Tell Way Energy DCM 200-600V/0-120A User manual

Instruction Manual
For
Lithium Ion Rechargeable Battery Charger
ConceptionⅠ
ⅠⅠ
Ⅰ
Lithium ion rechargeable battery charger can adjust and control the charging parameters with its
constant current & voltage charging mode. Along with BMS, it can protect the Li-ion batteries under
the ollowing circumstance: Over Voltage (OV), Under Voltage (UV), Over Current (OC), Short Circuit
(SC) and Over Temperature (OT), and/or emergencies.
Be ore charging, when any cell in the battery pack appears OV, charging will be prohibited
automatically. Recharging can be started unless the ailure is solved.
During charging, when any cell in the battery pack appears OV, OC, OT, BMS should give signals,
and the charger will automatically adjust the charge voltage and current to prevent the cells rom OV,
OC.
During charging, i the operating termperature is too low, BMS will give signals to warn the users
that they should take actions, and adjust charging methods at low temperature according to the
Instruction Manual for Lithium Power Battery (hereina ter “Li Battery Manual”).
During charging, i any abnormal circumstance occurs, such as too high voltage, BMS short
circuit, too high temperature and so on, BMS will give signals, burn out the main circuit use and cut
the power supply to the charger.
Ⅱ
ⅡⅡ
Ⅱ Charging mode, methods and controlling functions
1. Charging mode
Constant current & voltage charging mode
2. Charging methods and controlling unctions
1) Constant current charging mode
In the beginning o charging, charge the cells under constant curent at its limit maximum
(Generally, max curent ≤ 0.3CA, CA means the charge and discharge current, C means Capacity, A
means Ampere, 0.3CA means the current is 0.3 times o the capacity). During constant current charging,
the charge current keeps the same, but the charge voltage will gradually increase until it reaches the
limit maximum charge voltage.
2) Constant voltage charging mode
When the charge voltage reaches the limit maxium charge voltage (according to the Li Battery
Manual ), then it will be under constant voltage charging mode. At this moment, charge current will
decrease as time goes by. When it reaches at 0.015CA, charging stops. You can re er to the ollowing
charging procedure chart, it shows the relation among charge voltage, current and capacity.

2
4.0
3.0
2.0
1.0
0
charging time
charging
completed
charging current
0.3CA
nX4.25V(total)
charge volage
0
0.1
0.2
0.3
0.4
(CA)
(V)
charging
stop
(Ah)
400
300
200
100
0
charge capacity
consant current
charge
consant voltage
charge
0.0 5CA
charge voltage(xn)
charge current charge capacity
3) Adjust voltage automatically
During charging, especially when it is under constant voltage charging mode, i the charge voltage
o any cell in the battery pack exceeds the limit (Generally, limit charge voltage is 4.3V), the charger
can decrease the charge voltage and current to prevent the cell rom OV charging.
4) Prohibit charging automatically
Be ore charging, i the voltage o any cell in the battery pack is less than 2.5V (or 2.8V), the
charger will cut charging automatically. When it is con irmed that it can be charged again, the charger
will automatically adjust the charge current to 1/3 o that in constant charging mode. Only when the
battery voltage reaches 2.5V (or 2.8V), the charging mode will be nomal. When the charge current
decrease to 0.015CA, charging stops.
5) OT protection
During charging, i the temperature o the battery is higher than 75 ℃ , the charger will
automatically decrease the charge current until charging stops.
6) OC, SC protection
During charging, i the charge current is too high or any short circuit occurs, the charger will stop
charging automatically.
Charger operation mⅢ
ⅢⅢ
Ⅲethod and standard
1. Preparation
1) Pay attention to the positive and negative pole o the 12V power-supply, DON’T connect them
in a wrong way.
2) Set the “Power Switch” to “OFF”, and connect AC 380V power-supply, the input is AC 380V
3-phase 4-line system. Connect the yellow green cable with neutral cable, and connect the cable outside
the charger with the earth wire.
3) Set the “Power Switch” (which is only equipped on the medium power charger) on the charger
board to “OFF”; Set the “Charging Switch” to “Adjust”; Set the “Voltage Adjust” button & “Current
Adjust” button clockwise to minimum, then rotate 1/4 circle anti-clockwise.

3
4) Connect the battery pack charging lead with the charger, tighten it clockwise. Pay attention to
the positive and negative pole, DON’T connect them in a wrong way.
2. Start to charge
1) Switch on the AC 380V power-supply, the charger in turn. 8 seconds later, the charger starts to
work.
2) Check the status o the battery pack; I it is abnormal or any ailure occurs, deal with the ailure
irst, then charging is allowed.
3) Under the circumstances that the “Charging Switch” is set to “Adjust”, rotate the “Charge
voltage” button clockwise to set the charge voltage under constant voltage charging mode (the voltage
= N×4.25V, N stands or the quantity o batteries connected in series, 4.25V is the maximum charge
voltage o a single cell. Di erent battery model and temperature will result in di erent maximum
charge voltage. Detail technical in ormation please re er to the Li Battery Manual ). During adjustment,
i the green indicator light is on (30 seconds later the green indicator light will be on), press the “UV
Recharge” button, continue to adjust until it reaches to the limit voltage.
4) Set the “Charging Switch” (which is on the charger board) to “Charging”, then charging begins;
Rotate the “Charge current” button to set the charge current under the constant current charging mode
(Generally, the current ≤ 0.3CA).
5) When charging begins, i UV occurs violently in any cell, the UV indicator light will be on and
there is no voltage output, charging is not allowed. Only a ter the ailure is solved, press the “UV
Recharge” button, the charger begins charging slow, which is 1/3 o that under constant current
charging mode. When the voltage o this cell increases to the “UV alarm” voltage, the charging mode
will be nomal again.
6) I the battery quantity decreases, reset and re-adjust the charge voltage under constant charging
mode according to the methods mentioned above.
3. Observation during charging
Since the charging proceeds automatically, users only need to check at times the charger. I any
abnomality or ailure occurs, deal with it immediately.
During charging, i you need a pause, you can set “Charging Switch” to “Limit Voltage”. At this
moment, there is no voltage output, the charge capacity will stay the same. I the power is o , the
capacity data display will disappear. And because once the maxium capacity exceeded, it will go back
to “zero” and circle again, so DO memorize the circle times.
4. Charge complete
When the charge voltage reaches the limit voltage under constant charging mode, the charge
current decreases to (generally) 0.015CA, and has a limited time lapse, the charger stops charging
automatically. Cut the power-supply and remove the charging lead rom the battery pack.
I you need to stop charging hal way, set the “Charging Switch” to “Adjust” irst, then cut the
power-supply and remove the charging lead rom the battery pack.
IV Technical Specification of the charger

4
Technical Specification of the charger（1）
Charger Model DCM
200-600V/0-120A
DCM
460-600V/0-100A
DCM
100-425V/0-80A
Output Power 72kw 60kw 34kw
Power-Supply AC3-380V/ 50Hz AC3-380V/ 50Hz AC3-380V/ 50Hz
Output Voltage
DC200～600V DC460～600V DC100～425V
Output Current
DC0～120A DC0～100A DC0～80A
Efficiency ≧93 ≧93 ≧93
Fuse ： 290A Fuse ： 240A Fuse ： 140A
Input Protection
Disconnect ： 360A Disconnect ： 300A Disconnect ： 170A
Input ≧28 ㎜² Input ≧25 ㎜² Input ≧14 ㎜²
Output ≧25 ㎜² Output ≧20 ㎜² Output ≧16 ㎜²
Requirement o
cable section
Earth wire ≧16 ㎜² Earth wire ≧16 ㎜² Earth wire ≧16 ㎜²
Dimension
H×A×B 600×530×1185 mm 620×580×1115 mm 600×490×970mm
Weight 175kg 145kg
95kg
Technical Specification of the charger（2）
Charger Model DCM
4-258V/0-120A
DCM
28-280V/0-100A
DCM
100-180V/0-120A
Output Power 30．96 kw 28 kw 21．6 kw
Power-Supply AC3-380V/ 50Hz AC3-380V/ 50Hz AC3-380V/ 50Hz
Output Voltage
DC4～258V DC28～280V DC100～180V
Output Current
DC0～120A DC0～100A DC0～120A
Efficiency ≧93 ≧93 ≧93
Fuse ： 125A Fuse ： 115A Fuse ： 86A
Input Protection
Disconnect ：155A Disconnect ：140A Disconnect ：110A
Input ≧12 ㎜² Input ≧12 ㎜² Input ≧8 ㎜²
Output ≧25 ㎜² Output ≧20 ㎜² Output ≧25 ㎜²
Requirement o
cable section
Earth wire ≧12 ㎜² Earth wire ≧12 ㎜² Earth wire ≧8 ㎜²
Dimension
H×A×B 600×490×970mm 540×460×810mm 540×460×660mm
Weight 87kg 75kg
62kg
Technical Specification of the charger（3）
Charger Model DCM
100-430V/0-50A
DCM
4-4．25V/0-200A
DCM
60-260V/10-30A
Output Power 21．5kw 8．5kw 7．8 kw
Power-Supply AC3-380V/ 50Hz AC3-380V/ 50Hz AC3-380V/ 50Hz
Output Voltage
DC100～430V DC4～4。25V DC60～260V
Output Current
DC0～50A DC0～200A DC10～30A
Efficiency ≧93 ≧93 ≧93
Input Protection
Fuse ： 86A Fuse ： 34A Fuse ： 70A

5
Disconnect ：110A Disconnect ：43A Disconnect ：88A
Input ≧8 ㎜² Input ≧4 ㎜² Input ≧8 ㎜²
Output ≧10 ㎜² Output ≧35 ㎜² Output ≧6 ㎜²
Requirement o
cable section
Earth wire ≧8 ㎜² Earth wire ≧8 ㎜² Earth wire ≧8 ㎜²
Dimension
H×A×B 540×460×660mm 330×500×570mm 460×310×420mm
Weight 62kg 37kg
28kg
Technical Specification of the charger（4）
Charger Model DCM
20-32V/100-180A
DCM
50-85V/30-50A
DCM
18-60V/6-60A
Output Power 5．76kw 4．25kw 3．6kw
Power-Supply AC3-380V/ 50Hz AC220V/ 50Hz AC220V/ 50Hz
Output Voltage
DC20～32V DC50～85V DC18～60V
Output Current
DC100～180A DC30～50A DC6～60A
Efficiency ≧93 ≧93 ≧93
Fuse ： 86A Fuse ： 34A Fuse ： 70A
Input Protection
Disconnect ：110A Disconnect ：43A Disconnect ：88A
Input ≧55 ㎜² Input ≧40 ㎜² Input ≧32 ㎜²
Output ≧70 ㎜² Output ≧50 ㎜² Output ≧40 ㎜²
Requirement o
cable section
Earth wire ≧6 ㎜² Earth wire ≧4 ㎜² Earth wire ≧4 ㎜²
Dimension
H×A×B 440×470×580mm 500×265×200mm 460×170×280mm
Weight 39kg 12kg
11．5kg
Technical Specification of the charger（5）
Charger Model DCM
20-60V/10-60A
DCM
2-34V/0-100A
DCM
10-60V/10-50A
Output Power 3．6 kw 3．4 kw 3kw
Power-Supply AC110V/ 50Hz AC3-380V/ 50Hz AC220V/ 50Hz
Output Voltage
DC20～60V DC2～34V DC10～60V
Output Current
DC10～60A DC0～100A DC10～50A
Efficiency ≧93 ≧93 ≧93
Fuse ： 86A Fuse ： 34A Fuse ： 70A
Input Protection
Disconnect ：110A Disconnect ：43A Disconnect ：88A
Input ≧65 ㎜² Input ≧13 ㎜² Input 缆 ≧27 ㎜²
Output ≧82 ㎜² Output ≧17 ㎜² Output ≧35 ㎜²
Requirement o
cable section
Earth wire ≧6 ㎜² Earth wire ≧2 ㎜² Earth wire ≧3 ㎜²
Dimension
H×A×B 460×170×280mm 460×170×280mm 170×420×260mm
Weight 11．5kg 11．
5 kg
11kg
Technical Specification of the charger（6）

6
Charger Model DCM
2-65V/0-40A
DCM
20-60V/10-30A
DCM
30-77V/10-21A
Output Power 2．6 kw 1．8 kw 1．6 kw
Power-Supply AC110V/ 50Hz AC3-380V/ 50Hz AC220V/ 50Hz
Output Voltage
DC20～60V DC2～34V DC10～60V
Output Current
DC10～60A DC0～100A DC10～50A
Efficiency ≧93 ≧93 ≧93
Fuse ： 86A Fuse ： 34A Fuse ： 70A
Input Protection
Disconnect ：110A Disconnect ：43A Disconnect ：88A
Input ≧65 ㎜² Input ≧13 ㎜² Input ≧27 ㎜²
Output ≧82 ㎜² Output ≧17 ㎜² Output ≧35 ㎜²
Requirement o
cable section
Earth wire ≧6 ㎜² Earth wire ≧2 ㎜² Earth wire ≧3 ㎜²
Dimension
H×A×B 460×170×280mm 170×300×160mm 170×300×160mm
Weight 11．5kg 7．5 kg
7．5kg
Technical Specification of the charger（7）
Charger Model DCM
30-85V/10-17A
DCM
30-85V/10-17A
DCM
18-60V/6-20A
Output Power 1．45 kw 1．45 kw 1．2 kw
Power-Supply AC110V/ 50Hz AC220V/ 50Hz AC220V/ 50Hz
Output Voltage
DC30～85V DC30～85V DC18～60V
Output Current
DC10～17A DC10～17A DC6～20A
Efficiency ≧93 ≧93 ≧93
Fuse ： 13A Fuse ： 13A Fuse ： 11A
Input Protection
Disconnect ：32A Disconnect ：16A Disconnect ：13A
Input ≧2 ㎜² Input ≧2 ㎜² Input ≧2 ㎜²
Output ≧4 ㎜² Output ≧4 ㎜² Output ≧4 ㎜²
Requirement o
cable section
Earth wire ≧2 ㎜² Earth wire ≧2 ㎜² Earth wire ≧2 ㎜²
Dimension
H×A×B 170×300×160mm 170×300×160mm 170×300×160mm
Weight 7 kg 7 kg 6．5 kg
Technical Specification of the charger（8）
Charger Model DCM
24-60V/0-15A
DCM
24-30V/0-15A
DCM
18-46V/30-60A
Output Power 0．9 kw 0．45 kw 27．6 kw
Power-Supply AC220V/ 50Hz AC220V/ 50Hz AC3-380V/ 50Hz
Output Voltage
DC24～60V DC24～30V DC18～46V
Output Current
DC0～15A DC0～15A DC30～60A
Efficiency ≧93 ≧93 ≧93
Fuse ： 8A Fuse ： 4A Fuse ： 110A
Input Protection
Disconnect ：10A Disconnect ：6A Disconnect ：136A

7
Input ≧1 ㎜² Input ≧1 ㎜² Input ≧12 ㎜²
Output ≧3 ㎜² Output ≧3 ㎜² Output ≧12 ㎜²
Requirement o
cable section
Earth wire ≧1 ㎜² Earth wire ≧1 ㎜² Earth wire ≧12 ㎜²
Dimension
H×A×B 270×160×180mm 270×160×180mm 600×500×970mm
Weight 5 kg 5kg 72 kg
Technical Specification of the charger（9）
Charger Model DCM
60-340V/10-60A
DCM
DC4-30V/0-15A
DCM
DC4-60V/0-30A
Output Power 20．4 kw 0.45KW 1.8KW
Power-Supply AC3-380V/ 50Hz AC220V/50Hz/60Hz AC 220V/50/60 Hz
Output Voltage
DC60～340V DC4-30V DC4-60V
Output Current
DC10～60A DC0-15A DC0-30A
Efficiency ≧93 ≧93 ≧93
Fuse ： 80A 5A 15A
Input Protection
Disconnect ： 100A 10A 20A
Input ≧8 ㎜² ≧1 ㎜² ≧4 ㎜²
Output ≧12 ㎜² ≧4 ㎜² ≧6 ㎜²
Requirement o
cable section
Earth wire ≧8 ㎜² ≧2.5 ㎜² ≧4 ㎜²
Dimension
H×A×B
650×460×660mm 170*180*280MM 170*180*280MM
Weight 62 kg 5.6Kg 6.4Kg
Technical Specification of the charger（10）
Charger Model DCM
DC4-98V/0-60A
DCM
DC4-64V/0-100A
DCM
DC4-85V/0-50A
Output Power 5.88 kw 6.4kw 4.25 kw
Power-Supply AC220V/ 50Hz/60 Hz AC3*380V/50Hz/60Hz AC230V/50Hz/60 Hz
Output Voltage
DC4～98V DC4～64V DC4-85V
Output Current
DC0～60A DC0～100A DC0-50A
Efficiency ≧93 ≧93 ≧93
Fuse ： 50A Fuse ： 25A Fuse ： 40A
Input Protection
Disconnect ：63A Disconnect ：32A Disconnect ：50A
Input ≧7 ㎜² Input ≧4 ㎜² Input ≧6 ㎜²
Output ≧15 ㎜² Output ≧25 ㎜² Output ≧12 ㎜²
Requirement o
cable section
Earth wire ≧6 ㎜² Earth wire ≧6 ㎜² Earth wire ≧6 ㎜²
Dimension
H×A×B 320×315×430mm 320×315×430mm 320×315×430mm
Weight 23 kg 23kg 23 kg