Battery Service Hub PSW User manual

INSTRUCTIONS FOR POWER-SWITCH BATTERY CHARGES (PSW)
The baery charges of the PSW series use high frequency technology, which enables them to be compact, light and ecient and to have a
constant and repeve behaviour. An inner microprocessor enables automac recharging of baeries and stores the behaviour of the
baery charger during its use.
This device has been developed for a professional use.
For best results and safety, the user is required to read, follow and keep these instrucons carefully.
The manufacturer is not responsible for any damage due to improper use.
BATTERY
The baery voltage has to correspond to the PSW rated voltage (see rang data, for example 24V). A label on the PSW indicates the cor-
rect rechargeable baery type. Check that it matches the features of your baery. If necessary, it is possible to change the programming
in order to adapt the PSW to your baery. Make contact with the supplier in order to carry out this change.
INSTALLATION
To ensure maximum safety, installaon has to be carried out as indicated by the manufacturer. Any work on the charger must be carried
out by qualied and authorized technical personnel. Never open the metal box: it is not necessary to get inside for installaon.
WARNING: There is a risk of electric shock inside the box.
Aer unpacking be sure that the device is in perfect condion; in case of doubt, do not use and contact the supplier. It is beer to install
the PSW indoors, in a room free of humidity, acids or dust, with room temperature between 0 - 40°C. During use do not obstruct the ven-
laon holes. Any overheang of the PSW will reduce the output current; if overheang connues, charging will be stopped (see SPECIAL
SIGNALS).
FIXED INSTALLATIONS: considering the small weight in order to avoid damage due to being dropped, we recommend xing the PSW rmly
to the wall. For xing see Fig. 3.
ON BOARD INSTALLATION: x the PSW horizontally in a well-protected area of the vehicle, which allows dissipaon of the heat produced
(FIF. 4). It is beer to use vibraon mounts. Connect the PSW cables directly to the baery poles; never use exisng cables of the vehicle
equipment.
Any non-compliance with this rule can cause malfunconing or damage which cannot be aributed to the manufacturer.
More informaon is available in the ADDITIONAL FUNCTIONS secon.
ELECTRICAL SUPPLY
Be sure the rang data of the baery charger is compable with the mains power supply (single-phase, voltage, frequency, power). Plug
into a socket equipped with protecons that comply with local standard regulaons. If you have to use an extension cable, contact the
manufacturer for correct technical informaon. The replacement of the supply cable has to be carried out only by a qualied personnel.
BATTERY CONNECTION
Respect the polarity: red wire to + and black wire to -.
Incorrect connecon does not cause any damage, but prevents the charging cycle from starng.
Do not use extension cables without manufacturer’s approval.
USE
Connect the baery and the power supply cable. LEDs light up for 2 seconds (PAN. 1), then only the CHARGE LED stays on (PAN. 2). If this
does not happen, check the connecon on the baery and supply. The PSW is unable to acvate the charging if the voltage of the baery
is lower than 1V/Cell (i.e., 12V for a 24V baery).
If everything is funconing properly the charger performs the whole charge and stops with the STOP LED illuminang (PAN. 3).
The me of charge depends on the discharge level, the baery type and the programmed charge cycle. For lead acid, gel or AGM baer-
ies, 80% discharged, the whole recharge lasts 10-14 hours. For lead acid baeries it is possible to reduce the me to 7-8 hours by pro-
PSW Battery Chargers—User Guide (page 1 of 4)
Baery Service Hub Ltd
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gramming the fast cycle.
Shorter mes are possible if the baery is less than 80% discharged.
Longer mes are possible if the baery is more than 80% discharged.
SPECAIL SIGNALS
When the microprocessor detects a problem, it stops charging and signals this by ashing the two LEDs (PAN. 4).
The dierent possible problems are:
Overheang: the thermal condions interrupt the current in order to avoid damage
Defecve baery: the voltage trend shows a possible failure of the baery
Incorrect baery: the baery has a higher voltage than the charger (36V baery on a 24V charger).
In order to determine the king of problem it is necessary to read the internal PSW data memory (see DATA MEMORY secon).
If the two LEDs remain lit (connecng the baery) (PAN. 8), means an internal problem has occurred. Only the manufacturer can solve
this problem.
CHARGE INTERRUPTION
Power failures interrupt charging and all LEDs go out (PAN. 5); when the power supply is resumed charging starts again at the point it was
interrupted. If charging has to be interrupted for any reason, switch o the PSW using the buon provided and disconnect the baery.
To acvate STOP, hold the buon down unl the STOP LED begins to ash (PAN. 6).
To interrupt the charge in the PSW is ed on board, disconnect the mains supply and use the vehicle. Never disconnect the baery if the
charge is supplying current, as the resulng spark could ignite the gases produced by the baery and cause an explosion.
For best charging, disconnect the baery only when the microprocessor indicates STOP (PAN. 3).
HOLDING
If you leave the PSW on line and connected even during long periods of inacvity, it is possible to maintain a 100% charge level.
At the end of a charge cycle (device indicang STOP – PAN. 3). The holding starts: when the baery voltage falls under a minimum level,
the PSW goes into operaon and supplies a small current in order to let the baery voltage reach a maximum level and then it stops.
These charging pulses can be repeated indenitely when necessary. The length of each pulse and the me between pulses depends on
the baery condion. During charging pulses the display indicates STOP (PAN. 3).
If charging is interrupted by the pushbuon (PAN. 6), holding does not start.
We advise not to leave the PSW connected to the baery without mains supply for more than one week. Without mains supply, the PSW
absorbs energy from the baery and may cause its total discharge,
DATA MEMORY
The internal microprocessor can store a remarkable quanty of informaon throughout the life of the PSW. This informaon can be read
only through the suitable terminal (MUTLIPROGRAMMER) connected to the programming connector shown in Fig. 2.
Contact the supplier for purchase of a MUTLIPROGRAMMER-CLIENT.
Reading this informaon helps detect the problems and their cause.
It will be easily understood whether they are caused be a malfuncon of the charger of the baery. It is also possibly to understand
whether the problems are caused by the non-compliance of the user with the rules. Be parcularly careful when reading the user’s hand-
books.
ADDITIONAL FUNCTIONS
This secon contains direcons for the PSW when ed on board.
When the PSW is assembled on board, the LEDs are oen not visible.
PSW Battery Chargers—User Guide (page 2 of 4)
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It is possible to add am oponal external display (VISLED) in order to place the control LEDs in a visible area. Ask your supplier for this and
connect it to the auxiliary connector indicated in Fig. 1.
The PSW has two auxiliary contacts, which must be correctly connected to the vehicle equipment, with following funcons:
Mains presence: the contact is normally closed; it opens when the PSW is supplied for charging. It has to stop the vehicle during the
charging phases (contacts 1 and 7 of the auxiliary connector to be seen in Fig. 1);
Discharged baery: the contact is normally closed; it opens when the baery voltage is lower than the programmed value. It has to stop
the vehicle when the baery has exhausted 80% of its energy (contacts 3 and 5 of the auxiliary connector to be seen in Fig. 1).
When the PSW operates on a discharged baery, it illuminates the BLOCK LED (only visible on the outer display VISLED) and it stops the
vehicle.
In order to remove this block it is necessary to carry out a complete recharge.
The PSW will signal to the user when the technical maintenance is due. When this happens, the two LEDs ash alternately (PAN. 7). Make
contact with the supplier.
GENERAL RECOMMENDATIONS
Do not let the baery run down completely (maximum 80%): it will last longer. Keep the baery contacts free of oxidaon. Keep the
charging area well venlated.
MAINTENANCE
Keep the fan and the venlaon holes clean. To clean the outside, use a damp cloth, Use only original spare parts.
PSW Battery Chargers—User Guide (page 3 of 4)
Baery Service Hub Ltd
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PSW Battery Chargers—User Guide (page 4 of 4)
Baery Service Hub Ltd
www.baeryservicehub.co.uk