Ceil 5DTM User manual

Operation and Maintenance Manual
5DTM - 5DTT
The manual refers to chargers with AT 12 board with FW 6.4L or higher (dec 2021)
Slightly differences can be found using different versions
ADVANCED SMART
DERIVATIVE CHARGER
with Navigator Display &
Data Logging function

rev. 1904 (EX - FW 6.4)
3 /20
WARNING - SAFETY
FOR LEAD-ACID BATTERY AND ASSOCIATED BATTERY CHARGER SYSTEM
1.1 Electrical information
Read the electrical data on the charger identification plate and ensure they match your electric system and the battery it
should recharge:
1- Mains AC voltage. Usually. it is 420-50Hz for three-phase systems and 240V-50Hz for single-phase AC systems.
2- Battery voltage. It must correspond with battery charger voltage.
3- The maximum charging current. The correct value is about 16% of the nominal capacity C5 of the battery using the Wa
charging curve profile. while is about 24% using the W0Wa charging curve (Example : 600 Ah battery. initial current
using the Wa charging profile: 600x0.16=96A initial current using the W0Wa charging curve: 600x0.24=144 A)
If the electrical data of the Charger and your AC Mains system or your battery do not match, you must NOT connect them.
Do not try to repair Charger faults, please call our Service.
Any repairs or replacement of parts must be authorised in writing by our technical department.
Warning: this series is only 50Hz. the Wa profile is altered if connected to a 60Hz Mains
NOTE : Measure the site AC voltage during charge and check if it is the same as the voltage set on the
power transformer terminal. Power transformers can have 3 or 4 input Voltage options
(the photos below are examples, your transformer can be slightly different)
SINGLE PHASE
T-T (t°probe) 220V V 240V(nom)
THREE PHASE
T-T (t°probe) 380V 400V 420V(nom)
Please match the voltage to the nearest value. Suggested range set-up:
Single Phase: 215-225V (set 220V) – 226-235V (set 230V) – 236-245V (set 240V)
Three Phase (star connection): 350-370 (set 360V) 371-390V (set 380V) 391-410V (set 400V) 411-430V (set 420V)
Three Phase (delta connection): 202-214 (set 208V) 215-226V (set 220V) 227-237V (set 230V) 238-250V (set 243V)
NOTE: three-phase battery chargers with 420V power supply have a star connection. The three-phase 240V
battery chargers have a delta connection and a special terminal block (6 fixed base cylindrical studs) to
facilitate switching from 240V to 420V. Stickers with instruction are into the charger.
If necessary, drawings and more instruction can be required

rev. 1904 (EX - FW 6.4)
4 /20
1.2 Safety and Reference Rules
The Battery Charger is made in accordance with the following ECC rules:
2014/35/UE Rules for low voltage equipment
2014/30/UE Electromagnetic compatibility
and products norms EN60335-1 and 60335-2-29.
Chargers are manufactured under ISO9001 conditions
•Only certified electricians should arrange the connection of the Charger to AC Mains supply. We suggest you use an
electrician who is able to issue a declaration of conformity for the work carried out. The declaration must include the
connection to the earth. the verification of the line. circuit breaker / fuse. switch / isolator. plug / socket and the AC Main.
Electrical safety is assured only when the plug/ socket is connected to an efficient earthing point. You may request our
office for our Installation Form.
•If your Battery Charger AC plug needs to be replaced.it should be done by a qualified electrician.
•Protect the power supply cables with slow fuses or magneto thermal switch / Breaker (D curve).
We suggest using power socket with a rotary switch to avoid plug extraction.
•Do not disconnect the battery plug before the Battery Charger is switched off by the “Off” Push button located on the door.
To prevent casual or voluntary disconnection. we suggest the use of mechanical blocks or auxiliary contacts to feed the
Battery Charger.
•Do not open the Battery Charger cabinet / door before checking the power plug is disconnected. the main switch is off and
the battery is disconnected.
•If the AC power cables or the Battery Cables are worn or even if they are partially damage. please have them replacedby a
qualified electrician.
2. INSTALLATION AND POWERING
Please. read carefully the Chapters above “Electrical Information” and “Safety Rules”.
The installation must be made in accordance with the following instructions. The operation must be made in total absence of
electrical power. Terms of use:
-Working temperature and relative humidity: from 0° to 40°C (RH75%)
-Storage temperature: from -20°C to 60°C
2.1 Choosing the place
•Put the Battery Charger in a suitable place. allowing adequate ventilation. far from any heat source.
•Place the cabinet on a non-flammable surface such as stone. concrete or metal.
•Chargers are heavy devices. They must be secured to prevent accidental fall or tipping over. Place them on the ground or
use robust shelves.
•Make sure the Battery Charger front panel with OFF push button has easy access and that charging phase control panel
(LEDs and Display) are clearly visible.
2.2 Checking the electrical system line
•Ensure the electrical system line has been laid in accordance with related current standards in force.
•The electrical connection must be made by qualified electrician.
We suggest that you use a professional who is in a position to issue a "declaration of conformity"for the job performed.
•The electrical safety is guaranteed only when the power plug is correctly connected to an efficient earth/ground.
•Check that the electrical mains system can withstand the power of the battery charger (V/A) and that the voltage and
frequency of the line comply (Volts and Hz) with the rating of the charger.
•Make sure the charger is protected with appropriate time delay fuses/circuit breaker. Please refer Section 9.
2.3 Checking the charger and the battery
•Check that the input Vac cables, the output battery cables and the battery/charger plugs are in good condition and
properly insulated.
WARNING: charger installation or plugs replacement must be performed by qualified personnel.
•Ensure good ground insulation of the battery and the power cables.
•Make sure the " polarity " of the battery cables (through the plugs) correspond with the battery charger
cables. Positive to Positive and Negative to Negative.
•Check that the battery is matched to the charger in respect of both voltage (V) and capacity (Ah).
•The battery must be ready to be charged. clean and with proper electrolyte level.

rev. 1904 (EX - FW 6.4)
5 /20
2.4 Charging profile Wa - features
Chargers perform a decreasing current profile called Wa with dU/dt termination regulated by the rule DIN 41774
The charge cycle is divided in two parts:
The bulk phase: from beginning of the charge up to the gassing point (2.4Vel)
The final charger: from gassing point (2.4Vel) up to the end of the charge.
Once the cycle is completed the charger can perform additional equalisation and preservation charges.
Equalisation and preservation can be activated / deactivated as desired.
Stage 1 - Bulk Charge - Battery Voltage <2,40Vel (min 1/2h)
Stage 2 - Final Charge - Battery Voltage >2,40Vel (max 4-6h)
Stage 3 - Equalisation - 5 minutes every hour for the following 15h
Stage 4 - Conservation - 5 minutes every 15 h until the charger is
switched off
Charge termination dU/dt
3. VISUAL INDICATIONS
L1 L2 L3 L4 L5
Green Yellow Green Yellow Red
Battery / Bulk
Final charge
End
ON
Error
The battery is
connected or the
charge has started in
Bulk phase
Charger is in the final
charge phase
(V>2.4 V/cell).
The battery is
charged.
The charger is
supplying current.
There is a fault or an
anomaly.
The Charger is provided with 5 LEDs which provide essential information on charging status and possible alarms/error.
Legend: -- = LED off on = LED fixed light F = LED flashing
Key M << >> Eq (F)
Function Special function Scroll backwards or up Scroll forward or down Special function
If you need to Stop the Charge press the black Push button for 4 sec. Display shows Stop.
USB port: only
use USB cord
provided by
ESPEX

rev. 1904 (EX - FW 6.4)
6 /20
3.1 Navigator Display
The"Navigator" has been designed to provide a "unique" data which shows, depending on specific situation, the status of the
Battery Charger or an intuitive alarm code. This feature is available on all Chargers fitted with Navigator Display.
The Navigator provides various information during the charge process.
During the charging process, the first two digits of the display show in sequence three lines that rise upwards. The other two
digits show a number between 10 and 99 to indicate where the charging process is (%).
 then
 and so on
For example “--50” indicates that the battery has attained 50 % of recharge “--80” indicates 80 % and so on.
This parameter just gives an estimate of the battery’s recharge status; it is not an exact measure.
Display
Message
Description

Stop
Idle; battery can be disconnected avoiding electric arcs.
Stop button has been pressed or AC-Mains voltage is missing.

% charge
On charge; gives an estimate of battery recharge status %.

% charge
On charge; gassing threshold achieved and crossed over; final charging stage.

End n
Idle; Charge accomplished in reduced time. Battery probably fully charged or
sulphated.

End c
Idle; Battery may be disconnected now. Charge accomplished achieving pre-set
Ah capacity.

End d
Idle; Battery may be disconnected now. Charge accomplished by derivative
termination (dV/dt).

End t
Idle; Battery may be disconnected now. Charge ended on achieving maximal
Time admitted in Phase 2 (Tmax F2)

End u
Idle; Battery may be disconnected now. Charge ended on achieving pre-set
maximal Voltage (Vmax F2)

End p
Idle; Battery may be disconnected now. Charge ended on achieving absolute
maximal Time (Par 308)

Wait
Charge not started yet: DELAY START function is set;
Charger awaits pre-set delay hh:mm before start.
3.2 Display Information & Setting
The Charger is provided with a 7 segment high brightness display along with 4 key buttons for scrolling diagnostic parameters
and programming. Here are the functions of each key in Standard Mode.
Through the << and>> keys it is possible to scroll the following parameters:
No.
Parameter
Function
Description
1  Navigator shows the charging condition of the battery (in %) or identifies the alarms.
Its value goes on changing during the charge
2  Battery Current shows the charging current (Ampere)
3  Battery Voltage shows charge voltage (Volt)
4  Total Capacity Accumulated capacity (Ah)
5  Capacity: phase 1Capacity accumulated during bulk phase (Ah)
6  Overall Time Time elapsed since the beginning of the charge (h)
7  N. of charges Number of performed charges
7  Partial charges Showing the number of charges that lasted more than 30’
8   Equalisation
Shows the equalisation cycle setting:
0 = never active 1 = always active 2 = every 5 cycles 3 = every 20 cycles
9  Delay start - set Delayed start function (setting)
10  Delay start - clock Delayed start function (countdown)
11  code_1 (#) Vbat (12) Inom (34) eg: a 48/100 is
4 8 1 0
up to rev 6.5
12  code_2 Code (1) CF (23) CFmin (4) eg: a 5DTT could be
d 0 0 0
13  code_3 AC phase (1) Alarm (2) Firmware (34) eg: 5DTT
3 3 6 4
5DTM
1 2 6 4
The last 3 codes (11-12-13) are "setting identity codes". Necessary in case of fault or PCB replacement.
Numbers reported between brackets represents the digit of the display: 1 = digit 1. 2 = digit 2 etc
(#) From FW rev 6.6 on code 1 has been divided in two (Code_1A - Vbat - 48 and Code 1B - Inom - 100)

rev. 1904 (EX - FW 6.4)
7 /20
3.3 Special Functions and other useful information
Programming EQUALIZATION (Eq)
“Eq” parameter can be called onto the display.
Equalisation charge occurs 15 times sequentially; 5 minutes active cycle (ON) and 60 minutes sleeping cycle (OFF).
Preservation/Maintenance charge. if selected can continue indefinitely; 5 minutes in active cycle (ON) followed by 15 hours
sleeping cycle (OFF).
When Eq<>0 it means preservation active if the charger is ON.
Eq 0: no equalisation / no preservation (no Eq. no Con)
Eq 1: Equalisation after all cycles.
Eq 2: Equalisation every 5 cycles (full n/5) i.e.. once a week.
Eq 3: Equalisation every 20 cycles (full n/20) i.e.. once a month.
Display gives “Equl” message when funciton is on. while Leds are in 0011 0 position
(Eq) parameter can be changed when necessary. For instance. If equalisation setting Eq1=always active and you would like to
set it to "never active" here is how you have to proceed:
Go to parameter Equalisation pressing the key >> and up to "Eq 1".
Press M key (the first digit of the display starts flashing).
Scroll backwards until display shows "Eq0" (never active) then press M for confirmation.
NOTE: It is possible to select other types of equalizations (Eq4, Eq5 and Eq6) in addition to the standard ones (Eq1, 2 and 3).
They are complex equalizations. If you are interested, ask for the specific document that explains them to our assistance
service
Programming DELAY START (dELy)
System is enabled to set delayed starts up to 24h by intervals of 15 MINUTES each.
Power up the charger and scroll until “dELy” parameters (which enables to set up the delay time)
Press Button 1 (M). “dELY” disappears and a “00.00” clock is shown.
Increase/decrease time value by Buttons 2 and 3 (< and >) and confirm with M (for example: value 01:00 corresponds to 1
hour delay before the charging cycle start).
Press M again: clock disappears and “dELy” is shown again
Press Button 3 (>) forward to view the delay time set (for example 01:00)
Delay start countdown begins. Remaining time reduction will be shown (for example 00.59 and so on).
Call up “Navigator” parameter again and “UAIT” message will appear. which means “waiting”.
Once remaining minutes will have gone by. charger will start its regular charging cycle.
WARNING: delay start time remains saved for the following charging cycles as well!
To disenable the delay start. call “dELY” parameter and set a 00.00 value!
Main differences between 5DTM and 5DTT
1 - 5DTM is a single phase charger, while 5DTT is three phase
2 - 5DTM does not have an auxiliary transformer that powers the main board and the display, therefore it is not possible to
obtain information without connecting the battery.
For this reason, some indications on the display may differ
Repeated attempts to restart in case of failure
The charger is programmed to attempt to restart every minute in case of non-blocking errors due to current, thermal and
network errors. Here they are: cur, ter, terc and E_AC
The battery charger, on the other hand, remains blocked in the event of errors due to the battery or exceeding a maximum
time. Here they are: bat5, bat9, time, E_t2 and tout.
You will need to disconnect the battery to reset a blocking error.
The reason is that this error must be thoroughly evaluated before attempting a new charge
We remind you that "bat" is not an error but means "waiting for the battery" or "Battery disconnected"
Also "bat1" is not an error, but a warning, the charger is on, but the battery voltage is below the rated value and the current
output is very high. This situation should also be carefully considered
Indications on the display with special hardware
1 - Pilot Contact: If this option is present and the contact is open, the display shows the message "open"
2 - AT58 expansion card: If this card is present and there is no communication with the AT12 main card, the display will show
"Mbus"
3 - Air insufflation pump: If this option is present and the pressure sensor measures a low pressure, the display will show
"Air"

rev. 1904 (EX - FW 6.4)
8 /20
4. OPERATION
4.1 Charger Power-up and Battery Recharge
Charger performs the cycle automatically just after its connection to the battery and to AC Mains.
WARNING: The single phase 5DTM and the three phase 5DTT are slightly different during their starting up
This is the procedure to follow:
Legend: -- = LED is off 1= LED is ON steady F = LED is flashing
L1 = Battery-Bulk L2=Final charge L3=End L4=on (supplying current) L5= Error
LEDs
Charger
Action
Effect
L1 L2 L3 L4 L5
Display
5DTT Close AC switch PCB lights on (3 sec) 1 1 1 1 1 
PCB views FW revision (3 sec) 1 1 1 1 1 
PCB views Battery disconnected L -- -- -- -- 
Connect the battery plug Perform some internal checks (5 sec) 1 -- -- -- -- 
Charger supplies current 1 -- -- 1 -- 
5DTM Close AC switch PCB remains fully OFF -- -- -- -- --
Connect the battery plug PCB lights on (3 sec) 1 1 1 1 1 
PCB views FW revision (3 sec) 1 1 1 1 1 
Perform some internal checks (5 sec) 1 -- -- -- -- 
Charger supplies current 1 -- -- 1 -- 
(§) Both During Bulk Charge (<2,4Vel) Supplying current (Stage 1) 1 -- -- 1 -- 
During Final Charge (>2,4Vel) Supplying current (Stage 2) -- 1 -- 1 -- 
(*) End of Charge
Battery can be disconnetted and
ready to be used
-- -- 1 -- -- 
Equalisation or Preservation charge.
Supplying current for 5min / 1h
(Stage 3 and 4)
-- -- 1 1 -- 
(§) After starting up, these actions are common for both chargers
(*) There are some kind of End, please see table above (navigator)
it is assumed that no errors occur. If so, refer to the Troubleshooting section
The battery must be around the rated voltage and in good condition
Using the << and >> keys it is possible to display the recharge parameters.
4.2 Charging stop and battery disconnection
Battery can be disconnected if the display views END or STOP.
During the charge an electric spark occurs, please use the Push button to Stop the charge.
WARNING: this procedure must be followed in order to avoid electric sparks/arcs:
Action
Effect
L1 L2 L3 L4 L5
Display
Press OFF button (for 4 sec) Charger stops supplying current 1 -- -- -- -- 
Disconnect the battery plug (5DTM) - PCB turns fully off -- -- -- -- --
(5DTT) - PCB shows "bAt" F -- -- -- -- 
NOTE: if the charge is completed (green LED L3 – on) and the charger is not working (yellow LED L4 – off) battery plug can
be disconnected avoiding electric arcs.
Connecting another discharged battery will automatically re-start the charger.

rev. 1904 (EX - FW 6.4)
9 /20
5.A TROUBLE SHOOTING - Three Phase - 5DTT
This information relates to a 5DTT charger with a DC current reader andwith an auxiliary transformer (P4=3)
Legend: -- = LED is off On = LED is ON steady L = LED is flashing
Situations BEFORE the charge (1-9) and DURING the charge (10-20)
ref
L1
L2
L3
L4
L5
Display
BEFORE the charge
Both Mains and DC is missing: board is fully off
Battery is not connected to the charge or voltage is very low (<7-8V).
Vac mains is missing as well.
Possible reasons:
-The fuse protecting the diode bridge is burnt.
-The battery plug or battery cable is damaged, cut or disconnected.
-Electronic board not powered or faulty.
-Battery/Cell Terminal bolt is loose or missing.
-Check AC input plug connection, the main switch of the power line and
related input AC fuses/breaker
DC under voltage: Battery is connected to the charger but voltage is
below min threshold (1.7V/Cell or 85% nominal Voltage).
Charge can not be performed
1 -- -- -- -- --
2 On -- -- -- L 
3 On -- -- -- L 
AC Mains is missing:
Please check AC input plug connection. the main switch of the power line
and related input AC fuses/breaker.
If this occurs during the charge the charger stops, but when AC power is
back the system restarts automatically
4 On -- -- -- On  Overvoltage in battery;Battery voltage is over maximum permitted
threshold (>2.9V/Cell); Wrong battery connected or heavily sulphated.
DURING the charge
10 On -- -- On -- 
WARNING: Charger is supplying current but nominal voltage has not yet
reached (between 85-100% Vnom).
Battery Ah capacity is probably too big for the charger’s current rating.
After some minutes the charger might stop automatically for over-current
alarm (ter or terc). The charger will attempt to complete the charge by
taking multiple pauses
11 On -- -- -- L 
Under current: The current to the battery is below the minimum threshold
(2-3 A). Charger will try to restart every few minutes on.
Possible Reasons: A) There might be a possible bad contact or a connection
problem B) Check AC mains plug connection, the main switch of the electric
line and the input AC fuses/breaker. C) Battery sulphated. D) The Mains
and the transformer plug are not well-matched E) The current (Ammeter)
sensor or its connection cables are damaged.
12 On -- -- -- L


Thermal fault: Error "ter" occurs when one or more thermal probes into
the power transformer are open. It must be very hot.
When the temperature drops probes are restored and the system restarts.
The "terc" error is a preventive block of the charger to reduce the
temperature of the power transformer because too high current levels have
been detected. After a time it starts autmatically
Possible Reasons: A) Battery is too big (Ah) for the charger B) The Mains
are too high or the transformer plug are not well-matched C) Battery is too
discharged D) Ambient temperature is too high or there is not enough
fresh air around the charger E) thermal probe are defective F) board has
a wrong setting
13 On -- -- -- On



TiME Errors: many timers are set to protect the charger and the battery
Time: Maximum charging time Phase 1 has been exceeded: 11h (ph1)
t_t2: Maximum charging time Phase 2 has been exceeded: 9h (ph2)
tout: Maximum overall charging time has been exceeded: 18h (total)
Any of these alarms can be caused in following cases:
1) AC Mains is too low
2) Vac tapping on power transformer is not in the correct position
3) Battery is not suitable: Ah too big or battery is damaged. Battery does
not reach 2.4V/Cell at end of Phase 1.
4) Wrong card setting
5) Diode bridge failure
STAND-BY MODE: The 5DTT chargers have AC auxiliary power. When Mains is missing the display switches to standby
mode to preserve energy. For 1sec shows the last data and for 4sec it turns off ( )
Pressing any key it turns on for a minute. This can be useful to understand that the Mains is missing
NOTE 1: during start-upphase all LEDs light up and display shows  for some seconds to test the elements NOTE
2:Some errors can resolve themselves if the situation returns to normal (bat1, ter, terC and E_AC), the "cur" error retries
astart every minute. The others (bat5, bat9, time, tout) block the charger until the intervention of an operator who must
disconnect the battery and analyze the reasons

rev. 1904 (EX - FW 6.4)
10 /20
5.B TROUBLE SHOOTING - Single Phase - 5DTM
Here is a list of typical "FAULT" indications from LEDs signals or coming from the "Navigator".
This information relates to a 5DTM charger with a DC current reader, but without an auxiliary transformer (P4=2)
Legend: -- = LED is off On = LED is ON steady L = LED is flashing
Situations BEFORE the charge (1-9) and DURING the charge (10-20)
ref
L1
L2
L3
L4
L5
Display
BEFORE the charge
DC is missing: board is fully off
Battery is not connected to the charge or voltage is very low (<7-8V).
Vac mains might be present. Possible reasons:
The fuse protecting the diode bridge is burnt.
The battery plug or battery cable is damaged, cut or disconnected.
Electronic board not powered or faulty.
Battery/Cell Terminal bolt is loose or missing.
DC under voltage: Battery is connected to the charger but voltage is
below min threshold (1.7V/Cell or 85% nominal Voltage).
Charge can not be performed
1 -- -- -- -- --
2 On -- -- -- L 
3 On -- -- -- On  Overvoltage in battery; Battery voltage is over maximum permitted
threshold (>2.9V/Cell); Wrong battery connected or heavily sulphated.
DURING the charge
10 On -- -- -- L 
AC Mains is missing: 5DTM can not understand in advance is Mains is
missing, so charger has attempted to start charging but detected that Vac
Mains is missing. Please check AC input plug connection. the main switch of
the power line and related input AC fuses/breaker. When AC power is back
the system restarts automatically
11 On -- -- On -- 
WARNING: Charger is supplying current but nominal voltage has not yet
reached (between 85-100% Vnom).
Battery Ah capacity is probably too big for the charger’s current rating.
After some minutes the charger might stop automatically for over-current
alarm (ter or terc). The charger will attempt to complete the charge by
taking multiple pauses
12 On -- -- -- L 
Under current: The current to the battery is below the minimum threshold
(2-3 A). Charger will try to restart every few minutes on.
Possible Reasons: A) There might be a possible bad contact or a connection
problem B) Check AC mains plug connection, the main switch of the
electric line and the input AC fuses/breaker
. C) Battery sulphated. D) The
Mains and the transformer plug are not well-matched E) The current
(Ammeter) sensor or its connection cables are damaged.
13 On -- -- -- L


Thermal fault: Error "ter" occurs when one or more thermal probes into
the power transformer are open. It must be very hot.
When the temperature drops probes are restored and the system restarts.
The "terc" error is a preventive block of the charger to reduce the
temperature of the power transformer because too high current levels have
been detected. After a time it starts autmatically
Possible Reasons: A) Battery is too big (Ah) for the charger B) The Mains
are too high or the transformer plug are not well matched C) Battery is too
discharged D) Ambient temperature is too high or there is not enough fresh
air around the charger E) thermal probe are defective F) board has a wrong
setting
14 On -- -- -- On



TiME Errors: many timers are set to protect the charger and the battery
Time: Maximum charging time Phase 1 has been exceeded: 11h (ph1)
t_t2: Maximum charging time Phase 2 has been exceeded: 9h (ph2)
tout: Maximum overall charging time has been exceeded: 18h (total)
Any of these alarms can be caused in following cases:
1) AC Mains is too low
2) Vac tapping on power transformer is not in the correct position
3) Battery is not suitable: Ah too big or battery is damaged. Battery does
not reach 2.4V/Cell at end of Phase 1.
4) Wrong card setting
5) Diode bridge failure
STAND-BY MODE: The 5DTM chargers do not have AC auxiliary power but only battery power. To preserve energy, the
display switches to standby mode after aminute. For 1sec shows the last data and for 4sec it turns off ( )
Pressing any key it turns on for aminute.
NOTE 1: during start-upphase all LEDs light up and display shows  for some seconds to test the elements NOTE
2: Some errors can resolve themselves if the situation returns to normal (bat1, ter, terC and E_AC), the "cur" error retries
astart every minute. The others (bat5, bat9, time, tout) block the charger until the intervention of an operator who must
disconnect the battery and analyze the reasons

rev. 1904 (EX - FW 6.4)
11 /20
6. MAINTENANCE
The maintenance schedule depends on use and operating conditions but. generally. it should not exceed three months.
The maintenance operations have to be made by specialised personnel. in compliance with safety rules.
“Routine and Extraordinary Maintenance Forms” later in this manual.
WARNING: If you detect a problem and you can not take immediate action to solve it, please make sure the
charger is identified as not working and " NOT to be used "
6.1 Preliminary recommendations
•Before performing maintenance or repairs make sure the AC power plug and the battery are both disconnected.
•Carefully clean all parts: the charger, the battery, the cables, all the plugs etc.
•If the power cord or battery cables show signs of wear and are also partially damaged, please have them replaced
immediately by qualified personnel.
6.2 Put the equipment out of service
When you want to do a Routine or Extraordinary maintenance on your Battery Charger. or you do not want to use it for a long
time or there is a fault. you must put it out of service.
Please follow these instructions:
•If the charger is in use switch it Off.
•Turn the AC mains switch to “Off” position and disconnect the plug.
•Disconnect the battery plug.
Should you wish not to use your charger for a long period, store it in a cool, dry & safe place.
The AC main plug and the battery plug must be lifted off the floor and secured.
6.3 Routine Maintenance
Perform maintenance every 3 months or any time necessary.
•Clean carefully the AC and battery cables. Check they are not damaged or burnt. Replace them immediately if found
damaged in any way.
•Check the AC mains and battery plugs. If they are crushed or burnt or damaged. replace them immediately.
•Electrical equipment must not be exposed to dust and humidity. Clean the Battery Charger. Should it be too dirty or
damp. move it in a safer place. The same applies for the battery.
6.4 Extraordinary Maintenance
Perform maintenance every year or when a problem occurs (i.e. burnt fuse) or you notice a fault.
•Follow the checklist of “Routine maintenance”.
•Open the Battery Charger. Clean carefully the dust on each component: the printed circuits by a clean soft brush; on the
other components by a blow of compressed air; Blower should be at least 20 cm (8 inch) away.
•Check the screws and electrical connections are well tightened. The use of a thermal imaging camera is an excellent way
to understand if there are loose connections or weak points where you must intervene. The charger should be on for at
least 10 minutes before you make measurements
•Check the fuses. the fuse holders and the moving mechanical parts (contactor).
•Request in advance for replacement parts that are not available at your site.
7. WARRANTY
Duration Espex guarantees the Battery Charger against manufacturing defects for 3 years.
Starting date The delivery date from Espex is considered the starting date of the warranty.
Covering
•Defective components will be repaired or replaced free of charge.
•
Labour is free of charge at Espex site in Cardiff; If carried out nearby at customer/users’s site it will be
on chargeable basis.
•Delivery costs of replacement components are at consignee’s expense.
Loss of right
Warranty is not valid in case of:
•Instructions stated in this Manual and on the Charger front panel are not observed.
•Improper use, violation or modification of the charger.
•Charger being used out the permitted ranges specified.
•
Charger being used outside the defined parameters in accordance with product specifications. As a
general rule the number of charge cycles is <300 cycles / year for the Wa profile chargers.
•Evidence that both ordinary and extraordinary maintenance were not carried out on the charger.

rev. 1904 (EX - FW 6.4)
12 /20
8. INPUT AC CURRENT DRAW AND FUSE RATINGS
DC 1 phase AC 240V 3 phase AC 420V
Mains
Cur.
Fuse
Mains
Cur.
Fuse
Vdc Adc kVA Aac A Adc kVA Aac A
20
0,7
3,1
4
30
1,1
4,6
6
40
1,5
6,2
8
50
1,9
7,7
10
60
2,2
9,3
12
60
2,0
2,8
4
24
80
3,0
12,7
16
80
2,7
3,7
6
100
3,8
15,8
20
100
3,4
4,7
6
120
4,6
19,0
25
120
4,1
5,6
8
140
5,3
22,2
32
140
4,8
6,6
8
160
6,1
25,3
32
160
5,4
7,5
10
180
6,1
8,4
12
200
6,8
9,4
12
220
7,5
10,3
16
40
2,2
9,3
12
50
2,9
11,9
16
60
3,4
14,3
20
60
3,1
4,2
6
80
4,6
19,0
25
80
4,1
5,6
8
100
5,7
23,8
32
100
5,1
7,0
10
36
120
6,8
28,5
40
120
6,1
8,4
12
140
8,0
33,3
40
140
7,1
9,8
12
160
9,1
38,0
50
160
8,2
11,2
16
180
9,2
12,6
16
200
10,2
14,0
20
220
11,2
15,5
20
60
4,6
19,0
25
80
6,1
25,3
32
100
7,6
31,7
40
60
4,1
5,6
8
120
9,1
38,0
50
80
5,4
7,5
10
140
10,6
44,3
63
100
6,8
9,4
12
48
160
12,2
50,7
63
120
8,2
11,2
16
140
9,5
13,1
16
160
10,9
15,0
20
180
12,2
16,9
25
220
15,0
18,7
25
240
16,3
22,5
32
60
7.6
31,7
40
60
6,8
9,4
12
80
10,6
42,2
63
80
9,1
12,5
16
100
12,7
52,8
80
100
11,3
15,6
20
80
120
15,2
63,4
80
120
13,6
18,7
25
140
17,7
73,9
100
140
15,9
21,8
32
160
20,3
84,5
125
160
18,1
25,0
32
180
20,4
28,1
40
The chart shows the maximum values for 240Vac single phase and 420Vac three phase nominal input voltages.
These values refer to the initial charging stage of a fully discharged battery.
DC output Current in Wa Chargers progressively decreases during the charging cycle.
If the battery is not completely discharged, both Current and Power absorption will be lower than these values, starting from
the initial charging stage.
When using MCBs in incoming AC circuit please select Type D or C.

rev. 1904 (EX - FW 6.4)
13 /20

rev. 1904 (EX - FW 6.4)
14 /20
9- Installation Form
The purpose of this form is to:
1. Verify the compatibility among Charger. Battery and AC Mains.
Following these instructions will lead to verify the points that have the higher probability of fault.
This document will help confirm that the installation was carried out properly.
Statistically. a correct installation prevents about 80% of faults.
Charger Model
Customer – Firm
Serial number
Note
Nr OBJECT CONTROL – ACTION
OK
01 Conformity between
Charger and Battery
1.
Main features of a Charger are Current and Voltage. This data is on the Charger Serial
Plate. For example: 48V 80A
2. Main features of a Battery are Capacity and Voltage. This data is on the Battery Serial
Plate. For Example: 48V 500AH
3. Verify the charger is right for the battery. Relation between them is shown in the
table at the end of this manual. Recharge time should also be considered.

02 Conformity between
Charger and AC Mains
1. AC Mains voltage for the Charger is normal set at 240V for 1-phase and 420V for 3-
phase.
2. Measure the incoming AC Mains voltage at the terminals of the AC Contactor and
Power Transformer terminal block.
If necessary. change connection to tappings on terminal block to match the Mains AC
voltage. Follow instructions in clause 1.1

03 Battery Plug-Socket
and AC Main socket.
BATTERY PLUG-SOCKET
1. Check cables polarity of the DC plug-socket (red + positive and black – negative)
both from the battery and from charger and ensure they mesh correctly.
2. Check the Pins of the plug-socket are well secured to the cables and that the plugs
open and close properly.
AC MAINS PLUG-SOCKET
1. Verify that the cable sheath is secured the plug.
2. Earth cable connection in the AC plug and socket must be verified carefully

04 Cabinet Examination 1. The Charger cabinet must only be placed indoors. in a well ventilated, clean and dry
place. This will ensure proper heat and battery gas dissipation.

05 Special Condition
It is good pay attention to the following conditions
1. If the charger is standard (i.e. 12hour recharge), make sure the user gives enough
time for the battery to fully recharge.
2. If there are more than one forklift, put a mark or a label to link the charger and the
relevant forklift.
3. Check if there is a difference between AC Mains value during the day or the night.
4. If the Charger is to be used in a daily multi-shift operation, make sure the charger is
suitable for this use. You may contact our office for advice.

If one or more of the above points is non-compliant.we suggest the installer does not issue this statement.
Installation not authorised.
Not certified condition or Notes (if applicable):
Date
Installer name &
signature
Test Result

rev. 1904 (EX - FW 6.4)
15 /20
10-Routine Maintenance Form
The purpose of this form is to:
1. Verify the general condition of the charger.
Following these instructions will lead to verify the points that have the higher probability of fault.
This document will help confirm that periodical inspection has been conducted.
Routine maintenance is recommended to be carried out every two or three months.
Charger Model Customer - Firm
Serial number Note
OK
Nr
OBJECT
CONTROL – ACTION
01 AC Mains Cable and Battery &
Charger cables (red-black)
1. Clean carefully all the cables.
2. Check if they are damaged. There shouldn’t be signs of any cut,
crushing or damage in general.
Change cables if found damaged

02 Battery Charger Plug-Socket and
AC Mains socket.
BATTERY / CHARGER PLUG-SOCKET
1. Check the poles of the plug-socket are well fixed and it is easy open
and close the plug.
2. Plug Pins must not have signs of scorch/acr/pitting.
3. Check the terminals of the battery cables. The terminals must be well
tightened.
4. Plug-socket casing must not be damaged
AC MAINS PLUG-SOCKET
1. Verify that the cable sheath is well secured in the plug.
2. Plug-socket must not be damaged

03 Cabinet Examination 1. Cabinet should not be too dirty. If it is so. clean it up carefully and if
necessary relocate the charger.

04 Battery Examination
Efficiency of the charger depends of the battery condition.
You need to ensure the battery is regularly maintenaned.
Main checks:
1. Electrolyte level.
2. Any evidence of scorching / arcing on the battery poles or anywhere
on the cells.
3. Battery cell voltages are within permissible range.
4. All battery / cell terminals are tightly bolted to the cable connectors.
5. Battery end take-off cables are properly connected to the battery plug
and the plug is not damaged in any way.

If you have found one or more problems please carry out the controls of the “Extraordinary Maintenance” (Format on next
page)
Components replaced or Notes:
Date
Operator
Test Result

rev. 1904 (EX - FW 6.4)
16 /20
11- Extraordinary Maintenance Form
The purpose of this form is to:
1. Verify the general condition of the charger.
2. Prevent / rectify faults.
Following these instructions will lead to verify the points that have the higher probability of fault.
This document will help confirm that periodical inspection has been conducted.
This document also shows that Extraordinary Maintenance is carried out every six or twelve months depending upon the
usage of the charger.
Charger Model Customer - Firm
Serial number Note
OK
Nr OBJECT CONTROL – ACTION
01 Ordinary Maintenance Repeat the operations required from Routine maintenance.
Fill in the form “Routine Maintenance”.

02
Clean up inside of the Charger.
[First disconnect the Charger by
switching off and unplugging the
AC Mains.]
Open the charger and clean up from the dust every component.
1. Power Transformer
2. Auxiliary Transformer
3. Contactor
4. Electronic Card
Clean with an air blow (blower nozzler at least 200mm away) or with a
dry little brush. Do not use wet cloth or similar.

03 Cables and terminal examination
In general you must ensure all cables are well tightened in their
terminals.
If you notice signs of ageing such as changing of original color, or a
damaged terminal, do change them at once.

04 Overheating or aging of the
components
1. Power Transformer -
Check the power cables. terminals and especially the termination
of the secondary cables that are connected to Diodes Bridge.
They must not display signs of overheating.
2. Auxiliary Transformer -
Check in particular the Fuse holder terminal. It must do a good
contact and must be a 315mA-35VA and 1A-100VA.
3. Contactor -
Verify the contactor contacts are not stuck. Try to open and close
manually several times by pushing with screw driver.
4. Electronic card -
Check the dip-switches or the Jumper, if present, are in the right
position. The terminal block of the card must be efficient and not
show signs to scorching / arcing / melting.

It is very important You have the spare parts in advance.
Components replaced or Notes:
Date
Operator
Test Result

rev. 1904 (EX - FW 6.4)
17 /20
12. Charger Selection Table
Model
Battery Ah
Rechargred in
8 - 9 hours 12 - 13 hours
Starting Current
Amps
From 80% discharged state
(Ah at 5 hour rate)
20 110 160
30 165 240
40 220 320
50 275 400
60 330 480
80 440 640
100 550 800
120 660 960
140 770 1,120
160 880 1,280
180 990 1,440
200 1,100 1,600
Note: Data relates to DoD 80% and CF 17% margin +/- 1/2 h (4,7%)

rev. 1904 (EX - FW 6.4)
18 /20
NOTES
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