Deutronic DBL1200HV-60 User manual

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Manual
DBL1200HV-60
http://www.deutronic.com/FTP-Ordner/DBL-Tools/MPC4_1/BMW/DBL1200HV-60-Update-Tool.exe
http://www.deutronic.com/FTP-Ordner/DBL-Tools/MPC4_1/BMW/DBL1200HV-60-Update-Tool.zip
Important note: Do not use the device in applications for which it was not originally
designed! Only for use by qualified electrical personnel. Read
operating instructions carefully and always refer to the guidelines of
the battery manufacturer!

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Contents
1. Safety Instructions .................................................................................................3
2. Device Information ...............................................................................................12
2.1. Device Description and Scope of Supply.............................................................12
2.2. Technical Data.....................................................................................................12
2.2.1. Input...............................................................................................................12
2.2.2. Output............................................................................................................13
2.2.3. Environmental Requirements.........................................................................13
2.3. Unpacking............................................................................................................13
2.3.1. Checking for completeness and transport damage........................................13
2.3.2. Warning notices used on the housing............................................................14
2.3.3. Disposal of the packing material....................................................................14
2.3.4. Storage..........................................................................................................14
3. Connections..........................................................................................................15
4. Control Elements..................................................................................................16
5. Indicators ..............................................................................................................16
6. Commissioning.....................................................................................................16
7. Conditioning Operation........................................................................................18
7.1. Charging Current.................................................................................................19
7.2. Module – Target Voltage .....................................................................................20
7.3. Starting the Conditioning Process........................................................................21
7.4. Operating Screen.................................................................................................22
8. MENU.....................................................................................................................23
8.1. Language.............................................................................................................23
8.2. Diagnosis.............................................................................................................24
8.3. SUPERUSER – Menu .........................................................................................25
9. Version ..................................................................................................................29
10. Status Messages ..................................................................................................29
11. Maintenance instructions ....................................................................................31
12. Factory settings....................................................................................................31
13. Service Centre / Repairs ......................................................................................32
14. Contact Data .........................................................................................................33

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1. Safety Instructions
-The device contains components which are likely to generate electric arcs and sparks,
thus the device has to be placed in a special housing or in a room provided for this
purpose during operating.
- Warning: When charging batteries explosive gases may occur. Therefore, fire naked
lights and sparks should be avoided.
- Charge the batteries only in well ventilated rooms.
- The device is only for professional use by motor vehicle manufactureres and repair
workshops.
- The device is exclusively for the use on the specified applications.
- Charging non-rechargeable batteries with this device is not possible and is also not
allowed.
- Charging of defective batteries is explicitly forbidden.
- In all case refer to the specification supplied by the battery manufacturer!
- Mains cables must always be in a proper condition. Defective cables need to be
replaced immediately.
- The device should not be opened because the test certification as well as the warranty
will become null and void.
- Only spearately approved and short circuit protected battery cells shall be connected
to the device.
Important safety instructions:
Please read the following safety instructions carefully and follow them in every case. This
manual contains important safety and operating instructions. These operating instructions
of the device must be kept at the site of operation. Additional to these safety instructions,
the internal accident prevention regulations must be observed.

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General:
- The device is designed according to all relevant safety regulations.
Nevertheless, the health of the operator, the health of the operator, the
functionality of the device and the integrity of property and buildings
may be endangered if the provisions set down in this manual are
disregarded.
-Commissioning and operation of the device may only be conducted by
trained and qualified personnel, who are conversant with current
safety regulations, the internal operating guidelines as well as the
present manual.
-The safety instructions and warnings on the equipment must be clearly
legible at all times. They may not be damaged, covered, painted over
or removed.
-If safety-relevant defects are identified, they must be rectified prior to
operation.
Intended use:
The device is to be used exclusively for the intended purpose. Any
other use or usage beyond this scope is regarded as improper. The
manufacturer accepts no liability for any resulting damage caused, as
well as defective or faulty work results.
This also includes:
- Following all rules and regulations of the manual.
- Following all rules and regulations of the battery manufacturer.
Environmental conditions:
Please refer to the manual for the rules regarding the environmental
conditions governing the operation or storage of the device such as
humidity, temperature, contamination and cooling. By disregarding the
listed, parameters, the manufacturer assumes no liability.

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Site requirements:
-The supply, charging and sensor cables should be positioned so that
the risk of damage to the bonnet, doors, or moving engine parts is
minimized.
-Maintaining distance from fans / rotor blades, V-belts, V-belt pulleys
and any other parts that can cause personal injury.
-Never place the device directly above or below the battery which is
being charged; gases or liquids from the battery would corrode and
damage the device. Install the device as far away from the battery as
the charging cable allows.
-Use the device only in well ventilated rooms. Never prevent or limit the
ventilation. Do not use the device outdoors.
-Position the device so that the operation of the mains isolating device
is not impeded.
-Under no circumstances should the ventilation fan of the device be
covered. When positioning the device, make sure that both outputs of
the ventilation fan have at least 10cm distance from the wall.
Instruction regarding mains connection
When using devices above a certain power, some points must be
observed. In order to protect the mains supply from faults and failure.
- Restrictions of the number of connected devices.
- Provisions relating to the power factor of the device.
- Requirements relating to the minimum required short-
circuit power.
If any of these points exceeds the applicable guidelines, the operator
of the device must consult the responsible energy short-circuit power.

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Instruction regarding DC connection:
-To reduce the risk of damage to the device and health risks of the
operator and other persons present some safety points that need to be
observed when connecting the device to a battery:
-The battery clamps should only be connected or disconnected after
ensuring that the device has been set to the “OFF” position.
-The battery clamps must be connected to the same module as the
measurement connections (ZKS).
-Check the polarity of battery connections.
Electrical hazards:
- When working on electrical equipement, disregarding the safety
instructions may result in the risk of electric shock and damage to
implants such as pacemakers due to strong electric fields. This can
cause serious injury or even lead to death.
- To prevent this, live elements in and outside of the device including
the battery terminals should not be touched. Furthermore, short-
circuiting the battery connecting cable is strictly prohibited.
- In case of damaged, exposed, under-sized or stripped wires or cables,
the device must be repaired immediately by trained personnel.

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Chemical hazards:
Batteries contain harmful acids that cause severe skin and eye injury when
coming in contact with them. Furthermore, vapors and gases which may
cause respiratory injuries and explosions can arise during operation.
Therefore, some rules have to be observed when working with batteries:
-Have plenty of fresh water and soap nearby in case battery acid
contacts skin, clothing or eyes.
-Wear a closed eye protection and protective clothing. Don’t touch your
eyes while working near the battery.
-If battery acid contacts skin or clothing, it has to be washed off with
soap and water immediately. If acid gets into the eyes, immediately
flush them with cold water for at least 10 minutes and undertake a
medical examination without delay.
-Never smoke near the battery or machine and do not allow open flames
or sparks.
-Only work with batteries in well ventilated areas.
-Do not put tools and electrically conductive objects on top of the battery
to prevent short circuits.
-Gases and fumes must not be inhaled.
-Do not disconnect the device from the battery during charging.
Working with batteries:
-Protect batteries against thermal and mechanical stresses.
- Stop operation immediately if:
a) Undue temperature increase.
b) Other indications of a technical defect.

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Self and operator protection:
-During operation all unnecessary persons should be removed from the
danger area, the remaining people should be informed about the
possible dangers and risks (acid, gases, electrical currents,
temperatures).
-Use protective clothing and goggles.
-Ensure first aid for possible injured.
-Ensure fire safety.
- Before leaving the work area ensure that even after leaving the
workplace no damage to persons and property can occur.

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Safety instructions during operation:
-To reduce the risk of damaging the mains plug and cord while
disconnecting the device, always pull on the plug – not on the cord.
-An extension cord should only be used when absolutely necessary. The
use of an improper extension cord leads to an increased risk of fire and
electric shock. If an extension cord must be used, the following has to
be considered:
a) The pins on the connector of the extension cord must have the
same number, size and shape as those on the device.
b) The extension cord has to be wired properly and in a good
condition.
c) If an extension cord is used the correct cable cross section
must be selected according to the following table.
Table – Recommended minimum AWG/mm size for the extension cords
Cord length [feet] 25 50 75 100 150
AWG size of cord 18 15 13 12 10
Wire cross section [mm²] 0,75 1,5 2,5 4,0 6,0
-The device has to be operated within the limits of the IP-Code listed in
the data sheet.
-Do not use the device when it has suffered damage from a heavy blow,
fall or any other damage. In this case take it to a qualified service
technician.
-Ensure that cooling air can freely enter and escape from the cooling
slots provided.
-Safety devices should never be bypassed or put out of operation.

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Disposal:
The disposal of electrical devices in the household garbage is forbidden. The
consumer is obliged to dispose the device in the local collection and return
systems in accordance with the municipality.
Firefighting measures:
-Due to the fact that there is no metallic lithium in a lithium-ion battery
normally, common extinguishing agents (ABC powder extinguisher,
CO2 extinguisher or water) can be used. However, the use of the
extinguishing agent depends on the burning material (oil, plastic, etc.).
-If possible, remove the batteries from the vicinity of the fire.
-During firefighting, wear heavy-duty breathing protection and full-body
protective clothing.
-Combustile products contain amongst other things also hydrogen
fluoride, carbon monoxide and carbon dioxide.
-In-house fire safety regulations must always be observed.
First aid:
In case of contact with released electrolytes, gases or combustion by-
products of a lithium-ion battery, the following first aid measured are to be
observed:
-After contact, immediately rinse the eye for at least 15 minutes with
water. Make sure that the eye lids are open during the complete
flushing process.
-Take off contaminated clothes and rinse the skin for at least 15 minutes
under cold water.
-After injury of the respiratory system ensure a supply of fresh air. If
necessary, perform first aid measures.
-Subsequently, a doctor should be consulted in any case.

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Maintenance, service, repair:
-The device must not be opened. If a service or repair is required, the
unit must be sent to a qualified service technician. Incorrect installation
may result in an electric shock or fire.
-The use of accessories that are not sold or recommended by the
manufacturer may result in a risk of fire, electric shock or personal
injury.
- To reduce the risk of electric shock, the unit must be disconnected from
the mains before any maintenance or cleaning. Just switching off the
device does not reduce the risk.
Warranty / Liability:
If damage to the unit can be traced back to one or more of the following
causes, the manufacturer cannot accept any warranty:
-The use of the device outside of the stated electrical, mechanical and
thermal limits stated in the data sheet.
-Opening of the unit by unauthorized personnel.
-Force majeure or disaster.

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2. Device Information
2.1. Device Description and Scope of Supply
This device is a conditioning and diagnostic system for single modules for a high-voltage
vehicle battery. The device is used to adjust the voltage of individual modules in a high-
voltage battery which is installed in a vehicle. To achieve this, the device charges the
newly added module to the voltage level of the modules that are already installed in the
vehicle or it lowers the voltage by discharging to the existing voltage level. The actual
voltage of the modules contained in the vehicle must be entered manually on the device.
Then the device adjusts the voltage of the module to the entered value. To charge or
discharge the modules only the appropriate battery charging cables are to be used. The
battery charging cables are not included in the scope of the delivery of the device
and must be purchased separately. The used battery charging cables must be tested
separately and be suitable for the intended use. The battery charger can be optionally
used on a trolley or placed on a workbench.
Scope of delivery:
-Battery conditioning
-Manual
-International mains cord set (4-part)
Separate accessories (not included):
-Battery charging cables
- Trolley
2.2. Technical Data
2.2.1. Input
Input voltage range,
Frequency range 100-240VAC, 50-60Hz
Inrush current 30A at 264VAC, temperature independent Automatic circuit breaker: 16A slow
(for example characteristic B)
Input Current at nominal load 10A (115V) / 5A (230V)
Power factor Typ. 0,98
Current harmonics EN61000-3-2

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2.2.2. Output
Output voltage range max. 65,6 VDC
Operation Before charging, a target voltage within the
tolerance range has to be set.
Charging current limit Depending on the module type, the device
sets the maximum charging current. The
max. achievable charging current is 20A.
Efficiency >92%
Protection Short circuit, overvoltage, reverse-polarity
and transient overvoltage protection
2.2.3. Environmental Requirements
Storage temperature -25°C up to +80°C / +13°F up to +176°F
Operating temperature (environment) -20°C up to +40°C / -4°F up to +104°F
Protection IP20 (for indoor use only)
Pollution degree 2 (EN50178)
Humidity 95% (no condensation allowed)
Maximum operation altitude 2.000m
Cooling Convection cooled and active cooling by
internal fan
Weight Approx. 8,3kg / 18.5 lbs
Dimensions (wxdxh) Approx. 340 x 295 x 145,5mm
Approx. 13.4 x 11.6 x 5.7 inch
2.3. Unpacking
2.3.1. Checking for completeness and transport damage
The delivery must be checked immediately after receipt for possible damage in transit. If
necessary, this must be immediately reported to the transport company. If it is assumed
that transport damage could impair proper operation, commissioning may not be
undertaken.

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2.3.2. Warning notices used on the housing
Indication to read the manual
Warning of hot surfaces
2.3.3. Disposal of the packing material
If possible, put the used packing materials aside for a possible reuse. Ensure proper and
environmentally friendly disposal of all packing material with due consideration of
prevailing environmental guidelines.
2.3.4. Storage
Due to incorrect or improper storage the device could get damaged for example due to
humidity and pollution.
-Protect the device during storage against humidity, extreme temperatures and dirt.
-After a storage period of more than one year check the functionality of the device
before the use.

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3. Connections
1
Electrical supply:
A mains supply is required to power the device. Use a mains input connector of type
IEC60320/C14.
This battery charging device is intended for use in networks with more than 100 Volts
and is equipped by the manufacturer with a special mains cable with a compatible plug
that allows connection to corresponding mains supply. Ensure that the device is
connected to a power outlet which has the same design as the plug (adapters must not
be used in conjunction with this device).
2 D-SUB Interface (ZKS connection): The connection of the 37-pin D-SUB interface is used to monitor the individual cell
voltages and temperatures of the connected battery modules.
3 Serial signal interface:
Firmware updates are possible using the serial signal interface (Mini USB / type B)
4
Power output:
A charging cable is used to connect the module connector of the device to the battery.
Check the polarity of the battery terminals and only connect the battery module by
using the connecting cables exclusively designed for the purpose.
4
3
2
1

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4. Control Elements
1 Display
2 Power switch
3 Menu navigation buttons
5. Indicators
To display the current operating mode three LED lamps are provided on the front of the
device. They are interpreted as follows:
Red continuous Error occurred
Gelb flashing Stand-by mode
Gelb flashing Operating mode
Green
continuous Process finished charging or discharging complete
6. Commissioning
After pressing the power switch, a screen with the actual software versions is displayed for
a short time. By pressing the “OK” button, the screen can be frozen for 20 seconds.
1
2
3

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When no battery is connected, the status “Battery module not connected” appears on the
display.
All setting and diagnostic menus are accessible at all times via the MENU field.
To connect the battery module, the charging cable plug is guided with slight pressure into
the module connector. Due to its design an accidental swapping of the contacts (reverse
polarity) is rendered impossible. In order to prevent the connector from disconnecting, the
locking clamp is swiveled over the connector until it clicks.
To monitor the battery regarding the voltage and the temperature the ZKS plug must be
connected to the 37-pole D-SUB interface. For stability the plug should be fixed using the
screws provided.

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If one of the connectors is not inserted, the respective message will appear in the display.
To enable access to the conditioning operation menu, the missing connector must be
inserted.
7. Conditioning Operation
After a battery module is completely connected, the “OPERATION” menu appears
automatically in the display. This is used for conditioning the connected battery. In this
window the parameters of the connected battery as well as the required target voltage
must be entered.
Control field,
Display the possible control buttons
Title,
displays the actual menu
Battery module parameters
that can be charged

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7.1. Charging Current
The maximum charging current is 20A. If the connected battery is charged using a low
current, the current limit can be reduced using the menu item “CURRENT”. To reduce the
charging current limit press “OK” button. On the right side of the display a field appears
where the charging current limit can be modified. Using the arrow keys the desired value
can be entered. The required value must be confirmed using the “OK” button.
Possible setting range for the charging current limit: 1A – 20A
Increment: 1A
Note: If the battery connecting cable includes a resistor to limit the maximum charging
current, this will be automatically recognized. In this instance the “CURRENT” is not
changeable.
If the temperature is between Tu and Tvu or TVo and To, then the charging current will be
adjusted depending on the temperature.
Field for modifying the battery module parameter

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7.2. Module – Target Voltage
The target value for the voltage of the connected battery can be entered under the menu
item “VOLTAGE”. The default value will always be the current voltage of the connected
battery module. The limiting values for the adjustable target voltage are as follows:
Minimum limiting value module target voltage:
Number of measurable cell voltages x minimum cell voltage* (UZoE)
Example: 16 cell voltages x 2,8V = 44,8V
Maximal limiting value module target voltage:
Number of measurable cell voltages x maximum cell voltage* (UZoL)
Example: 16 cell voltages x 4,1V= 65,6V
*The minimum and maximum cell voltages can only be changed in the password protected SuperUser menu