Powerfinn Robust 1100/24 User manual

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Robust series Battery Chargers
Installation and User Manual
30.May.2017

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Table of Contents
Safety Instructions ...................................................................................................... 3
Installation .................................................................................................................. 4
Charging configuration................................................................................................ 6
Operation.................................................................................................................... 7
Indicators .................................................................................................................... 8
Troubleshooting and repair....................................................................................... 11
FCC/IC-information for optional radio module ......................................................... 12
General
Powerfinn Robust series chargers use modern switching technology. The intelligent
microcontroller extends the battery life by supervising the charging process. The
charger is compact, silent and meets the EU safety and EMC requirements.
For hardware specification, see separate document "Specification".
For detailed technical information, see "Robust technical handbook".
This document applies to software versions 5 and later, upto version 9, if not
otherwise stated.
Information is subject to change without notice.
Guarantee
The charger has a guarantee of two years from the date of purchase. Guarantee
covers manufacturing and component failures and is valid only if the equipment is
installed and used according to the instructions in this manual.
Keep the receipt as evidence of the date of purchase.

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Safety Instructions
In addition to the safety measures mentioned in chapter ‘Operations’, the following
personal precautions should be taken whenever charging batteries.
1. For emergency situations ensure in advance that help is available in time of need.
2. Batteries contain acid that is harmful to the eyes, skin and clothes. Always wear
overalls and safety goggles. Never touch the eyes with unwashed hands after
handling batteries.
3. Ensure that a working, fresh water tap is available. If acid gets into the eyes or on
the skin, immediately rinse the area with plenty of water for several minutes. If
visible injury occurs, contact a physician immediately. In case of eye injuries,
always contact a physician.
4. The charging process generates explosive hydrogen gas. Do not smoke or otherwise
bring burning or sparking matter to the vicinity of the battery when it is being
charged.
5. If a short circuit occurs, the battery may explode or the item causing the short
circuit may melt. Keep the work area clear from tools and debris. Remove jewelry,
watches, etcetera before working with the battery.
6. The power cord should be unplugged and the battery must be disconnected from
the charger in case the equipment is left unused for a longer period of time.
7. The charger must be located away from heat sources like radiators and heat
registers.
8. This device is not meant to be used by children or people whose physical, sensory or
mental attributes or lack of experience and knowledge prevent them from using the
device safely unless a person responsible for their safety supervises them or has
instructed them how to use the device.

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Installation
The charger should be installed indoors in a low humid area.
These instructions apply to all types of chargers produced at the time of writing; types
prefixed with "R" and "NSR".
The following points must be respected when installing the charger.
1. In fixed installation the operation temperature range is -35°C to +55°. Higher than
+40° ambient temperature will limit the output power.
2. The charging process generates explosive hydrogen gas. Install the charger as far
away from the battery as possible to prevent hydrogen gases from entering the
charger. Keep the space well ventilated. Never use an open flame or equipment
that produces sparks close to the battery or charger.
3. For unplugging the unit, make sure the wall socket is located in an easy access area.
Wall socket must provide protective earth terminal.
4. Install on concrete or other non-combustible surface only.
5. To ensure sufficient cooling, do not cover the charger. Leave a free space of at least
10 cm around all sides. For passive cooled model, leave 50 cm free space above
and below the charger. Passive cooled model is to be installed vertically, with
cable entry downward. Fan cooled model can be installed also horizontally.
Chargers are manufactured in various protection classes. IP class is usually marked
on the product label. If IP class is not marked, or it is IP20, charger should be
installed into a dry environment. To maintain protection class, install IP54 models
vertically, with cable entry downward. IP65 and IP66 models can be installed with
free orientation.

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Charger slides to mounting plate from above and can be secured using screws.
For fan cooled models, mounting plate is of different size but of similar type:

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Charging configuration
The charger voltage, charging algorithm and configured battery capacity should
correspond to the battery parameters. Attempting to charge a battery with wrong
charging configuration may result in considerable damage. For example, too large
configured battery capacity results in excessive charging current. Do not attempt to
charge non-rechargeable batteries.
When installing the charger, make sure that incompatible charger setups and batteries
cannot be connected together. Connector arrangement is a reliable method. Matching
battery type can be indicated by a label attached to the charger.
Voltage and number of cells
Chargers are available for a variety of battery voltages. Robust series chargers can
charge lead-acid batteries that have number of cells as follows:
charger type/ nominal voltage
number of cells in
the battery
nominal voltage of
the battery
1100/24, 2300/24, 3000/24
12
24
1100/36, 2300/36
18
36
1100/48, 2300/48, 3000/48
24
48
Also batteries with non-listed number of cells can be charged, if charger is properly
configured. For more information on this, see Robust series technical handbook.
Algorithm
Robust series chargers can charge freely ventilated and sealed lead-acid batteries.
Verify compatibility of the algorithm and the battery with your battery
manufacturer. For descriptions of algorithms, see Robust technical handbook,
chapter "Algorithms".
For step-by-step instructions on how to select an algorithm using the front panel,
see Robust technical handbook, chapter “Editing charging configuration”.
Capacity
Robust series chargers can charge lead-acid batteries that have nominal capacity
between 50 ... 2000 Ah.
For step-by-step instructions on configuring the battery capacity using the front panel,
see Robust technical handbook, chapter “Editing charging configuration”.

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Operation
Read these operating instructions carefully before using the charger for the first time.
Also read the chapter "Safety instructions" thoroughly. It must be ensured that
children do not play with the device.
To charge a battery with ”Robust" series charger, follow these instructions:
The factory default setting is
- Algorithm LK10-06 freely ventilated lead-acid
- Battery capacity 50 Ah
- Number of cells is set according to nominal voltage of the charger. For example
nominally 24 V charger is set to 12 cells.
To change the settings, see Robust technical handbook, chapter “Editing charging
configuration".
1. Ensure that the charger is unplugged and that the installation environment meets
the conditions described in chapter "Installation".
Warning: Explosive gases. Prevent flames and sparks. Provide adequate
ventilation during charging.
If charger has been stored in condensing or freezing temperature for an extended
period, allow it to warm up and dry for 12 h before operating.
2. Connect the charger cables to the battery terminals: the positive (+) cable to the
positive (+) terminal and the negative (–) cable to the negative (–) terminal. The
positive cable is red colored. The negative cable is black or blue.
Warning: Connection with wrong polarity might cause personal injuries and
damage the charger and battery.
3. Turn the power on by plugging the power cord in a mains outlet with protective
earth.
4. Charging starts automatically.
STOP
Pressing STOP will PAUSE charging. Pressing STOP again resumes charging.
F1 and F2
F1 and F2 buttons can be assigned various functionality. By default no function is
assigned, so pressing buttons during charging has no effect. Buttons are used when
settings are changed. See chapter “Editing charging configuration” in Robust
technical handbook.
5. To avoid sparking in output cables, press STOP button before disconnecting battery.

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Indicators
Mains is connected.
Radio module is ON. Charger can be assembled with optional radio
module. Module allows access to configuration and history log of the
charger.
Indicator definitions:
No light
Continuous
light
Flashing

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Indications:
Only blue mains indicator is lit. Charger is
waiting for a battery to be connected.
Green flashing: STOP pressed, charging
paused
Yellow continuously lit: main charging phase
Defined in charging algorithm. Also power
supply mode, power on.
Additional charging. Defined in charging
algorithm
Equalize charging. Defined in charging
algorithm
Charging ready, maintenance charging.
Defined in charging algorithm
Charging restricted by remote input
Alarm, no specific
Alarm, low battery voltage. Defined in
charging algorithm
Alarm, high battery voltage. Defined in
charging algorithm
Alarm, time limit exceeded. Defined in
charging algorithm
Alarm, Ah limit exceeded. Defined in
charging algorithm
Alarm, invalid charging parameters
Alarm, high charger temperature

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Alarm, low charger temperature or sensor
fault
Alarm, BMU init fail
Alarm, regulation fault
Alarm, battery error
Alarm, CAN timeout
Alarm, CAN slave timeout

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Troubleshooting and repair
If the cause of malfunction cannot be found, contact your retailer or the
manufacturer. If fuse is defective, charger has to be sent for control/repair. Only
authorized persons can repair the charger.
Determining operation mode
Charger has several operation modes; for example charger, SDO power supply and
several remote controlled power supply modes. Operation mode is not directly
indicated by front panel. Charger, SDO and PDO power supply mode can be read (and
set) using front panel; see section "Editing charging configuration" in Robust technical
handbook. Other modes can be read and set using CAN remote control; see Robust
series technical handbook.
Troubleshooting charger mode
Normal behaviour is as follows. Connect only AC input power cable. Only blue
indicator should be lit after startup (and small green if optional radio module is
installed). No voltage is present at power output. You can simulate battery with a
single quadrant DC power supply (capable of positive voltage output vs. its ground).
Power supply should be able to withstand counter voltage upto maximum output of
the charger, which is 1.5 * nominal voltage. After some seconds of suitable voltage
present at charger output, big yellow lits up and power output turns on. Since output
is not loaded, output voltage jumps to maximum. Charger considers this as
disconnected battery. Big yellow indicator and power output turn off. Capacitors
maintain voltage for some time. Disconnect the DC power supply. Voltage at DC cables
descends to zero in some seconds.
Troubleshooting SDO power supply mode
Normal behaviour is as follows. Connect only AC input power cable. Big yellow
indicator is lit after startup (in addition to small blue, also small green if optional radio
module is installed). Check using voltage meter that voltage is output according to
setting. Factory default settings are nominal voltage and maximum current. Voltage
and current setting can be read using CAN bus or optional radio module. For more
information on this, see Robust technical handbook or radio module documentation.
Troubleshooting PDO and other remote controlled power supply modes
Normal behaviour is as follows. Connect only AC input power cable. Only blue
indicator is lit after startup (and small green if optional radio module is installed).
Activating power output usually requires sending CAN messages. See Robust technical
handbook.

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FCC/IC-information for optional radio module
This product contains FCC ID: B7WACCESS, IC: 10687A-ACCESS.
------------------------------------------WARNING!-------------------------------------------------------
Changes/modifications not approved by the responsible party could void the user’s
authority to operate the equipment. This transmitter must not be relocated or
operated in conjunction with any other antenna or transmitter. This equipment
complies with FCC and IC radiation exposure limits set forth for an uncontrolled
environment. This equipment should be installed and operated keeping the radiator
at least 20cm or more away from person’s body (excluding extremities: hands, wrists,
feet and ankles).
----------------------------------------AVERTISSEMENT!------------------------------------------------
Les changements/modifications non approuvés par le parti responsable pourraient
invalider l'autorité de l'utilisateur à faire fonctionner l'équipement. Cet émetteur ne
doit pas être relocalisé ou être utilisé avec une autre antenne ou émetteur. Cet
équipement est conforme aux limites d'exposition de émissions de IC, FCC
résentéespour un environnement non contrôlé. Cet équipement devrait être installé
de façon à ce que l'antenne soit éloigné de 20 centimètres ou plus du corps humain
(en excluant les extrémités : les mains, les poignets, les pieds et les chevilles).
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