tbs electronics omnicharge OC24-20 Owner's Manual

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tbs electronics omnicharge OC24-20 Owner's Manual | Manualzz

Professional programmable battery chargers omnicharge OC

12-40 (12V-40A)

omnicharge OC

12-60 (12V-60A)

omnicharge OC

24-20 (24V-20A)

omnicharge OC

24-30 (24V-30A)

EN

Owner’s manual

Thank you for purchasing a TBS Electronics professional programmable battery charger.

Please read this owner’s manual for information about using the product correctly and safely.

Keep this owner’s manual close to the charger for future reference.

2. Dipswitch settings

During step 3 of the installation sequence, you can alter the factory settings of the dipswitches to change the charger’s functionality on a few points. The following settings can be made :

1. LOC. / EXT.

: Choose to configure the battery type locally (using dipswitch 2 and

3), or override these settings and setup the charger externally using the TBS Dashboard for Windows software.

on

Setting ON

1 on

: The local dipswitch settings of dipswitch 2 and 3 are ignored and configuration must be done externally.

Setting OFF : The local dipswitch settings are used (factory default).

1

2 & 3. BATTERY

TYPE

DS2 DS3 on on

2 on

2 on

2 on

3 on

3 on

3 on

: Select the type of lead-acid battery that you wish to charge. Each setting represents the best charging voltages for the given battery type listed below. If there are still other voltage levels or different charging programs needed for your battery, please use the TBS

Dashboard software to create your own and store this as Custom setting inside the charger.

BATTERY TYPE (12V/24V)

Flooded (factory default) absorption voltage 14.4V/28.8V, float voltage 13.5V/27.0V

GEL absorption voltage 14.2V/28.4V, float voltage 13.5V/27.0V

AGM absorption voltage 14.3V/28.6V, float voltage 13.3V/26.6V

Custom not available when dipswitch 1 is set to OFF (LOC.)

2 3

!

CAUTION

Invalid battery type settings can cause serious damage to your batteries and/or connected battery loads. Always consult your battery’s documentation for the correct charge voltage settings.

4. BYPASS REMOTE

SW.

: Bypasses the remote switch connection when no remote switch is connected.

on

Setting ON

4 on

Setting OFF

4

:

: remote switch connection terminals are bypassed (factory default).

remote switch connection terminals are open. A remote switch must be connected and switched ON in order to activate the charger. The local on/off switch on the frontpanel always overrides the remote switch. So in order to use the remote switch, the local on/off switch must be in the 'power on' or 'forced float’ position.

The fourth stage called “Pulse”, will perform a short refresh charge of approximately 1 hour each 7 days while the charger operates in the Float stage. This will keep the battery in optimal condition while prolonging it's lifetime. The battery can remain connected to the activated charger continuously, without risk of overcharging.

When the battery temperature sensor is installed, the charger automatically compensates the charge voltages against battery temperature. This means that the charge voltages are slightly increased at lower temperatures and decreased at higher temperatures (-30mV/°C at 12V chargers and -60mV/°C at 24V chargers). This way, overcharging is prevented which prolongs your battery's lifetime. A connected battery temperature sensor also enables the battery temperature protection, which stops the charging process when the battery's temperature is below -20°C or above +50°C.

When the standard selectable charging programs do not satisfy your requirements, or when different voltage- and current levels are needed, you can use the optional TBSLink communication kit and create your own charge programs using TBS Dashboard. Up to 8 different stages can be linked together and all individual stages can be configured extensively. Please contact your TBS equipment supplier for further information on the

TBSLink communication kit.

The Auxiliary battery output always follows the charge process of the Main battery automatically. You can use this output to charge a second (smaller) battery, like a starter battery. It is not possible to use this output when the Main battery is not connected!

4. Charging batteries

Before you start to charge batteries, read all enclosed safety instructions and warnings while following all safety precautions about working with batteries.

The list below globally describes the steps to follow for charging batteries :

1. Push the charger switch in the “O” (Off) position and disconnect the AC supply to the

charger

2. If possible disconnect or switch off all loads from the battery

3. Connect the battery to the charger

4. Switch on the AC supply and activate the charger by pushing the charger switch in the

“I” (power on) position. After a two tone beep, the charger will start the charging proces.

5. After charging is completed, push the charger switch in position “O” and switch off the

AC supply again, before disconnecting the battery. Or, keep all connections and the

charger switch position untouched and just re-connect all battery loads.

TBS ELECTRONICS BV

De Marowijne 3, 1689AR, Zwaag, The Netherlands http://www.tbs-electronics.com

5. Forced float mode

The forced float mode can be activated by pushing the main switch into position “II”. In this mode, the output voltage of the charger is set constantly to the float voltage (value is depending on selected battery type) while being able to deliver full rated output current.

Since no automatic charging programs are activated in this mode, it can be used for constant voltage charging or operating the charger as a battery buffered power supply.

3. Charge programs

All standard selectable charge programs (using dipswitches 2 and 3), perform a four stage

IUoUoP charging process comprising of a “Bulk” , an “Absorption”, a “Float” and a “Pulse” stage. The image below visualizes the four stage charging process :

Before proceeding with this owner’s manual, please make sure you have carefully read the enclosed safety flyer and the installation guide on the backside of this paper!

1. Omnicharge display and control overview

V(12V)

14.4V

13.5V

12.5V

Bulk Absorption Float Pulse Float Bulk

V(24V)

28.8V

27.0V

25.0V

output current bar

indicates the percentage of delivered output current.

Charge status bar

A rough indication of the charging progress.

100% full (ready)

80% full

50% full empty

“power on, off, forced float” switch

When in position “O” the

When switched to “I” the charger switches on in normal charging mode.

When switched to “II” the charger operates in forced float mode. See chapter 5 for more details on the forced float

“charger on” or “error” indicator

indicator mode : description : continuous green flashing red (1 flash per sec.) power on, normal operation

2) battery error flashing red (2 flashes per sec.) charger overload flashing red (3 flashes per sec.) high charger temperature 3) flashing red (4 flashes per sec.) charger error (return for service) note 1 : When the switch is in position “O”, it does not interrupt any internal AC or DC sources.

This means that there are still lethal voltages present inside the charger! In position “O”, the charger will still consume a small amount of AC current.

note 2 : A battery error can appear for several reasons. These are : battery voltage is too note 3 : low (too deeply discharged) or too high and battery temperature is too low or too high

(only available when battery temperature sensor is connected). The charger will not restart automatically in battery error mode, except when this error was generated due to a too low battery voltage or a too low battery temperature.

The charger automatically restarts when the temperature is below an acceptable level.

Ich

Imax absorption time-out max. 4hrs global charge time-out max. 8hrs float time-out

7 days battery load turned on

(Iload>Imax) restart four stage charging process pulse

1hr t

10% Imax t

In the Bulk stage, the charger delivers full output current and typically returns approximately 80% of charge back into the battery once the absorption voltage is reached.

During this stage, indicators and will be lit depending on the Bulk charge progress.

When the absorption voltage has been reached, the Absorption stage will be entered and indicator will be lit. This stage will return the final 20% of charge to the battery. The output voltage is kept at a constant level and the charge current decreases as a function of the battery's state of charge. When the charge current has dropped below a certain value or when the maximum absorption timer has been expired, the Float stage will be entered.

Indicator will be lit and an acoustical message will sound, indicating that the battery is full. In this stage the battery voltage will be held constant at a safe level for the battery. It will maintain the battery in optimal condition for as long as the battery remains connected to the activated charger. Connected battery loads will be directly powered by the charger up to the charger's maximum output current level. When even more current is drawn, the battery must supply this which results in a declining battery voltage. At a certain battery voltage level, the charger jumps back to the Bulk stage and will finalize a complete four stage charging process again, once the battery load consumption has dropped below the charger's maximum output current level.

6. Equalizing a flooded battery

If you are using a flooded lead acid battery, an occasional equalization charge cycle may be recommended by the manufacturer. This might also be true when the flooded battery has been very deeply discharged or often charged inadequately. During equalization, the battery will be charged up to 15.5V (or 31V for 24V models) at a reduced output current level. Before starting an equalization charge cycle, the following caution statements must be read carefully :

Equalization should only be performed on a flooded (wet) lead acid battery.

!

damaged by this process.

batteries.

CAUTION

During equalization, the battery generates explosive gasses. Follow all the battery

!

vicinity.

applied to the battery during this process may be above safe levels for some loads.

CAUTION

The Omnicharge chargers cannot automatically determine when to stop the

!

2 hours time-out timer of your charger is only intended as a safety feature, but may not be sufficiently short to prevent battery damage. Therefore, equalizing a battery is always a process that must continuously be supervised by the user.

When equalizing the main battery, the smaller battery connected to the auxiliary

!

Since equalization is only allowed for flooded (wet-) lead acid batteries, the Omnicharge chargers will only allow this function to be available when the “Flooded” charging program is selected (see chapter 2). Besides this, the charger also needs to have a full charge cycle completed and is operating in the Float mode. When these two conditions are met, the equalization charge mode can be activated by pressing the recessed pushbutton on the bottom side of the charger (see installation guide step 4) for 3 seconds until all charge status indicators start flashing. The charger will allow a maximum equalization time of 2 hours before it automatically jumps back to Float mode. If the specific gravity of each cell does not match the battery manufacturer's specifications yet, you can initiate a new 2 hours equalization cycle by pressing the pushbutton for 3 seconds again. Always keep on checking the specific gravity of each cell repeatedly during the equalization process. When these values are correct, you can manually exit the equalization process by pressing the recessed pushbutton once. The charger will then return to the Float mode.

7. Alarm relay

This charger is equipped with a potential free alarm relay. This relay will be activated when the charger shuts down and jumps to an error mode as described in chapter 1 (except for high/low battery temperature). The alarm relay de-activates again when the error mode has been cleared and the charger is running in normal operating mode again. On pins 1,2 and 3 of the 5 pins screw terminal located in the connection compartment, both normally closed and normally open contacts are available. Please make sure not to exceed the maximum relay contact rating of 60V and 1A to avoid damaging the relay.

8. Warranty conditions

TBS Electronics (TBS) warrants this charger to be free from defects in workmanship or materials for 24 months from the date of purchase. During this period TBS will repair the defective charger free of charge. TBS is not responsible for any costs of the transport of this charger.

This warranty is void if the charger has suffered any physical damage or alteration, either use in an unsuitable environment.

This warranty will not apply where the product has been misused, neglected, improperly installed or repaired by anyone other than TBS. TBS is not responsible for any loss, damage or costs arising from improper use, use in an unsuitable environment, improper installing of the charger and charger malfunctioning.

Since TBS cannot control the use and installation (according to local regulations) of their products, the customer is always responsible for the actual use of these products. TBS products are not designed for use as cricital components in life support devices or systems, that can potentially harm humans and/or the environment. The customer is always responsible when implementing TBS products in these kind of applications. TBS does not accept any responsibility for any violation of patents or other rights of third parties, resulting from the use of the TBS product. TBS keeps the right to change product specifications without previous notice.

1) Examples of improper use are :

- Too high AC input voltage applied

- Connecting wrong batteries (too high battery voltages)

- Mechanical stressed enclosure or internals due to harsh handling and/or incorrect

packaging

- Contact with any liquids or oxidation caused by condensation

9. Declaration of conformity

MANUFACTURER : TBS Electronics BV

ADDRESS : De Marowijne 3

1689 AR Zwaag

The Netherlands

Declares that the following products :

PRODUCT TYPE

MODELS

:

:

Professional programmable battery charger

OC12-40, OC12-60, OC24-20, OC24-30

Conforms to the requirements of the following Directives of the European Union :

EMC Directive 2004/108/EC

Low Voltage Directive 2006/95/EC

The above product is in conformity with the following harmonized standards :

EN61000-6-3 : 2001 EMC - Generic Emissions Standard

EN61000-6-2 : 2005

EN60335-1 : 1999

EMC - Generic Immunity Standard

Generic safety standard

EN60335-2-29 : 2004 Safety requirements for battery chargers

EN

INSTALLATION GUIDE

- Please read this document very carefully to avoid charger malfunction, shock and/or fire hazards!

- This document provides a brief overview of a stand alone charger installation. For long term safe and troublefree operation, it is very important to read the owner’s manual on the rear side of this paper as well!

- Please follow the exact installation sequence as given below. Skipping one or more steps could result in charger malfunctioning or shock and/or fire hazards!

2

CHARGER MOUNTING

= Approved

= Not recommended

3

CONNECTION COMPARTMENT WIRING DETAILS

1

UNPACKING

The charger package should contain the following items :

- Battery charger

- 3m temperature sensor

- This Installation guide / Owner's manual

- Safety flyer

- WEEE flyer

- 2x M8 crimp terminals.

- 4x Mounting screws.

After unpacking, check if the

!

when the enclosure shows any visual damage caused by harsh handling, or when it has been dropped accidentally.

Contact your local supplier for further information.

vertical wall mounting

(IP21) floor mounting vertical wall mounting

(upside down) ceiling mounting horizontal wall mounting

187mm

126mm drilling template

Access the connection compartment by removing the two screws and sliding the red cover downwards.

WARNING

This charger must be earthed. Always connect the PE wire!

PE / EARTH

GFCI/RCD

N

L1

Use a wire size of larger for the AC wires

Red cable

Black cable

Fuse

Fuse

For explanation on the dipswitch settings, please consult chapter 2 of the owner’s manual.

!

CAUTION

Please feed all connection compartment wiring through the rubber grommets and plastic gland.

max. length 50m (150ft)

!

CAUTION

Double check for correct polarity, before connecting the battery cables to the battery!

MAIN BATTERY

AUXILIARY OR

STARTER

BATTERY

(OPTIONAL)

!

CAUTION

Always connect the negative (-) cable directly on the negative terminal of the battery, or on the “loadside” of a current shunt. Always keep positive and negative cables close to each other to minimize electromagnetic fields.

1A fuse

Remote on/off switch

+60V max.

Alarm indicator light (1A max.)

- (return)

4

BOTTOM SIDE CONNECTIONS

Recessed pushbutton location to activate or deactivate the equalisation charge mode (see chapter 6 of the owner’s manual)

Universal Remote Control (optional)

MAIN BATTERY

Battery temperature sensor for temperature compensated charging

<

Alarm output expander art.# : 5055630

1

9

Alarm terminals

NO

NC

CM

NO

- External 1

- External 1

- External 1

- External 2

NC

CM

- External 2

- External 2

- External 3

NO

NC

CM

- External 3

- External 3

>

>

Alarm Output Expander (optional)

When all connections are made and double checked, slide the red connection compartment cover to it’s original position again and relocate the two screws.

Main battery cable sizes :

Model <3m(10ft) / 3-6m(10-20ft)

OC12-40 :

OC12-60 :

OC24-20 :

OC24-30 :

16mm²(AWG5) / 25mm²(AWG3)

25mm²(AWG3) / 35mm²(AWG2)

6mm²(AWG9) / 10mm²(AWG7)

10mm²(AWG7) / 16mm²(AWG5)

Auxiliary battery cable sizes :

Model 0-6m(0-20ft)

All : 2.5mm²(AWG13)

Troubleshooting guideline

Problem charger is not working (all indicators are off).

‘Battery error’ keeps on appearing.

‘Charger overload’ or

‘Battery error’ keeps on appearing.

Possible cause

Power switch in OFF (0) position.

No or too low AC input voltage.

Remedy

Push the power switch in the

‘I’ or ‘II’ position.

Check AC wiring and input voltage level.

Remote switch or remote control have deactivated the charger.

Activate the charger remotely or check dipswitch

4 for correct setting.

Battery voltage is too low or too high.

Check the battery for damaged or shorted cell(s).

Check if DC bus voltage is being pushed by another charging device.

Check low or high battery voltage alarm settings using

TBS ‘Dashboard’.

Battery temperature is too low or too high (only relevant when the battery temperature sensor is installed).

Check and try to correct the ambient temperature around the battery.

Check if the temperature sensor is not damaged.

There is a short circuit on the charger output.

Check DC wiring.

Check battery condition.

Charger is being overloaded in ‘Forced float’ mode.

When the charger is used in

‘Forced float’ mode without a battery attached (not recommended), try to reduce the load.

Problem

‘High charger temperature error’ keeps on appearing.

Note : Do not turn off the charger when it's operating in an ‘High temperature error’. The charger needs this error time to cool down.

‘Charger error’ keeps on appearing.

Charge voltage is too low.

Charge current is too low.

Possible cause

Airflow around the charger is obstructed.

Too high ambient temperature.

An internal error is detected.

Remedy

Make sure there is at least

10 centimeters of clearance around the charger. Remove any items placed on or over the charger. Keep the charger away from direct sunlight or heat producing equipment.

Move the charger to a cooler environment or provide additional cooling by an external fan.

Please return the charger to your nearest dealer for service.

The charge voltage is being compensated by the battery temperature sensor to protect your battery.

Do nothing or try to cool down the ambient temperature around the battery.

Wrong charge program selected by the dipswitches or custom charge program needs to be re-adjusted.

Select the correct charge program or adjust the custom charge program using TBS ‘Dashboard’.

DC cables too thin.

Battery load current is higher than the charger’s output current.

Install larger DC cables. See the DC cable size table in the installation guide.

Reduce or remove the battery load.

High ambient temperature.

Try to cool down the ambient temperature around the charger.

Charger is operating in the absorption charging stage.

Do nothing. The battery is almost fully charged and consumes less current by itself.

Technical specifications

Parameter

OC12-40 OC12-60 OC24-20 OC24-30

Input voltage

Full load consumption

AC input current (115V/230V)

Full load efficiency

Nominal output voltage 1)

Total output current 1) 4) (Aux.)

Charge characteristic 2)

Absorption voltage 2)

Float voltage 2)

Equalize voltage 2)

Supported Battery types 2)

Recomm. battery capacity 3)

DC current draw (charger off)

Operating temp. range 4)

Storage temp. range

700VA

100-260VAC / 47-63Hz / PF ³ 0.95

1050VA 700VA 1050VA

6A/3A

88%

9A/4.5A

88%

6A/3A

91%

9A/4.5A

91%

12V 24V

40A(4A) 60A(4A) 20A(2.5A) 30A(2.5A)

IUoUoP, intelligent 4-stage, temperature compensated

14.4V

13.5V

28.8V

27.0V

15.5V

31.0V

Flooded / GEL / AGM / Custom

80-400Ah 120-600Ah

£ 5mA

50-200Ah

£ 4mA

70-300Ah

-20°C … +50°C (humidity max. 95% non condensing)

-40°C … +80°C (humidity max. 95% non condensing)

Cooling

TBSLink enabled

Protected against

Indications

DC output connections

AC input connections

Enclosure body size

Total weight

Protection class

Standards

Variable speed fan controlled by temperature and load

Yes

Low AC voltage, output short circuit, high temperature, battery overcharging and reverse polarity (fuse)

Power on, output current bar, state of charge bar, error

M8 bolts (main output), Screw terminals (auxiliary output)

Screw terminals

351 x 210 x 114mm

5.8 kg

IP21 (mounted in upright position)

CE marked meeting EMC directive 2004/108/EC and

LVD 2006/95/EC complying with EN60335-1, EN60335-

2-29

Note: the given specifications are subject to change without notice.

1)

Maximum output current tolerance is +/-3%. Maximum setpoint voltage deviations are +/- 0.1V for 12V

and +/- 0.2V for 24V models. All setpoint voltages are temperature compensated when battery

temperature sensor is connected.

2)

Value is programmable

3) Always consult battery manufacturers specifications for maximum allowable charge current

4) At higher ambient temperatures (>40°C), maximum output current may be reduced automatically

OC20-60 Manual Rev5e / Printed in The Netherlands

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Questions and Answers

What are the different charging programs available on the TBS Electronics Omnicharge OC24-20?
The TBS Electronics Omnicharge OC24-20 offers four standard selectable charge programs: Flooded, GEL, AGM, and Custom.
What is the recommended battery type setting for a flooded lead acid battery?
For a flooded lead acid battery, the recommended battery type setting is 'Flooded'.
What is the maximum relay contact rating for the alarm relay?
The maximum relay contact rating for the alarm relay is 60V and 1A.
What is the absorption voltage for a Flooded battery?
The absorption voltage for a Flooded battery is 14.4V.
What is the float voltage for a GEL battery?
The float voltage for a GEL battery is 13.5V.
What is the pulse stage duration?
The pulse stage duration is approximately 1 hour every 7 days.
What is the maximum absorption time?
The maximum absorption time is 4 hours.
What is the float time?
The float time is 7 days.

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