tbs electronics omnicharge OC12-40 Owner's Manual

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.
TBS ELECTRONICS BV
De Marowijne 3, 1689AR, Zwaag, The Netherlands
http://www.tbs-electronics.com
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
Charge status bar
A rough indication of the
charging progress.
100% full (ready)
output current bar
80% full
indicates the percen-
50% full
tage of delivered
empty
output current.
"power on, off, forced
float" switch
When in position "O" the
charger is off .
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 power on, normal operation
2)
flashing red (1 flash per sec.) 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
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.
note 3 : The charger automatically restarts when the temperature is below an acceptable level.
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 : The local dipswitch settings of dipswitch 2 and 3 are ignored and
1 configuration must be done externally.
on
Setting OFF : The local dipswitch settings are used (factory default).
1
2 & 3. BATTERY : Select the type of lead-acid battery that you wish to charge. Each
TYPE 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.
DS2 DS3 BATTERY TYPE (12V/24V)
on on
Flooded (factory default)
absorption voltage 14.4V/28.8V, float voltage 13.5V/27.0V
2 3
on on
GEL
absorption voltage 14.2V/28.4V, float voltage 13.5V/27.0V
2 3
on on
AGM
absorption voltage 14.3V/28.6V, float voltage 13.3V/26.6V
2 3
on on
Custom
not available when dipswitch 1 is set to OFF (LOC.)
2 3
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.
CAUTION
4. BYPASS REMOTE : Bypasses the remote switch connection when no remote switch is
SW. connected.
on
Setting ON : remote switch connection terminals are bypassed (factory default).
4
on
Setting OFF : remote switch connection terminals are open. A remote switch
4 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.
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 :
Bulk Absorption Float
V(12V)
14.4V
13.5V
12.5V
restart four stage
charging process
absorption time-out float time-out
max. 4hrs 7 days
global charge time-out
max. 8hrs
Ich
Imax
1)
10% Imax
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.
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,
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.
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.
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
Pulse Float Bulk
V(24V) be read carefully :
28.8V
Equalization should only be performed on a flooded (wet) lead acid battery.
!
27.0V
Therefore the Omnicharge chargers only allow equalization when the battery
25.0V
type dipswitches are set to Flooded. Other battery types like GEL or AGM will be
CAUTION
battery load
damaged by this process.
turned on
(Iload>Imax)
! Always follow the battery manufacturer's instructions when equalizing flooded
batteries.
CAUTION
During equalization, the battery generates explosive gasses. Follow all the battery
!
safety precautions enclosed with your charger. Ventilate the area around the
pulse
t
1hr
battery sufficiently and ensure that there are no sources of flames or sparks in the
CAUTION
vicinity.
! Disconnect all loads connected to the battery during equalization. The voltage
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
!
equalization of a battery. The user must monitor the battery's specific gravity
throughout this process to determine the end of the equalization cycle. The internal
CAUTION
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
!
t
battery output will be equalized as well. When this is not desirable, please
disconnect this battery before starting the equalization cycle.
CAUTION
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. 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
internally or externally, and does not cover damage arising from improper use , or from
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.
read all enclosed safety instructions and warnings
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
ADDRESS
Declares that the following products :
PRODUCT TYPE
MODELS
Conforms to the requirements of the following Directives of the European Union :
The above product is in conformity with the following harmonized standards :
EN61000-6-3 : 2001
EN61000-6-2 : 2005
EN60335-1 : 1999
EN60335-2-29 : 2004 Safety requirements for battery chargers
1)
: TBS Electronics BV
: De Marowijne 3
1689 AR Zwaag
The Netherlands
: Professional programmable battery charger
: OC12-40, OC12-60, OC24-20, OC24-30
EMC Directive 2004/108/EC
Low Voltage Directive 2006/95/EC
EMC - Generic Emissions Standard
EMC - Generic Immunity Standard
Generic safety standard