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 +386 (1) 514 18 00, F +386 (1) 514 18 04

[email protected], www.itaia.si

Table of contents

1. SAFETY INFORMATION AND CAUTION..........................................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.

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.

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

2

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

3

Our technical support

Litostrojska cesta 44/d, SI-1000 Ljubljana

T +386 (1) 514 18 00, F +386 (1) 514 18 04

[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

4

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

5

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

6

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

7

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.

Operating manual: ADP 400(s) / 800

8

3. Maintenance

3. 1. Checking and maintenance

It is recommended to:



clean front screen of the photometer (minimum 2 months interval),



clean the housing (1 year interval) and



recalibrate (3 year interval).

Note!

The device requires regular checking and maintenance. Keep your maintenance and

service log up to date. Shorten check intervals if required.

•Maintenance personnel must be job qualified;

•Maintenance contractor company must provide education and training;

•Regular testing and checking must be exercised as described in this manual

and local standards;

-Any maintenance activity must be noted in the log.

3. 2. Servicing

•Servicing can only be done by authorised qualified personnel.

•Keep servicing log.

Servicing for the time of warranty is provided by manufacturer exclusively, after this time it

can be done by approved maintenance contractor.

Operating manual: ADP 400(s) / 800

9

3. 3. Troubleshooting

Error

Possible cause

Action

No LED is lit Burned fuse Change fuse or call service

Charger is not charging Burned fuse. Change fuse or call service

Red and green LED are lit.

interval sound signal Battery is deteroprated

Burned fuse Change battery

Change fuse or call service

Blinking red and green LED Poor battery connection Check battery connection

Yellow LED is blinking.

Continuous sound signal False battery connection

polarity Check polarity

Never try to open or repair the charger yourself. In case of burned fuse replace with

same type and rating.

3. 4. Spare parts

Parts to be changed must be replaced with original or function equivalent parts approved

by device manufacturer.

Operating manual: ADP 400(s) / 800

10

4. Technical data

Basic technical data is shown on the front side sticker.

ADP 400 12V / 30A

Nominal voltage AC 230 V

Nominal power 400 W

Temperatur range -20 °C do +50 °C

Efficiency rate > 90 %

Output voltage DC 6-16 V

Max. output current 30 A

Max. peak current 60 A

Steering Microcontroler

Battery connection clips (D/P) 3 m / 10 mm

2

Mains connection(D) 10 m / 3x0,75 mm

2

Casing Aluminium

IP protection IP 54

Size 210 x 220 x 100 mm

Weight 4 kg

ADP 400s 24V / 15A

Nominal voltage AC 230 V

Nominal power 400 W

Temperatur range -20 °C do +50 °C

Efficiency rate > 92 %

Output voltage DC 6-30 V

Max. output current 15 A

Max. peak current 30 A

Steering Microcontroler

Battery connection clips (D/P) 3 m / 10 mm

2

Mains connection(D) 10 m / 3x0,75 mm

2

Casing Aluminium

IP protection IP 54

Size 210 x 220 x 100 mm

Weight 4 kg

ADP 800 12V / 60A – 24V / 30A

Nominal voltage AC 230 V

Nominal power 800 W

Temperatur range -20 °C do +50 °C

Efficiency rate > 88 %

Output voltage DC 6-30 V

Max. output current 30 A

Max. peak current 60 A

Steering Microcontroler

Battery connection clips (D/P) 3 m / 10 mm

2

Mains connection(D) 10 m / 3x0,75 mm

2

Casing Aluminium

IP protection IP 54

Size 210 x 220 x 110 mm

Weight 5,5 kg

Operating manual: ADP 400(s) / 800

11

4. 1. Environmental conditions

Maximum environmental temperature at use is +50 °C; 24 hour average temperature

must not exceed +35 °C. Lowest environmental temperature at use is –40 °C. Relative

air humidity must not exceed 50 % at maximum temperature +50 °C. Higher humidity is

allowed at lower temperature (like: 95 % at +20 °C).

Sea-level elevation must not exceed 2000 metres. When using above 1000 metres

consider lower air dielectricity and different cooling conditions.

4. 2. Transport and stocking

Transport the device in it’s original packing. If it is not available use protection air bubble

foil and protect exposed areas with styropor. If needed place it on wooden pallets.

Temperature while transporting and stocking should wary between –25 °C and +55 °C.

Avoid long time stocking. After transport and mounting, allow at least 1 hour time to

settle down before commission. In case that device is not to be used for longer period,

store it in dry, well ventilated place at room temperature!

4. 3. Disposal

Lifetime of the device significantly depends on the way of use, installation, maintenance and

the working conditions. Production year is visible on the back side sticker. Deteriorated or

ruined device dispose to the place for industry electronic-components disposal according to

local regulation.

Components particularly danger for environment (batteries, chemicals, etc.) dispose to

special places.

5. CE declaration of conformity

CE declaration of conformity ensures that device is safe for use and it has been checked

and testedto the specified standards. CE statement is enclosed.

6. Warranty obligations

Manufacturer of the device ensures that the product will work in accordance to specification

for the time of limited warranty of 1 year. For this time we take full responsibility and costs

(transport not included) for removal of any malfunction due to materials or workmanship.

Warranty does not cover any mechanical damage or damage being result of natural cause

or unprofessional use.

http://www.itaia.si, [email protected]

ES - IZJAVA O SKLADNOSTI

CE DECLARATION OF CONFORMITY

Manufacturer (name, address):

ITAIA d.o.o.

Litostrojska 44/d

1000 Ljubljana

We declare under our sole responsibility that

product: Power supply

type, model:

ADP 400, ADP 400S

ADP 800

is in conformity with the provisions of the following regulations:

-Directive 2006/95/EC and its amendments (Uradni list RS, št. 27/04)

-Directive 2004/108/EC and its amendments (Uradni list RS, št. 132/06)

and complies with the requirements of the following standards:

SIST EN 60335-1:2003 +A11:2004 +A1:2005 Household and similar electrical appliances-Safety-Part1

SIST EN 60335-2-29:2004 Household and similar electrical appliances-Safety-Part2

SIST EN 61204:1999 Low-voltage power supply devices, d.c.output-Performance

characteristics and safety requirements

SIST EN 60529:1997 +A1:2000 Degrees of protection provided by enclosures

SIST EN 61204-3:2002 Low-voltage power supply devices, d.c.output-Part3:EMC

Year of affixing of CE mark: 07

Peter Strmčnik, direktor

Ime in priimek, funkcija

Name, surname, position

Limited warranty conditions

Our products are workmanship and materials fault free and will work according to

specification for minimum time of warranty -1 year. We provide spare parts and servicing

for at least 5 additional years. We will respond to failure notice immediately, at maximum

7 days and fix it in maximum time of 48 working days.

For warranty period we take full responsibility and costs (transport not included) for

removal of any malfunction due to materials or workmanship. After this period we charge

servicing according to used time and replaced parts.

Warranty related obligations come in power with full payment.

Warranty obligations cease to exist:

•in case of improper use or use in discordance to this manual;

•in case of mechanical damage;

•in case of consequential damage due to failure or damage of other devices,

•in case of natural or environmental cause (e.g. lightning discharge, flooding, fire,

etc.),

•if the device has been repaired by unauthorized personnel,

•if there are unoriginal spare parts built in the device,

•if there are changes made to the device or their parts without written approval of the

manufacturer.

Servicing obligations cease to exist:

•if the device has been ruined,

•if the device has been repaired by unauthorized personnel,

•if there are unoriginal spare parts built in the device,

•if there are changes made to the device or their parts without written approval of the

manufacturer,

•for the time of overdue payment for previous services.

Sale Data: ___________ Serial number: _________________

Notes:

------------------------------------------------------------------------------

V 1.0 rev. 08.2011

Litostrojska cesta 44/d, SI-1000 Ljubljana

T +386 (1) 514 18 00, F +386 (1) 514 18 04

info@itaia.si, www.itaia.si

itaia ADP 400 User manual

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