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Important note:
Do not use the device in applications for which it was not originally
designed! Only for use by qualified electrical personnel. Read
operating instructions carefully and always refer to the guidelines of
the battery manufacturer!
State: 22.08.2019
Manual
DBL1200HV-60
190822_Manual_DBL1200HV-60_EN_#33573.docx
Page 1 of 33
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Table of Contents
Related Manuals for EDWANZ group Deutronic DBL1200HV
Summary of Contents for EDWANZ group Deutronic DBL1200HV
- Page 1 Manual DBL1200HV-60 Important note: Do not use the device in applications for which it was not originally designed! Only for use by qualified electrical personnel. Read operating instructions carefully and always refer to the guidelines of the battery manufacturer! State: 22.08.2019 190822_Manual_DBL1200HV-60_EN_#33573.docx Page 1 of 33...
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Page 2: Table Of Contents
Contents Safety Instructions ....................3 Device Information ....................12 2.1. Device Description and Scope of Supply ............. 12 2.2. Technical Data ..................... 12 2.2.1. Input ....................... 12 2.2.2. Output ......................13 2.2.3. Environmental Requirements................. 13 2.3. Unpacking ......................13 2.3.1. Checking for completeness and transport damage ........13 2.3.2. -
Page 3: Safety Instructions
1. Safety Instructions The device contains components which are likely to generate electric arcs and sparks, thus the device has to be placed in a special housing or in a room provided for this purpose during operating. Warning: When charging batteries explosive gases may occur. Therefore, fire naked lights and sparks should be avoided. - Page 4 General: The device is designed according to all relevant safety regulations. Nevertheless, the health of the operator, the health of the operator, the functionality of the device and the integrity of property and buildings may be endangered if the provisions set down in this manual are disregarded.
- Page 5 Site requirements: The supply, charging and sensor cables should be positioned so that the risk of damage to the bonnet, doors, or moving engine parts is minimized. Maintaining distance from fans / rotor blades, V-belts, V-belt pulleys and any other parts that can cause personal injury. Never place the device directly above or below the battery which is being charged;...
- Page 6 Instruction regarding DC connection: To reduce the risk of damage to the device and health risks of the operator and other persons present some safety points that need to be observed when connecting the device to a battery: The battery clamps should only be connected or disconnected after ensuring that the device has been set to the “OFF”...
- Page 7 Chemical hazards: Batteries contain harmful acids that cause severe skin and eye injury when coming in contact with them. Furthermore, vapors and gases which may cause respiratory injuries and explosions can arise during operation. Therefore, some rules have to be observed when working with batteries: Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing or eyes.
- Page 8 Self and operator protection: During operation all unnecessary persons should be removed from the danger area, the remaining people should be informed about the possible dangers and risks (acid, gases, electrical currents, temperatures). Use protective clothing and goggles. Ensure first aid for possible injured. Ensure fire safety.
- Page 9 Safety instructions during operation: To reduce the risk of damaging the mains plug and cord while disconnecting the device, always pull on the plug – not on the cord. An extension cord should only be used when absolutely necessary. The use of an improper extension cord leads to an increased risk of fire and electric shock.
- Page 10 Disposal: The disposal of electrical devices in the household garbage is forbidden. The consumer is obliged to dispose the device in the local collection and return systems in accordance with the municipality. Firefighting measures: Due to the fact that there is no metallic lithium in a lithium-ion battery normally, common extinguishing agents (ABC powder extinguisher, CO2 extinguisher or water) can be used.
- Page 11 Maintenance, service, repair: The device must not be opened. If a service or repair is required, the unit must be sent to a qualified service technician. Incorrect installation may result in an electric shock or fire. The use of accessories that are not sold or recommended by the manufacturer may result in a risk of fire, electric shock or personal injury.
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Page 12: Device Information
2. Device Information 2.1. Device Description and Scope of Supply This device is a conditioning and diagnostic system for single modules for a high-voltage vehicle battery. The device is used to adjust the voltage of individual modules in a high- voltage battery which is installed in a vehicle. -
Page 13: Output
2.2.2. Output Output voltage range max. 65,6 VDC Before charging, a target voltage within the Operation tolerance range has to be set. Depending on the module type, the device Charging current limit sets the maximum charging current. The max. achievable charging current is 20A. Efficiency >92% Short circuit, overvoltage, reverse-polarity... -
Page 14: Warning Notices Used On The Housing
2.3.2. Warning notices used on the housing Indication to read the manual Warning of hot surfaces 2.3.3. Disposal of the packing material If possible, put the used packing materials aside for a possible reuse. Ensure proper and environmentally friendly disposal of all packing material with due consideration of prevailing environmental guidelines. -
Page 15: Connections
3. Connections Electrical supply: A mains supply is required to power the device. Use a mains input connector of type IEC60320/C14. This battery charging device is intended for use in networks with more than 100 Volts and is equipped by the manufacturer with a special mains cable with a compatible plug that allows connection to corresponding mains supply. -
Page 16: Control Elements
Control Elements Display Power switch Menu navigation buttons 5. Indicators To display the current operating mode three LED lamps are provided on the front of the device. They are interpreted as follows: Red continuous Error occurred Gelb flashing Stand-by mode Gelb flashing Operating mode Green... - Page 17 When no battery is connected, the status “Battery module not connected” appears on the display. All setting and diagnostic menus are accessible at all times via the MENU field. To connect the battery module, the charging cable plug is guided with slight pressure into the module connector.
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Page 18: Conditioning Operation
If one of the connectors is not inserted, the respective message will appear in the display. To enable access to the conditioning operation menu, the missing connector must be inserted. 7. Conditioning Operation After a battery module is completely connected, the “OPERATION” menu appears automatically in the display. -
Page 19: Charging Current
7.1. Charging Current The maximum charging current is 20A. If the connected battery is charged using a low current, the current limit can be reduced using the menu item “CURRENT”. To reduce the charging current limit press “OK” button. On the right side of the display a field appears where the charging current limit can be modified. -
Page 20: Module - Target Voltage
7.2. Module – Target Voltage The target value for the voltage of the connected battery can be entered under the menu item “VOLTAGE”. The default value will always be the current voltage of the connected battery module. The limiting values for the adjustable target voltage are as follows: Minimum limiting value module target voltage: Number of measurable cell voltages x minimum cell voltage* (UZoE) Example: 16 cell voltages x 2,8V = 44,8V... -
Page 21: Starting The Conditioning Process
7.4. Starting the Conditioning Process After the complete and correct entry of the battery module parameters and the required target voltages the “START“ field must be selected and confirmed using the „OK“ button. Skip the empty line “OK“ Select “START“ and confirm by selecting After selecting “START“, the user must enter a security code *. -
Page 22: Operating Screen
7.5. Operating Screen If the battery parameters and security code are both correctly entered, the conditioning process will begin. The device decides automatically whether a charge or discharge operation will be started, depending on whether the entered module target voltage values are greater or smaller than the actual values of the connected battery. -
Page 23: Menu
8. MENU The item “MENU” is selectable during all operational modes of the device. After selecting the item “MENU” the user reaches the main menu of the device. This is divided into the following user and diagnostic menus. LANGUAGE select a language DIAGNOSIS window: View of the battery parameters NTC Type select one of two types SUPERUSER-menu: Password protected security menu... -
Page 24: Diagnosis
8.2. Diagnosis To display the individual values of the connected battery module, select the menu item “DIAGNOSIS” in the above mentioned main menu and confirm using the “OK” button. In this window, up to 16 cell voltages and max. six temperature measurement points (NTCs) can be displayed. -
Page 25: Superuser - Menu
8.4. SUPERUSER – Menu Battery module limiting values and safety parameters can only be changed using the “SUPERUSER” menu. To enter this menu a password is necessary. After selecting and confirming the sub-menu the following widow to enter the password is displayed: After entering the correct password, the user enters the SuperUser menu, where he can configure the following limiting and security parameters: Display... - Page 26 3,5 … 4,2 Δ = 0,01 U ZoL Maximal cell tension limit Charging [V] 3,5 … 4,2 Δ = 0,01 U ZoE Maximal cell tension limit discharging [V] 0,0 … 1,0 Δ = 0,01 U ZG Maximal cell tension difference 0…10 Δ...
- Page 27 35 … 44 Δ = 1 T Vo Maximal temperature limit for max. current [°C] 45 … 55 Δ = 1 Maximal temperature limit battery module [°C] 1…10 Δ = 1 T delta Max. temperature-delta between two NTCs [K] 1…100 Δ...
- Page 28 Code Inquiry to start the conditioning 43 characters Password for SuperUser menu 43 characters To reset all the limit and safety parameters to the factory settings, the menu item “PARAMETER DEFAULT” should be selected and confirmed using “YES”. The passwords “Code”...
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Page 29: Version
9. Version By selecting the menu item “VERSION” it is possible to display the current version of the software. The scope of the functions described in this document is available commencing SW: 1.20. A simple update does not require the internal boot loader (BOOT:) to be changed. - Page 30 An error will for example be displayed like this: If there is no mistake prevailing, “OK” will appear in the display. By pressing “OK”, it is possible to display the mistake and to start the conditioning process. Operating status: Display Bedeutung / Ursache CHARGE Charging process running.
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Page 31: Maintenance Instructions
Maintenance instructions The DBL1200HV will operate reliably for years with a minimum of maintenance. Consider the following points to maintain the device in the optimal condition: Clean the housing of the device with a soft cloth. BEWARE: The warning notices on the housing must not be damaged by the cleaning. To prevent damage to the battery connecting cables, they should be loosely coiled when not in use. -
Page 32: Service Centre / Repairs
Service Centre / Repairs Instructions To ensure a fast and smooth processing it is absolutely important that every device sent to Deutronic for repair has a fully filled out return service form which should include all relevant data (e.g. address, name contact person, phone number etc.) as well as detailed fault description. -
Page 33: Contact Data
Contact Data Deutronic Elektronik GmbH Deutronicstrasse 5 D-84166 Adlkofen / Germany Tel.: +49 (0)8707 / 920-0 Fax: +49 (0)8707 / 1004 E-Mail: sales@deutronic.com http://www.deutronic.com ® ® D-IPS und DEUTRONIC sind eingetragene Marken der Deutronic Elektronik GmbH. DC Nr. 33573 All data has been measured with nominal input voltage, full load and 25°C ambient temperature if not indicated otherwise. Technical changes and mistakes are subject to change.
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