CEMONT VELOX 520.2 CD.2 Mounting instructions

EN Safety instruction for use and maintenance - Do not destroy this manual
FR Instruction de securite d’emploi et d’entretien - Conserver ce livret d’instructions
ES Instrucciones de seguridad, empleo y mantenimiento - Conservar el presente manual
IT Istruzioni per la sicurezza nell’uso e per la manutenzione - Conservare il presente libretto
DE Betriebs-Wartungs und Sicherheitsanleitung - Das vorliegende Handbuch gut aufbewahren
PT Instrucões de segurança de utilização e de manutenção - Conserve este manual
SV Instruktioner för säkerhet, använding och underåll - Spar denna handledning
NL Veiligheidsinstructies voor gebruik en onderhoud - Bewaar deze handleiding
RO Instructiuni privind siguranta in exploatare si intretinerea - Pastrati acest manual
SK Bezpečnostné pokyny pri používaní a pri údržbe - Odložte si tento návod na použitie
CS Bezpečnostní pokyny pro používání a údržbu - Návod na používání si uchovejte
PL Instrukcje bezpieczeństwa podczas obsługi i konserwacji - Zachować niniejszą instrukcję na przyszłość
EL Οδηγιεσ ασφαλειασ κατα τη χρηση και τη συντηρηση – φυλαξτε το παρον εγχειριδιο
RU Руководство по безопасной эксплуатации и техническому обслуживанию
www.airliquidewelding.com
Air Liquide Welding - 13, rue d’Epluches - BP 70024 Saint-Ouen L’Aumône
Cat. Nr.:
Rev.:
Date:
VELOX
520.2 / 650 CD.2 / 1200T CD.2
800035393
03
30. 10. 2009

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 CHARGING WITH THE TIMER ................................................ GB-4
6.0 STARTING OF AN ENGINE .................................................. GB-4
SPARE PARTS LIST ........................................................ I-VI
WIRING DIAGRAM........................................................ VII - IX

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.
VERSION 500A and 650ACheck that the mains voltage corresponds with that indi-
cated on the identification plate fixed to the battery charger (230 V a.c. or 240 V
a.c. 50/60 Hz). For the connection, use a three-pole plug (two phases earth) rated
at least 10 Amp.
VERSION 1250A Check that the mains voltage corresponds with that indicated on
the identification plate fixed to the battery charger (400 V a.c. 50/60 Hz). For the
connection, use a quadri-pole plug (two phases earth) rated at least 16 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.
500A 650A
Single-phase power supply A 230
Frequency Hz 50/60
Starting/charging voltage V 12 - 24
Effective charging current A 45 66
Average charging current
EN 60335–2-29
A40 60
Starting current 0 Volt A 500/500 650/650
Starting current 1.0 Volt/C
EN 60335-2-29
A300/270 400/400
Max. power absorbed
charging/starting
KW 1,3/10,2 1,8/15
Min. fuse with precharge A 16
Rated reference capacity Ah/15h 560 700
Battery startable min./max. Ah 45-65 65-120
Battery startable with precharge
min./max.
Ah 80-150 150-240
Dimensions mm 350 x 750 x 320
Weight Kg 20,7 24,2
Fuses 2 x 100A
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.

PANEL DESCRIPTION
GB
(GB) 3
GB
3.0 PANEL DESCRIPTION
Figure 1.
VERSION 500A
1 Switch power(ON/OFF)
2 Switch (Start/Charge)
3 Switch (Min/Max)
4 Switch /1/2)
5 Ammeter
6 Timer
Figure 2.
VERSION 650A and 1250A
1Fuse
2Remote control
3Switch
4Switch (Start)
5Lamp
6Ammeter
7Timer
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.
1250A
Three-phase power supply A 230/400
Frequency Hz 50/60
Starting/charging voltage V 12 - 24
Effective charging current A 165
Average charging current
EN 60335–2-29 A 160
Starting current 0 Volt A 1250/1250
Starting current 1.0 Volt/C
EN 60335-2-29 A 1000/1000
Max. power absorbed
charging/starting KW 5/29
Min. fuse with precharge A16
Rated reference capacity Ah/15h 2200
Battery startable min./max. Ah 120-200
Battery startable with precharge
min./max. Ah 240-240
Dimensions mm 470 x 800 x 360
Weight Kg 43
Fuses 4 x 100A

CHARGING WITH THE TIMER
GB
(GB) 4
GB
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:
5.0 CHARGING WITH THE TIMER
WARNING: with the timer in position “0”, the charge position are
off. In order to use the charges in the “traditional” manner, place
the timer in the “NORMAL CHARGING” position. All charging
position also function with the timer (up to 60’).
6.0 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:
VERSION 500A
a. Set the switch (Ref. 2- Fig. 1 page 3) on “START”.
b. Start engine normally.
c. At started engine, turn off battery charger setting the switch (Ref. 1- Fig.
1 page 3) on “OFF”.
VERSION 650A and 1250A
a. Set the switch (Ref. 3- Fig. 2 page 3) on “Stand-by - START”.
b. Start engine normally and in same time turn ON the booster by the button
“START” (Ref. 4- Fig. 2 page 3) or by the remote control (Fig. A- pag.
4).
c. At started engine, release the button “START” (Ref. 4- Fig. 2 page 3)
d. Disconnect the cable by the battery in the following sequence: NEGATIV -
POSITIV.
e. Turn OFF the battery charger by the switch in position (Ref. 3- Fig. 2 page
3) “0”.
POS. MEAN
CURRENT (A) NOMINAL CAPACITY (Ah)
VERSION
500 A
12V
MIN 1 14 125
MIN 2 16 165
MAX 1 19 240
MAX 2 24 325
24V
MIN 1 14 120
MIN 2 17 170
MAX 1 19 240
MAX 2 24 345
VERSION
650 A
12V
111 90
212 120
316 160
419 190
522 260
626 330
24V
113 110
216 140
320 200
423 260
526 320
630 390
Fig.A
VERSION
1250 A
12V
140 380
242 430
346 530
452 590
563 730
666 840
770 950
24V
130 310
233 350
335 380
440 410
550 590
656 680
762 760
POS. MEAN
CURRENT (A) NOMINAL CAPACITY (Ah)