EnerSys Hawker Powertech IQ Series User manual

ENGLISH
SAFETY INSTRUCTIONS
GOALS OF THIS MANUAL
This manual is aimed at any authorized personnel wanting
to use a single phase POWERTECH IQ charger to recharge
lead acid motive power batteries (vented, XFC FLEX, Gel or
WF200 ranges)
This manual contains information on:
• Charger functionality.
• Use and setting of charger parameters.
• Technical specifications of the Powertech IQ chargers.
EnerSys intends to provide clear and simple information
in this manual, and assumes no responsibility for misunder-
standing or improper interpretation of the information.
The owner of the equipment is required to preserve this
manual during the life of the equipment and to transfer said
manual to any subsequent purchaser.
WARRANTY
Warranty is offered by the manufacturer based on local
regulations. Please contact your local distributor for further
information.
RECOMMENDATIONS
Recommendations for safe operation
This manual should be carefully read, prior to using the
equipment, by anyone intending to use the charger. The
Powertech IQ:
• Must not have its air circulation impaired in any way,
primarily around the air inlet areas. Dust accumulation
must be removed every six months.
• Must be used within its protection norms, and never
be directly in contact with water.
• Must be used only within the temperature range
specified in the technical specifications
• Must not be installed on a surface subject to high
vibration levels (proximity of motors, compressors, etc.).
• Must not be installed close to the batteries in order to
avoid any
gassing that could damage it prematurely.
• Must not be installed in arduous environments such as:
• Harbour applications (saline air),
• Close to cold stores
• External locations with exposure to wind and rain.
Operator safety
All proper precautions must be observed when the
equipment is used in areas where accidents are possible.
Ensure proper ventilation when the charger is used with
lead-acid batteries, due to gassing. Never disconnect the
battery during the charging process.
General warnings
Requirements for use:
• The equipment must be properly grounded (earthed).
• The input voltage must match the charger requirements.
• The battery voltage must match the charger’s
capabilities.
• The battery capacity is within the charger’s range.
ELECTRICAL SAFETY
Safety regulations and requirements must be observed.
Safety devices installed on the electrical supply to the
chargers must be of the proper type and rating. It is
important to ensure that only fuses of the proper
capacity be used, should they need to be replaced.
This charger meets the Class 1 Electrical Safety requirements, and therefore needs to be properly grounded during installation. It must be connected to a power supply equipped with a ground cable, and the ground connection should be as short as possible.
The equipment must be totally disconnected from all power
sources (mains supply and battery) before it can be opened
for inspection or servicing. The battery can only be discon-
nected after the STOP/START button has been pushed.
Access to the inside of the charger should be restricted to
authorized maintenance personnel.
Please consult a qualified factory representative about any
problems or questions related to the installation of this
unit.
LIMITS OF USE
This charger is designed to be used in a sheltered area.
It is designed exclusively to recharge lead batteries in an
industrial environment.
PRODUCT RECYCLING - DESTRUCTION
When this charger becomes obsolete, it can be recycled
or destroyed by authorized facilities. Local regulations will
prevail and must be followed.
MODIFICATIONS AND IMPROVEMENTS
EnerSys reserves the right, at any time, to modify or
improve its products, without any obligation to update
this product or this manual accordingly.
RECEIVING - STORAGE
Upon receipt, please inspect visually the exterior of the
charger for any physical damage. If necessary, proceed
within 24 hours with the usual claims procedure with the
transport company.
If the charger is to be stored before use, it should remain
in the original packaging, carefully closed. Store in a clean,
dry area at a moderate temperature (0 °C to +40 °C). If the
equipment is stored at a temperature below 15°C, it must
be gradually (24 hours) restored to operating temperature
before use, to prevent the risk of condensation that could
cause electrical faults and short-circuits.
INFORMATION PLATE
Located on either side of the charger.
EEC DECLARATION OF CONFORMITY
Enersys hereby declares that the chargers in the
Powertech IQ range covered by this declaration
conform to:
Directive 2006/95/EC: Low voltage Directive
European Standard:
EN60335-1
EN60335-2-29
EN60950-1
Directive 2004/108/EC: Electromagnetic compatibility
EN61000-6-2 : 2001
EN61000-6-4 : 2001
Directive 2002/95/EC: ROHS
Safety and use instructions Powertech IQ - Single phase chargers

DESCRIPTION & USE
INTRODUCTION
The Powertech IQ range of chargers is designed to recharge
24V, 36 V or 48 V batteries, depending on the version
supplied, from a single-phase mains supply. The micro-
processor-controlled unit automatically recognises the
battery (voltage, capacity, charge level, etc.) and very
effectively analyses its condition for optimum handling.
Several charging profiles are available (vented lead/acid
batteries, VRLA batteries (XFC FLEX), gel batteries or WF200
batteries) depending on the configuration selected by the
user. The capability for desulphation, equalisation and
refresh charging is also included.
EXTERNAL COMPONENTS
Presented below:
Ref. Function
1. Ventilation louvres.
2. Display and control panel
3. AC input cable.
4. Battery cable.
5. Wall mounting frame.
6. Case retaining screw.
7. Navigation button – Stop/Start button of the charger
8. USB
9. Option connector (Electro-valve, BSI, Ethernet…).
Figure 1: Principal components of the charger.
CONTROL PANEL
Incorporates the Display and the Control Panel. See
Chapters “The Menus” and ”Using the charger” to get
more detailed information.
LCD Display
The display is fitted with 5 different colours indicating the
status of the charger:
Functions of keys
The keys offer the following general functions:
Key Function
Navigation in the menu.
Start/End of list (Press 2 seconds)
The central button is equipped with
a two-coloured LED Green/Red
(Green: charger is waiting, Red charger
operating)
GREEN/RED Stop or Start of charge
Selection of active menu or validation
of value stored
Cancel the value stored
(Press 2 seconds)
Start an equalisation charge.
Access to a sub-menu.
Access to the menus (press 3 seconds)
Close the window.
UNPACKING
The charger is delivered with the following:
• 3 m AC mains cable.
• 3 m DC battery cable.
• This technical manual.
MECHANICAL INSTALLATION
The charger must be mounted in a vertical position. For
wall mounted chargers, the bottom of the charger must be
at least 0.60 m from the floor and/or the charger below
and the top of the unit at least 1.0 m from the ceiling. The
minimum distance between two adjacent chargers must
be 0.30 m.
See paragraph Recommendations and avoid areas where
the chargers may be splashed with water, or saline
environments.
The charger is held by 4 x M6 screws suitable for the type
of support. The drilling pattern is depending on the charger
model. Refer to technical data.
ELECTRICAL CONNECTIONS
Single phase input
Connection to the mains supply will be 230V AC single
phase and must be connected using a suitable plug and
adequately sized circuit breaker (not included). Current
requirements in Amps are indicated on the charger
information plate.
Battery output
It is essential to ensure correct polarity. However, reversed
polarity will result in blowing the output fuse, inability to
charge and the fault code DF2 to be displayed. See Fault
Codes.
Connection to the battery should be done using the cables
supplied:
• RED cable: battery POSITIVE.
• BLACK cable: battery NEGATIVE.
FACTORY SETUP
The charger is delivered with a factory setup as follows:
Profile: As ordered
Output DC cable length: 3 m
Configuration: As ordered
Automatic equalisation: No
Delayed start enabled: No
002
FUNCTION
Waiting status until battery connected
Battery on charge
Alternating, on charge and defect pump
Battery charged
Charger faults DF1, DF2, DF3, TH
COLOUR
Dark blue
Light blue
Light blue Orange
Green
Red

CHARGING THE BATTERY
It is now assumed that the charger has been properly set up.
Charging can only begin with a battery of the proper type,
capacity and voltage connected to the charger.
Off-charge display
With the charger in waiting mode, the display shows
information concerning the charger(top and bottom lines):
1. Charger type (Battery voltage + current).
2. Last selected charging profile.
3. Software version.
4. Waiting indication.
5. Date and time of the charge.
6. Set up battery operating temperature.
Alternating battery temperature/capacity if the ‘manu’
capacity mode is selected.
Starting the charge
1. The charge starts automatically when the battery is
connected to the charger. To stop the charge, press the
central button .
The displays shows information relative to the connected
battery and counts down the time remaining until the
effective charge begins.
Ref. Without Wi-IQ With Wi-IQ
1. Charger status (CHARGE, AVAIL, DEFAULT, EQUAL..),
possible pump fault.
2. Alternating display of battery voltage, voltage per
cell, Ah restored, charging time, remaining charging
time, percentage of battery charge.
3. Set up operating Battery temperature and
battery T°C capacity given by the
Wi-IQ (*).
4. Charging current
5. Programmed charging Detected charging
profile. profile (*).
6. Various information can be displayed: equalisation
symbol required at the end of charge, USB
connection symbol, Wi-IQ link symbol, possibly
battery default DF4.
7. Empty line. Alternating, detected serial
number, as information is
received and alarms if
present. See § Fault codes .
(*) as information is received.
As soon as the countdown time has elapsed, the display
shows the information relative to the charge.
To induce the start of the charge if the delayed charge has
been programmed:
1. Connect the battery
2. Press the central button to stop the charger.
3. Press and hold the central button for 3 seconds.
Release.
Defaults DF1, DF2, DF3 and TH inhibit the charge. Refer to
section Fault codes .
End of charge without equalisation
1. The backlight of the screen becomes green at the end of
a correct charge.
And the indication AVAIL is displayed. Possible
alternating display between DF5 default and pump
default (ref.1). The displays shows alternately: (ref. 2):
• charging time achieved.
• number of Ah restored.
Refer to sections Memorisations or Status for detailed
information relevant to the end of charge.
If the battery remains connected, and in order to
maintain it in a fully charged condition, refresh charges
followed by equalisation charges will be automatically
initiated according to the battery technology.
2. If an equalisation charge has been programmed (vented
battery), it will start automatically. Alternatively, an
equalisation charge can be triggered manually; go to
section End of charge with equalisation .
3. Press the central button or disconnect the battery that is
now ready for use.
End of charge with equalisation
Equalisation only applies to vented batteries. Start can be
manual or automatic.
Manual start
1. At the end of charge (green lighted display on), press
the key .
The start of the equalisation charge is indicated by the
message EQUAL. During the equalisation charge, the
charger displays the current (ref 4) and alternating, the
battery voltage, voltage per cell, remaining time (ref 2).
2. The battery will be available as soon as the screen
becomes green.
Automatic start
If the equalisation charge has been programmed
( Configuration/Equalisation menu), the equalisation charge
is initiated automatically.
If the battery remains connected, and in order to maintain it
in a fully charged condition, refresh charges followed by an
equalisation charge will be automatically initiated according
to the battery technology. Similar indications to those
displayed in manual start (see above) are displayed.
010
WAIT
012

www.enersys-emea.com
Subject to technical modification without any prior notice.
MESSAGES AND FAULT CODES
Fault
DF1*
DF2*
DF3*
DF4
DF5
DF PUMP
Cause
Charger problem.
Output default.
Wrong battery.
Battery discharged
more than 80% of
its capacity.
Battery requires
inspection.
Fault in the air
circuit of the elec-
trolyte circulation
system.
Solution
DF1 appears when
the charger is not able
to supply its output
current. Follow the
breakdown procedure
for the charger with
control of the IGBT,
diode, mains voltage …
Check the correct
connection of the
battery (reversed
polarity cables) and
the output fuse.
Too high or too low
battery voltage. Battery
voltage must be between
1.6V and 2.4V per cell.
Use proper charger for
battery.
Charge continues.
DF5 appears when the
charging profile has
been achieved with
a fault condition,
that can be a current
increase in regulation
phase demonstrating
a battery heating or a
badly programmed
regulation voltage, or
the charging time is too
long and has exceeded
the safety limit.
Check charging
parameters: profile,
temperature, capacity,
cables.
Check the battery
(defective cells, high
temperature, water
level..).
Check the proper
operation of the pum
via the menu Option-
Option test .
Check the air circuit
(pump, tubes).
If this fault occurs, the
charger will adapt the
battery charging profile
for an optimised charge.
TH*
STOP*
TEMP*
DEF CFG*
DEF EEP*
DEF MENU*
IQ SCAN
IQ LINK
T
Thermal problem
in charger resul-
ting in charge
interruption.
Critical battery
electrolyte level
Critical battery
temperature.
Error in
Configuration/
Memory/Charger
menu.
Look for present
Wi-IQ
Set the link
Wi-IQ-Charger
Low electrolyte
level
Default of balance
voltage detected
by the Wi-IQ
Too high battery
temperature.
Verify the proper
operation of the fans
and/or absence of too
high ambient tempera-
ture, or wether there is
poor natural ventilation
to the charger.
Top up battery electro-
lyte. Do not fill in until
top of the cell in order
to avoid overflow by
the next charge.
Wait until the battery
temperature cools
down, check the battery
state (water, profile)
Verify the set up of
temperature in the
menu Configuration-
Battery-High tempera-
ture .
Control the temperature
sensor of the Wi-IQ.
Change of the main
board
Battery water topping
up or ensure that the
Wi-IQ is properly
adjusted and installed
(see Wi-IQ instructions
of mounting)
Check each battery
cell during discharge.
Control if the Wi-IQ
is properly adjusted
(see Wi-IQ instructions
of mounting).
Verify the battery
electrolyte level or the
correct set up of the
charger.
Check the temperature
sensor of the Wi-IQ.
(*) : blocking fault preventing charging from continuing.
02.2009