Zivan BC1 User manual

BATTERY CHARGER
BATTERY CHARGER
BC1
Installation and User Manual

Battery charger BC1
2D01001-02
ATTENTION: To reduce the risk of
electric shock, do not remove cover.
Refer servicing to qualified service personnel.
Disconnect the mains supply before connecting
or disconnecting the links to the battery.
Read the Instruction Manual carefully
before use. Verify that the selected
charge curve is suitable for the type
of battery You have to re-charge.
Explanation of Graphical Symbols
The lightning flash with arrowhead symbol, within an equilateral triangle, is intended to alert
the user to the presence of uninsulated “dangerous voltage” within the equipment’s
enclosure; that may be of sufficient magnitude to constitute a risk of electric shock to
persons.
The exclamation point within an equilateral triangle is intended to alert the user to the
presence of important operating and maintenance (servicing) instructions in the literature
accompanying the equipment.
This product is covered by warranty.
The relative warranty certificate is attached to the Instructions Manual.
If the Manual is not provided with this certificate, please ask your retailer for a copy.
For further references, please write the serial number in the proper space:
Serial No._____________________
Information contained in this Manual relates to ZIVAN S.r.l. property which reserves
the right to supply for the exclusive use of customers.
No other use is allowed without a written authorization supplied by ZIVAN S.r.l.
ZIVAN S.r.l. will be not responsible for inaccuracies contained in this manual due to
print or translation errors. ZIVAN S.r.l. has the right to make changes or
improvements, also for the user interest, without prejudicing the essential
characteristic of operation and safety.
Copyright ©2003 by ZIVAN S.r.l.
Second Edition

Battery charger BC1
D01001-02 3
Installation and safety instructions
Battery charger BC1 has been designed to provide safety and reliable. It is necessary to observe the
following precautions in order to avoid damage to persons and to the battery charger:
• Read the installation instructions contained in this Manual carefully. For further information put the
Manual in a proper place.
• Fix the battery charger to a stable surface through the appropriate holes inserted on the fixing
flanges. In case of installation on a vehicle it is advisable to use antivibration supports.
• Preferably the charger should be installed in the vertical position with the fan facing up. The
horizontal installation is allowed. Never install in the vertical position with the fan facing down.
• Ensure all ventilation ports are not obstructed, to avoid the overheating. Do not put the battery
charger near heat sources. Make sure that free space around the battery charger is sufficient to
provide adequate ventilation and an easy access to cables sockets.
• Protect the battery charger from ingress of water. Do not pour liquids inside the case.
• Verify that the available supply voltage corresponds to the voltage that is stated on the battery
charger name plate. In case of doubt, consult a retailer or local Electric Supply Authority.
• For safety and electromagnetic compatibility, the battery charger has a 3-prong plug as a safety
feature, and it will only fit into an earthed outlet. If you can not plug it in, chances are you have an
older, non-earthed outlet; contact an electrician to have the outlet replaced. Do not use an adapter to
defeat the earthing.
• To avoid damaging the power cord, do not put anything on it or place it where it will be walked on. If
the cord becomes damaged or frayed, replace it immediately.
• If you are using an extension cord or power strip, make sure that the total of the amperes required by
all the equipment on the extension is less than the extension’s rating.
• Disconnect the mains supply before connecting or disconnecting the links to the battery.
• To recharge Lead Acid batteries: WARNING: Explosive Gas – Avoid flames and sparks. The battery
must be positioned in a correctly cooled place.
• Do not use to charge batteries installed on board of thermal engine cars.
• Avoid recharging of non-rechargeable batteries.
• Verify that the nominal voltage of the battery to be re-charged corresponds to the voltage stated on
the battery charger name plate.
• Verify that the selected charging curve is suitable for the type of battery to be re-charged. In case of
doubt, consult Your retailer. ZIVAN S.r.l. will not accept any responsibility in case of mistaken choice
of the charging curve that may cause irreversible damage to the battery.
• In order to avoid voltage drop, thereby assuring 100% charge at the battery, the output cables must
be as short as possible, and the diameter must be adequate for the output current.
• Do not try to service the battery charger yourself. Opening the cover may expose you to shocks or
other hazards.
• If the battery charger does not work correctly or if it has been damaged, unplugged it immediately
from the supply socket and from the battery socket and contact a retailer.

Battery charger BC1
D01001-02 4
LED Indicator
RED LED shows that the battery is in initial charging phase.
YELLOW LED shows that the battery charger has reached 80% of charge.
GREEN LED shows that the battery has reached 100% of charge.
Further information can be found in the description of the Charging Curve.
Example: the RED LED on blinking indicates a constant tension phase.
Alarms
The flashing LED shows that an Alarm situation has occurred:
Condition Alarm Type Description (Action)
GREEN flash Timeout Phase 1 have a duration in excess of the maximal
allowed. (Verify the battery capacity).
RED-YELLOW flash Battery Current Loss of output Current control. (Failure of the control
logic).
RED-GREEN flash Battery Voltage Battery not in conformity (verify the nominal voltage)
or loss of output Voltage control. (failure of the control
logic).
RED-YELLOW-GREEN
flash Thermal Overheating of semiconductors. (Verify the fan operation).
YELLOW-GREEN flash Selection An unavailable configuration has been selected
(Verify the selector’s position)
When there is an alarm the battery charger stops supplying current.
Battery
A battery is characterised by two sizes: tension and capacity.
Tension:
Each element has a nominal tension, which depends on the type of battery (no
matter what size).
In order to reach higher tension, many elements are connected in series, so
creating a “BATTERY” of elements.
The number of elements is calculated by dividing the nominal tension of the
battery for the tension of each single element in the table:
Capacity:
It is the quantity of electric charge that the batteries can supply to an external circuit before the tension
decreases under the final limit value and it is obtained by multiplying the intensity of the discharging
current I, expressed in ampere (A), for the discharging time t expressed in hours (h): C = I x t
The traction battery capacity is normally referred to the discharging system of 5h: C5 = I x 5h.
The capacity values that can be recharged by the battery chargers can be found in the description of the
Charging Curve (this value is not present in the curves able to charge any capacity).
:
This device is in conformity with the Low Voltage directive 73/23/EEC
and EMC directive 89/336/EEC and their further modifications.
Type Nominal
Tension
Pb 2 V/cell
NiCd 1,2 V/cell
NiMH 1,2 V/cell
NiZn 1,714 V/cell
80%
100%
START

Battery charger BC1
D01001-02 5
6
=
105
=
12,5
285260
12,5
=
=
50
Mechanical dimensions
245
285
45
75
75
105
N.B. All dimensions are expressed in mm.
Drilling details
UP

Advised Installation
N.B. All dimensions are expressed in mm.

Battery charger BC1
D01001-02 6
TECHNICAL FEATURES
Ta=25°C unless otherwise specified.
Mains side
Description Symbol Test Condition
Value and/or
Range Unit
Supply Voltage Vin - 230 ± 10% Veff
Frequency f - 50 ÷ 60 Hz
Absorbed Maximum Current Iinmax P = Pmax 5 Aeff
Power Factor cosϕP = Pmax 0,7 -
Absorbed Maximum Power Pinmax P = Pmax 850 W
Battery side
Description Symbol Test Condition
Value and/or
Range Unit
Output current ripple - I = I1 < 5% -
Absorbed current IaEquipment turned off < 1 mA
Output voltage ripple - U = U1 < 1% -
Maximum power supplied Pmax U = U1, I = I1 720 W
Output capacity C - 1000 µF
General
Description Symbol Test Condition
Value and/or
Range Unit
Operating range of temperature ∆T - from -20 to +50 °C
Maximum relative humidity RH - 90% -
Switching frequency fc- 80 ± 5% kHz
Efficiency η At each condition > 85% -
Maximum size a×b×c Without connecting cable 285×105×75 mm
Weight - Without connecting cable 1390 g
Enclosure class - - IP20 -

Battery charger BC1
D01001-02 7
Protection and Safety
Description Symbol Test Condition
Value and/or
Range Unit
Insulation - Mains to Battery side 1250 VAC
Insulation - Mains side to Earth 500 VDC
Insulation - Battery side to Earth 500 VDC
Leakage current ILSupplied equipment < 3 mA
Input fuse F1 Inside the equipment 10 (delayed) A
Output fuse F2 Inside the equipment 40 A
Minimum output voltage of operation
(Battery Detector) - Equipment turn on 1,3 V/cell
Reverse output polarity - At the connection to the
Battery Protection provided by
fuse F2
-
Thermal protection of semiconductors
(Temperature of Thermal Alarm) - Ta=55°C 100 °C
Safety Requirements (Rules) - EN60335-1, EN60335-2-29 - -
EMC Requirements (Rules) - EN55014-1, EN61000-3-3
EN55014-2, EN61000-4-2
EN61000-4-4, EN61000-4-5
EN61000-4-6, EN61000-4-11
- -

Battery charger BC1
D01001-02 8
Options with connectors 6 poles
Pin Use
1 Common contact net presence
2 Normally closed contact for mains presence
3 Normally opened contact for mains presence
4 Red LED anode
5 Common cathode LED
6 Green LED anode
Technical features : exchange contacts
0,3A 125VAC
0,3A 110VDC
1A 30VDC
Connector - Diagram connection
64
32
5
1
1
2
3
4
5
6
INSIDE

Battery charger BC1
D01001-02 9
Options with connectors 4 poles and 2 poles
Connector 4 poles
Pin Use
1 Red LED anode
2 Not used
3 Common cathode LED
4 Green LED anode
Connector 2 poles
Pin Use
1 Common contact net presence
2 Normally closed contact for mains presence
Technical features: exchange contacts
0,3A 125VAC
0,3A 110VDC
1A 30VDC
Connector - Diagram connection
2
43
21
1
1
2
2
1
3
4
OUTSIDE
INSIDE
LR
LV

Battery charger BC1
10 D01001-02
Design, production and sale:
ZIVAN SRL
Via della Costituzione, 36
42028 Poviglio (RE) ITALIA
Tel. [phone]
Fax [phone]
[email protected]
SALES OFFICES
ITALY FRANCE SWITZERLAND
ZAPI SPA URMA SARL ASMO ENGINEERING AG
Via Parma, 59 30, Rue de Morvan Silic 503 Glashütte, 58
42028 Poviglio (RE) 94623 Rungis Cedex CH 4229 Beinwil (SO)
Tel. [phone] Tel. [phone] Tel. [phone]
Fax [phone] Fax [phone] Fax [phone]
[email protected] [email protected] [email protected]
SLOVENIA/CROATIA HOLLAND UNITED KINGDOM
PROTEUS ELECTRIC SRL SPI Special Product for Industry EZ ELECTROFIT ZAPI LTD
Via di Noghere, 94/1 Vlijtseweg 232 Unit 2 - Halesfield 17 - Telford
34147 Muggia Aquilina (TS) 7317 AN Apeldoorn Shropshire TF7 4PW
Tel. [phone]-232388 Tel. [phone] Tel. [phone]
Fax [phone] Fax [phone] Fax [phone]
U.S.A. GERMANY SPAIN
ELECTRIC CONVERSIONS ATECH Antriebstechnik GmbH VARELEC SCCL
215, 14th Sreet Gewerbepark Lindach D7 c / Lope de Vega 10-12 Bajos
95814 Sacramento CA 84489 Burghausen 08005 Barcelona
Tel. [phone] Tel. [phone] Tel. [phone]
Fax [phone] Fax [phone] Fax [phone]
[email protected] [email protected] [email protected]
SPAIN SWEDEN BELGIUM
JZ RECIELCA S.L. ETP KRAFTELEKTRONIK AB BATTERY SUPPLIES n.v.
C / Progrés, 2-A. Gavà Järningen, 15 Lindestraat, 89A
08850 Barcelona 43323 Partille 8790 Waregem
Tel. [phone] Tel. [phone] Tel. [phone]
Fax [phone] Fax [phone] Fax [phone]
[email protected] [email protected] battery[email protected]
GREECE CHINA
START Industrial Batteries CNEEC
7-9 Agiou Filippou Street N° 1 Lianhuahe Hutong
18540 Piraeus Beijing 100036
Tel. [phone] Tel. [phone]
Fax [phone] Fax [phone]
[email protected]hnet.gr [email protected]

Battery charger BC1
D01001-02 11

Battery charger BC1
D01001-02 12
Electric Conversions
Distributor of ZIVAN Battery Chargers
215 14th Street, Sacramento CA 95814
Tel. [phone]
Fax [phone]
E-mail: [email protected]
Web: www.zivanusa.com