SLH 200 - Jungheinrich
SLH 200
Operating Instructions
50452174
01.08
10.04 -
G
4156 EN
Contents
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
D-22047 Hamburg-Germany
Tel.: +49 (0) 40/6948-0
www.jungheinrich.com
2/30
4156 EN
Contents
Index
1
General ...........................................................................................................................4
1.1
Purpose of Operating Instructions ...........................................................................................4
2
Safety ..............................................................................................................................4
2.1
2.2
2.3
2.4
2.5
2.6
2.7
General ......................................................................................................................................4
Decal and Symbol Notices ........................................................................................................4
Personnel Qualification.............................................................................................................5
2.3.1 Commercial Use................................................................................................................5
Correct use and application......................................................................................................5
Assembly and Installation Safety Instructions ........................................................................6
Operating Safety Instructions...................................................................................................7
Troubleshooting and Repairs Safety Instructions...................................................................7
3
Product Specifications ..................................................................................................7
3.1
3.2
3.3
3.4
3.5
3.6
Product Functional Description................................................................................................7
Model Description .....................................................................................................................8
Accessory Functional Description ...........................................................................................8
3.3.1 Charger .............................................................................................................................8
Residual Risk.............................................................................................................................8
Protective Mechanisms.............................................................................................................9
Charger Labelling and Decals.................................................................................................10
4
5
Transport, Handling and Storage................................................................................10
Assembly / Installation / Commissioning ...................................................................10
5.1
5.2
5.3
5.4
5.5
Delivery scope.........................................................................................................................10
Site Requirements...................................................................................................................11
Mains Connection and Mains Fuses.......................................................................................11
Assembly and Installation.......................................................................................................12
Commissioning the charger for the first time and operational testing .................................12
6
Operation ......................................................................................................................12
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
Operating and Display Function.............................................................................................13
6.1.1 Charge Status Light.........................................................................................................14
6.1.2 Soft keys .........................................................................................................................15
6.1.3 Graphic display and menu structure.................................................................................16
6.1.4 Adjustable parameters.....................................................................................................17
6.1.5 Function – Battery Maintenance.......................................................................................17
6.1.6 Function – Measured values............................................................................................18
6.1.7 Graphic Display Information.............................................................................................18
6.1.8 Parameters – Consumption data......................................................................................18
6.1.9 Parameters - Statistics.....................................................................................................19
Charger Mains Connection .....................................................................................................19
Battery Connection .................................................................................................................19
Charging automatic start ........................................................................................................20
Interrupting a charge...............................................................................................................21
Charging automatic end..........................................................................................................21
Readings..................................................................................................................................22
Status messages .....................................................................................................................23
Faults and Error Messages .....................................................................................................24
Switching off the charger........................................................................................................25
7
Maintenance .................................................................................................................25
7.1
7.2
7.3
Cleaning, Inspection and Maintenance ..................................................................................25
Changing the charging program.............................................................................................26
Spare parts ..............................................................................................................................26
8
9
Disposal ........................................................................................................................26
Appendix.......................................................................................................................27
9.1
9.2
9.3
9.4
9.5
Dimension and Projection Drawings (not to scale) ...............................................................27
Specifications..........................................................................................................................28
Model table ..............................................................................................................................28
Charging programs .................................................................................................................29
Spare parts catalog .................................................................................................................30
3/30
4156 EN
General
1
General
1.1
Purpose of Operating Instructions
The aim of the present operating instructions is to ensure the correct and safe operation
of the SLH 200 charger. The SLH 200 will hereafter be referred to as the charger.
The operating instructions must always be available and stored in the vicinity of the
charger. The operating instructions must be read and applied by anyone involved in
operating the charger, including shipping, assembly and installation, operation,
maintenance and disassembly work.
For commercial use, the relevant work safety guidelines, standards and regulations of the
place or country of operation must be observed alongside the present operating
instructions.
For further information beyond the scope of the operating instructions, please consult
with the manufacturer's specialist technicians.
All documentation is copyright protected. The transfer or reproduction of
documentation, including excerpts, as well as the assessment and dissemination of its
content are prohibited unless expressly permitted.
2
Safety
2.1
General
The operating instructions are a major component of the charger.
The owner shall ensure that the operating instructions are permanently in the vicinity of
the charger, and that operating personnel shall be notified of these guidelines.
The owner shall add further instructions regarding national accident prevention and
environmental protection regulations to the operating instructions, including information
on supervisory and reporting obligations, taking into account particular company
practices e.g. in terms of work organization, work processes and the personnel
employed.
Apart from the operating instructions and the current accident prevention regulations in
force in the country and place of use, generally recognised technical regulations for safe
and proper use shall be observed.
2.2
Decal and Symbol Notices
This charger has been produced in accordance with generally accepted principles and
state-of-the-art technology. To ensure sufficient levels of safety for personnel, additional
safety instructions are issued. Sufficient safety when handling the charger is only
provided when these instructions are observed.
From time to time it is necessary to emphasize specific instructions. These sections have
different meanings:
4/30
4156 EN
Safety
Z
Note
Notes contain additional information to ensure safe and efficient handling of the
charger.
M
Attention
This warning indicates possible damage that could be caused by failing to take
precautionary measures or improper use.
Observe all warnings and measures needed to prevent damage from occuring to the
charger and other articles. Be particularly vigilant.
F
Danger
This warning indicates possible damage that could be caused to persons, by failing to
take precautionary measures or improper use.
Observe all warnings and measures required to prevent injuring yourself or other
people. Be particularly vigilant.
2.3
Personnel Qualification
Only qualified technicians should operate the charger. The levels of responsibility for
personnel operating and installing/repairing the charger should be clearly separated.
Qualified technicians in the sense of these basic instructions are people responsible for
assembly, installation, commissioning, operation, maintenance, de-commissioning and
disassembly, and who are suitably qualified to carry out their role.
The charger may only be installed, commissioned for the first time, repaired and
disassembled by qualified and authorized electrical engineers.
With trained electrical engineers it is assumed that they will observe and comply with
current regulations of the local energy supply company as well as the industry work
safety guidelines (e.g. BGV A2) an d all regulations governing the safe and proper use
of the charger (e.g. DIN VDE 0100 and IEC 60664 or DIN VDE 0110).
The manufacturer does not accept liability for any damage or loss of business arising
from the failure to comply with these operating instructions.
2.3.1
Commercial Use
If the charger is used in a commercial environment, the following also applies:
− The operator must undergo special instruction or training on how to charge lead acid
accumulators and how to operate them.
− Only authorised personnel may operate the charger.
2.4
Correct use and application
The SLH 200 charger is designed to charge lead acid accumulators. Depending on the
preset charging program, only wet cell batteries designed for the charger program or
suitably sealed, maintenance-free traction batteries should be charged. The charger is
unsuitable for all other accumulators and non-rechargeable batteries.
If required by the owner, the charger can be fitted with a range of different connectors.
The owner is therefore obliged,
− only to use connectors with the suitable fuse rating for the charger,
− to avoid connecting unsuitable battery types.
5/30
4156 EN
Safety
The latter could be achieved for example by colour-coding or mechanically coding the
connector.
Always observe and comply with the battery manufacturer’s instructions.
If the charger has a charging program which has been modified, the owner is obliged to
permanently advise of the suitable battery type on the housing exterior.
To ensure proper use, observe and comply with the details on the location site (see
sections 2.5 and 5.2), the data plate and the specifications (see Appendix).
F
Risk of injury
Serious damage to personnel and property could arise from:
improper use or incorrect operation,
unauthorised opening of the charger,
incorrect installation or improper service or repair work.
All instructions regarding the correct use, residual risk, installation, operation and
maintenance contained in these operating instructions must therefore be noted and
observed.
The charger must only be used for the purposes foreseen in the present operating
instructions and the technical description and only with the accessories or components
recommended and approved by the manufacturer.
Any other use beyond the scope of the above is not appropriate. The owner or user of the
charger shall be liable for any damage arising from the above.
The charger shall only be commissioned in accordance with electromagnetic
compatibility guidelines (89/336/EC).
2.5
Assembly and Installation Safety Instructions
Before installing the charger, check that all the components have been supplied against
the delivery notes. If anything is missing, immediately contact the manufacturer.
The place of operation must be weather-proof and dry.
The ambient temperature at the site must not fall below 0°C or exceed 40°C. Avoid the
build-up of heat within the charger, e.g. through heat sources or by blocking the air
vents.
The location site must be sufficiently ventilated to distribute (reduce) charging gases
which may arise (acid fog, electrolytic gas) and prevent the build-up of explosive gas
mixtures.
The site must not contain excessive dust. Avoid the occurrence of conductive dust (soot,
metal).
No liquid must enter the inside of the charger.
The distance between the charger and inflammable materials must be at least 2.5m
horizontally. It is forbidden to store inflammable materials, e.g. in shelves, or to use
inflammable materials above the charger. There must be at least a 5.00m gap between
fire and explosive-hazardous areas.
The charger must be protected against overload or stress. In particular, no components
must be damaged during transport and when being handled. Avoid contact with
electronic components.
The charger contains electrostatic endangered components which can easily be damaged
through improper handling. Electrical components must not be physically damaged or
destroyed.
6/30
4156 EN
Product Specifications
Electrical installation (wire cross sections, fuses, earth leads) must be performed in
accordance with current regulations.
Prior to electrical installation, the performance data on the data plate must be checked
against the performance data of the supply connections. The charger must be protected
against excessive shock-hazard voltages through a mains fuse connected in series.
Observe the mains connection values indicated on the data plate (voltage and
frequency).
2.6
Operating Safety Instructions
The charger must only be used when in technically good working order and when used
in accordance with the present operating instructions with attention paid to the safety
and hazard risks. Any faults that could affect safety must be removed immediately.
The data plate specifications regarding the appropriate battery voltage must be checked
and complied with prior to connecting the charger cable. The charger leads must be
connected to the correct battery terminals.
When connecting the battery, route the charging leads so that they cannot be tripped
over and that charging cannot be interrupted by unplugging the charging lead. If an
ongoing charge is interrupted by removing the charging lead, this may produce sparks
which could result in fire or explosions.
If the charger or the operating pattern of the charger is changed in a way that could
affect safety, shut down the charger and notify the relevant department of the fault.
2.7
Troubleshooting and Repairs Safety Instructions
Contact the manufacturer prior to opening the housing for maintenance and repair
purposes.
Prior to carrying out maintenance or repair work, always disconnect the charger from the
mains.
After switching off the charger, wait for at least five minutes before opening the panels
and housing.
No changes or modifications may be made to the charger which could affect safety
without obtaining the manufacturer’s approval. This also applies to the assembly and
setting of safety mechanisms. In particular make sure that no safety, leakage or air
distances are reduced.
Spare parts used must meet the technical requirements specified by the manufacturer.
This requirement is always met by original manufacturer’s spare parts.
3
Product Specifications
3.1
Product Functional Description
The SLH 200 charger is designed to charge lead acid accumulators. Depending on the
preset charging program, wet cell batteries or sealed, maintenance-free traction batteries
can be charged.
The charger has an adjustable, high-frequency power part, a micro-processor controlled
charging electronics system and a control/display panel with buttons and a charge status
light, as well as a graphic enhanced LCD display. The charging program for the
respective battery type is factory-set to the customer’s requirements.
7/30
4156 EN
Product Specifications
The various charger assemblies are installed in a secure steel sheet housing with a plastic
front panel. The charger is equipped with a mains cable and connector (optional for
threephase models) for connection to the mains.
3.2
Model Description
The SLH 200 charger is available in different options. The following is a typical model
description (e.g. for a 24 volt, 120 amp charger).
Type E 230 G 24/120 B-SLH200
Model description – SLH 200
Output rated current
Output rated voltage
Output current type ‘G’ – DC
Input rated voltage
Input current type
‘E’ – Single phase AC current
For the exact technical specifications refer to the data plate on the charger and the
technical specifications attached.
3.3
Accessory Functional Description
3.3.1
Charger
Various battery connectors can be used depending on the battery type. The charger can
therefore be supplied with or without a charging lead, as required. Refer to the attached
delivery notes.
3.4
Residual Risk
F
Warning: Hazardous Electrical Voltage!
The charger is an electric component conducting voltages and currents that are
hazardous to people.
The charger must therefore only be operated by trained technicians.
The charger must therefore only be opened, repaired and disassembled where
necessary by qualified electrical engineers.
The mains supply and a battery contact where necessary must be disconnected
before carrying out any work on the charger.
F
Explosion hazard
When a battery is charged, potentially explosive gases can escape.
The charger must therefore only be operated in well ventilated rooms.
Never remove the battery connection while charging. This could produce sparks
which could ignite the charging gases (electrolytic gas).
F
Danger of getting caught on charging leads
A removed charging lead could cause people to trip over it and run the risk of
interrupting a charge.
People can get caught on removed, loose cables, trip over them and pull the charging
lead out of the battery during charging. The sparks this produces could ignite the
charging gases and as a result cause a fire or trigger an explosion.
When connecting the battery always route the charging lead so that nobody can trip
over it. After charging, place the charging lead carefully on its bracket.
8/30
4156 EN
Product Specifications
M
M
3.5
Attention
Connecting an incorrect battery to the charger can result in damage to the charger
and battery: The battery could gas, decoct or even explode.
Always check that the charger is set for your battery type. If in doubt, contact the
relevant experts.
Attention
Corrosive acid gases can be produced when a battery is being charged. Acid gases
can cause short circuits in electrical equipment (risk of burning) and can corrode
components.
Therefore always position batteries next to charging stations in such a way that any
acid gases arising can be freely distributed (reduced) on site and can dissipate.
Protective Mechanisms
The charger has been designed and constructed in accordance with state-of-the-art
technology. If used properly, it therefore poses no danger to the health and safety of
those operating it or third parties.
All live assemblies are fitted with housings and panels that can only be undone with
tools. All cables and connectors are appropriately screened / earthed. The charger has an
IP 21 protection class.
All electric and electronic components bear the CE mark; all necessary isolating
distances have been observed. All circuits are fitted with primary and secondary fuses
with defined current rating and activation characteristics.
All metallic components are earthed via an earth lead system.
The charger is fitted with an automatic cutout function as soon as the preset maximum
charge status of the battery is reached. This avoids overloading and excessive release of
explosive gases.
9/30
4156 EN
Transport, Handling and Storage
3.6
Charger Labelling and Decals
Data plate
Baureihe
Line
Typ
Type
1
Serien-Nr.
Serial-No.
Baujahr
Year of manufacture
3
Eingang
Input
Attached to the side of the housing.
2
4
Sicherung
Fuse
5
6
Zellenzahl/Typ
Number of cells/type
7
Schutzart
Protection class
8
Ausgang
Output
9
Batteriekapazität
Battery Capacity
10
Hersteller
Manufacturer
e
Item
Description
Item
Description
1
Series
6
Input
2
Type
7
No. of cells/type
3
Serial no.
8
Protection class
4
Year of
manufacture
9
Output
5
Fuse
10
Factory setting
Jungheinrich AG, D-22047 Hamburg, Germany
öJUNGHEINRICH
Operating instructions notice
Attached to the top of the housing cover.
Model performance plate
48 V - 120 A
4
Attached to the front of the housing.
(Example: 48 volt / 120 amp)
Transport, Handling and Storage
The charger is supplied in a cardboard box.
Note the instructions on the cardboard box during transport, handling and storage.
Protect against the weather
Fragile
Top
5
Assembly / Installation / Commissioning
5.1
Delivery scope
The supply consists of the following (minimum) parts:
− Charger and preset charging program,
− the connected mains and battery cables,
− the operating instructions,
− a notice (attached to the charger),
− the delivery note.
Depending on the customer’s requirements, the delivery scope and the charger version
may deviate from this. The enclosed delivery papers (as well as the order confirmation)
contain additional technical specifications.
• Check the delivery immediately to make sure it is complete and undamaged.
• Check the delivery note and the data plate to make sure they agree.
10/30
4156 EN
Assembly / Installation / Commissioning
5.2
•
If anything is missing contact the manufacturer and the shipping company
immediately.
•
Check the charger for any loose screw connections etc. If necessary, retighten these
connections.
Site Requirements
Only use the charger in closed, frost-free and well ventilated rooms with ambient
temperatures of up to 40°C. Select an assembly site where the ventilation slots will not
be covered and the flow of cool air will not be affected. Do not assemble the charger
near radiators or other sources of heat.
Naked flames and smoking in battery rooms are prohibited.
There must be no flammable materials or spark-producing liquids within a 2.5 metre
radius of the charging station.
When assembling, note also that:
− no harmful gases, e.g. acid gases,
− no conductive dusts, such as soot or metallic dust,
− no excessive amounts of non-conductive dust and
− no fluids
may enter the inside of the charger.
When attaching the charger to the wall in an FWG 3 or FWG 6 housing, use the
enclosed wall attachment material (4 off S10 dowels, 4 off M6x60 screws). The drilling
plan is attached.
For chargers in the FDG 12 housing, make sure when assembling that there is sufficient
ventilation, lateral clearance of at least 50cm to the next model and at least 30cm to any
neighbouring walls.
It must be possible to connect to the mains and battery within a cable reach of 3m.
5.3
F
Mains Connection and Mains Fuses
Warning: Hazardous Electrical Voltage!
The charger is an electric component conducting voltages and currents that are
hazardous to people.
The charger must therefore only be operated by trained technicians.
The charger must therefore only be opened, repaired and disassembled where
necessary by qualified electrical engineers.
You will require a mains connection at the intended operation site to operate the charger.
The mains voltage and frequency must match the specifications on the data plate. The
mains connection must be properly earthed.
Protect the charger from excessive shock-hazard voltages in accordance with the local
energy supplier’s regulations.
11/30
4156 EN
Operation
• Arrange the mains fuses in series in accordance with the following table:
Rated current
0
>6
>10
>16
>18
>23
to
to
to
to
to
to
6
10
16
18
23
32
A
A
A
A
A
A
Mains rating
Comment
6 A gL
10 A gL
16 A gL
20 A gL
25 A gL
35 A gL
gL safety fuses or safety devices with B or
C characteristics can be used.
Table 1: Mains current and Mains Fuse Rating
5.4
Assembly and Installation
The following requirements must be met in order to assemble the charger:
a mains socket must be within reach,
there must be a surface next to the charger to place the battery on.
For exact details, refer to the technical specifications attached.
5.5
Commissioning the charger for the first time and operational testing
After assembling and installing the charger correctly, it must be commissioned for the
first time for a functional test.
The charger is already factory-set. However, before using it for the first time, check that
the charger is correctly set for the battery you wish to charge. For parameter checking,
see Section 6.1.3.
After commissioning the charger for the first time, it must be labelled on the outside
clearly, permanently and legibly with the details of the permissible battery type.
M
Attention
Connecting a non-authorised battery to the charger may result in material damage to
the battery and charger, and consequently to the truck.
The owner and responsible service personnel must eliminate any possibility of
confusion for the truck driver when connecting truck batteries.
•
Note the respective battery type on the front of the housing – depending on the
charging lead and the pre-set charging program installed.
• Also note any subsequent modifications to the charging program on the front of the
housing.
• Also note if the actual rated current (In) is set to a lower value than the one indicated
on the data plate.
6
F
Operation
Warning: Hazardous Electrical Voltage!
The charger is an electric component conducting voltages and currents that are
hazardous to people.
The charger must therefore only be operated by trained technicians.
The charger must therefore only be opened, repaired and disassembled where
necessary by qualified electrical engineers.
12/30
4156 EN
Operation
For a trained operator, battery charging generally includes the following stages:
− Check that the charger and battery type match,
− Connect the charger to the mains if necessary
− Connect the battery,
− (charging starts and ends automatically,)
− Disconnect the battery,
The following sections describe the various operating stages in more detail. Read them
carefully before using the charger for the first time.
6.1
Operating and Display Function
The front of the charger contains the operating and display unit with the charge status
light and the graphic display with soft keys:
1
2 3
Figure 1: Operating and Display Field
4
5
1 Charge status light 3 Stop/Start switch – Soft key 1
2 Graphic display
4 Soft keys 2 – 4
5 Charger performance specification plate, e.g. 48 volts – 120 amps
13/30
4156 EN
Operation
6.1.1
Charge Status Light
The charge status light shows, in conjunction with the graphic display, the current
operating status and the charging status.
Colour
Meaning
Explanation
Yellow
Charge
Lights up during the (main) charging phase
Orange
Charge
Lights up during the ährend der re-charging phase
Green Charge end
Fault
Red
Lights up when charging is complete
Lights up if there is an equipment fault or incorrect
operation:
−
−
−
Battery disconnected during charging
Power module faulty
Max. charging time or discharge rate
exceeded
− Overvoltage / low voltage cutout
Off
Ready
Charge status light out
No charge, no error (e.g. display after system re-start or
before using the charger for the first time)
Table 2: Charge Status Light
As well as the continually lit displays of the charge status light, some operating
conditions are displayed as a flashing sequence of various colours (1 second rhythm).
The following list shows the various flashing sequences and their meaning. As well as
the flashing sequence, the graphic display shows the respective messages in text form.
Flashing sequence
Yellow ► Off
Red ► Green
Meaning
Charge start
Explanation
Start of a new charging sequence
Charge end/ Charge complete / pump error or faulty
power module
fault
Yellow ► Red
Charge/fault
(Main) charge / pump error or faulty
power module
Orange ► Red
Charge/fault
Recharge / pump error or faulty power
module
14/30
4156 EN
Operation
Flashing sequence
Meaning
Explanation
Charge
break
Orange ► Off
Charge break (depends on set charging
program)
Charge
break / fault
Orange ► Red ► Off
Charge break / pump error or faulty power
module
Conservation Conservation or compensation charge
running
charge
Yellow ► Green
Red ►Yellow ► Green
Conservation Conservation or compensation charge /
charge / fault pump error or faulty power module
Table 3: Flashing sequences
6.1.2
Soft keys
There are four keys below the graphic display, known as the soft keys.
Figure 2: Soft keys
The layout and function of the various keys is shown as a symbol in the bottom line of
the graphic display. The following table explains the significance of the symbols:
Symbol
Meaning
Explanation
During charge: Charging stopped
(“S” key only)
In the menu control: Change from one menu level to the
one below it
(changes are not accepted)
During charge: Charging continues
(“S” key only)
In the menu control: Select the next highest menu level or
confirm a changed setting
X
Cancel
Confirm
Cursor left
Controls the display cursor to the left
Cursor right
Controls the display cursor to the rights
Cursor up /
increase value
Controls the display cursor up, increases the value of the
displayed setting
Cursor down /
decrease value
Table 4: Soft key meaning
Controls the display cursor down, decreases the value of
the displayed setting
15/30
4156 EN
Operation
6.1.3
Graphic display and menu structure
The graphic display gives information on the charger and the charge status in symbol
form and/or as text. The charger can be operated or changes made to the charger setting
in conjunction with the soft keys below.
The following graphic shows the menu structure:
Battery-info
> Battery nominal volt.
Battery capacity
Charging program
Basic setting
> Language
> German
English
French
Italian
others*)
Time
> Time setting
Date setting
Display
> Lighting intensity
Contrast
Release information
Functions
> Switch-on delay
Battery service
> Deep discharge-start
Equalisation once
Equalisation perman.
Measured values
> No. of measured values
Configurate...
> 1. Measured value
:
5. Measured value
History
> End of charge data
> Data set 1
:
Data set 10
Power consumption
> Recharged kWh
> Last cycle
Total
Statistics
> No. of charge cycles
No. of charge finished
No. of forced switch over
No. of safety switch off
No. of pump failures
*) Indication only if an additional language has been loaded
Figure 3: Menu structure
16/30
4156 EN
Operation
6.1.4
Adjustable parameters
Settings can be made and parameter values changed within the menu. An overview of
the various setting ranges and default values is given in the following table:
Menu item
Default value
Setting range
German
German
Language
English
French
Italian
others*
Time
00:00
00:00 - 23:59
Date
01.01.2000
01.01.2000 - 31.12.2099
Lightning intesity
70 %
0 - 100 %
Contrast
100 %
0 - 100 %
Switch-on delay
0 Min.
0 - 999 Min.
Battery service
--
Deep discharge-start
Equalisation once
Equalisation perman.
5
1–5
Charging voltage
Charging voltage [V]
Charging current
Charging current [A]
Charging voltage [V/Z]
Charging voltage [V/Z]
Charging current [%]
Charging current [%]
Charged Ah
Charged Ah [Ah]
No. of measured values
1. Measured value ..
5. Measured value
Battery temperature [°C]
Charging time [h]
Date
Time
Status of modules
* * Indication only if an additional language has been loaded
Table 5: einstellbare Parameter
6.1.5
Function – Battery Maintenance
Deep discharge-start:
If the message “Check battery voltage" appears in the graphic display after the battery is
connected, this means the battery voltage is insufficient to start charging. In this case a
depletion start can be performed. Select the Deep discharge start function in menu item
Functions>Battery service and confirm with OK. The charger starts in deep discharge
start mode and charges until there is sufficient battery voltage to start normal charging.
M
Attention
Before activating depletion start, check that the charger is preset for the battery to be charged (voltage,
capacity, type).
17/30
4156 EN
Operation
Equalisation once/perman.:
If a compensation charge is to be carried out after the normal charge, the equalisation
charge function must be activated prior to charging. Select the Equalisation once
function in menu item Functions>Battery service and confirm with OK. When the
Equalisation once function is activated, a compensation charge is then carried out after
the next charge. If the Equalisation perman. function is activated, a compensation
charge is performed after every charge.
Z
6.1.6
Note
The compensation charge starts 24 hours after the start of the normal charge.
For some charging programs a compensation charge is included as standard. In this
case the compensation charge cannot be activated.
Function – Measured values
The Measured values function allows you to set how many and which measured values
are displayed in the graphic display during charging. See also Table 5.
6.1.7
Graphic Display Information
Information on the default settings of the charger and charging end data can also be
taken from the graphic display, see following table:
Menu item
Information
Sample value
Battery-info
Battery nominal volt.
80V
Battery capacity
200 Ah
Charging program
LP2 (E)PzS
Release information
SLH 200
Basic setting
V1.3 605676.03
History
End of charge data
Voltage:
2,7 V/Z
Current:
10,2 A
Charged Ah:
250,0 Ah
Charging time:
08:00 h
Time:
12:00
Date:
01.07.2004
Error messages
Power consumption
Last cycle
Total
Statistics
20 kWh
100 kWh
No. of charge cycles
No. of charge finished
No. of forced switch over
No. of safety switch off
No. of pump failures
Table 6: Graphic Display Information
6.1.8
Parameters – Consumption data
The History>Power consumption menu item shows how many kWh were taken from the
mains in the last charge and overall.
18/30
4156 EN
Operation
Z
6.1.9
Note
The kWh meter is not calibrated and is therefore not permissible for accounting
purposes.
Parameters - Statistics
The History>Statistics menu item allows the values of the internal event meter to be
called up. They are as follows:
6.2
Display information
Explanation
No. of charge cycles
Number of charges started
No. of charge finished
Number of correctly completed charges
No. of forced switch over
Number of compulsory changes made
No. of safety switch off
Number of safety cut-outs due to charge time exceeded
No. of pump failures
Number of pump failures (pressure contact not applied)
Charger Mains Connection
The charger is fitted with a mains cable and lead for the power supply.
• Connect the charger to the mains circuit by inserting the connector in the socket.
The charger logo will then appear in the graphic display for approx. 3 seconds. The
nominal data is then collated, and “Collect nominal data” appears in the graphic display.
The charger then changes back to the standard display:
80V/35A
Waiting for:
- Battery
V1.0 605676.00
Figure 4: Standard alternating display (e.g. for an 80 volts / 35 amp charger)
6.3
M
Battery Connection
Danger
The battery contains sulphuric acid which is highly corrosive. The floating metalic
parts of a battery are always live. Do not open the battery housing and do not touch
any non-insulated metal parts.
For this reason, work on batteries or battery systems must only be carried out:
by trained personnel and
with regard to the battery manufacturer’s operating instructions.
Corrosive acid gases can be produced when a battery is being charged. Acid gases
can cause short circuits in electrical equipment (risk of burning) and can corrode
components.
Therefore always position batteries next to charging stations in such a way that
any acid gases arising can be freely distributed (reduced) on site and can
dissipate.
19/30
4156 EN
Operation
F
Explosion hazard
Connecting an incorrect battery to the charger can result in damage to the charger
and battery: The battery could gas, decoct or even explode.
Always check that the charger is set for your battery type. If in doubt, contact the
relevant service department of the manufacturer.
We shall now describe how to connect the battery with a charging lead. Please note that
charging automatically begins when the battery is connected.
Connect the battery as follows:
•
Route the charging lead in such a way that nobody can trip over it and interrupt the
charging.
• Connect the charging lead to the respective socket of the battery cable.
Automatic charging begins.
6.4
Charging automatic start
Charging starts automatically if
− the charger is connected to the mains,
− the battery terminals are connected correctly to the charger,
− the battery voltage is at least 1.6 volts/cell,
− the On/Off switch has not been pressed.
At the start of charging, the charger performs a self test. During this time the message
“Start new charging” appears in the graphic display.
i
Start
new charging!
Figure 5: Charge start shown in graphic display
At the end of the starting process, the preset readings are cyclically shown in the graphic
display. For reading details, refer to Section 6.7.
20/30
4156 EN
Operation
Charging voltage
80 V
Charging current %
100 %
Charging current
35 A
Recharged Ah
110 Ah
Charging voltage V/C
2,0 V/Z
Figure 6: Standard reading display during charging
6.5
Interrupting a charge
The charger should not be interrupted during charging. However, external influences
may necessitate interruption of the process. Note however:
F
Explosion hazard
Risk of serious damage to persons and property if the battery is disconnected during
charging. The sparks produced could ignite gases which form during charging.
Always press the ‘S’ key first, if you have to interrupt the charge.
Then disconnect the charging lead from the battery.
Charging is interrupted when you press the ‘S’ key at the front of the panel (see also
Section 6.1.2).
• Press the ‘S’ key once. The charging status light goes out.
Charging is continued when you press the ‘S’ key again.
• Press the ‘S’ key again. The charging status light is lit yellow or orange, depending
on the charge status.
Z
6.6
Note
In normal operation, charging should not end before the automatic cutout. Premature
cutout will result in a depletion charge. This reduces the available battery capacity.
Charging automatic end
Charging automatically ends when the charging program is finished, i.e. the battery is
fully charged. The charge status light is then lit green. You can now use the battery. The
graphic display now shows “Charge over”, alternating with the charge end voltage data
(battery voltage in volts/cell), current (charge end current in A) and overall Ah (charged
capacity in Ah).
21/30
4156 EN
Operation
End of charge data
Voltage:
2,7 V/Z
Current:
10,5 A
Recharged Ah: 120,00 Ah
Charging
finished!
Figure 7: Alternating charge end display (RH picture: sample values)
6.7
Readings
As described in Section 6.1.4, certain readings can be displayed before, during and after
the charge. The number of readings can be set from 1 to 5. For the various charger
conditions the readings have the following significance:
Reading
Charger condition
Value displayed
Charge voltage*
Charge, conservation charge
Charge voltage
Recharge interval
Battery voltage
Charge end, conservation charge interval
Charge end voltage
Charge, recharge interval, conservation
charge
Charge current
Charge end, conservation charge interval
Charge end current
Charge, conservation charge
Charge voltage [V/C]
Recharge interval
Battery voltage [V/C]
Charge end, conservation charge interval
Charge end voltage [V/C]
Charge, recharge interval, conservation
charge
Charge current [%]
Conservation charge interval
Charge end current %
Charge, recharge interval
Current Ah total
Charge end, conservation charge interval
Charge end Ah total
Charge, recharge interval, conservation
charge
Current temperature
Charge end, conservation charge interval
Charge end temperature
Charge, recharge interval, conservation
charge
Current charge time
Charge end, conservation charge interval
Overall charge time
Charge, recharge interval, conservation
charge
Current date
Charge end, conservation charge interval
Charge end date
Charge, recharge interval, conservation
charge
Current time
Charge end, conservation charge interval
Charge end time
All charging phases
Decimal value, display for
charger service only
Charge current*
Charge voltage
[V/C]
Charge current %
(of charge rated
current)
Ah total*
Battery
temperature
Charge time*
Date
Time*
Module status
*Default values
22/30
4156 EN
Operation
6.8
Status messages
Status messages are shown via the graphic display and some are also shown via the
charge status light.
Graphic display
message
Charge Status Cause
Light
Charge
complete
alternating with
Charge end data
voltage: ... V/C
current: ... A
Ah total: ... Ah
Charging completed
properly.
Gree
n
Charge ended by
user
Off
Battery
disconnected during
charging
Red
Compulsory change
Re-charge!
Effect
Orange
Charging cancelled
prematurely by user
Battery not fully
charged
Battery disconnected
without pressing the ‘S’
key
Operating error! See
6.5
Battery not fully
charged
The max. permissible
main charge time has
been exceeded.
Safety function!
See also section 6.9
Mains failure
Charge time is
extended!
Display during
charge
Mains failure
Red
Display during mains
failure
Table 7: Status messages
23/30
4156 EN
Operation
6.9
Faults and Error Messages
The charger reports faults via the graphic display and the charging status light. The
following table gives an overview of the various fault causes and how to rectify them.
Graphic display
message
Max. charge time
exceeded
Charge complete
Max. charge
capacity exceeded
Charge complete
Deviation
I max!
Charge complete
Battery
disconnected during
charging
Compulsory change
Re-charge!
Mains failure
Mains disconnected
Cause
Charge
Status Light
Remedy
The max. permissible
charge time has been
exceeded.
The max. permissible
charge capacity has
been exceeded.
Safety cutout
Battery capacity too great
for charger
Battery faulty
Notify battery service
department
Red
Too much current from
power part. Control
system damaged.
Charger error
Notify service
department
Red
Battery disconnected
without pressing the ‘S’
key.
Operating error
Press ‘S’ key before
disconnecting the battery,
see 6.5.
Check charging lead
contacts.
The max. permissible
main charge time has
been exceeded.
Safety function!
Battery capacity too great
for charger
Notify battery service
department
Mains failure
Mains fuse faulty
Check / replace mains
fuse
Charge current less than
controller specification
Notify service
department
Note: the charger does not
cut out.
Output voltage greater
than 3.0 volts/cell
Notify service
department
Output voltage less than
minimum cell voltage..
Wrong battery connected.
Battery depleted. Activate
depletion charge start.
Notify battery service
department
Power module failure
Notify service
department
Red
Display works
normally
Red
Display during
mains failure
Deviation
I min!
Overvoltage cutout
Overvoltage
Check battery
voltage
Low voltage cutout
Low voltage
Check battery
voltage
Module failure
Module failure 1,2...n
Display works
normally
Red
Red
Red
Display flashes
alternately with
current charge
status, see 6.1.1.
24/30
4156 EN
Maintenance
Graphic display
message
Cause
Charge
Status Light
Pump error
Pressure drop
Display flashes
alternately
Red with
current charge
status, see 6.1.1.
Overtemperature
Temperature error.
Red
Remedy
Pressure switch on pump
does not close.
Power part
overtemperature.
Check ventilation slots.
Allow the power part to
cool.
Notify service
department
Red
Table 8: Faults and Error Messages
6.10
Switching off the charger
The charger is energised via the mains cable. Disconnect the charger from the mains if:
− the charger is not permanently required,
− the charger electronic system is to be reset to the start status (reset), e.g. if a fault is
displayed.
7
F
7.1
Maintenance
Warning: Hazardous Electrical Voltage!
The charger is an electric component conducting voltages and currents that are
hazardous to people.
The charger must therefore only be installed, opened, repaired and disassembled
where necessary by qualified electrical engineers.
The mains supply and a battery contact where necessary must be disconnected
before carrying out any work on the charger.
Cleaning, Inspection and Maintenance
The charger is maintenance-free and will operate trouble-free if used correctly.
• Dust or dirt on the charger can be removed with a dry cloth.
Check at least monthly that
• the mains connection is undamaged,
• the housing is undamaged,
• the charging lead insulation is undamaged,
• the charging lead plug is undamaged,
• the additional earth conductor in three-phase devices is undamaged
• all screw connections are tight.
If any faults are detected, immediately put the charger out of service; all faults must be
immediately rectified by specialist technicians.
25/30
4156 EN
Disposal
If the housing has to be opened for maintenance and repairs, contact the charger
manufacturer.
7.2
Changing the charging program
The charging program is factory set (see Appendix). If the charging program has to be
changed, please contact the manufacturer.
7.3
Spare parts
Should you require spare parts, contact the manufacturer, stating the charger data
contained on the data plate.
8
Disposal
If the charger is to be finally decommissioned, all relevant laws and regulations
concerning disposal at the time must be adhered to.
For further information contact the specialist disposal companies or the local authorities.
M
Attention
Electronic waste contains a wide range of plastic, metal and heavy metal components
which pose a high hazard risk to the environment. Electronic waste should therefore
be collected and disposed of separately from household or trade waste.
Electronic waste must be dealt with by your company’s disposal department who will
arrange to have it removed by special disposal companies.
Dispose of the charger's packaging separately. Paper, cardboard and plastic should be
recycled.
26/30
4156 EN
Appendix
9
Appendix
9.1
Dimension and Projection Drawings (not to scale)
8*
2
4 8
27
8*
2
4 8
27
2
45
39
2
39
2
45
8
560
443
780
FWG 3
* (FWG 3T)
FWG 6
* (FWG 6T)
FSG 12
Figure 8: Dimension drawings (*housing depth for T version)
328,5
328,5
FWG 3
334,8
450
12
,5
FWG 6
11,5
6,5
Figure 9: Drill diagrams
Housing type
Dimensions (mm)
Height
Width
Depth
FWG 3
443
392
278
FWG 3 T
443
392
428
FWG 6
560
392
278
FWG 6 T
560
392
428
FSG 12
780
458
452
S 22
1093
553
410
Table 9: Dimensions
27/30
4156 EN
Appendix
9.2
Specifications
Series
Model no.
SLH 200
Battery type
Characteristic curve
Wet cell or maintenance-free battery
See data plate
See section 6.4.1
0 to 40 °C
Temperature range
9.3
Input rated frequency
Protection class
Housing
47.5 – 63 Hz
Standards
73/23/EWG – Low voltage guideline
89/336/EWG – EMC guideline
EN 60335-2-29 – Safety
EN 61558 – Transformers
EN 60146 – Semi-conductor power converters
EN 61000-6-2 and EN 61000-6-3 – EMC
EN 61000-3-2 – Mains feedback
EN 61000-3-3 – Voltage fluctuations and flickering
EN 61000-4-4 – Burst and surge
IP 21 in accordance with EN 60529
See appendix ‘Dimension and Projection Drawings’
Model table
The charger model can be clearly identified from the model description in the data plate.
Out-
Out
Mains
Mains
Min.
Mains
put-
Model type
Housing
put
current
voltage
mains
cable
voltage
current
[V]
24
48
80
Weight
Mains plug
Charge
power
cable
consumption
[mm²]
kVA
fuse
[kg]
[A]
[A]
[V]
[A]
[mm²]
E230 G 24/ 20 B-SLH200
FWG 3*)
22
20
2,3
230
6
3 x 1,5
Schuko
16
0,5
E230 G 24/ 25 B-SLH200
FWG 3*)
22
25
3
230
6
3 x 1,5
Schuko
16
0,7
E230 G 24/ 35 B-SLH200
FWG 3*)
22
35
4
230
6
3 x 1,5
Schuko
16
0,9
E230 G 24/ 50 B-SLH200
FWG 3*)
22
50
6
230
6
3 x 1,5
Schuko
16
1,4
E230 G 24/ 65 B-SLH200
FWG 3*)
22
65
8
230
10
3 x 1,5
Schuko
16
1,8
E230 G 24/ 85 B-SLH200
FWG 3*)
22
85
10
230
16
3 x 1,5
Schuko
16
2,3
E230 G 24/100 B-SLH200
FWG 3*)
22
100
12
230
16
3 x 1,5
Schuko
25
2,8
E230 G 24/120 B-SLH200
FWG 3*)
22
120
14
230
16
3 x 1,5
Schuko
25
3,2
D400 G 24/150 B-SLH200
FWG 6*)
36
150
6,5
3 x 400
10
5 x 2,5
CEE 16
35
4,5
D400 G 24/170 B-SLH200
FWG 6*)
36
170
7,5
3 x 400
10
5 x 2,5
CEE 16
50
5,2
D400 G 24/190 B-SLH200
S 22
61
190
11
3 x 400
16
5 x 2,5
CEE 16
50
7,6
E230 G 48/ 35 B-SLH200
FWG 3*)
22
35
8
230
10
3 x 1,5
Schuko
16
1,8
E230 G 48/ 50 B-SLH200
FWG 3*)
22
50
11,6
230
16
3 x 1,5
Schuko
16
2,7
E230 G 48/ 65 B-SLH200
FWG 3*)
22
65
15
230
16
3 x 1,5
Schuko
16
3,5
D400 G 48/ 85 B-SLH200
FWG 6*)
36
85
7,5
3 x 400
10
5 x 2,5
CEE 16
16
5,2
D400 G 48/100 B-SLH200
FWG 6*)
36
100
8,8
3 x 400
10
5 x 2,5
CEE 16
25
6,1
D400 G 48/120 B-SLH200
FWG 6*)
36
120
10,3
3 x 400
16
5 x 2,5
CEE 16
25
7,1
D400 G 48/150 B-SLH200
FSG 12
71
150
12,5
3 x 400
16
5 x 2,5
CEE 16
35
8,6
D400 G 48/170 B-SLH200
FSG 12
71
170
14,5
3 x 400
16
5 x 2,5
CEE 16
50
10,0
D400 G 80/ 50 B-SLH200
FWG 6*)
36
50
7,8
3 x 400
10
5 x 2,5
CEE 16
16
5,4
D400 G 80/ 65 B-SLH200
FWG 6*)
36
65
9,6
3 x 400
16
5 x 2,5
CEE 16
16
6,6
D400 G 80/ 85 B-SLH200
FWG 6*)
36
85
12
3 x 400
16
5 x 2,5
CEE 16
16
8,3
D400 G 80/100 B-SLH200
FSG 12
71
100
14,3
3 x 400
16
5 x 2,5
CEE 16
25
9,9
D400 G 80/120 B-SLH200
FSG 12
71
120
17
3 x 400
20
5 x 2,5
CEE 32
25
11,7
D400 G 80/150 B-SLH200
FSG 12
71
150
21
3 x 400
25
5x4
CEE 32
35
14,5
D400 G 80/170 B-SLH200
S 22
96
170
25
3 x 400
35
5x6
CEE 32
50
17,3
*) FWG 3T bzw. FWG 6T bei Option Spezialfilter
Table 10: Model table
28/30
4156 EN
Appendix
9.4
Charging programs
The charging program (CP) is factory set. If the charging program has to be changed,
please contact the manufacturer. If, when you connect the battery the graphic display
shows “No CP set”, there is no valid charging program and no battery capacity preset. In
this case you should contact the manufacturer.
DC
volt.
Charger type
[V]
24
(E)PzS
(E)PzS Puls
(E)PzV
LP 2
Charge time without EC (*)
LP 3
LP 4
Charge program:
LP5
LP 7
Evolution
LP 8
7 - 8,5h
9 - 11,5h
12 - 14h
7 - 8,5h
12 - 14h
8 - 10h
10 - 12h
12h
12 - 14h
Cap. (Ah)
Cap. (Ah)
Cap. (Ah)
Cap. (Ah)
Cap. (Ah)
Cap. (Ah)
Cap. (Ah)
Cap. (Ah)
E 230 G 24/ 20 B-SLH200
90 - 120
130 - 150
170 - 220
110 - 140
120 - 150
80 - 110
110 - 130
130 - 170
90 - 120
E 230 G 24/ 25 B-SLH200
110 - 150
160 - 190
210 - 280
140 - 190
150 - 185
100 - 140
140 - 170
160 - 210
110 - 150
E 230 G 24/ 35 B-SLH200
150 - 210
220 - 270
290 - 390
190 - 260
190 - 260
140 - 195
195 - 230
225 - 290
150 - 210
E 230 G 24/ 50 B-SLH200
210 - 290
310 - 390
420 - 560
260 - 360
270 - 370
200 - 280
280 - 330
320 - 420
210 - 300
E 230 G 24/ 65 B-SLH200
300 - 380
410 - 500
540 - 720
350 - 460
380 - 480
260 - 360
360 - 430
420 - 540
300 - 380
E 230 G 24/ 85 B-SLH200
390 - 500
530 - 650
710 - 940
460 - 610
490 - 630
340 - 470
470 - 560
550 - 710
380 - 500
E 230 G 24/100 B-SLH200 460 - 590
630 - 770
830 - 1110
540 - 710
605 - 740
400 - 560
560 - 670
645 - 830
450 - 580
E 230 G 24/120 B-SLH200 550 - 710
750 - 920 1000 - 1330
650 - 860
730 - 890
480 - 675
675 - 800
775 - 1200
540 - 700
680 - 880
D 400 G 24/150 B-SLH200 680 - 880 940 - 1150
-
810 - 1070
900 - 1110
600 - 840
840 - 1000
970 - 1250
D 400 G 24/170 B-SLH200 770 - 1000 1060 - 1310
-
920 - 1210 1030 - 1260
680 - 940
940 - 1130
1095 - 1420 775 - 1000
1050 - 1270 1225 - 1580
-
-
1030 - 1360
-
750 - 1050
E 230 G 48/ 35 B-SLH200
150 - 210
220 - 270
290 - 390
190 - 260
190 - 260
140 - 195
195 - 230
225 - 290
150 - 210
E 230 G 48/ 50 B-SLH200
210 - 290
310 - 390
420 - 560
260 - 360
270 - 370
200 - 280
280 - 330
320 - 420
210 - 300
E 230 G 48/ 65 B-SLH200
300 - 380
410 - 500
540 - 720
350 - 460
380 - 480
260 - 360
360 - 430
420 - 540
300 - 380
D 400 G 48/ 85 B-SLH200
390 - 500
530 - 650
710 - 940
460 - 610
490 - 630
340 - 470
470 - 560
550 - 710
380 - 500
D 400 G 48/100 B-SLH200
460 - 590
630 - 770
830 - 1110
540 - 710
605 - 740
400 - 560
560 - 670
645 - 830
450 - 580
D 400 G 48/120 B-SLH200
550 - 710
750 - 920 1000 - 1330
D 400 G 48/150 B-SLH200
680 - 880 940 - 1150
D 400 G 48/170 B-SLH200 770 - 1000 1060 - 1310
80
LP 5
Cap. (Ah)
D 400 G 24/190 B-SLH200 860 - 1120
48
WF 200 plus WF 200 plus Champion
-
650 - 860
730 - 890
480 - 675
675 - 800
775 - 1200
540 - 700
-
810 - 1070
900 - 1110
600 - 840
840 - 1000
970 - 1250
680 - 880
-
1095 - 1420 775 - 1000
920 - 1210 1030 - 1260
680 - 940
940 - 1130
D 400 G 80/ 50 B-SLH200
210 - 290
310 - 390
420 - 560
260 - 360
(**)
200 - 280
280 - 330
320 - 420
(**)
D 400 G 80/ 65 B-SLH200
300 - 380
410 - 500
540 - 720
350 - 460
(**)
260 - 360
360 - 430
420 - 540
(**)
D 400 G 80/ 85 B-SLH200
390 - 500
530 - 650
710 - 940
460 - 610
(**)
340 - 470
470 - 560
550 - 710
(**)
D 400 G 80/100 B-SLH200
460 - 590
630 - 770
830 - 1110
540 - 710
(**)
400 - 560
560 - 670
645 - 830
(**)
D 400 G 80/120 B-SLH200
550 - 710
750 - 920 1000 - 1330
650 - 860
(**)
480 - 675
675 - 800
775 - 1200
(**)
D 400 G 80/150 B-SLH200
680 - 880 940 - 1150
-
810 - 1070
(**)
600 - 840
840 - 1000
970 - 1250
(**)
D 400 G 80/170 B-SLH200 770 - 1000 1060 - 1310
-
920 - 1210
(**)
680 - 940
940 - 1130
1095 - 1420
(**)
(*) 1.5h less recharge time with EC
(**) Higher battery capacities and 80 V applications on request.
Table 11: Charging programs
29/30
4156 EN
Appendix
9.5
Spare parts catalog
30/30
4156 EN
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising