Inspired Energy CR12 User manual

Optional Discharge Kit:
The unit can be operated to provide backup
power or remote battery power for off-grid
applications.
A battery array kit is available to provide
battery output power from any battery
packs in the charge bays.
Each battery pack contains short circuit
protection and each board is diode-
protected to prevent one battery from charging an adjacent battery.
The battery packs will discharge in parallel, and the output will be battery voltage. Depending on the
batteries used, each CR12 unit can provide a battery array of up to 1.17kWh.
WARNING: the combined battery output from this unit can deliver 1600W / 96A continuously, with
peak power significantly higher.
DO NOT SHORT CIRCUIT. The battery packs are protected from damage but any source of short
circuit will suffer damage &/or may become extremely hot, causing injury.
Remove the battery packs and any personal jewelry (rings, bracelets etc) before working on the
discharge circuit.
To install the discharge kit (available separately):
Remove all battery packs from the unit & remove the CR12 unit from its rack housing.
Mount the discharge connector to the side of the rack unit using the screws & nuts provided.
Plug a discharge connector to each board
-
Fully Assembled Systems:
Rack-mount cases such as those shown below may be used to create a self-contained portable system.
Inspired Energy recommends Gator or SKB cases. Please contact us if you wish to purchase a fully
assembled system.
These units must be operated
with the front & rear covers
both removed to allow
sufficient airflow.
Batteries MUST be removed for
shipping or moving a rack-
mounted system, and also
before connecting AC or DC
power to the unit.
CR12 rack mount smart charger systems are designed & built to order in the USA by Inspired Energy.
For pricing or additional information, please contact us at:
Inspired Energy, LLC 25440 NW 8th Place, Newberry FL 32669
US toll free: 1-888-5-INSPIRE (1-888-546-7747) Tel: [phone] Fax: [phone]
www.inspiredenergy.com
CR12
12-Bay, 19” Rack-Mount Charging System
Operating Instructions.
Features:
24V DC operation
Standard 19” rack mounting (3U)
Fits Inspired Energy N-Series battery packs
12 independent, simultaneous charge bays
Adjustable charge power on each charge bay
LED charging / fully charged indication on each charge bay
Can be mounted in multiples to provide any quantity of simultaneous charge bays
Optional +1kWh battery-array kit enables all 12 batteries to discharge simultaneously
Description:
The CR12 rack-mount unit contains 12 independent SMBus quick chargers, and can be ordered to fit the
following Inspired Energy brand batteries:
Battery Model
CR12 Rack Part Number
NL2050 / NL2054 / NH2054 / NH2057
CR12H205
ND2053 / ND2054 / ND2057
CR12D205
NL2044 / Ni2040 / NF2040 / NF2047
CR12i204
NC2040
CR12C204
NF2030 / ND2034 / ND2037
CR12D203
NB2037
CR12B203
Ni2020 / NJ1020
CR12i202
NC2560 / ND2017 / NL2020 / NL2024 / Ni1030 / P-series
Not supported
The CR12 fits standard 19" racks with 3 or more standard spaces (3U). It will simultaneously charge all
the batteries at their maximum rate, reducing the cycle time for multi-battery applications. The CR12
is designed only for use with Smart SMBus battery packs manufactured by Inspired Energy.
CAUTION: THERE IS A RISK OF EXPLOSION OR FIRE IF AN INCORRECT BATTERY IS INSERTED.
Specification Summary
Weight:
8lb / 3.6kg
Height:
5.25" / 133.4mm (3U)
Length:
10.5" / 266.7mm
Width:
19" / 482.6mm
(Std. 19" rack/DIN41494)
LED Displays
(12 total)
Green flash: Charging
Green solid: Charged
Red solid: Error
Power
Consumption
24VDC, <720W

Connecting to the CR12:
Each circuit board requires 24V DC via a 2.1mm x
5.5mm, positive-center, coaxial socket on the back of
each board.
A mating connector molded onto a 2-conductor cable
is provided for each board. The cables are 6’/2m long
& supplied un-terminated to allow your 24V DC power
supply to be located to suit your needs.
Ring terminals are supplied so that the DC power
cables can be summed together for attaching to your 24V DC power supply. The positive wire is
identified by a white stripe running the length of the cable.
Power Supply:
Full power operation requires a 24V DC, 800W power supply. Your choice of power supply depends on:
Your desired charge time
oCharge rate can be adjusted by a jumper on each circuit board.
The power available from your AC mains circuit
oMultiple rack systems may require special AC circuits to support the power demand
The number of batteries you require to be charged simultaneously
oMore batteries recharging simultaneously will require larger power supplies
The battery capacity.
oHigher capacity batteries require higher power to recharge at the maximum rate.
Budget.
oLarger power supplies cost more.
Inspired Energy recommends the following Meanwell 19” rack-mount power supplies :
RCP-1UI rack chassis + up to three RCP-1000-24 supplies (1kW, 24VDC each) for up to three CR12 units
RKP-1UI rack chassis + up to three RKP-2000-24 supplies (2KW, 24VDC each) for up to six CR12 units
Adjusting the power consumption:
Each charge board features a user-adjustable power feature to
limit the charge-power to the battery & reduce the power
consumption of the CR12 unit. This enables the user to alter the
power consumption to suit a specific power supply or to reduce
the battery charge rate.
Adjustment is made by a jumper
located at the top of each board
towards the rear of the unit.
The CR12 unit should be removed
from the 19” rack frame, but there is no need to remove the circuit board
from the CR12 unit.
Each board in the rack must have the jumper position changed in order to
limit its power consumption / charge rate.
In this way the overall rack power consumption can
be reduced to suit a lower cost power supply.
If desired, one or two bays may be left at full-power
to provide quick charge bays.
Sizing your 24V DC Power Supply:
The list below shows the power consumed by differing battery packs. Smaller, lower capacity batteries
consume less power. The power consumption of each board may be adjusted using the above method.
Battery
Model
Rack
Model
Charge
Voltage
Charge
Current
Board Power
Consumption
Rack Power
Consumption
Power supply
required/rack
NB2037
CR12B203
8.4V
1.5A
18W
211W
300W
NC2040
CR12C204
12.6V
1.5A
24W
287W
300W
ND2053
CR12D205
4.2V
4A
22W
262W
300W
ND2054
CR12D205
16.8V
1.5A
30W
362W
400W
ND2057
CR12D205
8.4V
3A
30W
362W
400W
NF2047
CR12i204
8.4V
3A
30W
362W
400W
ND2034
CR12D203
16.8V
1.5A
30W
362W
400W
ND2037
CR12D203
8.4V
3A
30W
362W
400W
NH2057
CR12H205
8.4V
4A
39W
463W
500W
Ni2040
CR12i204
12.6V
4A
55W
665W
700W
NF2040
CR12i204
12.6V
3A
43W
514W
600W
NF2030
CR12F203
12.6V
3A
43W
514W
600W
Ni2020
CR12i202
12.6V
4A
55W
665W
700W
NH2054
CR12H205
16.8V
3A
55W
665W
700W
NL2050
CR12H205
12.6V
4A
55W
665W
700W
NL2054
CR12H205
16.8V
3.5A
60W
720W
800W
NL2044
CR12i204
16.8V
3.5A
60W
720W
800W
Using this table, and factoring-in any reduction in power consumption for each board; a 24VDC power
supply can be sourced to suit the quantity of CR12 charger units required.
Sizing your AC Supply:
The modular design allows multiple 12-bay rack units to
be stacked to provide charging for any quantity of battery
packs. However, doing so may overload the available AC
mains circuits. Therefore it is necessary to assess the AC
power requirements prior to specifying a power supply.
A system such as this, using 3 CR12H205 units charging
NL2054 battery packs requires 24VDC 2.7kW. This
requires a 30A AC supply in 110V countries & a 15V AC
supply in 220V countries.
If the charge power is throttled back on each board as
described above, then the recharge time will increase,
but the power consumption can be reduced to 15W per
board / 540W for the system & the AC supply can more
easily handle the load.
Operation:
Plug a battery into an open battery slot. The LEDs will flash once upon correct insertion
The battery will automatically begin charging & the LEDs will indicate the charge status
Certifications:
The CR12 is CE & FCC compliant for emissions & immunity and is safety tested to EN60950
Jumper
Location
Charge Power
/ Board
Rack Power
Consumption
Top (default)
60W
720W
Center
30W
360W
Bottom
15W
180W