Installation & Operation Manual HF Fast Charger System STS-320 STS E. Kimberly Ave. Fullerton, CA (877) ACT-5922

Transcription

1 HF Fast Charger System STS-320 STS E. Kimberly Ave. Fullerton, CA 231 (77) ACT E. Kimberly Ave. Fullerton, CA 231 (77) ACT-522

2 A.C.T. HF Fast Charger System A.C.T. HF Fast Charger System 4.3 Recommended PM Inspection items Table Of Contents Safety Instructions And Warnings 1.0 Installation 1.1 Location And Mounting 1.2 Floor Mounting 1.3 AC Power Connection 2.0 Operation 2.1 Start Charging 2.2 Stop Charging 2.3 LED And Stack Light Operational Status Indicators Front Panel Led Indicators 2.4 Front Panel Display And Keypad Operation Display Mode Overview Real-Time Status Display Charging History Display Manual Operations Display Manual Equalization Manual Watering Manual Operation Of External Scavenging Fan Fault History Display 3.0 Troubleshooting 4.0 Maintenance 4.1 Replacing Cables 4.2 Working Environment Service Frequency 4.3 Recommended PM Inspection Items 5.0 Technical Specifications Risk of High Voltages Lethal voltages are present within the RISK OF ELECTRIC SHOCK - After turning off ACispower for charger enclosure whenever the AC mains supply energized servicing, allow 5 minutes for the system to bleed down before and/or the battery or load is connected. The bus bars and other touching the AC connections. internal components present the risk of electric shock a) AC Input Voltages, connections and fuses. b) Cleaning out Charger cabinet must be performed with the Air Filter removed. Risk of Explosive Working lead acid Using dry compressed air not Gases exceeding 20psi. in Orthe an vicinity electricof blower batteries is dangerous. Batteries generate explosive gases (A.C.T. preferred method) not to exceed 30cfm. during charging and discharging. To reduce the risk of battery c) Buss Bar bolts are tight along with DC fuse. explosion, ensure adequate ventilation and follow these instrucd) Visually inspect DC Cables, connectors and tips for tightness and damage. tions as well as those published by the battery manufacturer. e) Check all plugs and Harnesses are secure. f) Check communication cable when BFD installed. Risk of Improper Grounding The charger must be connected to (BF displayed in bottom right hand corner of display). an AC mains supply incorporating an earth/ground. Theloaded. groundg) Check for correct charge start rate. Check for correct Battery type ing conductor must be of a size equal or larger than the line h) Check Finish and EQ windows for settings that match Customer idle times. (phase) conductors. 5.0 TECHNICAL SPECIFICATIONS Protect Eyes and Skin Wear safety goggles and skin protection when installing or servicing the battery charging system or working in the vicinity of lead-acid batteries. To reduce the risk of injury, only charge rechargeable lead-acid batteries. Charging or trying to charge other types of batteries may cause damage or result in personal injury. Risk of Fire - To reduce the risk of fire, install battery charger on a floor of non-combustible material, such as stone, brick, concrete, or metal. Do not install on or over combustible surfaces. Risk of Fire Use only on circuits provided with appropriate branch circuit protection in accordance with the National Electrical Code, NFPA 70. The appropriate branch circuit protection is: Charger model STS-320: 30 Amperes Charger model STS-400: 35 Amperes IOM320 Rev

3 3.0 TROUBLESHOOTING The Charging System does not contain user serviceable parts. Please contact A.C.T. at 77-22(ACT)-522 in case of malfunction. 4.0 MAINTENANCE Regularly inspect air filter at the bottom of the charger and clean or replace as necessary. Inspect DC cables for wear. 4.1 Replacing Cables If The DC output cables or Euro connectors become worn or are damaged, they should be immediately replaced by qualified personnel, with cables of the same ratings. 4.2 Working Environment Service Frequency Location and environmental conditions must be taken into to account when determining the frequency that the Air Filter is cleaned or replaced. A.C.T. guidelines are as follows: Normal A normal daily operation Conventional Charging basic material handling of clean product in dry environments. Clean or replace Filter annually Severe Extended operating hours or constant use when Fast or Opportunity charging in dusty hot but dry environments. Clean or replace Filter Bi Annually Extreme All Dusty or sandy conditions such as in cement plants, lumber or flour mills, coal dust or stone-crushing areas. Exposure wet to cool or cold air in enclosed applications. Corrosive atmosphere such as in chlorine or salt-sea air environments. Clean or replace Filter Quarterly Air Filter can be blown out or washed in warm soapy water (Filter must be completely dried prior to re- install) IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS. THIS MANUAL CONTAINS IMPORTANT SAFETY AND OPERATING INSTRUCTIONS WORKING IN THE VICINITY OF A LEAD-ACID BATTERY IS OUS. BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR THIS REASON IT IS OF THE UTMOST IMPORTANCE THAT EACH TIME BEFORE USING YOUR CHARGER, YOU READ AND FOLLOW THE INSTRUCTIONS PROVIDED EXACTLY. TO REDUCE RISK OF BATTERY EXPLOSION, FOLLOW THESE INSTRUCTIONS AND THOSE MARKED ON THE BATTERY. NEVER SMOKE OR ALLOW AN OPEN SPARK OR FLAME IN THE VICINITY OF THE BATTERY. USE CHARGER FOR CHARGING A LEAD-ACID BATTERY ONLY. IT IS NOT INTENDED TO SUPPLY POWER TO AN EXTRA-LOW-VOLTAGE ELECTRICAL SYSTEM OR TO CHARGE DRY-CELL BATTERIES. CHARGING DRY-CELL BATTERIES MAY CAUSE THEM TO BURST AND CAUSE INJURY TO PERSONS AND DAMAGE TO PROPERTY. NEVER CHARGE A FROZEN BATTERY. STUDY ALL BATTERY MANUFACTURER S SPECIFIC PRES SUCH AS REMOVING OR NOT REMOVING CELL CAPS WHILE CHARGING AND RECOMMENDED RATES OF CHARGE. NEVER PLACE THE CHARGER DIRECTLY ABOVE OR BELOW THE BATTERY BEING CHARGED; GASES OR FLUIDS FROM THE BATTERY WILL CORRODE AND DAMAGE THE CHARGER. LOCATE THE CHARGER AS FAR AWAY FROM THE BATTERY AS DC CABLES PERMIT. DO NOT OPERATE CHARGER IN A CLOSED-IN AREA OR RESTRICT VENTILATION IN ANY WAY. BEFORE INSTALLING, USING OR MAINTAINING THE A.C.T. CHARGER SYSTEM, READ AND UNDERSTAND THE ABOVE AND THE FOLLOWING INSTRUCTIONS. ONLY QUALIFIED PERSONNEL SHOULD INSTALL, OPERATE OR SERVICE THIS EQUIPMENT. 1

4 Risk of High Voltages Lethal voltages are present within the charger enclosure whenever the AC mains supply is energized and/or the battery or load is connected. The bus bars and other internal components present the risk of electric shock. Risk of Explosive Gases Working in the vicinity of lead acid batteries is dangerous. Batteries generate explosive gases during charging and discharging. To reduce the risk of battery explosion, ensure adequate ventilation and follow these instructions as well as those published by the battery manufacturer. Risk of Improper Grounding The charger must be connected to an AC mains supply incorporating an earth/ground. The grounding conductor must be of a size equal or larger than the line (phase) conductors. Protect Eyes and Skin Wear safety goggles and skin protection when installing or servicing the battery charging system or working in the vicinity of lead-acid batteries. To reduce the risk of injury, only charge rechargeable lead-acid batteries. Charging or trying to charge other types of batteries may cause damage or result in personal injury. Risk of Fire - To reduce the risk of fire, install battery charger on a floor of non-combustible material, such as stone, brick, concrete, or metal. Do not install on or over combustible surfaces. Risk of Fire Use only on circuits provided with appropriate branch circuit protection in accordance with the National Electrical Code, NFPA 70. The appropriate branch circuit protection is: Charger model STS-320: 30 Amperes Charger model STS-400: 35 Amperes 2 11

5 Manual Equalization In automatic operation, equalization proceeds if either (a) a Finishing charge event completes when the equalization window is open, or (b) if a battery that has completed a Finishing charge when the equalization window is not open is left connected to the charger until the equalization window opens. By invoking manual equalization, the user effectively forces the equalization window open at the end of the present charging event, such that an equalization will be carried out regardless of time of day or day of week. After the single forced equalization, the Charging Station reverts to automatic operation, i.e., the forced equalization is a one-time event. Manual equalization is invoked by using the down arrow to get to the manual equalization window, and using the left and right arrows to toggle between force equalize off and on Manual Watering The second window down in the Manual Operation menu is the manual watering window. This window allows the user to manually operate watering valves. One reaches this window by scrolling down from the manual equalization window with the down arrow. Once in the manual watering window, the left and right arrow keys increase and decrease the watering duration setting. Once the desired duration has been selected, the selection is accepted and watering initiated by pressing the ENTER key. Watering can be immediately stopped by pressing the BACK key. This immediately terminates watering and returns the display to the Real Time Status display Manual Operation of External Scavenging Fan The third window down in the Manual Operation menu is the manual fan window. This window allows the user to manually operate an external scavenging fan for removal of fumes. One reaches this window by scrolling down from the manual watering window with the down arrow. Once in the manual watering window, the left and right arrow keys turn the fan on or off. Pressing the BACK key returns the display to the Real Time Status display Fault History Display The Fault History Display enables the user to view a summary of recent fault events on the Charging Station. The summary information is: Type of fault Time and date of fault If fault is an HPE fault, HPE number The up and down arrow keys allow the user to scroll through the history of recent events. Risk of Electric Shock from Stored Energy Wait at least five minutes after de-energizing the AC power supply and disconnecting the battery or load before opening the charger enclosure or touching any of the de-energized AC supply parts. Risk of Electric Shock and/or Electric Energy from High Current Levels Do not touch un-insulated battery, connectors, bus bars or terminals. All tools used should be adequately insulated to avoid the possibility of shorting connections. Inspect cables often for damage to the insulation. Replace cracked, worn or otherwise damaged cables immediately. Risk of Fire or Explosion from Gases Vented by Batteries Discharge static electricity from tools and technician by touching a grounded surface when working in the vicinity of batteries. Improper Connection - Damage to the charging system or battery, or personal injury may occur if the charger is incorrectly wired to AC supply or its output devices. Always observe local safety codes and standards. Indoor Use Only This charger is for INDOOR use only. Do NOT expose the charging system to rain or snow. Air Filter Maintenance To prevent damage from overheating or internal contamination, check air filters regularly (at least every two weeks), and clean or replace as necessary. 3

6 1.0 INSTALLATION 1.1 Location and Mounting The charging area should be well ventilated, dry and adequately clean before the charger is mounted. The A.C.T. series chargers offer a wide variety of mounting options such as floor mount, wall mount, or stacked on top of each other. The charger has four air vent openings around its top, and air inlet openings at its right side. To allow proper cooling of the charger, at least the following should have unobstructed airflow: The air inlet at the bottom of the front. AND Two of the four air outlet vents at the top of the charger. This means that two of the four air outlets at the top are allowed to be covered by a wall, other charger or other obstruction, which allows great installation flexibility. The following are examples of acceptable installations. Two chargers against a wall, side by side: Front Panel Display and Keypad Operation Display Mode Overview There are four top-level menu categories: Real-time charging status Charging history Manual operations Fault log The left and right arrows allow the user to select between these categories. Up and down arrows allow the user to navigate within categories Real-Time Status Display The Real-time Status Display shows the real-time value of several charger and battery parameters: Charging current Battery voltage Amp-hours returned during the present charging event Battery state of charge Battery temperature Duration of present charging event The Real-time Status Display has no sub-categories Charging History Display The Charging History Display enables the user to view a summary of recent charging events on the Charging Station. The summary information is: Type of event (Fast Charge, Finish, Equalization) and whether it was completed or aborted by a disconnection Amp-Hours returned during the charging event Battery state of charge (only if event is completed - zero percent is displayed if the event is terminated by a user disconnection) Date of event Time of event Duration of event The up and down arrow keys allow the user to scroll through the history of recent events Manual Operations Display There are several operations that the user can initiate from the keypad: Manual equalization Manual watering Manual operation of external scavenging fan

7 1.3 AC Power Connection AC power connections should be made by a licensed electrician only. Verify if the charger s ratings match the available utility voltage. The charger should be permanently connected ( hard-wired ) and meet local electrical or National Electrical Code requirements. Knock out the opening for the conduit on either side of the charger and install conduit. The ground connection should be made to the compression lug provided on the side wall of the charger. Use THHN or similar type, 600V, suitable for conduit use. Use copper conductors only. The charger must be grounded in accordance with the Facilities Utility grounding method. All connections must comply with all local codes and ordinances Two chargers stacked on top of each other in a corner of two walls: RISK OF ELECTRIC SHOCK - After turning off AC power for servicing, allow 5 minutes for the system to bleed down before touching the AC connections. POTENTIAL SYSTEM DAMAGE Turn charger off before applying AC power. Use external circuit breaker to turn on AC power. 2.0 OPERATION 2.1 Start Charging To charge a battery, connect the Euro connector of the charger to the battery. Charging will start automatically. 2.2 Stop Charging Unplug the Euro connector from the battery. There is no need to press the STOP button first. 2.3 LED and Stack Light Operational Status Indicators Front Panel LED Indicators The Front Panel LEDs indicate the activity status of the Charging Station. NOTE: THE MAXIMUM NUMBER OF STS CHARGERS THAT CAN BE PLACED ON TOP OF EACH OTHER IS TWO. Although not strictly necessary for cooling of the charger as long as the above restrictions are met, it is advised to maintain a clearance of at least inches from the back of the charger to a wall or other obstacle, to facilitate future field servicing. Power module replacement, if needed, is done from the back of the charger. 5

8 For wall mounting, only use mounting brackets especially designed for the STS series chargers, available from your local A.C.T. dealer: 1.2 Floor Mounting If the charger is mounted on the floor, make sure the charger is mounted on non-combustible material, such as concrete. The four mounting holes in the bottom of the charger are 3/ (mm) diameter. Use 5/16 x 4 bolts or larger bolts that are suitable for use with the installation surface. Hole can be predrilled following the bolt pattern below: For installations in Canada: Regardless of the installation surface, the metal STS charger mounting plate (available from your local A.C.T. dealer) should be installed between the charger and the installation surface: 1/16 (306mm) 1 (42mm) Mounting holes are 3/ (mm) diameter. Use 5/16 x 4 bolts or larger bolts that are suitable for use with the installation surface. 6 7