Delta-q IC SERIES User manual

IC SERIES
INSTALLATION &
TROUBLESHOOTING GUIDE

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GETTING STARTED...........................6
High Voltage Safety ......................... 7
Electrical Safety Information .......... 8
Battery Safety Information ............. 9
Precautions ..................................... 10
IC SERIES CHARGER INTERFACE......11
NOTES ............................................. 15
Normal Operation ........................... 17
Bulk Charging,
<80% Complete ...........................17
Absorption/Finish Phase,
>80% Complete ...........................18
Charging Complete...................... 19
Configuring the IC650
Charger Using a USB Flash Drive ... 20
ELECTRICAL INSTALATION ..............22
General Considerations
for Machine Wiring.......................... 24
TABLE OF CONTENTS

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Cable Dressing................................ 26
IC650 DC OUTPUT.............................28
IC900/1200 DC OUTPUT ....................31
IC650 DC WIRING INSTRUCTIONS.....35
IC900 & IC1200 DC
WIRING INSTRUCTIONS ...................40
SIGNALS & CONTROL CONNECTOR... 44
TROUBLESHOOTING.........................48
Fault Codes - Internal
Condition Preventing Charging ....... 52
Error Codes - External Conditions.. 53
10 Most Common Error Codes ........ 54
Software / Algorithm errors........... 56
Configuration Errors....................... 57

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GETTING STARTED

Getting Started 7
Before installing your Delta-Q Technologies
battery, please review and follow these
safety guidelines.
HIGH VOLTAGE SAFETY
WARNING: This product can
contain potentially lethal levels
of voltage. Exercise extreme care
when working with the equipment.
WARNING: DO NOT open the case of the
charger. No serviceable parts are contained
inside the unit.

Getting Started 8
ELECTRICAL SAFETY
INFORMATION
DANGER: Risk of electric shock.
Connect charger power cord
to an AC outlet that has been
properly installed and grounded
in accordance with all local codes and
ordinances. A grounded AC outlet is required
to reduce the risk of electric shock. Do not
use ground adapters or modify the plug. Do
not touch uninsulated portions of the output
connector or uninsulated battery terminals.
Disconnect the AC supply before making or
breaking the connections to the battery. Do
not open or disassemble the charger. Do not
operate this charger if the AC supply cord or
DC output cord is damaged or if the charger
has received a sharp blow, been dropped, or
is damaged in any way. Refer all repair work
to the manufacturer or qualified personnel.
This charger is not intended for use by
persons (including children) with reduced
physical, sensory, or mental capabilities,
or lack of experience and knowledge on
electrical systems and battery charging,
unless they have been given supervision or
instruction concerning use of the charger
by a person responsible for their safety.
Children should be supervised to ensure
they do not play with the charger.

Getting Started 9
BATTERY SAFETY
INFORMATION
WARNING: Use the charger
only with an algorithm that is
appropriate to the specific battery
type and capacity. Other usage may cause
personal injury and damage. Lead acid
batteries may generate explosive hydrogen
gas during normal charging. Keep sparks,
flames, and smoking materials away from
batteries. If this charger is used with lithium-
ion type batteries, an integrated battery
management system (BMS) must be used.
The BMS must ensure that, in all operating
modes, the battery cells are protected from
inappropriate levels of voltage, current,
temperature, and state of charge. Do not
operate the charger in a closed-in area or
restrict its ventilation. Never charge a frozen
or non-rechargeable battery. Observe all
battery manufacturers’ precautions (e.g.,
maximum charge rates and if cell caps
should be removed while charging).

Getting Started 10
PRECAUTIONS
HOT SURFACES: During charging,
the surface of the charger may
become hot to the touch, especially
in higher ambient temperatures. This is
normal. Avoid touching the surface of the
charger.
EXTENSION CORD RATING: Extension cords
used with the charger must have appropriate
safety approvals for the country in which it
is used (e.g., Nationally Recognized Testing
Laboratories (NRTL) approval in the United
States). Wire gauge must be appropriate for
the input current of the charger.

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IC SERIES CHARGER INTERFACE

IC Series Charger Interface 12
Battery
Charging
Indicator
AC Power
Indicator
USB Host
Port
Status bar
Fault/Error/
USB Indicator

IC Series Charger Interface 13
Display
Panel
Charge
Algorithm/
Error Display
Select Charge
Profile Button
Charging
Output
Indicator

IC Series Charger Interface 14
LEGEND
Solid blue - AC power available
Flashing amber - External error
condition - caution see display
panel details
Solid red - Charge fault see
display panel details
Flashing green - USB port active
Solid green - Safe to remove USB
flash drive
Flashing green - Low state of
charge
Solid green - High state of
charge
Flashing green - High state of
charge
Solid green - Charge complete

IC Series Charger Interface 15 IC Series Charger Interface 15
NOTES
The Charging Output Indicator is
solid yellow when the charger output
is active. Take appropriate actions
while handling the charger, as there
is a risk of electric shock.
The USB Host Port provides read
and write USB functionality. Using
a standard USB flash drive, a user
can download charge tracking data,
and update the charger’s software
and charging profiles.
The Charge Profile/Error Display
shows one of four possible codes to
indicate different conditions:

IC Series Charger Interface 16 IC Series Charger Interface 16
The E and F codes are followed by three
numbers and a period to indicate different
conditions (e.g., E-0-0-4.). See Charger
Fault Codes or Charger Error Codes for
details on these conditions and their
solutions.
USB CODE
meaning the USB interface is active,
and the USB flash drive should not be
removed.
E CODES
mean an external error condition that
may cause the charging to stop.
P CODES
indicate the charge profile number.
F CODES
mean an internal fault condition has
caused charging to stop.

IC Series Charger Interface 17
<80% Slow
Flashing
AC Status ON
Charging
Indicator ON
NORMAL OPERATION
BULK CHARGING, <80% COMPLETE

IC Series Charger Interface 18
>80% Quick
Flashing
AC Status ON
<80% ON
Charging
Indicator ON
ABSORPTION/FINISH PHASE, >80% COMPLETE

IC Series Charger Interface 19
>80% Quick
Flashing
AC Status ON
<80% ON
Charging
Indicator OFF
CHARGING COMPLETE

IC Series Charger Interface 20
CONFIGURING THE IC650
CHARGER USING A USB
FLASH DRIVE
Using the Delta-Q software, USB storage
drives can be pre-programmed to certain
charger configurations. To use the USB port,
follow these steps:
1. Insert the USB flash drive at any time,
but preferably not during a charge cycle.
Stop the charge cycle by removing AC
power or the DC connection to the
batteries. The charger can power the
USB port from the AC connection (DC
disconnected) or from the DC connection
(AC disconnected).
2.
If there is enough disk space (about 2 MB),
the charger will write charge tracking
data to the drive. The Fault/Error/USB
Indicator will flash green during reading
and writing.
3.
If the drive contains compatible
configuration files, the charger will load
them.
4. The charger will briefly reset.
5.
Remove the drive when the Fault/Error/
USB indicator is solid green. Add note: