B A T T E R Y C H A R G E R

BATTERY CHARGER

NG5 – NG7 – NG9

Installation and User Manual

Battery charger NG5-7-9

ATTENTION: To reduce the risk of electric shock, do not remove cover.

Refer servicing to qualified service personnel.

Disconnect the mains supply before connecting

or disconnecting the links to the battery.

Read the Instruction Manual carefully before use. Verify that the selected charge curve is suitable for the type

of battery You have to re-charge.

Explanation of Graphical Symbols:

The lightning flash with arrowhead symbol, within an equilateral triangle, is intended to alert the user to the presence of uninsulated “dangerous voltage” within the equipment’s enclosure; that may be of sufficient magnitude to constitute a risk of electric shock to persons.

The exclamation point within an equilateral triangle is intended to alert the user to the presence of important operating and maintenance (servicing) instructions in the literature accompanying the equipment.

This product is covered by warranty.

The relative warranty certificate is attached to the Instructions Manual.

If the Manual is not provided with this certificate, please ask your retailer for a copy.

For further references, please write the serial number in the proper space:

Serial No. _____________________

Information contained in this Manual relates to ZIVAN S.r.l. property which reserves the right to supply for the exclusive use of customers.

No other use is allowed without a written authorization supplied by ZIVAN S.r.l.

ZIVAN S.r.l. will be not responsible for inaccuracies contained in this manual due to print or translation errors. ZIVAN S.r.l. has the right to make changes or improvements, also for the user interest, without prejudicing the essential characteristic of operation and safety.

Copyright

© 2003 by ZIVAN S.r.l.

First Edition

2 D01090-02

Battery charger NG5-7-9

Installation and safety instructions

Battery charger NG5-7-9 has been designed to provide safety and reliable. It is necessary to observe the following precautions in order to avoid damage to persons and to the battery charger:

• Read the installation instructions contained in this Manual carefully. For further information put the

Manual in a proper place.

• Fix the battery charger to a stable surface through the appropriate holes inserted on the fixing flanges. In case of installation on a vehicle it is advisable to use antivibration supports.

• Preferably the charger should be installed in the vertical position with the fan facing up. The horizontal installation is allowed. Never install in the vertical position with the fan facing down.

• Ensure all ventilation ports are not obstructed, to avoid the overheating. Do not put the battery charger near heat sources. Make sure that free space around the battery charger is sufficient to provide adequate ventilation and an easy access to cables sockets.

• Protect the battery charger from ingress of water. Do not pour liquids inside the case.

• Verify that the available supply voltage corresponds to the voltage that is stated on the battery charger name plate. In case of doubt, consult a retailer or local Electric Supply Authority.

• For safety and electromagnetic compatibility, the battery charger has a 3-prong plug as a safety feature, and it will only fit into an earthed outlet. If you can not plug it in, chances are you have an older, non-earthed outlet; contact an electrician to have the outlet replaced. Do not use an adapter to defeat the earthing.

• To avoid damaging the power cord, do not put anything on it or place it where it will be walked on. If the cord becomes damaged or frayed, replace it immediately.

• If you are using an extension cord or power strip, make sure that the total of the amperes required by all the equipment on the extension is less than the extension’s rating.

• Disconnect the mains supply (turn off the switch) before connecting or disconnecting the links to the battery.

• To recharge Lead Acid batteries: WARNING: Explosive Gas – Avoid flames and sparks. The battery must be positioned in a correctly cooled place.

• Do not use to charge batteries installed on board of thermal engine cars.

• Avoid recharging of non-rechargeable batteries.

• Verify that the nominal voltage of the battery to be re-charged corresponds to the voltage stated on the battery charger name plate.

• Verify that the selected charging curve is suitable for the type of battery to be re-charged. In case of doubt, consult Your retailer. ZIVAN S.r.l. will not accept any responsibility in case of mistaken choice of the charging curve that may cause irreversible damage to the battery.

• In order to avoid voltage drop, thereby assuring 100% charge at the battery, the output cables must be as short as possible, and the diameter must be adequate for the output current.

• Do not try to service the battery charger yourself. Opening the cover may expose you to shocks or other hazards.

• If the battery charger does not work correctly or if it has been damaged, unplugged it immediately from the supply socket and from the battery socket and contact a retailer.

D01274-00 3

Battery charger NG5-7-9

Operating principle

The battery charger considerably affects battery life and performances, which is the main part of every electric vehicle.

A non controlled traditional battery charger (rectifier) provides a simple direct AC/DC conversion. v i i i

AC

DC

Batteria

Disadvantages of this solution are:

• Low efficiency

• Large physical size

• Long charge times

• Charge depends on changes in the mains supply (with overcharge danger in the final charge phase)

In modern battery chargers these disadvantages are solved with an indirect AC/DC conversion, by passing through an intermediate DC/DC conversion. v i i i

AC

DC

DC

DC

Batteria

This is the usual method of operation for the SMPS (Switching Mode Power

Supply) at high power. This solution gives a good performance for minimum costs and physical dimensions using switches more faster and powerful

(modern technology).

The main advantages of this solution are:

• High efficiency

• Reduced dimensions

• Short charge times

• Charge independent from the changes of the mains supply

• Electronic control that provides the desired charge curve

The advent of electrical problems (due to commutation) has imposed the introduction of adequate filtering to satisfy requirements of EMC 89/336/EEC directive for electromagnetic compatibility.

R

S

T

E

F0

F1

F2

EMI

FILTER

RECTIFIER

AND

FILTER

POW ER

STAGE

RECTIFIER

AND

FILTER

EMI

FILTER

F4

RECTIFIER

AND

FILTER

CONTROL

LOGIC

D01274-00 4

Battery charger NG5-7-9

Charging Level Indicator

80%

100%

START

80%

RED LED shows that the battery is in the initial charging phase.

YELLOW LED shows that the battery charger has reached 80% of charge.

GREEN LED shows that the battery has reached 100% of charge.

Further information can be found in the description of the Charging Curve.

Line Alarm Indicator

LINE

ALARM

This RED LED turns on when there is a phase missing on the mains.

In this situation the battery charger will not operate and the charging level indicator changes to yellow.

(Check mains and input fuses).

Alarms (Two-tone audible message)

An two-tone audible message and the flashing LED shows that an Alarm situation has occurred:

Condition

Audible message +

RED flash

Audible message +

YELLOW flash

Audible message +

GREEN flash

Audible message +

RED-YELLOW flash

Audible message +

RED-GREEN flash

Audible message +

YELLOW -GREEN flash

Audible message +

RED-YELLOW-GREEN flash

Alarm Type Description (Action)

Battery Presence Battery disconnected or not in conformity. (Verify the connection and the nominal voltage).

Thermal Sensor The thermal sensor is disconnected during the recharge or it is out working range. (Verify the connection of the sensor and measure the temperature of the battery).

Timeout

Battery Current

Battery Voltage

Phase 1 and/or Phase 2 have a duration in excess of the maximal allowed. (Verify the battery capacity).

Loss of output Current control. (Failure of the control logic).

Loss of output Voltage control. (Battery disconnected or failure of the control logic).

Selection

Thermal

An unavailable configuration has been selected (Verify the selector’s position)

Overheating of semiconductors. (Verify the fan operation).

When there is an alarm the battery charger stops supplying current.

Thermal Sensor and/or External Indicator

Thermal Sensor and External Indicator are Options that have to be connected to the 5 poles socket 180°.

Unless otherwise stated, the compensation of the Battery Voltage in function of the temperature of the Thermal Sensor is of -5mV/°C for battery cell.

The control range of the Thermal Sensor goes from -20°C to +50°C.

The External Indicator reflects exactly the LED Indicator which is placed on the equipment.

Further information can be found in the description of the Charging Curve.

D01274-00 5

NC

AUX1

C NO NC

AUX2

C NO

Battery charger NG5-7-9

Technical Features: changeovers contacts

Connector: faston

× 0,8 mm

Unless otherwise stated, the auxiliary contacts provide the following functions:

Section Function

AUX1 Mains Presence

Description

When the equipment is switched on, the contact

Normally Open (NO) CLOSES and instead the contact

Normally Closed (NC) OPENS.

AUX2 End of charge or Trickle

Phase

When the Stop Phase or the No Stop Phase is reached, the contact Normally Open (NO) CLOSES and instead the contact Normally Closed (NC)

OPENS.

100%

50%

CURRENT

LED Bar Graph and Digital Instrument

The LED Bar Graph is an Option that shows a percentage indication of output current in comparison with its max. value.

The Digital Instrument indicates the output tension expressed in

Volt (V) and the output current expressed in Ampère (A).

The corresponding unit of measure of the visualised numbers is indicated by the LED V or A.

By means of the MODE button, it is possible to select A or V to be visualised.

N.B. The instrument indicates by

-L0

the output tensions, which are inferior to the nominal value of the battery.

LINE

ALARM

V A

V

MODE

A

Battery

A battery is characterised by two sizes: tension and capacity.

Tension:

Each element has a nominal tension, which depends on the type of battery (no matter what size).

In order to reach higher tension, many elements are connected in series, so creating a “BATTERY” of elements.

The number of elements is calculated by dividing the nominal tension of the battery for the tension of each single element in the table:

Type

Nominal

Tension

Capacity:

It is the quantity of electric charge that the batteries can supply to an external circuit before the tension decreases under the final limit value and it is obtained by multiplying the intensity of the discharging current I, expressed in ampere (A), for the discharging time t expressed in hours (h): C = I x t.

The traction battery capacity is normally referred to the discharging system of 5h: C5 = I x 5h.

The capacity values that can be recharged by the battery chargers can be found in the description of the

Charging Curve (this value is not present in the curves able to charge any capacity).

:

This device is in conformity with the Low Voltage directive 73/23/EEC and EMC directive 89/336/EEC and their further modifications.

D01274-00 6

Battery charger NG5-7-9

Mechanical dimension

270

130 105

470

550

N.B. All dimensions are expressed in mm.

260

9

16

518 550

UP

70 130 70

16

D01274-00

N.B. All dimensions are expressed in mm.

7

Battery charger NG5-7-9

TECHNICAL FEATURES

Ta=25°C unless otherwise specified

Description

Supply Voltage Three-phase

Absorbed Maximum Current per phase

Inrush Current

Power Factor

Absorbed Minimum Power

Absorbed Maximum Power

Symbol

Vin

Test Condition

-

Value and/or

Range

400 ± 15%

Unit

Veff

If max

Pin

-

P = P max

Vin=400Veff cos ϕ P = P max

Pin min

End of charge max

P = P max

10 (NG5)

14 (NG7)

18 (NG9)

< 2,35

Aeff

A

0,72 -

< 10

5 (NG5)

7 (NG7)

9( NG9)

W kW

Description

Output current

Maximum output current

Output current ripple

Absorbed current

Output voltage

Constant output voltage

Thermal compensation of output voltage

Operating range of Temperature

Sensor

Output voltage ripple

Maximum power supplied

Output capacity

D01274-00

I

I1

-

I a

U

U1

Symbol

∆

T

Test Condition

-

Phase 1

I = I1

Equipment turned off

-

Phase 2

-

Value and/or

Range

See curve

See curve

< 5%

< 0,5

See curve

See curve

-5

Unit

-

A

- mA

-

V mV /

(°C·cell) from -20 to +50 °C

- U = U1

P max

U = U1, I = I1

C -

< 1%

4350 (NG5)

6100 (NG7)

7830 (NG9)

Depend on the model (>0,2)

-

W mF

8

General

Description

Operating range of temperature

Maximum relative humidity

Switching frequency

Efficiency

Maximum size

Battery charger NG5-7-9

Symbol Test Condition

∆

T

-

RH f c

η

-

-

At each operation condition a×b×c Without connecting cable

Value and/or

Range

Unit from -20 to +50 °C

90% -

25 ± 5% kHz

> 87% -

550×270×120 mm

9 kg

Enclosure class -

Protection and Safety

Description Symbol

Insulation

Insulation

Insulation

Leakage current

Input fuses

Output fuse

Minimum output voltage of operation

(Battery Detector)

Maximum output voltage

Reverse output polarity

Thermal protection of semiconductors

(Temperature of Thermal Alarm)

Safety Requirements (Rules)

EMC Requirements (Rules)

-

-

-

F4

-

Um

- cable

-

Test Condition

Mains to Battery side

Mains side to Earth

Battery side to Earth

I

L

Supplied equipment

F0-F1-F2 Inside the equipment

IP20 -

Inside the equipment

Equipment turn on

Phase 3 (IUIa - IUIUo)

At the connection to the

Battery

- Ta=55°C

-

-

EN60335-1, EN60335-2-29

EN55014-1, EN61000-3-3

EN55014-2, EN61000-4-2

EN61000-4-4, EN61000-4-5

EN61000-4-6, EN61000-4-11

Value and/or

Range

1250

500

500

< 1

20 (NG5)

20 (NG7)

25 (NG9) about 1,2

×I1

1,5

Unit

A

V/cell

V

AC

V

DC

V

DC mA

A

See curve

Protection provided by fuse F4

V

-

100 °C

- -

- -

D01274-00 9

Design, production and sale:

ZIVAN SRL

Via della Costituzione, 36

42028 Poviglio (RE) ITALIA

Tel. +39 0522 960593

Fax +39 0522 967417 [email protected]

SALES OFFICES

ZAPI SPA

Via Parma, 59

42028 Poviglio (RE)

Tel. +39 0522 960050

Fax +39 0522 960259

Battery charger NG5-7-9

URMA SARL

30, Rue de Morvan Silic 503

94623 Rungis Cedex

Tel. +33 1 45609477

Fax +33 1 46750871

ASMO ENGINEERING AG

Glashütte, 58

CH 4229 Beinwil (SO)

Tel. +41 61 3136400

Fax +41 61 3136401

SLOVENIA/CROATIA HOLLAND

PROTEUS ELECTRIC SRL

Via di Noghere, 94/1

SPI Special Product for Industry

Vlijtseweg 232

EZ ELECTROFIT ZAPI LTD

Unit 2 - Halesfield 17 - Telford

34147 Muggia Aquilina (TS)

Tel. +39 040 232188-232388

Fax +39 040 232440

7317 AN Apeldoorn

Tel. +31 55 5211111

Fax +31 55 5222366

Shropshire TF7 4PW

Tel. +44 1 952 582482

Fax +44 1 952 581377

ELECTRIC CONVERSIONS

215, 14th Sreet

Sacramento CA 95814

Tel. 916- 441-4161

Fax 916- 444-8190

ATECH Antriebstechnik GmbH

Gewerbepark Lindach D7

84489 Burghausen

Tel. +49 8677 98090

Fax +49 8677 980920

VARELEC SCCL c / Lope de Vega 10-12 Bajos

08005 Barcelona

Tel. +34 93 3032565

Fax +34 93 3032565

JZ RECIELCA S.L.

C / Progrés, 2-A. Gavà

08850 Barcelona

Tel. +34 93 6382383

ETP KRAFTELEKTRONIK AB

Järningen, 15

43323 Partille

Tel. +46 31 440715

BATTERY SUPPLIES n.v.

Lindestraat, 89A

8790 Waregem

Tel. +32 56 617977

Fax +34 93 6383166 Fax +46 31 449720 Fax +32 56 617955 [email protected] [email protected] [email protected]

GREECE CHINA

START Industrial Batteries

7-9 Agiou Filippou Street

CNEEC

N° 1 Lianhuahe Hutong

18540 Piraeus

Tel. +301 4179 951

Beijing 100036

Tel. +86 10 63403913

Fax +301 4179 950 Fax +86 10 63261083 [email protected] [email protected]

10 D01274-00

Battery charger NG5-7-9

D01274-00 11

Electric Conversions

Distributor of ZIVAN Battery Chargers

215 14th Street, Sacramento CA 95814

Tel. 916-441-4161

D01274-00