Büttner Elektronik E-Bike Charger User manual

Introduction
Dear Customer,
with the purchase of the E-Bike charging
system you have chosen a quality product
from HYMER in cooperation with BÜTTNER
ELEKTRONIK.
This E-Bike charging system meets the
highest standards of quality and functio-
nality for a simultaneous charging option
of up to 2 bike batteries, even without an
external mains connection, in fully
automatic charging mode via alternator
while driving or in manual charging mode,
but also as usual with 230 V mains supply
with always optimal monitoring of your
leisure- / bord battery.
Before the first start-up, the E-bike Charger
control must be set-up. Please read about
this section “Basic Settings” on page 31.
We hope you enjoy your new E-bike
charger charging system.
EN
Your HYMER / BÜTTNER ELEKTRONIK Team
Note
i
Tips and tricks
This icon is used to designate tips, which
help you to utilize your equipment even
easier and more efficient.
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Warning!
Danger!
!
! Warns of dangers to persons, damage to
the device or other objects. Injuries or
damage may result from improper hand-
ling. Failure to do so can lead to serious
damage, fire and personal injury!

Table of contents
Introduction............................................................................................................. 24
Table of contents..............................................................................................25
Scope of delivery .............................................................................................25
1General informations and safety instructions....................................................... 26
2Functional description E-Bike Charger control...................................................... 27
Overall diagram..................................................................................................... 28
3Commissioning.............................................................................................30
3.1. Quick overview –E-Bike Charger control........................................................ 30
3.2. Basic settings.................................................................................................. 31
4Operating the E-Bike Charger ............................................................................... 33
4.1. Automated charging while driving.................................................................. 33
4.2. Manual charging mode................................................................................... 34
5General operation ................................................................................................ 35
6Expert set-up E-Bike charge control...................................................................... 36
7Troubleshooting................................................................................................... 38
8Technical Data....................................................................................................... 41
9Warranty .....................................................................................................44
EN
Scope of delivery
BÜTTNER ELEKTRONIK –HYMER E-Bike Charger
25
Quantity
Description
1
E-Bike Charger Control (MT 5005iQ) with display, 200 A shunt with minus cable
adaptor and wiring cable set (10 m control cable, main minus-cable, power supply
cable with fuse and D+ control cable
1
PowerLine Sinus inverter 600 W (MT PL 601) with battery cabling (supply and
fusing, remote control and grounding) and 230 V output with Wago Winsta
coupling system
1
Mains supply tranfer switch unit (MT NU 2301) with mains- and inverter input
and 230 V output with Wago Winsta coupling system
1
RCDI device 10 A –AC fusing with Wago Winsta coupling system
1
Operation manual

1 General Information
Please read all the following instructions
carefully before starting commissioning
your new device.
Safety instructions
The manufacturer does not accept any
liability for damages caused by im-proper
handling and non-compliance with safety
precautions or improper installation.
Changes to the device may result in a loss
of operating license or violation of other
legal requirements (e.g. Equipment and
Product Safety Law, Electronic Compatibi-
lity Law). Upon resale of the conversion,
the per- son responsible for the conversion
becomes the manufacturer and is liable
accordingly. Furthermore, the manufactu-
rer’s warranty is no longer applicable and
a loss of warranty rights may result.
The E-Bike Charger system is suitable for
stationary and for mobile use. The devices
as well as the individual components are
to be protected from moisture and
generally not suitable for outdoor use.
EN
i
For an efficient function of this automated
charging system for e-bike batteries we
recommend,
→
urgently the review of the existing
board battery capacity, as well
the installation of a charging booster
with appropriate cable cross-sections
for efficient charging option while
driving, as well
retrofitting a solar system for charging
when stationary
→
→
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2 Function description of the E-Bike Charger Control
With the help of the measuring shunt in
the main minus cable on the board battery
system, the control system constantly de-
tects whether the board battery is being
charged or discharged and uses this to de-
termine the remaining capacity which is
actually available. This is the basic require-
ment for automated charging of the E-bike
batteries, which is only possible in defined
capacity ranges of the board batter, both
in driving and stationary mode.
When driving, in addition to checking the
capacity range of the board battery, the
inverter is only switched on after the dy-
namo + signal of the alternator has been
detected, so that the connected chargers
can charge the E-bike batteries.
EN
A charging booster is required for efficient
charging, especially for E6 vehicles!
For a E-Bike charger with 180 W power
consumption, the inverter consumes about
18 A DC current. With a 30 A charging
booster, the bike battery and the board
battery can be charged at the same time.
A charging booster with at least 50 A should
be available for 2 connected E-bike batteries.
i
At the camp site with a power connection,
the mains transfer switch unit ensures that
the sockets for the e-bike power packs are
also automatically supplied.
Without mains supply, recharging can also
be started manually, as long as there is
sufficient board-battery capacity available
until the system switches off automatically.
For efficient charging while stationary, the
board-battery capacity must be available
and a solar system is recommended!
Up to 500 Wh from the board battery
system can be required to recharge just
one e-bike battery. This already corres-
ponds to the maximum amount of energy
that can be drawn from a 100 Ah lead type
battery! This means that the board battery
system should have at least twice the capa-
city, and it should be possible to compen-
sate the consumption for charging with a
solar system.
With a 125 Wp module, 500 Wh can be
harvested on a sunny day.
i
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2 Function description of the E-Bike Charger Control
Overall diagram
EN
E-Bike Charger
1
control
%D+
E-B IKE CHARGER
ON
OFF
Central electrics
Vehicle engine
and alternator
(EBL)
D+ Signal
E-Bike Charger
Shunt
Starter-battery
Board-battery
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Remote Input

2 Function description of the E-Bike Charger Control
EN
Pure sine inverter
PowerLine PL 601
RCD device
Charging sockets
Mains transfer
switch unit
NU 2301
MT NU 2300
Charging sockets
max. 600 W
RCD device
Mains input
Vehicle
Mains input
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3Commissioning
3.1 Quick overview –E-Bike Charger control:
❶
EN
❶
❶
❶
2
% D+
E-B IKE CHARGER
ON
OFF
❶
❶
❶
Operation mode –selection button
Automated charging while driving:
short push on button →Operation
mode displaying ❶ : „1“
Manual charging mode: 3 s –push on
button →Operation mode displaying
❶ : „2“
Displaying operation mode:
1: Automated charging while driving
2: Manual charging mode
Displaying operational readiness %:
An arrow in the display above the %
symbol indicates that the board bat-
tery provides sufficient remaining ca-
pacity for charging the E-bike batteries.
Displaying operational D+:
An arrow in the display above the D+ -
symbol indicates that the charging
current is provided while vehicle engine
is running
❶
❶
Display screen –selection button
For displaying power consumption
(negative sign) or charge in A, available
capacity in Ah and %, remaining time
display in h, as well as voltage display
of the board battery in the main dis-
play ❶
❶
Graphical displaying of available
battery-capacity
Function control „On“ and
will only be displayed when E-Bike bat-
tery chargng takes place and the board
battery provides sufficient capacity
❶
Menu –button
Switching display On/Off: →short push
on button
Set-up: 3 s –long push on button →Set-
❶
❶
up nominal capacity in Ah,
type and display brightness
battery
Main screen
❶
Expert Mode: 10 s –long
push on
button → Set-up of switch-on / switch-
off thresholds in %
(see 6. Expert set-up)
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3 Commissioning
3.2 Basic settings
Set-up of the E-Bike charger control:
EN
Push Menu-button
for 3s
Set-up the total nominal capacity of the battery-system
(Factory default 100 Ah)
Increase capacity +1
Decrease capacity -1
Set-up battery type acc. table 1
(Factory default 34):
Increase value +1
Decrease value -1
Set-up display brightness
brighter
darker
save set-up
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Battery type
Battery charging voltage
Set-up value
Blei-Säure/Nass
14.4
24
Gel
14.4
53
AGM 14.4
14.4
34
AGM 14.4–14.8
14.7–14.8
47
LiFePO4 13.9 V
13.9
89
LiFePO4 14.2 V
14.2
82
LiFePO4 14.4 V
14.4
84
LiFePO4 14.6 V
14.6
86
LiFePO4 14.8 V
14.8
88

3 Commissioning
Commissioning pure-sine inverter
EN
3-step switch
Must be in position I
= Remote !
+
–
The PowerLine inverter has an ON / OFF / REMOTE device
switch ❶ . In this way, the functionality of the inverter can be
determined.
When the switch is in the OFFposition, the inverter is switched off.
In the ON switch position, the inverter is permanently switched
on regardless of the remote control input
REMOTE
OFF
❶
ON
❶
❶
CHECK
POWER
TheswitchpositionREMOTEenablestheinvertertobeoperated
via the remote control input.
The operating status of the inverter is indicated by 2 LEDs on
the front of the device.
The green “POWER” ❶ lights up when the inverter is switched
on and 230 V AC voltage is generated at the output.
The red “CHECK” ❶ indicates when operation is restricted or
has been canceled.
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Warning!
No intelligent and monitored
!
! E-bike charging possible!

4Operating the E-Bike Charger
4.1 Automated charging while driving (Operation mode 1)
❶
EN
❶
❶
1
% D+
E-B IKE CHARGER
ON
OFF
To proceed automated charging of the
E-bike batteries the basic settings must be
carried out first!
i
❶
Preparations:
1. Connect the E-Bikebattery to thepower
supply unit
2. Connect the power supply unit or up to
2 units to the referenced E-bike
charging socke(s) up to max. 600 W
(usually in the rear garage)
3.
By briefly pressing the button ❶ the
automated charging mode is activated
while driving –operation mode 1!
For control, the number “1” must be
i
shown in the lower left corner of the dis-
play ❶ !
Start of charging:
When the vehicle engine is started and the
board battery has sufficient capacity, a
small arrow appears in the display ❶
above the % - and D+ symbol.
This activates the switching output of the
measuring shunt and switches the inver-
ter on. As a control, in the display ❶ “On”
If no arrow is displayed above the %
symbol, the board battery will be charged
first while driving until sufficient capacity is
ensured and then recharging of the E-bike
battery starts automatically.
The display ❶ then shows “blinking“ “On”
i
and no
symbol.
This display also applies if the engine has
not yet been started or switched off.
and
will be shown.
Charging progress:
When driving will be interrupted or the
motor is switched off in start / stop mode,
the inverter remains switched –on for a
limited time. Will be within 5min. no en-
gine running (D+ signal) be detected, the
inverter is switched –off, but charging is
automatically resumed within 5 hours if
the engine will be retarted again. The pro-
gram is then terminted and may have to
be restarted again. A short press on the
On / Off button deactivates the active
mode manually at any time.
i
For control, no number will be shown in
the left corner of the display ❶ !
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