Adel System CB1224xA SERIES User manual

Via Luigi Barchi 9/B – Reggio Emilia 42124 – Italy
Tel. [phone] – Fax [phone] – mail: [email protected]t
www.adelsystem.com Instruction Manual CB12245A r8.doc
Page 1 - Chapter:
General data
CB1224xA: Smart Battery Charger
Thank you for having chosen one of our products for your work.
We are certain that it will give the utmost satisfaction and be a notable help on the job.
General Description
The CB series is a “Switching technology” and “Battery Care philosophy” since many years parts of
the know-how ADEL system, led to the development of this advanced multi-stage battery charging ,
completely automatic and suited to meet the most advanced requirements of battery manufacturers.
The Battery Care concept is based on algorithms that implement rapid and automatic cycle of
battery charging, battery charge optimization during time, flat batteries recovery and real time
diagnostic during installation and operation. The Real Time Auto-diagnostic system, monitoring
battery faults such as, elements in short circuit, accidental reverse polarity connection, disconnection
of the battery, they can easily be detected and removed by help of Blink Code of Diagnosis Led;
during the installation and after sell. Each device is suited for all battery types, jumper selection sets
a predefined curves for: Open Lead Acid, Sealed Lead Acid, Gel, Ni-Cd and Ni-Mh. A rugged casing
with bracket for DIN rail mounting provide IP20 protection degree.
Main Characteristic
•Input: Single-phase 115 – 230 – 277 Vac
•Output Battery: charging: 24 Vdc 5 A; 12 Vdc 6 A
•Suited for the following battery types: Open Lead Acid, Sealed
Lead Acid, lead Gel and Ni-Cd Ni-Mh.
•Automatic diagnostic of battery status. Charging curve IUoUo,
constant voltage and constant current Battery Life Test function
(Battery Care)
•Switching technology
•Three charging levels: Boost, Trickle and Recovery
•Protected against short circuit, Over Load and inverted polarity
•Signal output (contact free) for discharged or damaged battery
•Protection degree IP20 - DIN rail; Space saving
Safety and warning notes
WARNING – Explosion Hazard Do not disconnect Equipment unless power has been switched off or the area is
known to be non-hazardous.
WARNING – Explosion Hazard. Substitution of components may impair suitability for class I, Division 2.
WARNING – Switch off the system before connecting the module. Never work on the machine when it is
live. The device must be installed in according with UL508. The device must have a suitable isolating
facility outside the power supply unit, via which can be switched to idle. Danger of fatal Injury!
Connection (terminal and wiring):
Cable Connection: The following cable cross-sections may be used:
Solid
(mm
2
)
Stranded
(mm
2
) AWG Torque (Nm) Stripping Length
1 Phase L N PE
Input AC
1 Phase L N PE
Input AC
In: 0.2 – 2.5 0.2 – 2.5 24 – 14 0.5 – 0.6 Nm 7 mm
Out: 0.2 – 2.5 0.2 – 2.5 24 – 14 0.5 – 0.6 Nm 7 mm
Signal: 0.2 – 2.5 0.2 – 2.5 24 – 14 0.5 – 0.6 Nm 7 mm
Use only copper cables that are designed for operating temperatures of > 75 °C. Wiring terminal shall be marked to
indicate the proper connection for the power supply.
Page 3
- Chapter
: Operating and Display Element:
No. 3: Signal Ports (output Isolated):
Connections for Fault Alarm Relay: Low Battery, Fault connections systems, Battery replacement. Contact: 3,4,5
Relay Contact Rating:
Max.DC1: 30 Vdc 1 A; AC1: 60 Vac 1A : Resistive load (EN 60947-4-1)
Min.1mA at 5 Vdc: Min. permissive load
Signal Output port
true table:
Led N°8 Battery Fault
3
-
4 Closed
3
-
5 Closed
Battery or system Fault? YES ■- led On
NO ■- led off
Please see the NOTE at the bottom of this page.
No. 4: Battery Connection Port:
Connect the battery between pin. 1 (+) and 2 (–).
One battery (12 Vdc) for 12 Vdc Output;
Two battery (12 Vdc) for 24 Vdc Output;
No. 5: Output Voltage Configuration
This setting must be do with mains off. This jumper set the voltage of the batteries connected at the CB, is most
important to check the correct voltage value on the batteries. If is connected a wrong battery the device show the
fault indication of 1 blink.
No. 6: Enable Power Supply
This function allow at the Battery Charger to work like a Power Supply. To enable this function the operator must insert
a jumper in Pos. 6 Enable Power Supply with the CB unpowered. When the device is turned ON we will have voltage
to the output terminals OUTPUT BATTERY even if the battery is not present. After about 10 sec. without detecting a
battery the CB signals with 2 blink Battery Not connected and switches the alarm relay. If the battery was already
present at power on or if it is connected at a later time, the CB detects the battery and starts to charge, if there is no
fault deactivates the alarm relay and the LED DIAGNOSIS indicates the charging status. In Back Up (no Mains) and
cell voltage < 2.18V (Pb batteries) or < 1.37V (NiCd batteries) for more than 30 sec. the system turns off completely.
No. 7 and 8 Display Signals
No.8: Led Battery Fault connections systems, Battery Fault.
No.7: Led Diagnosis,
Led Diagnosis. Diagnosis of the system through “blinking code” signal
Monitoring
Control
Chart:
State LED Diagnosis
(No.7)
LED Battery
Fault (No.8)
Charging
Type
Trickle 1 Blink/ 2 sec OFF
Absorption 1 Blink/sec OFF
Boost 2 Blink/sec OFF
Recovery (*) 5 Blink/sec OFF
Auto
diagnosis of
the system
Reverse polarity or wrong battery voltage (for example:
CB set for 24Vdc and battery 12Vdc) 1 Blink/pause ON
Battery Not connected 2 Blink/pause ON
Element in Short Circuit 3 Blink/pause ON
Over Load or Short Circuit on the load (with Enable Power
Supply) 4 Blink/pause ON
Alarm Low Battery Voltage: 12Vdc, range 8-10 Vdc
ONLY on REQUEST 24Vdc, range 18-21 Vdc 9 Blink/pause ON
Alarm High Battery Voltage: 12Vdc, over 14 Vdc
ONLY on REQUEST 24Vdc, over 28 Vdc 10 Blink/pause
ON
NOTE: (*) In Recovery the LED Battery Fault (No.8) is OFF but the Relay is in failure mode (3-5 Closed) to indicate a
battery with very low voltage.
Via Luigi Barchi 9/B – Reggio Emilia 42124 – Italy
Tel. [phone] – Fax [phone] – mail: [email protected]t
www.adelsystem.com Instruction Manual CB12245A r8.doc
Page 2 - Chapter:
Output Power connections:
Output Power connections:
Normal connection
Typical application:
- One battery (12Vdc) for 12 Vdc Output.
Set No Jumper in Pos. 5
- Two battery (12Vdc) for 24 Vdc Output
Set Jumper in Pos. 5
(See the table below at the point No. 2.)
Operating and Display Element:
No. 1: Input AC Port pin. L – N:
1 Phase Switching Power Supplies L, N, PE .
No. 2: Battery Management Configurations
Preliminary Operations: One device for all battery types.
Completely automatic, all devices are suitable to charge most
batteries types thank to User Selectable charging curves. They
can charge open lead acid, sealed lead acid, Gel and Ni-Cd, Ni-Mh
batteries. It is possible to change or add other charging curves
connecting the device to a portable PC.
Caution: Switch off the system before setting the jumper.
Battery Type
Selection Jumper Position
Trickle/Float charge
(Volt/Cell)
Fast/Bulk charge
(Volt/Cell)
Open Lead
2.23 2.40
Sealed Lead Low
2.25 2.40
Gel Battery
2.30 2.40
NiCd – NiMh (Note 1)
1.40 – (12V) 10cells
1.40 – (24V) 20cells
1.50 – (12V) 10cells
1.50 – (24V) 20cells
Functional Setting
Function
Jumper Fast
Charge Enable
(Note 2)
Jumper present:
Fast charge enabled.
Not used in Ni-Cd option
Output Voltage
Configuration
(Pos. 5)
Jumper Not Present: 12 V Output
Jumper present: 24 V Output
Power Supply
Function
(Pos. 6)
Jumper Present:
Power supply function enabled.
Note:
1 NiCd-NiMh: End-of-charge detected by a “flat” profile. If flat profile is detected, fast charge is terminated after 10
min. General end-of-charge timeout set to 8 hours.
2 This function is a hot swap (is possible to enable or disable with mains on).
2
1
7
6
5
9
3
4
8
Page 4
- Chapter
: Battery Care
No. 9: Charging Level Current:
It is possible set the max recharging current for the batteries by trimmer (Charging
Level). The current adjustment goes from 10% ÷ 100% of In. Set the maximum
charging current between 10% and 20% of the battery capacity.
Charging Curve
Automatic multi-stage operation and real time diagnostic allows fast recharge and recovery of deep discharged
batteries, adding value and reliability to the system hosting the CB device. The type of charging is Voltages
stabilized and Current stabilized IUoUo.
Four charging modes are identified by a flashing code on a Diagnosis LED.
To maintain the Output Load in lower Voltage state, don’t put jumper in position 4, in this case no boost charge
but only Float charge.
State Diagnosis LED
Battery Fault
LED
Charging Type
Trickle/Float 1 Blink/ 2 sec OFF
Absorption 1 Blink/sec OFF
Boost/Bulk 2 Blink/sec OFF
Recovery 5 Blink/sec OFF
Battery Care
The Battery Care philosophy is base on algorithms that implement rapid and automatic charging, battery charge
optimization during time, flat batteries recovery and real time diagnostic during installation and operation. The Real
Time Auto-diagnostic system, monitoring battery faults such as, elements in short circuit, accidental reverse polarity
connection, disconnection of the battery, they can easily be detected and removed by help of Blink Code of Diagnosis
Led; during the installation and after sell. Each device is suited for all battery types, by means of jumpers it is possible
setting predefined curves for Open Lead Acid, Sealed Lead Acid, Gel, Ni-Cd(option).They guarantees battery reliability
in time by continuously testing the internal impedance status, avoids any possible risk of damages and grants also a
permanent, reliable and safe connection of the battery to the power supply. The system, through a battery stimulation
circuit with algorithms of evaluation of the detected parameter, is able to recognize batteries with a short-circuited
element. Battery test: Automatic.

Page 5
- Chapter
: Diagnostic Type Checks:
Every time a battery will be connected to the Battery Charger, the device will do followings check: reverse battery
polarity, wrong battery connected (like batteries 24 – 36Vdc or higher) with Jumper n.5 not present = Battery charger
for 12Vdc. After 120 minutes, with jumper in pos. 5 present (24 Vdc output configuration) the device make the test of
wrong battery connected like batteries 12Vdc.
Every 240 minutes, make the test element in short circuit.
Diagnostic Type Checks:
Check for accidental disconnection of the battery cables:
The device detects accidental disconnection and immediately switched off the output power.
Battery not connected:
If the battery is not connected no output power.
Reverse Polarity check:
If the battery it is connected with inverted polarity, the device is automatically protected.
Test of battery voltage connections:
Appropriate voltage check, to prevent connection of wrong battery types, more or less than the nominal voltage.
End of Charge check
When the battery it is completely full, the device automatically switch in trickle charging mode.
Check for Battery Cells in short circuit
Thanks to specific algorithms of evaluation, the CBs recognize batteries with cells in internal short circuit.
In trickle charge every 4 hours test of element in short circuit.
Diagnosis of battery and device
All CB devices support the user during installation and operation. A Blink code of Diagnosis Led allows to
discriminate among various possible faults.
Error conditions, “LED Battery Fault” ON and “LED Diagnosis” blinking with sequence; see Display Signal section.
Protection Features
On the primary side: the device is equipped whit an internally fuse. If the internal fuse is activated, it is most probable
that there is a fault in the device. If happen, the device must be checked in the factory.
On the secondary side Battery and load: The device is electrically protected against short circuits and overload.
Inversion polarity: the module it is automatically protected against inversion of battery polarity and connection of load
inverted.
Over current and output short circuit: the unit limits the output current (see the technical data).
Thermal behaviour
Surrounding air temperature 50°C. For ambient temperature of over 50°C, the output current must be reduced by
2.5% per °C. Max 70°C At the temperature of 70°C the output current will be 50% of In. The equipment does not
switch off in case of ambient temperature above 70°C or thermal overload. The devices are protected for Over
temperature conditions “worst case”; in this situations the device Shut-down the output and automatic restart when
temperature inside fall.
Standards and Certification
Electrical Safety:
Assembling device: IEC/EN 60950 (VDE 0805) and EN 50178 (VDE 0160).
Installation according : IEC/EN 60950.
Input / Output separation : SELV EN 60950-1 and PELV EN 60204-1. Double or reinforced insulation.
EMC Standards Immunity :
EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-5.
EMC Standards Emission:
EN 61000-6-4, EN 61000-6-3, EN 61000-3-2 (see data sheet for each device)
Standards Conformity:
Safety of Electrical Equipment Machines: EN 60204-1.
The CE mark in According to EMC 2004/108/EC and Low voltage directive 2006/95/EEC
In According to UL 1236 and CSA C22.2 N° 107.2
Norms and Certifications
In Conformity to: UL1236, IEC/EN 60335-2-29 Battery chargers; EN60950 / UL1950; Electrical safety EN54-4 Fire
Detection and fire alarm systems; 2014/30/UE Directive; 2014/35/UE (Low Voltage); DIN41773 (Charging cycle);
Emission: IEC 61000-6-4; Immunity: IEC 61000-6-2. CE.
Page 7
- Chapter
: Technical Data:
Technical Data:
CB
Battery Charger Multi Output voltage 12 – 24Vdc
Input (Volt)
115 – 230 – 277Vac
Output (Vdc – A – W)
12Vdc – 6A – 120W
24Vdc – 5A – 120W
Model
CB12245A
INPUT DATA
Nominal Input Voltage / Tensione d’ingresso nominale 115 – 230 – 277Vac
Input Voltage Range / Campo di funzionamento 90 – 305Vac
Inrush Current (Vn and In Load) I
2
t / Corrente di Inserzione ≤16 A ≤5msec
Frequency /Frequenza di Ingresso 47 – 63 Hz ±6%
Input Current (115 – 230Vac) / Assorbimento 2.4 – 1.2A
Internal Fuse / Fusibile Interno (non sostituibile) 4A
External Fuse (recommended)/ Fusibile Esterno raccomandato 10A (MCB curve B)
OUTPUT DATA
Output Vdc / I
N
/ Tensione di uscita Vdc / I
N
12Vdc – 6A
24Vdc – 5A (230Vac)
24Vdc – 4A (120Vac)
Minimum load / Carico minimo No
Efficiency (50% of In) / Rendimento tipico ≥90%
Short-circuit protection / Protezione contro il corto circuito Yes
Over Load protection / Protezione sovraccarico Yes
Over Voltage Output protection / Protezione sovratensione in uscita Yes
Reverse battery protection / Protezione inversione batteria Yes
Detection of element in short circuit / Rilevazione elemento in corto circuito Yes
BATTERY CHARGER OUTPUT / USCITA CARICA BATTERIA
Boost – Bulk charge (Typ. at I
N
) / Carica Veloce (1) 14.4Vdc (12Vdc)
28.8Vdc (24Vdc)
Max.Time Boost–Bulk charge (Typ. at I
N
) / Tempo massimo Carica Veloce 15h
Min.Time Boost–Bulk charge (Typ. at I
N
) / Tempo minimo Carica Veloce 4 min.
Trickle-Float charge (Typ. at I
N
) / Carica di mantenimento (1) 13.75Vdc (12Vdc)
27.50Vdc (24Vdc)
Recovery Charge / Carica di recupero 3 – 8 Vdc (12Vdc)
6 – 18 Vdc (24Vdc)
Switching on after applying mains voltage 2.5sec
End of charging current Bulk - Absorption to Float - Trickle 1/8 of Iadj
Start up with capacitive load / Start up con carichi capacitivi ≤ 30.000µF
Residual Ripple / Ripple Residuo ≤ 80 mVpp
Charging max I
batt
/ Corrente max. di Carica 6A ± 5% (12Vdc)
5A ± 5% (24Vdc) Ta < 40°C (In)
3.5A ± 5% (24Vdc) Ta > 40°C (In)
Charging current Limiting I
N
(I
adj
) / Limitazione Corrente di Carica Yes, 10 ÷ 100 % / In
Quiescent Current / Consumo da batteria max. ≤5mA
JUMPER CONFIGURATION
Battery Type / Tipo Batteria VRLA --------------
------------------------------------------Ni-Cd option
2.23;2,25;2,27;2,3;
1,4–1,5 (20 elem.)
Battery Voltage 12 or 24 Vdc / Selezione Tensione di Batteria 12 o 24 Vdc Yes
Power Supply Function / Funzione Alimentatore Yes
Boost Charge Enable / Abilitazione Carica Rapida Yes
Characteristic Curve / Caratteristiche di Carica IUoUo
SIGNAL OUTPUT (RELAY) / SEGNALAZIONE RELÈ USCITA
Main or Backup Power
No
Low Battery and Fault Battery Yes
Main or Backup - Fault Battery Yes
Page 6
- Chapter
: Rail Mounting:
Rail Mounting:
All modules must have a minimum vertical and horizontal distance of 10 cm to this power supply in
order to guarantee sufficient auto convection. Depending on the ambient temperature and load of the
device, the temperature of the housing can become very high!
Mounting Steps: 1, 2, 3, 4.
Removing Steps: 4, 3, 2, 1.
MOUNTING – REMOVING
Step 1 Step 2
Step 3 Step 4
REMOVING
h
d
w
-5°/+5° max
Page 8
- Chapter
: Technical Data:
AUXILIARY OUTPUT (RJ 45 CONNECTION) FOR:
Temp. Charging probe / Carica Compensata in Temperatura
No
Voltage drop compensation / Comp. Tensione di ricarica No
Remote monitoring display / Display Esterno No
CLIMATIC DATA
Ambient Temperature operation / Temperatura Ambiente di Lavoro
-25 – +70°C
De rating Tª > (In) / De rating Tª > (In) > 50° 2.5% °C
Automatic De rating / De rating Automatico Yes
Ambient Temperature Storage / Temperatura max. Magazzino -40 – +85°C
Humidity at 25 °C / Umidità 95% to 25°C
Cooling / Raffreddamento Auto Convection
GENERAL DATA
Isolation Voltage (IN / OUT) / Tensione di Isolamento (IN / OUT)
3000Vac
Isolation Voltage(IN / PE) / Tensione di Isolamento(IN / TERRA) 1605Vac
Isolation Voltage(OUT / PE) / Tensione di Isolamento(OUT/TERRA) 500Vac
Protection Class (EN/IEC 60529) / Protezione Classe IP 20
Reliability (MTBF IEC 61709) / Affidabilità > 300 000 h
Pollution Degree Environment / Grado d'inquinamento ambientale 2
Connection Terminal Blocks Screw Type / Dimensione morsetti 2,5mm(24–14AWG)
Protection class (with PE connected) /
Grado di protezione (con cavo di terra collegato) I, with PE connected
Dimension (w-h-d)/Dimensioni (l-h-p) mm 45x105x100 mm
Weight / Peso 0.30 kg approx
Safety Standard Approval / Conformità ed Approvazioni
CONNECTION DIAGRAM / SCHEMA DI CONNESSIONE
(1) - Depend on jumper selection
All specification are subject to change without notice