Energic Plus AR-D User manual

BATTERY CHARGER
BATTERY CHARGER
AR-D
AR-D
USER'S MANUAL
USER'S MANUAL

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TABLE OF CONTENTS
· ............................................................................................................................3
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· ............................................................................................................................3
· ............................................................................................................................3
· ............................................................................................................................3
· ............................................................................................................................3
· ............................................................................................................................3
· 1. Intro uction.................................................................................................4
· RESPONSIBILITY DISCLAIMER..................................................................................4
· 2. Safety instructions an warnings.............................................................5
· GENERAL......................................................................................................................5
· SHOCK PREVENTION.................................................................................................5
· BURN AND BODILY INJURY PREVENTION...............................................................6
· FIRE AND EXPLOSION PREVENTION.......................................................................6
· MEDICAL AND FIRST AID TREATMENT....................................................................6
· EQUIPMENT ARNING LABELS................................................................................6
· 3. Description..................................................................................................7
· 4. Installation...................................................................................................9
· INTERNAL VIE OF THE CHARGER, CABINET A..................................................11
· 5. Operation...................................................................................................15
· PRELIMINARY CONTROLS.......................................................................................15
· BATTERY CONNECTION, VOLTAGE CHECK AND AUTOSTART..........................16
· CHARGE OPERATION...............................................................................................16
· AUTOMATIC DATA SAVING......................................................................................19
· AUTOMATIC AND MANUAL CHARGE TERMINATION............................................19
· EQUALIZATION..........................................................................................................20
· MAINTENANCE...........................................................................................................21
· 6. Trouble Shooting......................................................................................22

Battery Charger RLD
User's Manual
1. Intro uction
This manual contains instructions an suggestions for the users of Energic plus RLD battery
chargers. Before to install, use or repair the charger, it's necessary to rea an un erstan this
manual completely.
It’s recommen e to keep the manual in goo con ition for all the lifetime of the charger. It
shoul be kept in a ry an clean place, always available to the users.
Throughout this manual, the following special annotations have been use to in icate important
information.
RESPONSIBILITY DISCLAIMER
The manufacturer of the Energic plus RLD battery charger will not be responsible for amages
an /or injuries cause by the charger in these situations:
•The charger is not installe properly by a qualifie electrician;
•Maintenance operations are not one by a qualifie electrician;
•The charger is not use accor ing to the instructions inclu e in this manual;
•The charger is not connecte to the correct input supply (see ata label on the box);
•The battery is amage uring the charge;
•The charger has been mo ifie without the authorization of the manufacturer;
•Non-original spare parts are use in the charger;
•Wrong spare parts are use in the charger.
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WARNING !
Gives important information regar ing
possible personal injury
CAUTION !
Gives important information regarding
possible equipment damage
NOTE
Gives additional information and tips concerning
important procedures and features of the charger

Battery Charger RLD
User's Manual
2. Safet instructions and warnings
GENERAL
Battery chargers can cause injury or eath, or amage to other equipment or property, if the user
oes not strictly observe all safety rules an take precautionary actions.
Safe practices must be learne through stu y an training before using this equipment.
Only qualifie personnel shoul install, use, or service this battery charger.
SHOCK PREVENTION
Bare con uctors, or terminals in the output circuit, or ungroun e , electrically-live equipments
can fatally shock a person. To protect against shock, have competent electrician verify that the
equipment is a equately groun e an learn what terminals an parts are electrically HOT.
The bo y’s electrical resistance is ecrease when wet, permitting angerous current to flow
through the bo y. Do not work in amp area without being extremely careful. Stan on ry
rubber mat or ry woo an use insulating gloves when ampness or sweat cannot be avoi e .
Keep clothing ry.
INSTALLATION AND GROUNDING – Electrica equipment must be installe an mantaine in
accor ance with all the applicable national an local co es.
A power isconnect switch must be locate at the equipment. Check the ata label for voltage
an phase requirements. If only 3-phase power is available, connect single-phase equipment to
ONLY TWO WIRES of the 3-phase line.
DO NOT CONNECT the equipment groun ing con uctor to the thir live wire of the 3-phase line
as this makes the equipment frame electrically HOT, which can cause a fatal shock.
If a groun ing con uctor is part of the power supply cable, be sure to connect it to a properly
groun e switch box or buil ing groun . If not part of the supply cable, use a separate
groun ing con uctor. Don’t remove a groun prong from any plug. Use correct mating
receptacles. Check groun for electrical continuity before using equipment.
The groun ing con uctor must be of a size equal to or larger than the size recommen e by
Co e or this manual.
CHARGING LEADS – Inspect lea s often for amage to the insulation. Replace or repair cracke
or worn lea s imme iately. Use lea s having sufficient capacity to carry the operating current
without overheating.
Never exten the charging lea s without prior approval of the manufacturer. Exten ing the
charging lea s without prior approval of the manufacturer may cause wrong operation of the
charger an voi s the warranty.
BATTERY TERMINALS – Do not touch battery terminals while equipment is operating.
SERVICE AND MAINTENANCE – Shut OFF all power at the isconnect switch or line breaker
BEFORE inspecting, a justing, or servicing the equipment. Lock switch OPEN (or remove line
fuses) so that the power cannot be turne ON acci entally.
Disconnect power to equipment if it is to be left unatten e or out of service.
Disconnect battery from charger.
Measure voltage on capacitors an , if there is any voltage rea ing, wait 5 minutes before to
procee .
Keep insi e parts clean an ry. Dirt an /or moisture can cause insulation failure. This failure
can result in high voltage at the charger output.
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Battery Charger RLD
User's Manual
BURN AND BODILY INJURY PREVENTION
The battery pro uces very high currents when short circuite , an will burn the skin severely if
in contact with any metal con uctor that is carrying this current.
Do not permit rings on fingers to come in contact with battery terminals or the cell connectors
on top of the battery.
Battery aci is very corrosive. Alwais wear correct eye an bo y protection when near batteries.
FIRE AND EXPLOSION PREVENTION
When batteries are being recharge , they generate hy rogen gas that is explosive in certain
concentrations in air (the flammability or explosive limits are 4.1% to 72% hy rogen in air). The
spark-retar ing vents help slow the rate of release of hy rogen, but the escaping hy rogen may
form an explosive atmosphere aroun the battery if ventilation is poor.
The ventilation system shoul be esigne to provi e an a equate amount of fresh air for the
number of batteries being charge . This is essential to prevent an explosion.
Always keep sparks, flames, burning cigarettes, an other sources of ignition away from the
battery recharging area. Do not break "live" circuits at the terminals of batteries. Do not lay tools
or anything that is metallic on top of any battery.
To prevent arcing an burning of the connector contacts, be sure the charger is OFF before
connecting or isconnecting the battery. The igital isplay must be completely OFF.
MEDICAL AND FIRST AID TREATMENT
First ai facilities an a qualifie first ai person shoul be available for each shift for imme iate
treatment of electrical shock victims.
EMERGENCY FIRST AID: Call phisician an ambulance imme iately an use First Ai techniques
recommen e by the American Re Cross.
In case of aci in the eyes, flush very well with clean water an obtain professional me ical
attention imme iately.
EQUIPMENT WARNING LABELS
Inspect all precautionary labels on the equipment.
Or er an replace all labels that cannot be easily rea .
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DANGER: ELECTRICAL SHOCK CAN BE FATAL.
If person is unconscious an electric shock is suspecte , o not touch person if he or she is in
contact with charging equipment, battery, charging lea s, or other live electrical parts.
Disconnect power at wall switch an then use First Ai .
Dry woo , woo en broom, an other insulating material can be use to move cables, if
necessary, away from person.
IF BREATHING IS DIFFICULT, give oxygen.
IF NOT BREATHING, BEGIN ARTIFICIAL BREATHING, such as mouth-to-mouth.
IF PULSE IS ABSENT, BEGIN ARTIFICIAL CIRCULATION, such as external heart massage.

Battery Charger RLD
User's Manual
3. Description
Energic plus RLD battery chargers have been esigne to charge lea -aci batteries.
These units can convert the AC input voltage to a DC voltage at the correct level, in or er to
charge the battery cells.
The igital electronic control is use to monitor the state of the charge, to automatically turn off
the charger when the charge is complete an to visualize all the necessary information.
All the features of the igital control will be explaine in the next chapters.
These are the principal evices inclu e in the charger, available to the user:
•External box;
•Control panel with igital isplay;
•STOP pushbutton (0-1);
•No.2 Cables for battery connection;
•No.1 Cable for main supply connection;
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Battery Charger RLD
User's Manual
Insi e of the charger, there are the following evices, not available to the user:
•Power contactor;
•Power transformer;
•Rectifier;
•Microprocessor controlle electronic boar ;
•Output fuse;
•Plugs for input voltage selection;
•Plugs for input voltage a justment.
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Battery Charger RLD
User's Manual
4. Installation
The charger is marke with a technical label, containing the following ata:
•Mo el;
•Serial number (S/N);
•Weight (kg an lbs);
•Input voltages (V);
•Maximum input current (A);
•Maximum input power (KVA);
•Input frequency (Hz);
•Battery voltage (V);
•Maximum output current (A).
Con itions of use:
•Operating temperature: 5°C to 45°C
•Storage temperature: -20°C to 60°C
•Relative humi ity: less than 75%
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WARNING !
The charger can be installe by qualifie personnel only!
To avoi the risk of injuries, the user is not allowe to open the cabinet.
Always refer to qualifie electricians for installation an service operations.

Battery Charger RLD
User's Manual
OWM-AR-D-[] Page 10 of 23
WARNING !
To prevent fire or shock hazar , o not expose the charger to rain or moisture.
Do not use the e charger in presence of flammable gas, because it can generate sparks!
Do not install the charger near flammable materials.
WARNING !
To re uce the risk of fire, the charger must be installe on a floor
of non-combustible material.
If this is not possible, a floor plate of at least 1,6mm steel exten e
at least 150mm beyon the charger on all si es must be installe .
CAUTION !
Allow a equate air circulation to prevent internal heat buil up.
Do not place the unit near materials that may block the ventilation slots.
Do not install the unit near heat sources such as ra iators or air ucts, or in a place
subject to irect sunlight, excessive ust, mechanical vibration or shock.
CAUTION !
The operations an settings escribe in this chapter are
fun amental for the goo functionality of the charger.
Improper settings can cause severe amage to the charger an the battery!
Before to install the charger:
Check that the charger input voltage (V) is i entical to your AC power supply voltage.
Check that the charger max input power (KVA) is available from your AC power supply.

Battery Charger RLD
User's Manual
INTERNAL VIEW OF THE CHARGER
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NOTE
The BOARD FOR INPUT OLTAGE SELECTION is present only in chargers with
3x 220 / 380 ac input, and it's NOT present in chargers with 3x440 ac input.
The PLUGS FOR INPUT OLTAGE ADJUSTMENT are present in all the chargers.

Battery Charger RLD
User's Manual
AC VOLTAGE SELECTION 3 x 220/380 V
The BOARD FOR INPUT VOLTAGE SELECTION is compose by six terminal blocks, to be
connecte in one of the two configurations represente on the picture insi e the charger.
PROCEDURE:
•Check that the charger is isconnecte from AC input an battery;
•Open the cabinet an move the three wires (WHITE) in position 220V or 380V;
•Close the cabinet.
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Battery Charger RLD
User's Manual
AC INPUT VOLTAGE ADJUSTMENT
The local AC input voltage must be measure with an a equate voltmeter, then the charger input
must be a juste by moving the three wires marke with the letters A, B, C on the PLUGS FOR
INPUT VOLTAGE ADJUSTMENT.
PROCEDURE:
•Check that the charger is isconnecte
from AC input an battery;
•Open the cabinet an move the wires A, B,
C to the esire position.
•Close the cabinet.
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Battery Charger RLD
User's Manual
GROUNDING AND LINE CONNECTION
If the charger is to be connecte to the AC power supply with a flexible jackete cable, one
having a separate groun ing con uctor shoul be use .
If, for any reason, an input cable which oes not inclu e a groun ing con uctor is use , the
equipment must be groun e with separate con uctor. Minimum size an color co ing
requirements must be in accor ance with any applicable national or local co e.
PROCEDURE
•Rea on the ata label the AC current value correspon ing to the line voltage to which
charger is to be connecte . Using that current value, select the proper fuses, isconnect
switch an power cable sizes, accor ing with any applicable national or local co e.
•Check that the charger is isconnecte from AC input an battery;
•Open the cabinet;
•Mount the input cable an connect the four power con uctors (three phase + groun ) to the
terminal blocks;
•Close the cabinet;
•With isconnect switch on AC input power line on position “OFF” or “OPEN”, connect the
power cable coming from the charger to the switch an , then, install the fuses in the switch.
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WARNING !
The cabinet of the battery charger must be properly groun e to protect
personnel against hazar of electrical shock in case of fault on the charger!
The groun ing con uctor must have a current carrying capacity equal or
higher than the current carrying capacity of the AC-input wires.

Battery Charger RLD
User's Manual
5. Operation
PRELIMINARY CONTROLS
•Inspect the charger completey for loose screws, electrical connections or other amages;
•Check that all the ventilation slots are not obstructe to assure proper air flow;
•Make sure that the charger is installe as instructe in this manual an in accor ance with
any applicable national or local norm.
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WARNING !
DON'T connect the battery to the charger if the igital isplay is ON.
DON'T isconnect the battery from the charger while it is being charge .
ARCING AND BURNING OF CONNECTORS
OR BATTERY EXPLOSION MAY RESULT!

Battery Charger RLD
User's Manual
BATTERY CONNECTION, VOLTAGE CHECK AND AUTOSTART
•Connect the battery to the charger, using an a equate connector.
When the battery is correctly connecte , the isplay will show the battery voltage.
If the battery voltage is below the minimum threshol of 1,62 V/cell, the charger will not start,
an the isplay will show the error message “Voltage Low”:
If the battery voltage is higher than the maximum threshol of 2,60 V/cell, the charger will not
start, an the isplay will show the (flashing) error message “Voltage High”:
If the battery voltage is between the minimum an maximum threshol s, the charger will turn on
automatically after 5 secon s.
If, uring the charge, the battery voltage excee s the maximum threshol of 2,80 V/cell, the
charger will shut own automatically, an the errore message “Voltage High” will appear on the
isplay.
CHARGE PROCESS
While the charge is in progress, the following parameters are continuously isplaye in
sequence:
•Battery Voltage/cell (Output voltage) (U) (Volt);
•Charge current (Output current) (A) (Ampere);
•Effective time of charge (h) (Hours);
•Capacity charge (C) (Ah);
The letter after the value (U-A-h-C) in icates which parameter being is isplaye .
To isplay the time, the charger uses this format:
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CAUTION !
ENERGIC Plus RLD chargers are programme to o a complete cycle of charge
automatically, however it’s always recommen e to survey the operations, especially
when the battery is connecte to the charger for more than 12 hours.

Battery Charger RLD
User's Manual
(HOURS) . (MINUTE DECADES) h
Examples:
Time of charge 3h 30minutes: Displaye 3.3h
Time of charge 7h 50minutes: Displaye 7.5h
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Battery Charger RLD
User's Manual
•STANDARD CHARGERS WITH Wa CHARGE CURVE
The current of charge follows the Wa charge curve, as escribe in the DIN 41774 Stan ar .
After some hours, epen ing by the con itions of the battery, when the battery’s voltage reaches
the value of “gassing” (2,4 Volt per cell), the LED “FINAL CHARGE” starts to flash an the
charge continues.
Wa charge curve.
•FAST CHARGERS WITH WoWa CHARGE CURVE
The current of charge follows the WoWa curve, as escribe in the DIN 41773 Stan ar , while
the LED “CHARGE ON” continuously flashes.
The current value, when the charge starts, is 20-40% higher than the stan ar Wa value, to
re uce the time of charge.
When the "gassing" voltage (2,4 Volt per cell) is reache , the current value is re uce to avoi
overheats in the battery, an the charge continues in the same way of stan ar Wa mo els.
WoWa charge curve
When the battery reaches the gassing voltage, the charge continues for one half of the time
nee e to reach the gassing voltage, with a minimum total time of 30 minutes.
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Battery Charger RLD
User's Manual
SAFETY TIMER – EMERGENCY STOP
•If the battery oesn't reach the gassing voltage within 12 hours, the charge is terminate by
the Emergency timer. The isplay will show the error message “Time Error”:
If this error message appear, it's recommen e to call the service for a complete check of the
system.
The cause if this problem may be a wrong setting of the input voltage: if the input is set to a
certain value (for example: 610 V) but the real voltage is lower (for example: 575 V), the charging
current will be significantly lower than the nominal value, therefore it will take more time to
reach the gassing voltage.
AUTOMATIC DATA SAVING
•If, while the charge or the equalization are in progress, a black-out of the AC input occurs, the
charger saves automatically all the relevant information about the state of the charge.
While the input power is absent, the message “Black Out” is isplaye :
•When the power supply will be available again, the charger will re-start automatically from the
exact point of interruption, an the charge will be normally complete .
AUTOMATIC AND MANUAL CHARGE TERMINATION
•AUTOMATIC CHARGE TERMINATION:
When the charge has been normally complete , the charger turns off automatically.
The isplay shows the flashing message “En ”.
At this point, it's possible to isconnect the battery.
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WARNING !
DON'T isconnect the battery from the charger while it is being charge .
ARCING AND BURNING OF CONNECTORS OR BATTERY EXPLOSION MAY RESULT!

Battery Charger RLD
User's Manual
•MANUAL CHARGE TERMINATION:
The charge can be manually terminate in any moment, by pressing the re STOP pushbutton.
The isplay will show the message “Stop”:
At this point, it's possible to isconnect the battery.
EQUALIZATION
The EQUALIZATION function is useful to keep all the cells of the battery at the same voltage
level, even after years of continuous work. When a battery is charge / ischarge every ay, it's
suggeste to equalize it weekly.
The charger, after a normally complete charge cycle, will a 4 extra charges of 30 minutes,
with 15 hours interval between each charge.
During the interval between each equalization charge, the isplay will show the scrolling
message: “En ”:
When the equalization chargers are in progress, the isplay will show the message“F1”,
followe by the current value:
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NOTES
After the charge termination, while the battery remains connected, the final values of
[ oltage/cell], [Time] and [Capacity charged] remain stored in memory.
If the red STOP pushbutton is pressed, the display will show these values in sequence.
If the charge has been terminated manually, equalization and
maintenance functions are automatically disabled.