protech BFS-180 User manual

BFS-180
User Guide
EV Works Dual Power Supply Version
Product of:
143A Hepburn Road Tel [phone]
Glendene Fax [phone]
Auckland 0602 www.ProTechNZ.com
New Zealand [e-mail]

BFS-180
User Manual
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Table of Contents
Specifications ........................................................................................................... 4
Features....................................................................................................................4
Connecting the charger .......................................................................................... 5
Connecting Single Phase .....................................................................................5
Connecting Three Phase....................................................................................... 5
Connecting and Disconnecting the Battery....................................................... 5
User Inputs and Outputs .....................................................................................5
User Interface.......................................................................................................... 6
The Charger Buttons ...........................................................................................6
The Menu Basics ....................................................................................................6
Backlight Time-Out ................................................................................................ 7
Starting a Charge................................................................................................. 7
Stopping a Charge ................................................................................................ 7
Lithium Ion Charging ................................................................................................8
How a Lithium Ion Charge Works......................................................................... 8
How to Setup a Lithium Ion Charge..................................................................... 8
How to Start/Stop a Lithium Ion Charge............................................................9
Lead Acid Charging ................................................................................................10
How a Lead Acid Charge Works .........................................................................10
How to Setup a Lead Acid Charge.....................................................................10
How to Start/Stop a Lead Acid Charge ............................................................11
Power Limits............................................................................................................11
How Power Limits Work ......................................................................................11
How to Setup Power Limits ................................................................................11
Data Logging...........................................................................................................12
How the Data Logging Works ............................................................................12
How to Setup the Data Logging ........................................................................12
Misc Setup...............................................................................................................13
How to Lock/Unlock the System........................................................................13
How to Change the Lock Password ..................................................................13
How Auto Charge Works ....................................................................................13
How to Enable/Disable the Auto Charge..........................................................13
Trouble Shooting ...................................................................................................14
Error Conditions ................................................................................................14
Retrieving Software Revision Number ..............................................................14
Reprogramming Firmware ....................................................................................15
Appendix A, Boot Screens .....................................................................................17
Appendix B, Lithium Charge Screens ....................................................................18
Appendix C, Lead Acid Charge Screens ................................................................19
Appendix D, Main Menu Screens............................................................................20

BFS-180
User Manual
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Appendix E, Charge Profiles Menu Screens ........................................................21
Appendix F, Edit Lithium Profile Screens ............................................................22
Appendix G, View Lithium Profile Screens............................................................23
Appendix H, Edit Lead Acid Profile Screens........................................................24
Appendix I, View Lead Acid Profile Screens .........................................................25
Appendix J, Data Logging Screens .......................................................................26
Appendix K, Power Limits Screens ........................................................................26
Appendix L, User Interface Screens ....................................................................27
Appendix M, Input / Output Screens .....................................................................27
Appendix N, Error Screens ...................................................................................28
Appendix O, Other Options Screens.....................................................................29
Appendix P, Software Version Screen..................................................................29
Appendix Q, Device Manager ..................................................................................30
Appendix R, User Inputs/ Outputs Layout............................................................30
Appendix S, Programming Firmware.......................................................................31

BFS-180
User Manual
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Specifications
-Automatic dual mode operation
-Adjustable Output: 120-180VDC
-Adjustable Power: 300W-5400W
-Adjustable Current: 10A-30A
-Weight: 10.4kg (including 5m Mains Cables)
-Size: 370 x 160 x 170mm
-Efficiency: Maximum of 92% (under full load conditions)
-2 x Inputs suitable for interfacing with a BMS
-2 x Dry Contact Outputs for Status/Alarm signalling
-1 x RS232 Comprehensive Data Logging Output
-Fully power factor corrected (PF = 0.99)
-Operating temperature: -40 to +70 deg C
Features
-User interface via LCD screen and buttons to provide user feedback
and programming interface
-Over temperature protected
-Short circuit protected
-Reverse Polarity Protected
-Fan forced cooling
-Industry standard Grey) SB-50 'Anderson' output connector
-Firmware Upgradable
-1 year warranty

BFS-180
User Manual
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Connecting the charger
Both mains cables should be terminated in a suitable fashion before use.
-Five core cable = three phase, neutral and earth connection
-Three core cable = single phase, neutral and earth connection
The three phase connection MUST be connected with the neutral wire in place
(ie. All 5 wires must be connected) and must be rated to at least 30A. The
single phase connection must be rated to at least 10A.
Connecting Single Phase
-Blue - Phase 1
-Grey - Phase 2
-Brown - Phase 3
-Black - Neutral
-Green - Earth
Connecting Three Phase
-Brown - Phase
-Blue - Neutral
-Green - Earth
Connecting and Disconnecting the Battery
The battery stack gets connected through the Anderson connector on the
right side of the charger. An active charge profiles must be stopped (by
holding the “Back” button and waiting for the charge sequence to finish as
shown in Appendix B, Lithium Charge Screens and Appendix C, Lead Acid
Charge Screens ) before disconnecting the battery stack. Once finished, the
battery stack can be safely removed. The charger will not start a charge
without a battery connected so it is impossible to connect the battery at the
„wrong time‟.
User Inputs and Outputs
The ProTechNZ BFS-180 has a RS232 port and a 12 pin connector for user
inputs and outputs. These inputs provide BMS Inputs for current limiting and
shut down as well as dry contact outputs for two alarms. These features
are setup in the menu as displayed in Appendix M, Input / Output Screens on
page 27. The connections to the connector are as follows.
1. Temperature Probe One Positive
2. Temperature Probe Ground
3. Temperature Probe Two Positive
4. Power On Relay, Normally Open
5. Power On Relay, Normally Closed
6. Power On Relay, Common
7. User Defined Relay, Normally Open
8. User Defined Relay, Normally Closed
9. User Defined Relay, Common
10. BMS Shutdown Input
11. BMS Input Ground
12. BMS Current Limit Input
A visual representation of the layout and pin numbers can be found in
Appendix R, User Inputs/ Outputs Layout on page 30

BFS-180
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Temperature Probes
The temperature probe feature is not currently implemented but will be used
for temperature compensation on Lead Acid batteries as well as general data
logging. The temperature probes will be available from ProTechNZ at a later
date.
Power On Relay
This relay will turn on when the ProTechNZ BFS-180 charger turns on. This
feature can be enabled and disabled as seen in Appendix M, Input / Output
Screens on page 27.
User Defined Relay
This relay can be setup to enable on a start of charge and/or on any errors.
The setup for this is done as explained in Appendix M, Input / Output Screens
on page 27.
BMS Inputs
The BMS inputs are designed to be shorted to the available ground using a
Dry Contact Relay, Silicon Device (MOSFET, BJT), SSR, Button or Switch.
When the BMS inputs are shorted to ground, the feature is active. These
features can be enabled and disabled as seen in Appendix M, Input / Output
Screens on page 27.
User Interface
The Charger Buttons
There are four buttons on the ProTechNZ BFS-180 charger. The four
buttons are, from left to right, Back, Enter, Down and Up. These buttons
help you navigate through the menu of the ProTechNZ BFS-180 charger. The
Back and Enter buttons also have a second use; they start or stop a charge.
This is covered in the Starting a Charge section on page 7 and Stopping a
Charge section on page 7
The Menu Basics
Menu Navigation
The menu is based on a simple structure that lets you navigate and setup the
ProTechNZ BFS-180 charger with ease. To enter the menu, press the Enter
button once the unit has powered on and has completed its initialization as
shown in Appendix A, Boot Screens on page 17. Once you are in the menu, you
can press the up and down button to select a menu. Once a menu is selected
you can go deeper into that menu to select a sub function or to save a
variable by pressing the Enter button. To go back up a level, simply press the
Back button and you will go back up to the previous menu of the ProTechNZ
BFS-180 charger.
The main menu items are laid out as in Appendix D, Main Menu Screens on page
20. For specific menu items, see the appropriate appendix at the end of the
document.

BFS-180
User Manual
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ProTechNZ BFS-180 boot up
The charger will boot up when power is applied to the mains. When the unit
boots up, it will display what the settings for the current profile are and
what power mode it is in. Sample boot screens are shown in Appendix A, Boot
Screens on page 17 and High power and Low power mode are explained in the
Power Limits section on page 11.
Backlight Time-Out
The timeout of the backlight can be set from zero to ten minutes. On top of
this it can also be set to always on. This menu is shown in Appendix L, User
Interface Screens on page 27. The backlight will time out based on the last
button press. The menu will time out and return to the ProTechNZ BFS-180
main menu thirty seconds after the last button press, or ten seconds after
the backlight turns off, whichever is longest. If the backlight is set to
always on, the menu will time out thirty seconds after the last button press.
Starting a Charge
To start a charge, the ProTechNZ BFS-180 charger must first be connected
to a battery and have the charge settings initialized. The factory shipped
settings may damage your batter stack.
The first charge is started by going into the menu and selecting the “Start
Profile” option in the menu of the charge profile you wish to use. This profile
becomes the default profile and the charge will begin. The charge profiles
menu is shown in Appendix E, Charge Profiles Menu Screens on page 21
Once a default profile is set, the ProTechNZ BFS-180 charger can start a
charge by pressing and holding the Enter button until the Start Charge
screen appears as shown in Appendix B, Lithium Charge Screens on page 18
and Appendix C, Lead Acid Charge Screens on page 19.
Stopping a Charge
A lithium charge profile has a defined end so it will eventually stop charging
on its own accord. A Lead Acid charge does not have a defined end. To end
any charge before it comes to its own finish, hold the Back button until the
disconnect sequence is started as shown in Appendix B, Lithium Charge
Screens on page 18 Appendix C, Lead Acid Charge Screens on page 19. The
ProTechNZ BFS-180 will now equalize the voltages between the unit itself
and the battery stack and once that is done, it will disconnect the battery
stack so that it is safe to remove. Alternatively, turning off the AC mains
will completely depower the unit and make it safe for disconnection.

BFS-180
User Manual
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Lithium Ion Charging
How a Lithium Ion Charge Works
The ProTechNZ BFS-180 charger uses the Constant Current, Constant
Voltage charge profile (CC-CV). A CC-CV charge profile will charge a battery
by setting up a voltage and a charge current. Once the battery stack
reaches this voltage, the current will start to fall away and after a set
amount of time, the charge will finish.
How to Setup a Lithium Ion Charge
To setup a Lithium Ion charge, you must setup a number of parameters before
you can use the charge profile in the ProTechNZ BFS-180 charger. These
settings can be found in the menu under Charge Profiles/Lithium CC CV x/Edit
Settings/. The ProTechNZ BFS-180 can hold four different Lithium CC-CV
profiles. The menu screens are shown in Appendix D , Main Menu Screens ,
Appendix E , Charge Profiles Menu Screens and Appendix F , Edit Lithium
Profile Screens.
Number of Cells
The number of cells in your battery stack. This value is automatically limited
so that the stack voltage (number of cells x voltage per cell) stays within
the available range of the BFS-180. If you cannot select the right number of
cells, please set the Voltage per Cell as instructed below first.
Voltage per Cell
The voltage per cell of your battery stack. This value is automatically limited
so that the stack voltage (number of cells x voltage per cell) stays within
the available range of the BFS-180. If you cannot select the right voltage
per cell, please set the Number of Cells as instructed above first.
Current Limit
The current limit during Constant Current charging. This value is adjustable
from 10A to 30A. The Current Limit may not be in obtainable if Power Limits
on page 11 is set lower than the Current Limit required.

BFS-180
User Manual
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End of Charge
The time spent in Constant Voltage mode. The total time of this step of the
profile is set by adding both Percentage of Constant Current Time and Fixed
Time together.
Percentage of Constant Current Time
A percentage of the amount of time spent in Constant Current mode can be
used to determine the time spent in constant voltage mode. If not required,
simply set to 0%. E.g. if the constant Current took one hour and this setting
is set to 75%, the unit will stay in Constant Voltage mode for 45 minutes.
Fixed Time
A set time can be used to determine how long to remain in Constant Voltage
mode. The set time is adjustable from one minute to four hours. If not
required, simply set to 1 minute.
Profile Name (optional)
You can name each profile in the ProTechNZ BFS-180 with your own 7
character name. This it to be able to easily select the correct charge profile
when using the ProTechNZ BFS-180 charger on multiple battery stacks.
Maintain Voltage (optional)
The ProTechNZ BFS-180 can automatically restart a charge when the battery
voltage drops below a set voltage. This is suitable for maintaining a battery
stack if it will not be used for an extended period of time. When this is setup,
the unit will continuously monitor the battery after a charge. To cancel this
feature temporarily, simply hold the Back button if the ProTechNZ BFS-180
displays the maintain battery screen as shown in Appendix B, Lithium Charge
Screens on page 18.
How to Start/Stop a Lithium Ion Charge
Starting a Lithium Ion charge is done by going into the menu and navigating
to the desired charge profile and selecting Start Profile as shown in
Appendix E, Charge Profiles Menu Screens on page 21. Entering this menu
will start the charge and save the selected profile as its default profile.
This menu is displayed in Appendix E, Charge Profiles Menu Screens on page
21.
The default profile can now be quick started using the Enter and Back
buttons as explained in sections Starting a Charge and Stopping a Charge
under the
User Interface on page 6.

BFS-180
User Manual
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Lead Acid Charging
How a Lead Acid Charge Works
The lead acid charging of the ProTechNZ BFS-180 charger is done using a
three stage boost, absorption, float profile. The boost stage brings the
battery stack up to voltage and equalizes the cells in the stack. Once the
boost voltage has been reached, it will go into absorption mode. In this mode
we will wait for the current draw to drop below a specific value. Once that is
reached, we will lower the voltage of the charger to the float voltage, the
charge is then effectively complete and the battery can be left connected
indefinitely as a maintenance charge.
How to Setup a Lead Acid Charge
To set up a Lead Acid charge, you must setup a number of parameters before
you can use the charge profile in the ProTechNZ BFS-180 charger. These
settings can be found in the menu under Charge Profiles/3St. Lead Acid x/Edit
Settings/. The ProTechNZ BFS-180 can hold two different Lead Acid profiles.
The menu screens are shown in Appendix D, Main Menu Screens , Appendix E,
Charge Profiles Menu Screens and Appendix H, Edit Lead Acid Profile
Screens.
Boost Voltage
This is the voltage we will boost the battery to. A recommended value for
this is 2.4V per cell, or 57.6V for a 48V battery.
Boost Current
The current limit during Boost charging. This value is adjustable from 10A
to 30A. The Current Limit may not be in obtainable if Power Limits on page 11
is set lower than the Boost Current required. A recommended value for a
fast charge is C/4 and a regular charge is C/8, where C is the capacity of the
battery stack in Amp Hours.
Absorption End Current
If the battery stack drops below this value, we move into float mode. A
recommended value for this is C/50 where C is the capacity of the battery
stack in Amp Hours.