Energic Plus RX User manual

USER MANUAL
IN CHARGE OF YOUR BATTERIES
www.energicplus.com
BATTERY CHARGER RX

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USER MANUAL
BATTERY CHARGER RX
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Responsibility disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2. Safety instructions and warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Shock prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Burn and bodily injury prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Fire and explosion prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Medical and first aid treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Equipment warning labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Installation of the charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Internal view of the charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Electrical installation of the charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Ac voltage adjustment – single phase – box s-a-b . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Ac voltage adjustment – single phase – box b-c. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ac voltage adjustment – three phases – box b-c-d-e . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Charging cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Preliminary controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Rx singlephase – box s-a-b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
567sce control board – charge operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Rx theephases – box b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Mrg4-3 control board – charge operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Mrg4-3 control board – alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Rx singlephase and threephases – box c(rl) – box d(rtc) – box e (Maxi. . . . . . . . . . . . . . 21
Mrg5-7 control board – charge operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Mrg5-7 control board – alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6. Trouble shooting guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Table of contents

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BATTERY CHARGER RX
1. Introduction
This manual contains instructions and suggestions for the users of Energic plus RX battery chargers. Before to install, use or
repair the charger, it’s necessary to read and understand this manual completely.
It’s recommended to keep the manual in good condition for all the lifetime of the charger. It should be kept in a dry and
clean place, always available to the users.
Throughout this manual, the following special annotations have been used to indicate important information.
RESPONSIBILITY DISCLAIMER
The manufacturer of the Energic plus RX battery charger will not be responsable for damages and/or injuries caused by the
charger in these situations:
• The charger is not installed properly by a qualified electrician;
• Maintenance operations are not done by a qualified electrician;
• The charger is not used according to the instructions included in this manual;
• The charger is not connected to the correct input supply (see data label on the box);
• The battery is damaged during the charge;
• The charger has been modified without the authorization of the manufacturer;
• Non-original spare parts are used in the charger;
• Wrong spare parts are used in the charger.
CAUTION !
Gives important information regarding
possible equipment damage
WARNING !
Gives important information regarding possible
personal injury
NOTE
Gives additional information and tips concerning
important procedures and features of the charger

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2. Safety instructions and warnings
GENERAL
Battery chargers can cause injury or death, or damage to other equipment or property, if the user does not strictly observe
all safety rules and take precautionary actions. Safe practices must be learned through study and training before using this
equipment. Only qualified personnel should install, use, or service this battery charger.
SHOCK PREVENTION
Bare conductors, or terminals in the output circuit, or ungrounded, electrically-live equipments can fatally shock a person.
To protect against shock, have competent electrician verify that the equipment is adequately grounded and learn what
terminals and parts are electrically HOT. The body’s electrical resistance is decreased when wet, permitting dangerous
current to flow through the body. Do not work in damp area without being extremely careful. Stand on dry rubber mat or
dry wood and use insulating gloves when dampness or sweat cannot be avoided. Keep clothing dry.
INSTALLATION AND GROUNDING – Electrical equipment must be installed and mantained in accordance with all the applicable
national and local codes. A power disconnect switch must be located at the equipment. Check the data label for voltage and 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 grounding conductor to the third live wire of the 3-phase line as this makes the equipment frame
electrically HOT, which can cause a fatal shock. If a grounding conductor is part of the power supply cable, be sure to connect
it to a properly grounded switch box or building ground. If not part of the supply cable, use a separate grounding conductor.
Don’t remove a ground prong from any plug. Use correct mating receptacles. Check ground for electrical continuity before using
equipment. The grounding conductor must be of a size equal to or larger than the size recommended by Code or this manual.
CHARGING LEADS – Inspect leads often for damage to the insulation. Replace or repair cracked or worn leads immediately.
Use leads having sufficient capacity to carry the operating current without overheating. Never extend the charging leads
without prior approval of the manufacturer. Extending the charging leads without prior approval of the manufacturer may
cause wrong operation of the charger and voids the warranty.
BATTERY TERMINALS – Do not touch battery terminals while equipment is operating.
SERVICE AND MAINTENANCE – Shut OFF all power at the disconnect switch or line breaker before inspecting, adjusting,
or servicing the equipment. Lock switch OPEN (or remove line fuses) so that the power cannot be turned ON accidentally.
Disconnect power to equipment if it is to be left unattended or out of service. Disconnect battery from charger. Measure
voltage on capacitors and, if there is any voltage reading, wait 5 minutes before to proceed.
Keep inside parts clean and dry. Dirt and/or moisture can cause insulation failure. This failure can result in high voltage at the
charger output.
BURN AND BODILY INJURY PREVENTION
The battery produces very high currents when short circuited, and will burn the skin severely if in contact with any metal
conductor 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 acid is very corrosive. Always wear correct eye and body protection when near batteries.
FIRE AND EXPLOSION PREVENTION
When batteries are being recharged, they generate hydrogen gas that is explosive in certain concentrations in air (the
flammability or explosive limits are 4.1% to 72% hydrogen in air). The spark-retarding vents help slow the rate of release of
hydrogen, but the escaping hydrogen may form an explosive atmosphere around the battery if ventilation is poor.
The ventilation system should be designed to provide an adequate amount of fresh air for the number of batteries being
charged. This is essential to prevent an explosion. Always keep sparks, flames, burning cigarettes, and 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 and burning of the connector contacts, be sure the charger is OFF before connecting or disconnecting
the battery. The digital display must be completely OFF.

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MEDICAL AND FIRST AID TREATMENT
DANGER: ELECTRICAL SHOCK CAN BE FATAL.
If person is unconscious and electric shock is suspected, do not touch person if he or she is in contact with charging
equipment, battery, charging leads, or other live electrical parts. Disconnect power at wall switch and then use First Aid.
Dry wood, wooden broom, and other insulating material can be used 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.
First aid facilities and a qualified first aid person should be available for each shift for immediate treatment of electrical
shock victims.
EMERGENCY FIRST AID: Call phisician and ambulance immediately and use First Aid techniques recommended by
the Red Cross. In case of acid in the eyes, flush very well with clean water and obtain professional medical attention
immediately.
EQUIPMENT WARNING LABELS
Inspect all precautionary labels on the equipment. Order and replace all labels that cannot be easily read.
3. Description
Energic Plus RX battery chargers have been designed to charge Pb batteries. These units can convert the AC input voltage
to a DC voltage at the correct level, in order to charge the battery cells.
These are the principal devices included in the charger, available to the user:
• External box;
• Led control panel;
• Main switch (0-1);
• No.2 Cables for battery connection;
• No.1 Cable for main supply connection; External Box
LED Control
panel
Main Switch 0-1
N°2 cables for
battery connection
N°1 cable for main
supply connection
External Box
LED Control panel
Main Switch 0-1
N°2 cables for
battery connection N°1 cable for main
supply connection

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4. Installation of the charger
Conditions of use:
• Operating temperature: 5°C to 45°C
• Storage temperature: -20°C to 60°C
• Relative humidity: less than 75%
CAUTION !
The charger can be installed by qualified personnel only.
NOTE
Check that the unit’s operating voltage is identical to your local power supply.
Check that the unit’s maximum input power is available from your power supply.
CAUTION !
To prevent fire or shock hazard, do not expose the unit to rain or moisture.
Do not use the unit in presence of flammable gas, because it can be generate sparks.
CAUTION !
To avoid electrical shock, do not open the cabinet.
Refer servicing to qualified personnel only.
CAUTION !
Allow adeguate air circolation to prevent internal heat buildup. Do not place the unit near materials
that may block the ventilation slots. Do not install the unit near heat sources such as radiators or air
ducts, or in a place subject to direct sunlight, excessive dust, mechanical vibration or shock.

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INTERNAL VIEW OF THE CHARGER
Box S/A/B internal view
Box C(RL)/D(RTC)/E(MAXI) internal view

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ELECTRICAL INSTALLATION OF THE CHARGER
• Check the efficiency of earth circuitry (yellow/green wire);
• Connect the charger to the mains using an adeguate plugs, with pushbutton and fuses;
• Use an adeguate plug to connect the charger to the battery;
CAUTION !
These settings can be done by qualified personnel only.
For more information please contact the manifacturer.
AC VOLTAGE ADJUSTMENT – SINGLE PHASE – Box S-A-B
• Disconnect the charger from main supply and battery;
• Open the cabinet;
• Locate the terminal block for AC input voltage setting;
• Disconnect the wire A from the original terminal block (position 2);
• Connect the wire A to the desired position. [Check the table to find the correct position];
• Close the cabinet;
• Connect the charger to main supply.

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AC VOLTAGE ADJUSTMENT – SINGLE PHASE – Box B-C
• Disconnect the charger from main supply and from the battery;
• Open the cabinet;
• Find the terminal blocks for AC input voltage setting;
• Connect the wires A and B to the desired position. [Check the table to find the correct position];
• Close the cabinet;
• Connect the charger to main supply.
AC VOLTAGE ADJUSTMENT – THREE PHASES – Box B-C-D-E
• Disconnect the charger from main supply and battery;
• Open the cabinet and identify the terminal blocks (transformer taps) for AC input voltage adjustment;
• Disconnect the wires A, B, C from their original positions;
• Connect the wires A, B, C to the desired position, according with the voltages reported on the yellow label.
• Check the table to find the correct position;
• Close the cabinet;
• Connect the charger to main supply.

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AC Voltage Setting – Three Phase Box B
AC Voltage Setting – Three Phase Box C-D-E

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5. Operation
CHARGING CYCLES
The standard model of the RX chargers follows the Wa charging curve as described in the DIN 41774 norm.
Current
Voltage
Initial Current
(about 16% of battery capacity)
Voltage
Current
Time
Voltage = 2.40 V/cell
Current = 50% of initial current
Voltage = 2.00 V/cell
On the Wa charge curve, the relationship between the battery voltage and the output current of the charger can be
described in 3 points:
• 100% of the rated current at the beginning of the charge (when the battery voltage is at 2,10 V/cell),
• 50% of the rated current at 80% of the charge (when the battery voltage reaches the “gasing point” that corresponds to
2,40 V/cell),
• 25% of the rated current at the end of the charge (when the battery voltage reaches its maximum value, that may vary
depending on the battery type and manufacturer).
PRELIMINARY CONTROLS
• Inspect the charger completely for loose screws, electrical connections or other damages;
• Check that all the ventilation slots are not obstructed to assure proper air flow;
• Make sure that the charger is installed as instructed in this manual and in accordance with any applicable national or local norm.
• Connect the charger to the battery;
WARNING !
When the charge is started, check that the LED “CHARGE ON” is flashing at frequency of about 1
second. This control is useful to be sure that the electronic control is working correctly.
WARNING !
ENERGIC Plus RX chargers are programmed to do a complete cycle of charge, however it’s
recommended to survey the operations when the battery must remain connected to the charger for
more than 12 hours (example: week-ends)

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NOTE
The operations described in these chapters are done by ENERGIC Plus RX chargers automatically.
WARNING !
Before disconnecting the battery, check it is not being charged. If it is charging turn off the charger
using the main switch or the stop pushbutton, to avoid sparks between connectors.
RX SINGLEPHASE – BOX S-A-B
The RX SINGLEPHASE Chargers made on the Box S,A,B mount the 567SCE Control Board. The Front Panel of the 567SCE
Control Board is composed by 4 Status Leds that indicate the state of charge.
After the connection of the battery, the Control Board turns on.
If the battery and the AC Input are properly connected and the main switch is in position 1 the charger cycle starts
automatically.
If, after the connection of the battery, the main switch is in position 0, all the leds start to blink and the charge cycle doesn’t
start. To begin the charge cycle, move the main switch in position 1.

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567SCE Control Board – CHARGE OPERATION
The charge current follows the Wa charge curve as described in the DIN 41774 norm.
During the first phase of charge, since the beginning of the charge cycle until the reaching of the gasing point, the led
‘CHARGE ON’ blinks.
If the gassing point , equal to 2,4V/cell, isn’t reached within 12 hours since the beginning of the charge process, the charge
process stops and the led ‘Emergency Stop’ blinks.
First Phase of Charge
Emergency Stop – Safety Time reached
When the gasing point is reached the Final Phase of Charger begins. The Final Phase of charge lasts for 3 hours. During the
Final Phase of charge the leds ‘CHARGE ON’ and ‘FINAL CHARGER’ blink alternately.

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Final Phase of Charge
When the three hours of Final Charge are completed the Control Board 567SCE stops the charge process.
The led STOP blinks; the charge process is succesfully completed.
End of the charge process
If, during the charge process, the AC Input fails the 567SCE Control Board stores in memory the status of the charge process.
When the AC Input comes back the charge process starts from the point of interruption. While the AC Input fails all the 4
Status Leds blink alternately.

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AC Input Fails
After the end of the charge process, if the battery remains connected to the charger for more than 15 hours the 567SCE
Control Board executes the Equalizations cycles. The equalization cycles consist of 4 extra charge cycles of 30 minutes
executed every 15 hours. During extra charge cycles the LEDs “ FINAL CHARGE” and “STOP” flash alternately.
Equalization Cycle
The EQUALIZATION function, performed by ENERGIC Plus RX chargers, has been developed to keep all the cells of the
battery at the same level, even after years of continuous work.

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RX THEEPHASES – BOX B
The RX THREEPHASES Chargers made on the Box B mounts the MRG4-3 Control Board. The Front Panel of the MRG4-3
Control Board is composed by 4 Status Led that indicate the state of charge and 3 Leds that indicate the charge current
level. After the connection of the battery, the Control Board turns on.
If the battery and the AC Input are properly connected the charger cycle starts automatically.
MRG4-3 Control Board – CHARGE OPERATION
The charge current follows the Wa charge curve as described in the DIN 41774 norm. During the first phase of charge, since
the beginning of the charge cycle until the reaching of the gassing point, the led ‘CHARGE ON’ blinks.
If the gassing point , equal to 2,4V/cell, isn’t reached within 12 hours since the beginning of the charge process, the charge
process stops. See the next paragraph for the details of the alarm situations.
First Phase of Charge

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When the gasing point is reached the Final Phase of Charger begins. The Final Phase of charge lasts for 4 hours.
During the Final Phase of charge the leds ‘CHARGE ON’ and ‘FINAL CHARGER’ blink alternately.
Final Phase of Charge
When the four hours of Final Charge are completed the Control Board MRG4-3 stops the charge process.
The led STOP blinks; the charge process is succesfully completed.
End of the charge process
If, during the charge process, the AC Input fails the MRG4-3 Control Board stores in memory the status of the charge process.
When the AC Input comes back the charge process starts from the point of interruption. While the AC Input fails all the 4
Status Leds blink alternately.

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AC Input Fails
After the end of the charge process, if the battery remains connected to the charger for more than 15 hours the MRG4-
3 Control Board executes the Equalizations cycles. The equalization cycles consist of 4 extra charge cycles of 30 minutes
executed every 15 hours. During extra charge cycles the LEDs “ FINAL CHARGE” and “STOP” flash alternately.
Equalization Cycle
The EQUALIZATION function, performed by ENERGIC Plus RX chargers, has been developed to keep all the cells of the
battery at the same level, even after years of continuous work. After the End of 4 Equalization Cycles the Led’ STOP ‘ is fixed
ON to indicate that also the equalization cycles have been succesfully completed.
End of the charge process and equalization cycles

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MRG4-3 Control Board – ALARMS
If the Led ‘Emergency Stop’ blinks means that the charge cycle or an Equalization cycle has been interrupted because an
alarm has occurred. The MRG4-3, lighting the current leds on the left, can indicate the cause of the allarm.
Stop Pushbutton pressed during the charge cycle or during an equalization cycle.
The battery voltage read after the connection of the battery is too low (under 1,60V/cell).
The charge cycle doesn’t begin.
The battery voltage read after the connection of the battery is too high (over 2,50V/cell).
The charge cycle doesn’t begin.

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The battery voltage reached during the charging cycle or during an equalization cycle is too high
(over 2,80V/cell). The charge cycle stops.
The charge current reached during the charge cycle is too high (over the 140% of the nominal value).
The battery voltage hasn’t reached the gassing point within 12 hours of charge.