Delta-q QUIQ Series User manual

INSTALLATION &
TROUBLESHOOTING GUIDE
QUIQ SERIES

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4
GETTING STARTED...........................6
High Voltage Safety ......................... 7
Electrical Safety Information .......... 8
Battery Safety Information ............. 9
Installation Safety Information ....... 10
MECHANICAL INSTALLATION...........11
Environment.................................... 12
Mounting Instructions ..................... 14
Safety .............................................. 16
Vibration.......................................... 17
Cable Strain .................................... 18
ELECTRICAL INSTALLATION ............20
AC Input........................................... 21
Interlocks........................................ 26
Standard Interlock ......................26
Signal Interlock ...........................26
TABLE OF CONTENTS

5
Wetting Circuit ............................27
Standard DC Output ........................ 29
Inline Connector
(ICON) DC Output............................. 33
Part numbers ..............................33
QuiQ-dci Models DC Outputs........... 37
QUIQ CHARGER
TROUBLESHOOTING ........................40
Indications on the Charger 10-LED
Display ............................................ 41
Fault Indications.............................. 44
Fault LED ....................................44
QUIQDCI CHARGER/CONVERTER
TROUBLESHOOTING.........................51
Symptoms ....................................... 52
Other Conditions ............................. 54

6
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 produces
hazardous output voltages under
normal operation. Exercise
extreme care when working with the
equipment and the batteries.
WARNING: DO NOT open or disassemble
the charger. No user-serviceable parts are
contained inside the unit. Do not operate the
charger if the AC supply cord is damaged or if
the charger has received a sharp blow, been
dropped, or otherwise damaged in any way.
Refer all repair work to qualified personnel.
Not for use by children.

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. On versions of the charger with
connectors, using mating connectors of
different manufacturers may void regulatory
certifications and result in a hazardous
situation. Always use mating connectors
approved by the connector manufacturer.

Getting Started 9
BATTERY SAFETY
INFORMATION
WARNING: Only use the charger
with a charging profile that is
appropriate to the specific battery
type. 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. Do
not operate charger in a closed-in area or
an area with restricted ventilation. Never
charge a frozen or non-rechargeable battery.
Study all battery manufacturers’ specific
precautions such as recommended rates of
charge and removing or not removing cell
caps while charging. Use care to prevent
personal objects or metal tools from
contacting terminals of the batteries. Severe
burns can result.

Getting Started 10
INSTALLATION SAFETY
INFORMATION
DANGER: Charger outputs and
battery voltages pose an energy
and/or shock hazard under normal
use. These units must be installed in the
host equipment in such a manner that the
output cable and battery connections are
only accessible with the use of a tool by
qualified personnel.

11
MECHANICAL
INSTALLATION

Mechanical Installation 12
Proper mechanical installation of the
QuiQ charger is essential to its effective
operation.
ENVIRONMENT
Locate the charger with adequate
ventilation. Ideally, it will be
mounted horizontally with airflow
from below as per the arrows in the
illustration below. See Mounting Instructions
for more options.
The QuiQ Series charger case is an IP66
enclosure. It is well protected against
fine dust (IEC60529 IP6x), and capable of
operation in heavy seas, temporary flooding,
and heavy water streams (IEC60529 IPx6).
The input cord IEC60320 connector is rated
IP20 at this time. It is suitable for indoor use
only and must always be kept clean and dry.
Use of heat shrink over the mated connection
is strongly suggested for general use.
Delta-Q Technologies offers an AC cord that
will seal the connection to IP66. Contact
the manufacturer of your vehicle/machine
or the distributor of the charger for more
details. During charging, the surface of
the charger may become warm, especially
in higher ambient temperatures. This is
normal. Install so risk of human contact
with hot surfaces is reduced.

Mechanical Installation 13
Proper Mechanical Installation
M4 Ground
Stud
AIR
AIR

Mechanical Installation 14
MOUNTING INSTRUCTIONS
Mount the charger by the mounting
plate using appropriate fasteners
(i.e., locking ¼” or M6 bolts),
and all of the mounting slots provided.
If mounting in an enclosed area, test
the charger and monitor it for reduced
power operation. If mounting the charger
vertically, there are two considerations:
charger performance and charger life. The
charger’s internal temperature sensor is
located approximately 2.5cm (1”) behind the
DC output cord strain relief. For performance
closest to horizontal installation: Place the DC
output at the lower end of the charger to delay
thermal cutback, maximize charger output,
but potentially cause higher temperatures
inside the charger.
For potentially better life: Keeping
the temperature sensor higher will
result in earlier thermal cutback
of power, minimizing internal temperatures
and minimizing potential component failures.
However, there is no data to demonstrate the
amount of lifetime savings that may be gained
by using this orientation over the above.

Mechanical Installation 15
Mounting Example
Internal
Temperature Sensor

Mechanical Installation 16
SAFETY
For UL2202 1st Edition safety
compliance in electric vehicle
applications, a 12AWG green
bonding wire must be attached from the M4
stud located on the charger (see page 6) to
the vehicle frame. This is for electric shock
safety. The recommended torque is 1.6±0.1N-
m. Alternatively, M6 star washers can be
used on the mounting holes to “bite” through
the paint on the base plate to make electrical
contact. The recommended torque for this
is 7.0N-m±0.2N-m. If used in an electric
vehicle application, UL2202 1st Edition and
the National Electrical Code (NEC) requires
the charger’s AC plug be located at least 18”
above the ground and the display should be
visible to the user.
NOTE: UL2202 1st Edition has
been obsoleted. This information is
provided only for reference. Typical
maximum surface temperature of
the QuiQ charger is 60°C (140°F).

Mechanical Installation 17
VIBRATION
QuiQ Series chargers are designed
to UL2202 1st Edition and the
vibration test specified within.
It is not intended for heavy-duty vehicle
applications.
Minimum Bend
Radius on Cables
Minimum Bend Radius on
Cables (60mm - 2.36")

Mechanical Installation 18
CABLE STRAIN
High strain on the AC Input Cord
combined with heating and cooling
over time may cause one or more
conductors in the cord to break and the
charger to fail. The recommended minimum
bend radius on all cables leaving the charger
is 60mm (2.36”). This is illustrated below on
the AC input cord.
If it is necessary to clamp the AC cord to
the machine, it is recommended to clamp
the AC attachment cord that is brought to
the QuiQ charger’s AC input, not the QuiQ
Series charger’s AC input cord itself. This
is to isolate any possible wear or damage to
the easily replaceable attachment cord, and
not the charger.
An illustration of this appears below:

Mechanical Installation 19
CLAMP
this side
only
DO NOT
CLAMP
this side
To
Charger

20
ELECTRICAL INSTALLATION