battery charge optimization during time, flat batteries recovery and real time
diagnostic during installation and operation. The Real Time Auto-diagnostic system, monitoring
battery faults such as, elements in short circuit, accidental reverse polarity connection, disconnection
of the battery, they can easily be detected and removed by help of Blink Code of Diagnosis Led;
during the installation and after sell. Each device is suited for all battery types, jumper selection sets
a predefined curves for: Open Lead Acid, Sealed Lead Acid, Gel, Ni-Cd and Ni-Mh. A rugged casing
with bracket for DIN rail mounting provide IP20 protection degree.
Main Characteristic
•
Input: Single-phase
115 – 230 – 277 Vac
•
Output Battery: charging: 24 Vdc 5 A; 12 Vdc 6 A
•
Suited for the following battery types: Open Lead Acid, Sealed
Lead Acid, lead Gel and Ni-Cd Ni-Mh.
•
Automatic diagnostic of battery status. Charging curve IUoUo,
constant voltage and constant current Battery Life Test function
(Battery Care)
•
Switching technology
•
Three charging levels: Boost, Trickle and Recovery
•
Protected against short circuit, Over Load and inverted polarity
•
Signal output (contact free) for discharged or damaged battery
•
Protection degree IP20 - DIN rail; Space saving
Safety and warning notes
WARNING
– Explosion Hazard Do not disconnect Equipment unless power has been switched off or the area is
known to be non-hazardous.
WARNING
– Explosion Hazard. Substitution of components may impair suitability for class I, Division 2.
WARNING
– Switch off the system before connecting the module. Never work on the machine when it is
live. The device must be installed in according with UL508. The device must have a suitable isolating
facility outside the power supply unit, via which can be switched to idle. Danger of fatal Injury!
Connection (terminal and wiring):
Cable Connection:
The following cable cross-sections may be used:
Solid
(mm
2
)
Stranded
(mm
2
)
AWG
Torque (Nm)
Stripping
Length
1 Phase L N PE
Input AC
1 Phase L N PE
Input AC
In:
0.2 – 2.5
0.2 – 2.5
24 – 14
0.5 – 0.6 Nm
7 mm
Out:
0.2 – 2.5
0.2 – 2.5
24 – 14
0.5 – 0.6 Nm
7 mm
Signal:
0.2 – 2.5
0.2 – 2.5
24 – 14
0.5 – 0.6 Nm
7 mm
Use only copper cables that are designed for operating temperatures of > 75 °C. Wiring terminal shall be marked to
indicate the proper connection for the power supply.
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No. 3: Signal Ports (output Isolated):
Connections for Fault Alarm Relay: Low Battery, Fault connections systems, Battery replacement. Contact: 3,4,5
Relay Contact Rating:
Max.DC1: 30 Vdc 1 A; AC1: 60 Vac 1A : Resistive load (EN 60947-4-1)
Min.1mA at 5 Vdc: Min. permissive load
Signal Output port true table:
Led N°8 Battery Fault
3-4 Closed
3-5 Closed
Battery or system Fault?
YES
■
- led On
NO
■
- led off
Please see the NOTE at the bottom of this page.
No. 4: Battery Connection Port:
Connect the battery between pin. 1 (+) and 2 (–).
One battery (12 Vdc) for 12 Vdc Output;
Two battery (12 Vdc) for 24 Vdc Output;
No. 5: Output Voltage Configuration
This setting must be do with mains off. This jumper set the voltage of the batteries connected at the CB, is most
important to check the correct voltage value on the batteries. If is connected a wrong battery the device show the
fault indication of 1 blink.
No. 6: Enable Power Supply
This function allow at the Battery Charger to work like a Power Supply. To enable this function the operator must insert
a jumper in Pos. 6 Enable Power Supply with the CB unpowered.
When the device is turned ON we will have voltage
to the output terminals OUTPUT BATTERY even if the battery is not present. After about 10 sec. without detecting a
battery the CB signals with 2 blink Battery Not connected and switches the alarm relay.
If the battery was already
present at power on or if it is connected at a later time, the CB detects the battery and starts to charge, if there is no
fault deactivates the alarm relay and the LED DIAGNOSIS indicates the charging status. In Back Up (no Mains) and
cell voltage < 2.18V (Pb batteries) or < 1.37V (NiCd batteries) for more than 30 sec. the system turns off completely
.
No. 7 and 8 Display Signals
No.8: Led Battery Fault connections systems, Battery Fault.
No.7: Led Diagnosis,
Led Diagnosis. Diagnosis of the system through “blinking code” signal
Monitoring
Control
Chart:
State
LED Diagnosis
(No.7)
LED Battery
Fault (No.8)
Charging
Type
Trickle
1 Blink/ 2 sec
OFF
Absorption
1 Blink/sec
OFF
Boost
2 Blink/sec
OFF
Recovery (*)
5 Blink/sec
OFF
Auto
diagnosis of
the system
Reverse polarity or wrong battery voltage (for example:
CB set for 24Vdc and battery 12Vdc)
1 Blink/pause
ON
Battery Not connected
2 Blink/pause
ON
Element in Short Circuit
3 Blink/pause
ON
Over Load or Short Circuit on the load (with Enable Power
Supply)
4 Blink/pause
ON
Alarm Low Battery Voltage: 12Vdc, range 8-10 Vdc
ONLY on REQUEST
24Vdc, range 18-21 Vdc
9 Blink/pause
ON
Alarm High Battery Voltage: 12Vdc, over 14 Vdc
ONLY on REQUEST
24Vdc, over 28 Vdc
10 Blink/pause
ON
NOTE: (*) In
Recovery
the LED Battery Fault (No.8) is OFF but the Relay is in failure mode (3-5 Closed) to indicate a
battery with very low voltage.
Via Luigi Barchi 9/B – Reggio Emilia 42124 – Italy
Tel. +39 0522 345518 – Fax +39 0522 345551 – mail: [email protected]
www.adelsystem.com
Instruction Manual CB12245A r8.doc
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Output Power connections:
Normal connection
Typical application:
- One battery (12Vdc) for 12 Vdc Output.
Set No Jumper in Pos. 5
- Two battery (12Vdc) for 24 Vdc Output
Set Jumper in Pos. 5
(See the table below at the point No. 2.)
Operating and Display Element:
No. 1: Input AC Port pin. L – N:
1 Phase Switching Power Supplies L, N, PE .
No. 2: Battery Management Configurations
Preliminary Operations: One device for all battery types.
Completely automatic, all devices are suitable to charge most
batteries types thank to User Selectable charging curves. They
can charge open lead acid, sealed lead acid, Gel and Ni-Cd, Ni-Mh
batteries. It is possible to change or add other charging curves
connecting the device to a portable PC.
Caution: Switch off the system before setting the jumper.
Battery Type
Selection
Jumper Position
Trickle/Float charge
(Volt/Cell)
Fast/Bulk charge
(Volt/Cell)
Open Lead
2.23
2.40
Sealed Lead Low
2.25
2.40
Gel Battery
2.30
2.40
NiCd – NiMh (Note 1)
1.40 – (12V) 10cells
1.40 – (24V) 20cells
1.50 – (12V) 10cells
1.50 – (24V) 20cells
Functional Setting
Function
Jumper Fast
Charge Enable
(Note 2)
Jumper present:
Fast charge enabled.
Not used in Ni-Cd option
Output Voltage
Configuration
(Pos. 5)
Jumper Not Present:
12 V Output
Jumper present:
24 V Output
Power Supply
Function
(Pos. 6)
Jumper Present:
Power supply function enabled.
Note:
1
NiCd-NiMh: End-of-charge detected by a “flat” profile. If flat profile is detected, fast charge is terminated after 10
min. General end-of-charge timeout set to 8 hours.
2
This function is a hot swap (is possible to enable or disable with mains on).
2
1
7
6
5
9
3
4
8
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No. 9: Charging Level Current:
It is possible set the max recharging current for the batteries by trimmer (Charging
Level). The current adjustment goes from 10% ÷ 100% of In. Set the maximum
charging current between 10% and 20% of the battery capacity.
Charging Curve
Automatic multi-stage operation and real time diagnostic allows fast recharge and recovery of deep discharged
batteries, adding value and reliability to the system hosting the CB device. The type of charging is Voltages
stabilized and Current stabilized IUoUo.
Four charging modes are identified by a flashing code on a Diagnosis LED.
To maintain the Output Load in lower Voltage state, don’t put jumper in position 4, in this case no boost charge
but only Float charge.
State
Diagnosis LED
Battery Fault
LED
Charging Type
Trickle/Float
1 Blink/ 2 sec
OFF
Absorption
1 Blink/sec
OFF
Boost/Bulk
2 Blink/sec
OFF
Recovery
5 Blink/sec
OFF
Battery Care
The Battery Care philosophy is base on algorithms that implement rapid and automatic charging, battery charge
optimization during time, flat batteries recovery and real time diagnostic during installation and operation. The Real
Time Auto-diagnostic system, monitoring battery faults such as, elements in short circuit, accidental reverse polarity
connection, disconnection of the battery, they can easily be detected and removed by help of Blink Code of Diagnosis
Led; during the installation and after sell. Each device is suited for all battery types, by means of jumpers it is possible
setting predefined curves for Open Lead Acid, Sealed Lead Acid, Gel, Ni-Cd(option).They guarantees battery reliability
in time by continuously testing the internal impedance status, avoids any possible risk of damages and grants also a
permanent, reliable and safe connection of the battery to the power supply. The system, through a battery stimulation
circuit with algorithms of evaluation of the detected parameter, is able to recognize batteries with a short-circuited
element. Battery test: Automatic.
