Via Luigi Barchi 9/B – Reggio Emilia 42124 – Italy
Tel. +39 0522 345518 – Fax +39 0522 345551 – www.adelsystem.com
Instruction Manual CB120-240-280-480W_R10_A24.AAA.009A2
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CB120W CB240W CB280W CB480W: S
mart
B
attery
C
hargers
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
CB series is Charge & Testing devices in “Switching
technology” and “Battery Care philosophy”, since many
years parts of the know-how ADEL system. This
technology 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 base 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 Characteristics
•
Input: Single-phase 115 – 230– 277 Vac
•
Output Battery: charging: 24 Vdc 10A – 20 A
12 Vdc 10A – 35 A
•
Suited for the following battery types: Open Lead Acid,
Sealed Lead Acid, Lead Gel, Ni-Cd and Ni-Mh
•
Automatic diagnosis of battery status and battery Life Test
function (Battery Care)
•
Switching technology- High efficiency
•
Three charging levels: Boost, Float and Recovery
•
Protected against short circuit, Over Load and inverted
polarity
•
Output dry contact for discharged or damaged battery
•
Output dry contact for Mains or Back-Up
•
Protection degree IP20 - DIN rail; Space saving
•
Temperature Compensated Charging
•
ADELBus connection: ModBus (RTU)
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 or UL 60950. 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
All In One
(Size)
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
Size 1 and 2
4.0
6.0
30 – 10 0.8 – 1.0 Nm
7 mm
Size 3
Out:
0.2 – 2.5 0.2 – 2.5
24 – 14 0.5 – 0.6 Nm
7 mm
Size 1 and 2
4.0
6.0
30 – 10 0.8 – 1.0 Nm
7 mm
Size 3
Signal: 0.2 – 2.5 0.2 – 2.5
24 – 14 0.5 – 0.6 Nm
7 mm
All types
The connection is made by the screw type 2.5 mm
2
or 4.0 mm
2
(CB2420A – CB1235A) terminal blocks. 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. Output Power connections:
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No. 4, 5 Signal Ports (Output Isolated):
Connections for,
No. 5: MAINS OR BACKUP: Input Mains On/Off. Contact: 5,6,7
No. 4: LOW BATTERY, BATTERY REPLACEMENT, FAULT BATTERY or FAULT SYSTEM Contact: 8,9,10
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:
Port N°2 - Led N°6
Mains/Back-Up
Port N°1 - Led N°7 Fault
Battery
5-6 Closed
5-7 Closed
8-9 Closed
(OK)
8-10 Closed
Mains Input Vac
ON
■
- led Off
■
- led Off
OFF
■
- led On (1)
■
- led Off
The battery in
BackUP it is less than
30% cap?
YES
■
- led On
■
- led On
NO
■
- led On
■
- led Off
Battery or system
Fault?
YES
■
- led Off
■
- led On (2)
NO
■
- led Off
■
- led Off
Note
:
(1) For better efficiency of the system, filter relay Mains/Back up with a delay of at least 5 seconds before give alarm
Main Lost, example: connection to PLC.
(2) See Diagnosis Led
No. 6, 7 and 8 Display Signals
No.6: Led Mains/Back Up: Input Mains On/Off
No.7: Led Low Battery(capacity less than 30%), Fault connections systems, Battery replacement.
No.8: Led Battery charge mode,
No.8: Led DIAGNOSIS: Battery charge mode,
Led Diagnosis. Diagnosis of the system through “blinking code” signal Light
State of Charge
Monitoring
Control
Chart:
State
Led
DIAGNOSIS
(No.8)
LED
BATTERY
FAULT (No.7)
Charging
Type
Float
1 Blink/2 sec
OFF
Absorption
1 Blink/sec
OFF
Boost
2 Blink/sec
OFF
Recovery
5 Blink/sec
OFF
Fault Battery / Fault System
System Auto
Diagnosis
Reverse polarity or high battery Voltage
(over 32.5Vdc for CB 24xxA)
1 Blink/pause
ON
Battery No connected
2 Blink/pause
ON
Element in Short Circuit
3 Blink/pause
ON
Over Load or short circuit on the load
4 Blink/pause
ON
Bad battery; Internal impedance Bad or Bad battery wire
connection
5 Blink/pause
ON
Life test not possible
6 Blink/pause
ON
Boost condition; battery discharge after 4 min. of overload.
8 Blink/pause
ON
Internal fault
9 Blink/pause
ON
Low battery (under 18.5Vdc for CB 24xxA) Only if started
from battery, no Mains input, from Jumper N°5 or Push
Bottom
10 Blink/pause
ON
MODBUS error
11 Blink/pause
ON
Life test not possible; Parallel mode on Slave Device
12 Blink/pause
ON
Bad battery wire connection; Parallel mode on Slave Device 13 Blink/pause
ON
Boost condition; battery discharge after 4 min. of overload;
Parallel mode on Slave Device
15 Blink/pause
ON
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Normal connection: Battery & Testing Charger:
Typical application for CBxxyy device:
N°1 battery (12 Vdc) for CB12yy;
N°2 battery (12 Vdc) connected in Series for CB24yy;
“Redundancy” Connection
It's
possible to request the
Redundancy
option
for the model
CB2420AP
.
Just connect
the two
CB
via
the RJ45 cable
to AUX2
and power on them
(also
at different times), automatically one of
the CB
becomes
the
real
battery charger
(indicated
by a flashing
LED
diagnosis
according to the
usual
frequency
)
while the
second
holds
steady on
the
L
ED
diagnosis
.
On both pieces
is
active
the
management
of alarms.
If the piece
that
charge
turns
off (
or
break
!) the second
automatically
begins c
harging
.
If there
is no
communication between
the two
CB
has
alarm
with
flash =
code
11
blinks,
under these conditions
both
the
CB
trying to
charge the battery
(
situation
not
recommended) to
which
it is
appropriate to
human intervention
, just
reconnect the
two pieces
and the situation
normalizes
.
Auxiliary Load Connection
Typical application for
Auxiliary device, one output for Load “DC Bus”, one
Input/Output for connection to the battery.
N°1 battery (12 Vdc) for CB 122410A;
N°2 battery (12 Vdc) connected in Series for CB;
Operating and Display Element:
No. 1: Battery Connection Port:
Connect the battery between pin. 3 (–) and 4 (+)
One battery (12 Vdc) for CB12yy;
Two battery (12 Vdc) connected in Series for CB24yy
No. 2: Output Load: (Size 4)
If Present on the device
Connect this Output to the load 1 (–). 2 (+).
(Output Load It is to supply Auxiliary Load)
No. 3: Charging Level Current:
In order to protect the battery from excessive charging currents, the device allows you to limit the maximum charge current
by adjusting the trimmer. It allows you to limit from max In up to 20% of current In. To determine the
maximum battery charge current, see the battery manufacturer's Data Sheet, If it is not possible,
consider that on average the maximum charge current is 10% of Ah's rated battery current; The data
is suitable for both Lead Acid and NiCd batteries.
3
Size 1
1
4
5
6
7
8
11
10
18
Size 2
6
7
8
3
11
10
18
1
4
5
Size 3
10
1
18
6
7
8
3
11
13
5
4
Size 4
10
2
1
5
4
11
17
15
6
8
9-12
16
14
13
18
3
7
15
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Size 4
No. 9, 12: Start From Battery Only; No Mains Vac (Size 4)
No. 9: Push-bottom, for 3 sec., in the front panel for switch ON the system without the “Mains input Vac”
but only the battery connected.
No.12: (Jumper n.5) It is also available the same function for remote start from the battery, via RTCONN
cable connected in the Push-bottom mounted on front Panel of the external system. Standard function for
all products,
N.B.: This Function it is present only if it is enabled Jumper in Option position
No. 10: Input AC Port pin. L – N:
1 Phase Switching Power Supplies L, N, PE
.
Size 2 and Size 3 BRIDGE ONLY for input 115 Vac, and connect L, N, PE
.
No. 11: Auxiliary Output “AUX 1”
Remove the window label to find the connector.
It is possible to connect the Temperature sensor probe and apply it on the battery.The function of the probe is for
temperature battery compensation. With this it is possible to active the specifications of the EN54-4 fire norm.
Battery Temperature Compensation Charge (not for NiCd)
Connecting to Auxiliary Output AUX1 the cable RJTEMP (supplied separately), the CB will vary the voltage of
battery charging depending on the temperature:
Fast Charge
Float charge
+/-5mV/°C x n. of Cells from -8°C to +45°C
+140mV/Cell ÷ -200mV/Cell compared to the
value at 20°C
+/-3mV/°C x n. of Cells from -20°C to +45°C
+120mV/Cell ÷ -120mV/Cell compared to the
value at 20°C
The device stop to charge the battery If the temperature is less than -20°C or greater than +45°C. The alarm fault
battery could be signalled by 7 blink code.
The sensor placed on cable RJTEMP must be applied on the battery.
No. 13: Auxiliary Output “AUX 2” (Size 3-4)
Present only in Sizes 3 and Sizes 4, connection MODBUS via RJ45 connector. See instruction MODBUS
communications protocol. (CANBUS to be implemented).
No. 14: Auxiliary Output “AUX 3” (Size 4)
Present only in Sizes 4. The function is the same of Auxiliary Output “AUX 2”
No. 15: Buffering Time Setting (Size 3-4)
On models Size 3 and Size 4 is possible to set a buffering time. It can be selected by setting the desired value on
the rotary switch 13. Buffering time is initiated when the mains is switched OFF. The LOAD output will be ON for the
selected time.
Switch position
0
1
2
3
4
5
6
7
8
9
Buffering Time (min.)
∞
0.5
2
5
10
15
20
30
45
60
If the switch is in position 0, the LOAD output will be in ON state until the battery is completed discharged. Any way
to prevent damage risks, the unit disconnects the batteries when a minimum voltage level is reached.
For units Size 1 or 2 you have to version with the extention CBxxxxATBx. The LOAD output will be in ON state until
the battery it is completed discharged. It is however possible to request factory customized versions with specific
buffering time setting.
No. 16: Bus Termination (Size 4)
Caution: Switch off the system before Setting the Jumper.
Read the MODBUS/CANBUS instruction manual to learn about the operational functions available.
Jumper Setting always active during all states of the system.
No. 17: Select Output Voltage (Size 4)
Caution: Switch off the system before Setting the Jumper
Output Voltage Selection
12 Output Voltage
Output Voltage Selection
24 Output Voltage
Size 1,2,3
