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CH4100 Series High Efficiency Intelligent Charger

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CH4100 Series High Efficiency Intelligent Charger

User Manual Ver.1.5.3

Table Of Contents

I.Product Overview.. 1

II.Safety Instructions 2

III.Preventing Leakage and Fire. 3

1.Correct use of Breakers, Sockets and Cables 3

2.Correct Use of Input Connections 4

3.Charging Environment Requirements 4

IV.Regularly Maintenance. 5

IV.Product Models 5

V.Technical Specifications 6

VI.parts list 7

VII.Input and output interface. 8

VIII.Charging Indicator Information Description. 10

IX. Methods of Operation. 12

X. Appearance and Installation Dimensions 13

XI.Faults & solutions 14

Product

Overview

CH4100 series high efficiency intelligent charger is designed to charge power batteries of electric vehicles. This series of products adopt the most advanced

technologies such as LLC resonant, active power factor correction, microcomputer measurement and control, digital adjusting, fully sealed waterproof

technology and so on. Its features include: wide input voltage range adapted to global general voltage; High input power factor that significantly reduces the

ELECTRIC VEHICLES

BATTERY CHARGERS

MOTOR CONTROLLERS

ELECTRIC ACCELERATORS

DC-DC CONVERTERS

BDI

Skype01

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input current as well as heat generated by input cables, so the charger can be safely used in family; Low harmonic current that reduces interference to other

electric equipment. Full range soft switching is realized to achieve high conversion efficiency and slight electromagnetic interference, the charger is more

energy-saving and money-saving to use; the charger is designed according to IP66 protection grade and achieved high waterproof performance. Another

feature includes small size, light weight, quiet operation, beautiful appearance, simple installation, operation and maintenance and so on.

The charger adopts microcomputer measurement and control technology, embedded CPU can accurately detect various states of battery. Advanced

multi-stage charging mode can prevent the battery from be over-charged and over-discharged, minimize overheating and water loss phenomenon caused by

over-charge, slow down polar plate vulcanization phenomenon caused by over-discharge, extend the service life of batteries. The charger will stop

automatically after fully charged.

The charger has functions of temperature compensation, automatically shut down after fully charged, battery reverse connection protection, output short circuit

protection, AC input under-voltage protection, overheating protection and so on, and these functions can ensure safe and reliable use.

II Safety Instructions

Please read these instructions carefully before you use the charger

：

(1) For safety consideration, the charger adopts AC single-phase three-wire inputs which contain live, neutral and protective grounding wire. The shell of

charger connects protective grounding wire. When using the charger, you should connect it to power grid with a quantified 16A three-hole socket which

contains a grounding pole and controlled by a leakage protection air breaker with leakage protection function to prevent leakage and fire.

(2) Please use dedicated 16A plug and socket of reliable quality for the charger (Socket requirements: flame-retardant shell and cables of the socket, thick

internal springs that not less than 0.8mm and has a good elasticity), or it may burn the plug and socket, even cause severe fire! Copper core cables thicker

than GB 2.5mm

are suggested to be used as power connections to prevent the cables from becoming too hot when charging ,so to prevent fires.

(3) Please do not disassemble the charger; this may cause electric shock or other injuries.

(4) If the charger need to be connected to AC power supply with extension cables, please make sure that the extension cable can withstand the maximum

input current(GB 2.5mm

copper core cable is recommended to be used), and limit the extension cable length within 10m.

(5) Don’t place the charger in water or rain position; otherwise there is a danger that may cause electric shock and damage to the charger.

(6) The charger’s DC output plug should be connected reliably to the socket, if they are damaged or loose, please replace them immediately, otherwise it will

cause overheating in the plug position, and even cause serious fire.

(7) If the charger product any abnormal sound or smell during working, please unplug the power plug immediately and contact the service department. Do not

attempt to open the shell of charger, to prevent electric shock.

(8) Make sure that all air vents are unobstructed to prevent charger overheating. Do not place the charger near a heat source; the charger should be left

enough space to ensure ventilation and use of connectors.

(9) Please disconnecting the charger's AC input power if you need to move it.

(10) Make sure that AC power supply voltage matches chargers’ input voltage. For inquiries, please contact your supplier or local power Supply Corporation.

(11) Battery voltage and the nominal voltage of the charger must be matched; otherwise it will damage the charger or batteries.

(12) Do not pull, twist or shake the cables to avoid damage to the charger’s cables and connection terminals. If the cable is worn, please replace it

immediately.

III Preventing Leakage and Fire

1. Correct use of Breakers, Sockets and Cables

(1) Its required to use a leakage protection air breaker with leakage protection function.

(2) Its required to use reliable qualified 16A three-hole socket to connect the charger to AC power.

(3) Input cables of leakage protection air breaker is required to use copper core cables with flame-retardant jacket, the cables’ core diameter is not less than

2.5mm

(4) The cables between leakage protection air breaker and 16A socket are required to use copper core cables with flame-retardant sheath, the cables’ core

diameter is not less than 2.5mm

(5) Prevent plugs, sockets from dripping or splashing.

Note: According to statistics, 80% fire accident caused by an electric car occurred during charging, main reasons for this are insufficient core diameter size of

cables, poor quality plugs and sockets, poor contact of plugs and sockets, poor flame-retardant sheath or shells of breakers, plugs and sockets and so on.

2. Correct Use of Input Connections

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(1) It’s required to use a dedicated 16A power plug for the charger;

(2) It’s required to use copper core cables with flame-retardant sheath; the cables’ core diameter is not less than 2.5mm

(3) Make sure that the plug is clean (no dirty) and no damage before charging.

3.Charging Environment Requirements

(1) Spacious and airy;

(2) No flammable materials; prohibited charging in warehouse.

(3) Keep away from valuables such as automobiles.

(4) Keep away from bedroom when charging at night.

(5)Prohibit placing the charging plugs, charging cables or charger itself on car cabs, plastics chairs and other inflammable objects.

IV Regularly Maintenance

(1) Check 16A sockets regularly, if the connection between the socket and the plug is loose or poor contacting, they should be firmly connected or replaced

before the charger be used. The poor contact may result in overheating and burning of the plug and socket, and even cause a fire.

(2) Check the leakage protection air breaker regularly using the test button to ensure its protection function is valid.

(3) Make sure to use a dedicated input cable and plug for the charger.

(4) Make sure that there are no foreign matters between the charger’s shell and the cooling fan to avoid damage to the fan．

(5) Make sure that the appearance of battery is not ballooning; the battery is not overheating when charging.

IV Product Models

1. Naming Rules

2. Available Product Models

CH4100-4825， CH4100-4830，CH4100-4835

CH4100-6025， CH4100-6030，CH4100-6035

CH4100-6425， CH4100-6430，CH4100-6435

CH4100-7220， CH4100-7225，CH4100-7230

CH4100-9615， CH4100-9620，CH4100-9625

Note: Portable versions are available for above models, these models will be ended with a structure code ‘B’ such as ‘CH4100-4825B’.

V Technical Specifications

Rated input voltage: 220Vac 50/60Hz

Input voltage range: 85~265Vac (Note: When the Input voltage is lower than 185Vac, the output power will be limited to

1.5KW)

Input Current: ≤ 16A (Note: except models of “CH4100-9625”)

Power Factor: ≥ 0.99 @ 220Vac input, full power output;

Total Harmonic Current: ≤ 5% @ 220Vac input, full power output;

Nominal output voltage (Un): See Model Description

Maxim output voltage: 140%Un

Rated output current (Ir): See Model Description

Voltage regulation accuracy: ≤ 0.5%

Current regulation accuracy: ≤ 2%

Conversion efficiency: ≥ 95% @ 220Vac input, full power output

Protection class: IP66

Audible Noise: ≤ 40dB

Seismic rating: Designed according to IEC60335-2-29-2004-Part.21

Working temperature: -25~55℃ (Note: models whose output power greater than 2KW will ensure 2KW output at 60℃. )

Storage temperature: - 40~80℃

Recognition certificates: CE SGS

VI parts list

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A AC input Cables B DC output cables C Signal Cables

D Charging indicator E Mounting plate F Shell

G Cooling fan and fan cover

VII Input and output interface

Input Cables

Terminal Model

DJ7031-4.8-11

Direction of view: form the cables to terminal.

Terminal Model for

matching

DJ7031-4.8-21

Needle

No.

Wire Color

Wire core diameter

Description

brown

2.5

L——Live wire

blue

2.5

N——Neutral wire

Yellow and green

2.5

PE——Protective grounding wire

Output Cables

Terminal Model

SB50

Needle No.

Wire Color

Wire core diameter

Description

red

Output positive pole

black

Output negative pole

Signal Cables

Needle No.

Wire Color

Wire core diameter

Description

Needle No.

brown

Blue

DJ7031Y-2.3-21

external LED indicator interface

DJ7031Y-2.3-11

yellow

purple

DJ7021-1.5-21

Battery Temperature sensor interface

DJ7021-1.5-11

white

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LED Indicator Information Description

I. Charging Process Information

Low battery power

R---

Battery charge lower than 80%

R-

Battery charge between

80%--90%

Y-

Battery charge between

90%--100%

G-

Full charge

Normal process of

charging

continuous Green light

Battery

temperature

sensor fault

Green light (3S) Yellow light (0.3s)

II. Alarm Information

Battery Not connected

R-G---

Charger over-temperature

protection

R-G-Y---

Input fault protection

R-G-Y-Y---

Charging timeout

R-G-Y-Y-Y---

Battery Overheating

R-G-Y-Y-Y-Y---

Pre-Charge timeout

R-G-Y-Y-Y-Y-Y---

Internal temperature sensor fault

R-G-Y-Y-Y-Y-Y-Y---

Output voltage feedback fault

R-G-Y-Y-Y-Y-Y-Y -Y---

pink

DJ7043-2-21

Serial communication

interface

DJ7043-2-11

Yellow and green

Blue and white

Green and white

10#

orange

DJ7021-2-11

Forbidden signal interface

(normal close)

DJ7021-2-21

11#

grey

Wire core diameter

0.5 mm2 for all Signal wires

Signal Cables Terminal Diagram

Direction of view: form the cables to terminal.

VIII Charging Indicator Information Description

The charger installed a LED indicator internally, this built-in indicator display information through the window on the shell of charger. Besides the charger

provides an external LED indicator interface that can connect the optional external LED indicator. Internal and external LED indicator can light synchronously

with "red, green, yellow" three colors; the LED indicator can express a variety of working conditions of the charger with different color combinations. The

following table is a description of indicator information.

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Low temperature start delay

(When the internal temperature

of charger is between -20 to -30

° C, the charger will delay

starting for 1~2 minutes)

R-G-Y-Y -Y-Y-Y-Y-Y-Y---

Note：

1."-" represents led that does not light for 0.5s, a color word represents that

the LED of this color lights for 0.2s.

2. R --red G —green Y—yellow

IX Methods of Operation

(1) Connect the output terminal of the charger to the battery terminal

(2) Connect the input plug of the charger to AC power socket until the charger turns into normal charging process (observe the LED Indicator), then Charger

will automatically charge the batteries. When fully charged, the charger will automatically shut down, and display ‘full power’.

(3) If observed the battery become overheating or ballooning during charging process, you should stop the charger immediately by unplug the plug from the

AC socket.

X Appearance and Installation Dimensions

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XI Faults & solutions

If your charger can not work correctly, you can refer to table below

Fault Phenomenon

Analysis

Solutions

Battery temperature

Sensor Fault

External battery temperature

sensor is fault or not

connected

Check sensor connection

or change a new one

Battery not

connected

Battery is not connected or

reverse connected

Check and connect the

battery correctly

Over-temperature

protection

Charging environment

temperature is too high;

cooling fan is fault;

air vents are obstructed

Place the charger in lower

temperature environments

and recharge;

Check whether cooling fan

is fault or air vents are

obstructed

Input fault protection

Poor contact of charger’s

input side ; Charger is broken

If no poor contact

phenomenon occurs,

please contact us

Charging timeout

Battery is damaged or aging

Check and replace battery

Battery Overheating

Battery is damaged or aging

Check and replace battery

Pre-charge timeout

Battery is damaged or aging

Check and replace battery

Internal temperature

sensor fault

Charger is broken inside

Please contact us

Output voltage

feedback fault

Charger is broken inside

Please contact us

“Full Power ”after

short charging

Battery is broken;

Poor contact between charger

and battery;

Battery has been fully

charged;

Check whether the battery

is damaged; battery

connecting cables are firm

; the battery is fully

charged

Battery temperature

becomes more than

50℃ and produces

a lot of bubbles

Battery is aging ;

Battery voltage is lower than

the nominal voltage of the

charger

Check the battery, and

replace bad battery;

Reselect charger that

match battery voltage

level .

Low battery capacity

Battery is aging

Replace the battery

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Links:

after fully charging

Cables are too long or too thin

Between the charger and

battery

resume The output cables

back to initial state

Charging time

becomes too short

or too long

Battery is aging

Replace the battery

Charger overheating

protection

Check if there are foreign

matters around the fan

and remove them

Check whether the cooling

fan is working correctly, or

fan.

LED indicator lights

but no charging

Connectors are not connected

firmly, or the polarity is

reversed; Battery is

disconnected

Connect all connectors

correctly and recharge

Battery is broken

Replace new battery

LED indicator

doesn’t light

AC input is not connected

firmly

Check AC power supply

and chargers’ input cables

Charger is broken inside

Please contact us

If your charger still cannot work correctly after above treatment, please record the state of the fault phenomenon and charging indicator information, then

Contact:David Yu Email:[email protected] Mobile:(+86)13924639378 Tel:(+86)755-26959270

Fax:(+86)4006981163-23090

UK EASY POWER CO., LIMITED

Support：

zke360

Manage

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