itaia ADP 400 User manual

Operating manual
Automatic-diagnostic lead-acid battery
charger ADP 400(s) / 800
ELECTRONICS
RESEARCH
DEVELOPMENT
Litostrojska cesta 44/d, SI-1000 Ljubljana
T [phone], F [phone]
[email protected], www.itaia.si

Table of contents
1. SAFETY INFORMATION AND CAUTION..........................................1
1. 1. G ENERAL ...............................................................................................1
1. 2. F IRE - EXTINGUISHING GEAR ....................................................................2
1. 3. S AFETY PRECAUTIONS ............................................................................2
2. GUIDELINE FOR CONNECTION AND USE ......................................4
2. 1. F IELD OF USE ..........................................................................................4
2. 2. C ONECTION OF CHARGING ......................................................................5
2. 3. I NDICATIONS AND HANDLING .................................................................6
2. 3. 1. Automatic-diagnostic charging ...................................................7
2. 3. 2. Fast charging ...............................................................................7
2. 3. 3. Discharge-charge.........................................................................7
2. 4. G UIDELINE FOR SAFE AND PROPER USE OF CHARGER ..............................7
3. MAINTENANCE.......................................................................................8
3. 1. C HECKING AND MAINTENANCE ..............................................................8
3. 2. S ERVICING .............................................................................................8
3. 3. T ROUBLESHOOTING ...............................................................................9
3. 4. S PARE PARTS ..........................................................................................9
4. TECHNICAL DATA...............................................................................10
4. 1. E NVIRONMENTAL CONDITIONS .............................................................11
4. 2. T RANSPORT AND STOCKING .................................................................11
4. 3. D ISPOSAL .............................................................................................11
5. CE DECLARATION OF CONFORMITY ...........................................11
6. WARRANTY OBLIGATIONS..............................................................11

Operating manual: ADP 400(s) / 800
1
1. Safety information and caution
1. 1. General
The device, connected and used in accordance with following instructions, is safe to use.
All electrical parts are protected against water, dust and dirt by the relevant IP class.
Housing prevents direct contact with any parts under voltage.
! CAUTION: For any injury resulting from improper use, the user
takes full responsibility.
!
BEFORE MOUNTING AND CONNECTING THE
DEVICE READ MANUAL CAREFULLY!
!
THE CONNECTING OF DEVICE MUST BE CARIED
OUT BY QUALIFIED PERSONNEL!
!
WHEN CONNECTING, DISCONNECT ELECTRICAL
POWER!
!
DO NOT BLOCK ACCESS TO ELECTRICAL PARTS
USED FOR EMERGENCY STOP, CLEANING AND
MAINTENANCE!
!
ALL METAL PARTS OF HOUSING MUST BE
GROUNDED!
!
MAKE SURE THAT WATER DOES NOT GET IN
TOUCH WITH PARTS UNDER VOLTAGE!
Connecting of the device must be done by qualified personnel and in accordance with
local standards. After mounting and connection control measurements must be carried
out to ensure safe and correct operation.
!

Operating manual: ADP 400(s) / 800
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1. 2. Fire-extinguishing gear
In case of fire use CO
2
based fire extinguisher and other equipment following procedures
in accordance with fire-safety regulations.
1. 3. Safety precautions
Safety precautions are meant to provide personal safety and long service life of device.
Any person take part of mounting, connecting or maintenance of the device must follow
this manual and local safety regulations. They have to be qualified for the job and use
appropriate technical equipment.
Before starting:
 Disconnect circuit breakers at input and output of the device and make
sure there is no voltage present.
 Make sure power is disconnected during the time of mounting and
connecting.
 Check the voltage presence with an instrument.
 Check grounding connection.
 Provide protection against touching the parts under voltage.
Qalified personnel
Transport, mounting, connecting, commissioning and maintenance of the device can
only be preformed by personnel:
 with job qualification and experience,
 familiar with up to date safety standards and
 with knowledge of basic working principles of the device.
Responsibility
We take no responsibility for proper operation and any consequences resulting from use
in discordance with this manual. Safety measures must be provided by user working with
device.
In case of malfunction, please, provide us following information:
 type of the device,
 serial number,
 errors detected,
 overall time of operation,
 environmental conditions and
 application information.

Operating manual: ADP 400(s) / 800
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Our technical support
Litostrojska cesta 44/d, SI-1000 Ljubljana
T [phone], F [phone]
[email protected], www.itaia.si
Declaration of conformity
The device complies with relevant European directives (CE declaration of conformity):
– Electromagnetic compatibility (ULRS, no. 132/2006)
Directive 2004/108/EC and its amendments
– Low voltage Directive (ULRS, no. 27/04)
Directive 2006/95/EC and its amendments

Operating manual: ADP 400(s) / 800
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2. Guideline for connection and use
2. 1. Field of use
Automatic charger ADP 400(s) / 800 is used for charging 12 or 24-volt Lead-Acid
bateries. It ensures proper charging of battery and providing best capacity and service
life of battery.
Basic element of charging system is microprocesor-based switching modul which
converts mains voltage into voltage suitable for battery charging. Microcontroller
supervises and controlls parameters for proper and safe charging for batteries. Soft-start
functin eliminates glitches when beeing switched on.
Main features of switching moduls comparing to regular transformers are:
•smaller dimensions
•lower mass (up to 15 times less)
•less heat disipation
•better responsivity.
ADP charger provides three charging modes:
•automatic diagnostic charging
•fast charging
•discharge/charge mode

Operating manual: ADP 400(s) / 800
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2. 2. Conection of charging
Charger must be placed away of heat sources, splashed water and dirt. Place must be
well ventilated and provided with heat exhaust. Mains power supply must be provided.
Connection is shown on Picture 1.
Take care of right polarity when connecting clips to the battery. When the charger is fully
connected we can switch on the main switch.
Picture 1: Battery charger connectionto battery
Picture 2: Connecting more batteries
For optimal result all batteries must be the same type, age and condition.
1 2 V / 3 0 A
I T A I A
e l e c t r o n i c s
N a p e t o s t : 2 3 0 V A C
F r e k v e n c a : 5 0 - 6 0 H z
N a z i v n a m o ~ : 4 0 0 W
L e t o i z d e l a v e : 2 0 0 5
+ + R D E ^ A - - M O D R A
2 X F 5 A
T i p :
I
0
mains connection
230 V AC

Operating manual: ADP 400(s) / 800
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2. 3. Indications and handling
In every of 3 modes, charger checks battery connection, condition, voltage and capacity.
Based on those data it defines charging time and current. Charging is set to optimal voltage
and current. When battery is full, charger goes to maintenance state. In this state it checks
charge regularly and if needed add some more charge to the battery. Time in this state can
be unlimited. When battery is disconnected, it is always fully charged and in optimal
condition. Charging/maintenance is indicated on control LED-s. Meaning of control lights and
sound signals during charging is shown In table 1.
CHARGING MODES SOUND SIGNAL RED GREEN YELLOW
Automatic – diagnostic
Charging - blinking blinking -
Fast charging - blinking - -
Discharge – charging - - blinking -
ACTIVITY STATE SOUND SIGNAL RED GREEN YELLOW
Charging - ON - -
Maintenance - - ON -
SOUND SIGNAL RED GREEN YELLOW
FALSE CONNECTION continuos sound
signal - - blinking
CHARGER FAULT interval sound signal
ON ON -
BATTERY FAULT interval sound signal
ON ON -
Table 1: Meaning of control lights and sound signals
You can always check charging mode durring charging by pressing a button. After this
control LED-s shows charging mode for 10 seconds.
You can choose or change charging mode with doubble press on the button durring
charging, or pressing the button during the charging mode indication. Charging mode
changes cyclic: Automatic charging – Fast charging – Discarge-charge charging.
When battery is damaged or deteriorated, charger will sond continuos sound signal. At the
same time red and green LED will lit continuosly. The same indication also shows burned
fuse in the charger.

Operating manual: ADP 400(s) / 800
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2. 3. 1. Automatic-diagnostic charging
This mode is most offtenly used and is choosen automaticly when charger is switched on.
We can always change to this mode by pressing the button. After 10 seconds charger
begins charging - red LED is on, orgreen LED is on when battery is fully charged.
In this mode charger checks connection, battery condition, voltage and capacity. Based on
those data it defines charging time and current. Charging is set to optimal voltage and
current. When battery is full, charger goes to maintenance state. In this state it checks
charge regularly and if needed add some more charge to the battery. Time in this state can
be unlimited. When battery is disconnected, it is always fully charged and in optimal
condition.
Automatic charging envolve 3 states: battery condition detection, charging the battery,
maintenance in fully charged condition.
2. 3. 2. Fast charging
Fast charging is done with the fastest but still safe current for battery and it provides the
biggest possible charge in lowest time. After the charging, charger goes to maintenance
state (the same as in automatic mode). We can always change to this mode by pressing the
button. After 10seconds charger begins charging.
This charging technique is only recommended to use in rare occasion when time limit is
short.When using this mode frequently, battery service lifecan be reduced.
2. 3. 3. Discharge-charge
Discharge-charge is best way to maintain optimal capacity and life service of battery, but can
be very time consuming. After connection battery is safe discharged completely and then
slowly charged with optimal charge. This mode eliminates so called memory effect on the
batteries, resulting from unproper charging or discharging.
We can always change to this mode by pressing the button. After 10 seconds charger
begins discharde-charging process.
2. 4. Guideline for safe and proper use of charger
•Chargingthe battery must be done indoors or in weather protected places
•During charging proper ventilation of the room must be provided
•Always connect charger only to grounded main supply socked
•Use charger only for charging of Lead-Acid batteries
•Battery capacity should be between 45 and 300 Ah , 12 or 24 V
•When paralel charging of more batteries, they should be all of the same type, age
and condition
•CAUTION! During charging charger surface can become hot.