AXItrac

TRACTION BATTERY CHARGER

OPERATING INSTRUCTIONS

Use

The AXItrac charger is intended for industrial applications, mainly for charging of traction batteries for electric high lift trucks and manipulation and cleaning technology devices. With regard to the perfect electric parameters, it is suitable even for different types of batteries (e.g. maintenance-free batteries, gel batteries,

AGM etc.).

Operational safety

The following requirements must be met when operating the chargers:

- chargers are for indoor use only

- proper ventilation must be insured during charging

- charger can be connected only to a regular main supply

- prevent spark ejection and open flame near the battery, explosion hazard during charging!

- charger must not be operated without the cover

- charge only chargeable batteries

- during the charging do not touch the wires leading to the battery terminals

- do not transfer the charger during the charging

- it is not allowed to disconnect the battery during the charging

- charger may be operated only by qualified staff

- changes of charger parameters may be made only by a service engineer

Technical parameters

Basic technical parameters

Input voltage range

Input protection

Efficiency

Power factor

Tolerance for voltage measurement

Tolerance for current measurement

LVD see type label

-10 %, +15% circuit breaker, C or D type characteristics up to 92% (one-phase); up to 95% (three-phase)

0,98 (one-phase); 0,95 (three-phase)

±2 %

±2 %

EN 60950-1, 4250 VDC I/O, protection IP20

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AXItrac

NABÍJEČ TRAKČNÍCH BATERIÍ

EMC

Protection class

Contamination class

Ambient temperature operational

Ambient temperature storage

EN 61000-6-2, EN 61000-6-4

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-10 °C až +40 °C, max. rel. air humidity 95%, (non-condensing) dry place, -25 °C to +80 °C, max. rel. humidity 95%

Charger installation

The charger is designed for operation in a vertical position. It can be placed on the floor or hung on the wall.

Chargers 24-60, 24-100, 48-30, 48-50, 80-27, 96-25 can be operated either in a vertical or horizontal position. Hanging on the wall is more suitable for dusty environments.

Charger cooling is very important and must be considered during installation. The air is sucked by fans from the bottom of the case and exhausted through vent holes in the sides and in the front part. There must be a minimum clearance of 100mm from other devices in order to ensure free air circulation.

The charger is supplied by socket plug. Protection must be made in the charging station wiring.

A PE-wire must be connected in the installation.

A two-pole cable is for the battery, the plus pole is marked in red. The voltage drop in the cable is calculated in the charging process, therefore it is not allowed to change the cable´s length and type without the modification of the parameter in the Set Up Menu.

Optional equipment

Optionally there is a hose leading out of the charger for air blasting into the battery cells for electrolyte circulation.

Optionally a water-supply valve and a battery identification unit can be connected.

The battery identification module is connected using a twin cable. The temperature sensor is placed between the battery cells.The electrolyte level sensor is placed directly in the battery cell.

Function of the charger

For charging (standard and special modes) the following sequence of steps must be performed:

- connect the charger to the supply network,

- connect a battery to the charger,

- the standard charging procedure will start, proceed and end automatically, without pressing any buttons,

- regeneration modes, if necessary, can be started by pressing the REGEN button,

- disconnect the battery when the charging process has been completed (the green lamp flashes permanently),

- if the battery has to be disconnected during the charging process (the green signal lamp blinks), terminate the process by pressing the STOP button and disconnect the battery,

- the charger cannot be disconnected from the supply network until BATTERY NOT CONNECTED appears on the display (this is suitable for longer operation pauses; not necessary during regular use).

Main charging

Main charging starts automatically after a battery is connected, without REGEN or STOP button is pressed.

Do not press REGEN button, when main charging is required.

Battery parameters will be read and after 15s charging will start automatically. If the IM is connected, the parameters will be read from this module.

The main charging proceeds according to one of three preset charging curves.

The green LED flashes - charging proceed

During charging are displayed: number of supplied ampere hours (Ah), charging phase code (TST-battery test, PRE-precharging, CHA-charging, PST-postcharging), time from the start of the charging process

(hh:mm), unit voltage per 1 cell (V), current flowing to the battery (A), error code

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The green LED lights steadily - the battery is charged, charging process is succesfully finished

The red LED lights - failure by charging

Special modes

Equalization

If the voltage of individual cells in the battery is different, it is advisable to perform equalization. It can be started manually or automatically.

Manual equalization

This mode is entered into by pressing the REGEN button within the 15s waiting time after the battery is connected. The button must be pressed and held for 0.5 to 3s. Then the main charging process is started. After it is successfully completed, the equalization mode will be started automatically. The battery will be charged with a current at the value set in the Parameters menu for the set time. Then the charging mode will be finished automatically.

Automatic equalization

If a battery with a voltage lower than 1.9 V/cell is connected to the charger, the equalization will be performed automatically without pressing the REGEN button. However, the main charging process will take place before the equalization, as described in the previous chapter.

Desulphating

This mode is used to remove the lead sulphate crystals from the plates in the cells.

This mode is entered into by pressing the REGEN button within the 15s waiting time after the battery is connected. The button must be pressed and held for more than 3s. Then this charging mode is started. The battery is charged with a current whose value has been set in the Parameters menu. Desulphating is finished automatically as soon as the voltage of 2.40 V/cell is reached and the calculated number of Ah is filled.

Maintaining charging

In case the battery remains connected to the charger after the charging has been successfully finished (i.e. on Sundays and holidays), the battery will be charged periodically. The parameters of the maintaining charging can be modified.

Postponed charging

This function allows to postpone the start of the charging , i.e. at night time.

The time of the postponed charging can be set and modified by PC in a menu.

The charging will start automatically when the selected time is reached.

Data entry and data statement by means of a PC

The charging parameters are set in the form of tables and graphs. All parameters for correct and gentle battery charging must be set. The PC is connected to the charger using the USB connector.

First, the communication program “AXItrac configurator” must be installed.

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AXItrac

TRACTION BATTERY CHARGER

Error code

Description of the error

E1x Failures of the starting condition or of the battery

E11 The battery voltage is lower than 1,9 V/cell.

E12 Battery was disconnected during the charging process without the charger having been switched off properly. The message is displayed for 30s after battery disconnection.

E13 Battery temperature >t1; if this is detected before charging, the charging will not start. If the temperature exceeds this limit during charging, the current value will sink to 50% of the original value and the charging will be completed. If the temperature then sinks under t1, the current will increase to its original value.

E3x Deviations of charging current

E31 The current <80% the required value.

E32 The current >110% the required value.

E5x Failures of the aeration system

E51 Low pressure in the aeration system, If the pressure is not restored and the correct pressure value is not reached within 1 minute, the charging current value decreases to the 80% Ichar-value in the “charging” and the pump is not switched any more.

E52 High pressure in the aeration system, fault in the pump or in hose system. If the pressure is not restored and the correct pressure value is not reached within 1 minute, the charging current value decreases to the 80% Ichar-value in the “charging” and the pump is not switched any more.

E53 More than 5 faults in the aeration pump (pressure too low or too high) during the common charging cycle; the charging current value decreases to the 80% Ichar-value in the “charging” and the pump is not switched any more.

E54 Leakage in the air system, the pressure goes down too fast.

E55 Charger blockage due to pump faults.

F1x Failures of the starting condition

F11 Battery with high impedance.

F12 The initial battery voltage is higher than 2,7 V/cell, i.e. not suitable battery.

F13 The battery voltage is higher than 2,3 V/cell, battery will not be charged.

F14 The battery voltage during the charging is higher than 3,0 V/cell, after 10 seconds the charging is stopped.

F16 Battery temperature during charging >t2, the charging will stop (for control unit temperature sensor communication error too).

F2x Incorrect time of the charging

F21 The pre-charging phase takes more than setting value, the charging is stopped.

F22 The pre-charging and charging phases take more than setting value, the charging is stopped.

F3x Deviations of charging current

F31 The charging current <50% of the desired value, watchdog is activated, after 60 seconds the charging is stopped.

F32 The charging current >120% of the desired value, watchdog is activated, after 60 seconds the charging is stopped.

F33 The charging current >120% of the Inom - value, watchdog is activated, after 15 seconds the charging is stopped.

www.axima.cz

AXIMA, spol. s r.o., Vídeňská 125, Brno CZ 619 00 tel.: +420 547 424 011 • fax: +420 547 424 030 • e-mail: [email protected]

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