ComAp InteliCharger 240 24 User manual

Copyright © 2016 ComAp a.s.
Written by Dan Svanda
Prague, Czech Republic
ComAp a.s., U Uranie 14a/1612,
170 00 Prague 7, Czech Republic
Tel: [phone]
E-mail: i[email protected], www.comap.cz Global Guide
InteliCharger
240 24
Inovative advanced battery
charger
SW version 1.0.0
1 Document information 3
2 Charger overview 5
3 Wiring 7
4 Charger setup and operation 9
5 Standards and certifications 15
6 Mechanical specifications 16
7 Technical data 17

InteliCharger 240 24 Reference Guide 2
Table of contents
1 Document information 3
1.1 Clarification of notation 3
1.2 About this guide 3
1.3 Legal notice 3
2 Charger overview 5
2.1 General description 5
2.2 Package content 5
2.3 Main characteristics 5
3 Wiring 7
3.1 AC input wiring diagram 7
3.2 Battery output wiring diagram 7
3.3 Wires parameters 8
4 Charger setup and operation 9
4.1 Front panel description 9
4.2 Detailed description 9
AC input terminal 9
Charging current level 9
Battery output terminal 9
Signal output terminals 10
Status indicators 10
Battery type selection 11
Boost charge selection 11
Life Test function 12
Power supply mode 12
Battery care 12
Charging curve 12
Diagnostic checks 13
Protection 13
Thermal behavior 14
Rail mounting 14
5 Standards and certifications 15
6 Mechanical specifications 16
7 Technical data 17

InteliCharger 240 24 Reference Guide 3
1 Document information
1.1 Clarification of notation
Note: This type of paragraph calls readers attention to a notice or related theme.
IMPORTANT: This type of paragraph highlights a procedure, adjustment etc., which can cause a
damage or improper function of the equipment if not performed correctly and may not be clear at
first sight.
Example: This type of paragraph contains information that is used to illustrate how a specific function
works.
1.2 About this guide
This guide describes InteliCharger 240 24. This guide provides general information on how to install, configure,
operate and maintain the charger.
1.3 Legal notice
This End User's Guide/Manual as part of the Documentation is an inseparable part of ComAp’s Product and
may be used exclusively according to the conditions defined in the “END USER or Distributor LICENSE
AGREEMENT CONDITIONS – COMAP CONTROL SYSTEMS SOFTWARE” (License Agreement) and/or in
the “ComAp a.s. Standard terms for sale of Products and provision of Services” (Terms) and/or in the
“Standardní podmínky projektů komplexního řešení ke smlouvě o dílo, Standard Conditions for Supply of
Complete Solutions” (Conditions) as applicable.
ComAp’s License Agreement is governed by the Czech Civil Code 89/2012 Col., by the Authorship Act
121/2000 Col., by international treaties and by other relevant legal documents regulating protection of the
intellectual properties (TRIPS).
The End User and/or ComAp’s Distributor shall only be permitted to use this End User's Guide/Manual with
ComAp Control System Registered Products. The Documentation is not intended and applicable for any other
purpose.
Official version of the ComAp’s End User's Guide/Manual is the version published in English. ComAp reserves
the right to update this End User's Guide/Manual at any time. ComAp does not assume any responsibility for its
use outside of the scope of the Terms or the Conditions and the License Agreement.
Licensed End User is entitled to make only necessary number of copies of the End User's Guide/Manual. Any
translation of this End User's Guide/Manual without the prior written consent of ComAp is expressly prohibited!
Even if the prior written consent from ComAp is acquired, ComAp does not take any responsibility for the
content, trustworthiness and quality of any such translation. ComAp will deem a translation equal to this End
User's Guide/Manual only if it agrees to verify such translation. The terms and conditions of such verification
must be agreed in the written form and in advance.

InteliCharger 240 24 Reference Guide 4
For more details relating to the Ownership, Extent of Permitted Reproductions Term of Use of the
Documentation and to the Confidentiality rules please review and comply with the ComAp’s License
Agreement, Terms and Conditions available on www.comap.cz.

InteliCharger 240 24 Reference Guide 5
2 Charger overview
2.1 General description
The InteliCharger 240 24 is an advanced, automatic, multi-stage battery charger using “Switched mode
technology” and “Battery care philosophy”, suited to meet the most advanced requirements of battery
manufacturers. The battery care concept is based on algorithms that implement automatic battery charging,
battery life optimization, flat batteries recovery and real time diagnosis. The real time auto-diagnostic system
monitors battery faults such as cells in short circuit, accidental reverse polarity connection, disconnection of the
battery. These faults can be easily detected and fixed by help of blink code of diagnostic LED during the charger
installation and operation. Charger is suited for all battery types. By jumper setting it is possible to change
parameters of charging curve for: Open Lead Acid, Sealed Lead Acid, Gel and NiCd–NiMH battery type. A
rugged casing with bracket for DIN rail mounting provide IP20 protection degree.
2.2 Package content
InteliCharger 240 24
3 Jumpers
2.3 Main characteristics
Wide input voltage range.
Battery charging output 24 V: 2–10 A.
Suited for the following battery types: Open Lead Acid, Sealed Lead Acid, Lead Gel and NiCd–NiMH.

InteliCharger 240 24 Reference Guide 6
Automatic battery status diagnosis.
Four charging stages: Recovery, Bulk, Absorption and Float.
Switched mode power supply technology.
High efficiency (≥ 88 %).
Protected against short circuit, reversed polarity, overload and over temperature.
Signal output terminal (voltage free contact) for discharged or damaged battery and charging fail signaling.
Signal output terminal (voltage free contact) for Mains power input fail signaling.
IP20 protection.
DIN rail mounting.

InteliCharger 240 24 Reference Guide 7
3 Wiring
3.1 AC input wiring diagram
With respect to mains earthing system used, please choose proper AC input wiring.
for TN-S (L, N, PE) for TN-C (L, PEN)
115 VAC input voltage
When 115 VACinput voltage is used bridge corresponding terminals
on AC input terminal block (see left).
Note: Use appropriate wire cross-section. See Wires parameters
(page 8) for details.
3.2 Battery output wiring diagram
InteliCharger 240 24 support single 24 V output. It is possible to connect two 12V batteries in series.
Fuse position example is for installations where ´-´ battery pole is grounded.
for single 24 V battery connection for two 12 V batteries connection in series

InteliCharger 240 24 Reference Guide 8
Note: See Detailed description (page 9) for charger configuration details.
3.3 Wires parameters
Use wires with following parameters for all connection type (Input / Output / Signal):
Solid
[mm2]
Stranded
[mm2]
AWG
[–]
Torque
[Nm]
Stripping length
[mm]
0.2–2.5 0.2–2.5 24–14 0.5–0.6 7
Note: The connection is made by the screw type 2.5 mm2terminal blocks. Use only copper cables that are
designed for operating temperatures higher than 75 °C.

InteliCharger 240 24 Reference Guide 9
4 Charger setup and operation
4.1 Front panel description
AC input terminal
Maximum charging current adjustment
Battery output terminal
Mains fail signal output terminal
Battery or charge fail signal output
terminal
Mains fail indicator
Battery or charge fail indicator
Diagnostic indicator
Battery type selector
Boost charge selector
Life Test function selector
4.2 Detailed description
AC input terminal
Use 3 wires connection (L - phase, N - neutral, PE - protective earth) according to description in chapter AC
input wiring diagram (page 7).
Charging current level
Using this adjusting element it is possible to set max. charging current for battery. The current adjustment goes
from 20–100 % of charger nominal current In. Set the maximum charging current (in A) as 20–100 % of the
battery capacity (in Ah).
Battery output terminal
Connect the battery between pin 1 (- polarity) and pin 2 (+ polarity).
use two batteries (12 V) for 24 V charger output

InteliCharger 240 24 Reference Guide 10
See chapter Battery output wiring diagram (page 7) for details.
Signal output terminals
Isolated, voltage free, output contacts of mains fail alarm relay (pin 3,4 and 5) are active under AC input fail
conditions. See details in table below.
Mains fail? Relay output pair Fail indicator
pin 3–4 pin 3–5
YES open closed – led on
NO closed open – led off
Note: For better system reliability set up at least 5 s input delay when signal is further processed, for example
by PLC.
Isolated, voltage free, output contacts of battery or charge fail alarm relay (pin 6,7 and 8) are active under low
battery, wrong battery connection, charging fail or battery to be replaced conditions. See details in table below.
Battery or charge fail? Relay output pair Fail indicator
pin 6–7 pin 6–8
YES open closed – led on
NO closed open – led off
Note: In Recovery the Battery or charge fail indicator is OFF but the Relay is in failure mode (pin 6–8
closed) to indicate a battery with very low voltage.
Max 30 VDC, 1 A
60 VAC, 1 A Resistive load (EN 60947-4-1)
Min 5 VDC, 1 mA Min. permissive load.
Relay contact rating
Status indicators
Mains fail indicator.
Battery or charge fail indicator.
Diagnostic indicator.
Charging phase Diagnostic indicator Fail indicator
Float 1 blink / 2 s – led off
Absorption 1 blink / s – led off

InteliCharger 240 24 Reference Guide 11
Bulk 2 blink / s – led off
Recovery15 blink / s – led off
State Diagnostic
indicator
Fault
indicator
Reverse polarity or high battery voltage 1 blink / pause – led on
Battery not connected (Power supply mode) 2 blink / pause – led on
Cell in short circuit 3 blink / pause – led on
Bad battery: Internal impedance or battery connection problem (Life
Test result) 5 blink / pause – led on
Life test not possible 6 blink / pause – led on
Internal fault 9 blink / pause – led on
Charger diagnosis
Battery type selection
InteliCharger 240 24 is completely automatic charger suitable to charge most battery types. Charger can charge
open lead acid, sealed lead acid, gel and NiCd–NiMH batteries.
IMPORTANT: Power off the charger before setting the jumper.
Battery
type
Jumper
position
Standard Bulk, Absorption, Float
cell / battery voltage
Bulk, Absorption cell / battery
voltage in Boost mode
Open
lead 2.23 V /26.76 V 2.40 V / 28.80 V
Sealed
lead 2.25 V / 27.00 V 2.40 V / 28.80 V
Gel 2.30 V / 27.60 V 2.40 V / 28.80 V
NiCd–
NiMH N/A N/A
Note: For NiCd–NiMH batteries end-of-charge is determined by negative ΔV detection of battery voltage (-5
mV/cell). If no negative ΔV but only a “flat” profile is detected fast charge is terminated after 10 min. General
end-of-charge timeout set to 16 h. Float charge current is regulated at 10% of max current corresponding to
trimmer position. In order to detect end-of-charge negative ΔV, charging current must be set at least at 30% of
nominal battery capacity (0.3 C). With lower values of charging current negative ΔV detection is not
guaranteed.
Boost charge selection
Set jumper on position 5 to enable boost charging.Using this option charging voltage in Bulk
and Absorption stage is adjusted to 28.80 V (2.40 V / cell).

InteliCharger 240 24 Reference Guide 12
This option is not applicable for NiCd–NiMH batteries.
Note: It is allowed to set this option when charger is powered.
Life Test function
Charger check periodically battery internal impedance and determines whether the battery
is sulphated when Life Test function is enabled. Test is performed every two hours during
float charging stage. Two consecutively checks with the same result have to be performed
prior Life Test results are announced. If a sulphated battery is detected, this fault is
signalized by battery or charge fail indicator , battery or charge fail relay is in failure
mode (pin 6–8 closed) and diagnostic indicator is blinking 5 blink code. During fault
signaling the charger operates as usual and continues with charging the battery.
Note: It is essential to connect battery properly to ensure right results of battery life test function.
Power supply mode
The charger is switched automatically to power supply mode when there is no battery connected to charger
battery output. Output voltage is the float charging voltage and depends on battery type selected. See Battery
type selection (page 11) for details. Maximum output current in power supply mode is the same as maximum
charging current.
Battery care
The Battery Care philosophy is based on algorithms that implement rapid and automatic charging, battery
charge optimization, flat batteries recovery and real time diagnosis. The realtime auto-diagnostic system
monitors battery and charging proces during the installation and operation.Faults such as cells in short circuit,
accidental reverse polarity connection, disconnection of the battery, can be easily detected and fixed by help of
blink code of diagnosis indicator. The charger is suited for all battery types. It is possible to choose predefined
charging curves for Open Lead Acid, Sealed Lead Acid, Gel and NiCd–NiMH battery. Battery reliability in time is
guaranteed by continuously testing the internal impedance status. It avoids any possible risk of damages and
grants also a permanent, reliable and safe connection of the battery to the charger. The system, through a
battery stimulation circuit with algorithms of evaluation of the detected parameter, is able to recognize batteries
with a short-circuited cell.
Charging curve
Automatic multi-stage operation and real time diagnosis allows fast recharge and recovery of deeply discharged
batteries, adding value and reliability to the system hosting the InteliCharger 240 24 device. The type of
charging is Voltage stabilized and Current stabilized IUoU.
Each of four charging stage is identified by a flashing code on the Diagnosis indicator.
To maintain the output battery voltage in lower levels, don’t enable boost charging. (No jumper set in position 5.)
There are four charging stages:
recovery2
bulk
absorption
float.

InteliCharger 240 24 Reference Guide 13
You can see details in charging curve diagram below:
Diagnostic checks
accidental battery cable disconnection
when detected, output power is switched off
battery not connected
when detected, output power is switched off
reverse polarity
when detected, charger is automatically protected
battery voltage
to prevent connection of wrong battery types, with higher voltage than the nominal voltage. Important:
Do not connect battery with lower nominal voltage than the charger output voltage. Battery might be
damaged.
end of charge
when baterry is full, charger goes into float charging
battery cells in short circuit
performed every 4 hours in float charge
Protection
primary side
The charger is equipped whit an internal fuse. If the internal fuse is blown, it is most probable that there is
a fault in the device. If happen, the device must be checked by manufacturer.
secondary side
The charger is electrically protected against short circuits and overload. Output current is electronically
limited.
The charger is automatically protected against reversed battery polarity.

InteliCharger 240 24 Reference Guide 14
Thermal behavior
Standard surrounding air temperature is up to 50°C. For ambient temperature over this limit, the output current
is reduced by 2.5% per °C. Maximum temperature is 70°C. At the temperature 70°C the output current will be
50% of nominal current. The charger does not switch off in case of ambient temperature above 70°C or in case
of thermal overload. The device is protected for over temperature conditions “worst case”. In this situation the
device shut-down the output and automatically restart when internal temperature fall down into limits.
Rail mounting
The charger module must have a minimum vertical and horizontal distance of 10 cm to the other used DIN rail
modules in order to guarantee sufficient auto convection for proper cooling.
It is allowed to install the unit only in horizontal positioning (DIN rail horizontal). Maximal inclination is +/- 5 %.
IMPORTANT: Depending on the ambient temperature and load of the charger, the temperature of
the housing can become very high!
Image 4.1 DIN rail mounting
1Recovery state is not available at the types of chargers with power supply mode always on. Recovery state
will not be triggered at this particular product.
2Recovery state is not available at the types of chargers with power supply mode always on. Recovery state
will not be triggered at this particular product.

InteliCharger 240 24 Reference Guide 15
5 Standards and certifications
Electrical Safety:
Assembling device: IEC/EN 60950 (VDE 0805) and EN 50178 (VDE 0160).
Installation according: IEC/EN 60950.
Input / Output separation: SELV EN 60950-1 and PELV EN 60204-1. Double or reinforced insulation.
EMC Standards Immunity:
EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-5.
EMC Standards Emission:
EN 61000-6-4, EN 61000-6-3, EN 61000-3-2
Standards Conformity:
Safety of Electrical Equipment Machines: EN 60204-1.
The CE mark in According to EMC 2004/108/EC and Low voltage directive 2006/95/EEC.
In conformity to:
UL1236, IEC/EN 60335-2-29 Battery chargers; EN60950 / UL1950; Electrical safety EN54-4 Fire Detection and
fire alarm systems; 89/336/EEC EMC Directive; 2006/95/EC (Low Voltage); DIN41773 (Charging cycle);
Emission: IEC 61000-6-4; Immunity: IEC 61000-6-2. CE.

InteliCharger 240 24 Reference Guide 16
6 Mechanical specifications
Case A rugged aluminum case for DIN rail mounting with top and bottom perforation for auto
convention cooling.
Weight 0.85 kg (1.9 lbs)
Dimension
(W×H×D) 112 mm × 114 mm × 136 mm (4.41" × 4.48" × 5.35")
Image 4.2 Drawing and dimensions

InteliCharger 240 24 Reference Guide 17
7 Technical data
Nominal input voltage 115 / 230VAC
Input voltage range 90–135 / 180–305VAC
Inrush current (VNand INload) ≤ 16 A, ≤ 5ms
Frequency 47–63 Hz ± 6 %
Input current (115 / 230 VAC)3.3 / 2.2 A
Internal fuse 6.3 A
Recommended external fuse 16 A (MCB curve B)
Input data
Output VDC / IN24 VDC / 10A
Efficiency (50 % of IN)≥ 88 %
Ripple voltage ≤ 80 mVPP
Output data
Short–circuit protection Yes
Overload protection Yes
Overvoltage output protection Yes
Reverse battery polarity protection Yes
Detection of element in short–circuit Yes
Thermal protection Yes
Protection
Operating ambient temperature range -25–+70 °C
Storage ambient temperature range -40–+85 °C
Max humidity (25 °C) 95 %
IP protection class (EN/IEC 60529) IP20
Reliability (MTBF IEC 61709) > 300000 h
Protection class (with PE connected) I
Dimension (w×h×d) 112 mm × 114 mm × 136 mm
Weight approx. 0.85 kg
General data