CEMONT VELOX 220.2 Mounting instructions

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RU РУКОВОДСТВО ПО БЕЗОПАСНОЙ ЭКСПЛУАТАЦИИ И ТЕХНИЧЕСКОМУ ОБСЛУЖИВАНИЮ
СОХРАНИТЕ НАСТОЯЩЕЕ РУКОВОДСТВО
Cat. n° :
Rev. :
Date :
800035392
01
10/07
VELOX 220.2 - 320.2 - 420.2
8 rue des arts - ZI la petite motte 77220 Tournan en brie - France - Tél [phone] - Fax [phone] - Email:[email protected]

GB
(GB) 1
GB
CONTENTS
1.0 INSTALLATION......................................................... GB-2
1.1 CONNECTING TO THE MAINS............................................... GB-2
1.2 CONNECTING TO THE BATTERY (PREPARING FOR THE CHARGE). ........................... GB-2
1.3 SIMULTANEOUSLY CHARGING MORE THAN ONE BATTERY. .............................. GB-2
1.4 PROTECTIONS. ..................................................... GB-2
1.5 USEFUL TIPS. ...................................................... GB-2
2.0 TECHNICAL SPECIFICATIONS ................................................ GB-2
2.1 DATA PLATE ....................................................... GB-2
3.0 PANEL DESCRIPTION..................................................... GB-3
4.0 GENERAL DESCRIPTION CHARGING ............................................ GB-3
5.0 STARTING OF AN ENGINE .................................................. GB-4
SPARE PARTS LIST ........................................................ II-V
WIRING DIAGRAM........................................................VI-VIII

INSTALLATION
GB
(GB) 2
GB
1.0 INSTALLATION
Before installing the battery charger, make sure that:
1. It is protected from humidity and rain.
2. It is installed on a stable, safe surface.
3. There is sufficient space at the back of the charger to ensure good ventila-
tion.
4. The clamps are not short-circuiting.
5. The mains cable and the clamp cables are in perfect condition.
1.1 CONNECTING TO THE MAINS.
Check that the mains voltage corresponds with that indicated on the identification
plate fixed to the battery charger (230 V a.c. or 240 V a.c. 50/60 Hz). For the con-
nection, use a three-pole plug (two phases earth) rated at least 10 Amp.
1.2 CONNECTING TO THE BATTERY (PREPARING FOR THE CHARGE).
Before starting to charge the battery, check that the capacity (Ah) of the battery
concerned is within the maximum and minimum Cr values indicated on the identi-
fication plate of your battery charge
a. Cr max (Ah): maximum battery capacity, chargeable with the maximum
current that can be supplied in 15 hours.
b. Cr min (Ah: minimum battery capacity,chargeable with the minimum cur-
rent that can be supplied in 4 hours.
1. With the mains cable being disconnected, insert the negative cable plug in
the output terminal with the voltage that corresponds with the battery to be
charged (12V or 24V depending on the battery).
2. Connect the battery to the charger: the red cable to the battery’s positive
terminal and the black cable to its negative one. First of all, connect the pos-
itive cable to the battery’s positive terminal (which is not earthed), then con-
nect the negative cable to the car body, well away from the battery and the
fuel lines.
3. Plug the unit into the mains socket.
4. When the battery has been charged, remove the power plug or set the
charger’s power switch to “OFF”. Then remove the conductor from the car
body and the battery; finally, remove the clamps from the battery.
After use, store the battery charger in a dry place.
1.3 SIMULTANEOUSLY CHARGING MORE THAN ONE BATTERY.
If you have to charge more than one battery simultaneously, you can connect
them in series or in parallel. Of the two systems, connection in series is prefera-
ble, as in this way you can check that the current in each battery corresponds to
that indicated by the ammeter.
1.4 PROTECTIONS.
The battery charger is fitted with an overload cut-out that intervenes in the event
of:
1. Over-charging (excessive current supplied to the battery).
2. Short-circuiting of the charging clamps.
3. Inversion of polarity on the battery terminals.
Battery chargers with fuses: replace, if necessary, with an identical fuse having the
same rating.
BEFORE CHANGING THE FUSE, DISCONNECT THE POWER CABLE
FROM THE MAINS. IF THIS WARNING IS IGNORED, CEMONT DECLI-
NES RESPONSIBILITY FOR ANY CONSEQUENCES THAT MAY RESULT.
1.5 USEFUL TIPS.
1. To avoid gas building up, always charge batteries in a well-ventilated area.
2. Before starting charging, take the cap off each element.
3. Check that the level of liquid inside the battery covers the tops of the plates;
if it does not, top-up with distilled water to the maximum level indicated on
the battery.
4. The liquid in the battery is highly corrosive, and must not be allowed to
come into contact with the skin.
5. Clean the positive and negative terminals of any oxide scale, so as to ensure
good contact with the clamps.
6. Never let the two clamps make contact when the battery charger is con-
nected to the mains.
7. If the battery with which you intend to use this battery charger is perma-
nently installed in a vehicle, refer to the “ELECTRICAL SYSTEM” or “MAIN-
TENANCE” section/s of the owner’s handbook and/or maintenance manual.
Before starting charging, it is advisable to disconnect the positive cable of
the vehicle’s electrical system.
8. Check the battery’s voltage before connecting it to the battery charger.
Remember that a 6-Volt battery has three caps and a 12-Volt battery has
six. In some cases, there may be two 12-Volt batteries; if so, you will
require a voltage of 24 Volt to charge both.
9. Check the polarity of the terminals. The positive terminal is marked “+”:
the negative one is marked “-”. If these symbols are indistinguishable,
remember that the negative terminal is the one connected directly to the
vehicle’s body.
2.0 TECHNICAL SPECIFICATIONS
2.1 DATA PLATE
WARNING.
NEVER CONNECT OR DISCONNECT THE CLAMPS FROM THE BATTERY WITH
THE BATTERY CHARGER FUNCTIONING. FIRST SWITCH THE UNIT OFF.
WARNING:
REPLACING THE FUSE WITH ONE HAVING A CURRENT RATING DIFFERENT
FROM THAT INDICATED ON THE IDENTIFICATION PLATE COULD CAUSE
DAMAGE TO PROPERTY OR INJURY TO PERSONS. FOR THE SAME REA-
SON, YOU SHOULD NEVER REPLACE THE FUSE WITH COPPER WIRE OR
OTHER MAKESHIFT MEANS.
200A 300A 400A
Single-phase power supply A 230
Frequency Hz 50/60
Starting/charging voltage V 12 - 24
Effective charging current A 24 32 38
Average charging current
EN 60335–2-29 A202834
Starting current 0 Volt A 200 300 400
Starting current 1.0 Volt/C
EN 60335-2-29 A 180 230 280
Max. power absorbed
charging/starting KW 0,6/6,5 0,9/8 1/8,4
Min. fuse with precharge A 16
Rated reference capacity Ah/15h 265 355 430
Battery startable min./max. Ah 20 20-35 35-50
Battery startable with precharge
min./max. Ah 20-45 45-65 65-100
Dimensions mm 360x670x380
Weight Kg 13 15 15
Fuses 1x80A 2x50A 1x50A +
1x80A

PANEL DESCRIPTION
GB
(GB) 3
GB
3.0 PANEL DESCRIPTION
Version 200A and 300A
Figure 1.
1. Ammeter
2. Switch (Min/Max)
3. Switch (Start/Charge)
4. Switch power(ON/OFF)
5. Power cable
6. Coupling 12V (-)
7. Coupling 24V (-)
8. Red cable (+)
Version 400A
Figure 2.
1. Ammeter
2. Switch (1/2)
3. Switch (Min/Max)
4. Switch (Start/Charge)
5. Switch power(ON/OFF)
6. Power cable
7. Coupling 12V (-)
8. Coupling 24V (-)
9. Red cable (+)
4.0 GENERAL DESCRIPTION CHARGING
Make the connections as described at Para. 1.2, set the switches in accordance
with the battery charger model until you obtain the desired charge; you can
check this on the ammeter scale.
On starting charging, the ammeter on the battery charger will indicate a high current
value (generally towards full scale) which will slowly go down until reaching a very
low value (0.5 - 2A).
This value depends on the battery’s capacity and condition.
✓ When the battery is fully charged, the electrolyte will be near boiling point.
✓ It is advisable to stop charging at this point so as not to overheat the elements,
and to prevent oxidation of the plates. In this way you can keep the battery in good
condition.
✓ Ensure you select the appropriate charging current. Excess charging current can
cause serious damage to batteries.
✓Generally, it is best to select a charging current corresponding to 1/10 of the bat-
tery’s capacity (Ah); initially, you can select a current slightly above this value.
The currents available while starting up are as follows:
1234
8765
1345
9876
2

STARTING OF AN ENGINE
GB
(GB) 4
GB
5.0 STARTING OF AN ENGINE
The starting of a vehicule by booster is necessary any time that the battery does
not have enough power to feed the starter. In this case the energy needed can be
supplied by the booster in starting mode.
Make the connections as described at Para. 1.2:
a. Set the switch (START/CHARGE) on “START”.
b. Start engine normally.
c. At started engine, turn off battery charger setting the switch (ON/OFF) on
“OFF”.
The currents available while starting up are as follows:
WARNING: Keep the booster on position Start only for the time that is needed for
starting the engine avoiding to overcome a time of 5 seconds, as long times of
booster and not in the right sequence produce the burning of the fuse or the turn
ON of the thermal protection. The operation of booster shall be given before to
feed the starter and it shall be token away when the starter is stopped. If the
engine requires a power higher than that delivered by the battery charger, or if it
fails to start because the battery is very discharged, put the battery on rapid
(boost) charge for 10-15 minutes.
To start a diesel engine, pre-heat the glowplugs before setting the battery
charger in the starting position, otherwise the glowplugs will damaged.
The table below defines the maximum sizes of battery that can be started by the
battery charger in normal or extreme conditions:
*Extreme conditions: battery very discharged, with an outside temperature of -
18°C or lower.
* Average conditions: battery not very discharged (e.g. vehicle left all night with
the lights on);
battery relatively new; an ambient temperature of about 5 - 10°C
POS. MEAN
CURRENT (A) NOMINAL CAPACITY (Ah)
Version
200 A
12V MIN 8 80
MAX 10 100
24V MIN 8 80
MAX 10 100
Version
300 A
12V MIN 9 85
MAX 15 185
24V MIN 11 100
MAX 18 225
Version
400 A
12V
MIN 1 12 115
MIN 2 15 170
MAX 1 18 240
MAX 2 24 325
24V
MIN 1 12 105
MIN 2 15 170
MAX 1 19 240
MAX 2 24 345
BATT. 12V BATT. 24V
VERSION
200A
Start-up current at 1.5V per ele-
ment (in acc. with norm 60335) 155 140
Start-up current at 1V per element 180 170
200 200
Start-up current at 0V 175 190
VERSION
300A
Start-up current at 1.5V per ele-
ment (in acc. with norm 60335) 225 230
Start-up current at 1V per element 300 300
Start-up current at 0V
VERSION
400A
Start-up current at 1.5V per ele-
ment (in acc. with norm 60335) 195 195
Start-up current at 1V per element 280 230
Start-up current at 0V 400 400
IMMEDIATE START START WITH PRE-CHARGING
Vers. EXTREME
CONDITIONS AVERAGE CONDITIONS EXTREME CONDITIONS AVERAGE CON- DITIONS
200A 20Ah 20Ah 20Ah 45Ah
300A 20Ah 35Ah 45Ah 65Ah
400A 35Ah 50Ah 65Ah 100Ah