Battery Charger [PDF]

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Operating Instructions

Charger LGW 22406

A.S.T. Leistungselektronik GmbH _______________________________________________________________________

Charger LGW 22406 OPERATING INSTRUCTIONS

Version 04/05 Subject to technical modifications A.S.T. Leistungselektronik GmbH Brook-Taylor-Str. 10, D- 12489 Berlin www.astle.de

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T:++49 / 30 / 63925700 Fax: ++49 / 30 / 6392 5709

Operating Instructions

Charger LGW 22406

A.S.T. Leistungselektronik GmbH _______________________________________________________________________

TABLE OF CONTENTS 0

General………………………………………………..3

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Safety Guidelines……………………….……………4

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Technical Data……………………………………….6

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Charging characteristic………………………………7

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Charge level indications……………………………..8

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Battery test…………………………………………….9

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Battery temperature control………………………..10

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Specification of signal outputs……………………..10

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Report signals………………………………………..11

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Connection diagram…………………… ………….12

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Dimensions…………………………………………..13

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Mounting……………………………………… ……14

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Electrical Installation………………………………..14

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Error signals………………………………………….15

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Automatic error acknowledgement………………..16

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Repair………………………………………………...17

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Operating Instructions

Charger LGW 22406

A.S.T. Leistungselektronik GmbH _______________________________________________________________________

0 General The present operating instructions have been created with utmost care and have extensively been tested several times. For reasons of clarity, neither all detailed information about each product type nor each conceivable kind of installation, operation or maintenance could be taken into account. We also point out that the content of the operating instructions is not part of or modifies an older or existing agreement, confirmation or legal relationship. All obligations of the manufacturer arise from the respective purchase agreement which also contains the complete and only valid warranty regulations. Considering the operation instructions neither extends nor restricts these contractual warranty specifications. The manufacturer reserves the right to correct or to change the content and the product specifications and omissions without prior notice. He is not liable for damages, injuries or expenses due to above mentioned reasons.

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Operating Instructions

Charger LGW 22406

A.S.T. Leistungselektronik GmbH _______________________________________________________________________

1 Safety Guidelines Intended conditions of use The devices are electrical components intended to be installed in electrical installations or machines. The devices' availability is limited and they are exclusively intended for professional use in terms of the standard EN 61000-3-2. The commissioning and the start-up are prohibited until the machine or plant was deemed to conform to the EC machine guideline 98/37/EEC and EN 60204. ATTENTION, Danger to life: If there are reasons to suspect that a safe operation is no longer possible, the device has to be shut down and must be prevented against unintentional operation. It can be assumed that safe operation is no longer possible • if the device shows visible damages. • if the device is no longer working. • after prolonged storage under unfavorable conditions. • after severe transport stresses. ATTENTION: Prior to installation or commissioning, these operating instructions must be carefully read by qualified personnel familiar with electric traction equipment. Mishandling can lead to personal injuries and/or property damage. The installation and the commissioning may only be performed by qualified personnel. ATTENTION, Danger to life: Electrical devices are not fail-safe in principle. The output voltage reaches values requiring protection against accidental contact. The user is responsible for ensuring that, in case the device breaks down, the plant will be transferred into a safe state, since otherwise personal injuries and/or property damage can occur. NOTICE: The trouble-free and safe operation of the charger requires proper transport, professional storage, installation and mounting as well as careful operation and maintenance. ATTENTION: The device contains electrostatic sensitive devices (ESD). The relevant treatment instructions shall be observed. 4

Operating Instructions

Charger LGW 22406

A.S.T. Leistungselektronik GmbH _______________________________________________________________________

BEFORE EACH MANIPULATION, THE DEVICE MUST BE DISCONNECTED FROM THE POWER SUPPLY AND THE BATTERY. AFTER A WAITING PERIOD OF APPROX. 5 MINUTES, WHEN THE INTERMEDIATE CIRCUIT CAPACITORS HAVE BEEN DISCHARGED AND HAVE A RESIDUAL VOLTAGE OF LESS THAN 50 V, WORK ON THE DEVICE MAY BE CARRIED OUT. BETWEEN DISCONNECTING THE DEVICE FROM THE MAIN POWER SUPPLY AND RECONNECTING THE SUPPLY VOLTAGE, A WAITING TIME TARGET OF 1 MINUTE MUST BE MET. THE GALVANIC ISOLATION BETWEEN POWER SIDE AND CONTROL SIDE DOES NOT CORRESPOND TO THE VDE REGULATION FOR SAFETY EXTRA-LOW VOLTAGE (SELV). THERE IS NO GALVANIC ISOLATION BETWEEN INPUT AND OUTPUT. THE LEAKAGE CURRENT CAN BE ≥ 3,5 mA. ACCORDING TO VDE 160, A FIXED CONNECTION FOR THE GROUND WIRE MUST THEREFORE BE PROVIDED. DO NOT TRY TO CHECK THE DIELECTRIC STRENGTH OF THE CHARGER. DO NOT DISCONNECT ITS CONNECTIONS BEFORE AN ISOLATION TEST OF THE PLANT HAS BEEN PERFORMED.

During the electrical installation, the general installation rules must be followed: -VDE 0100 Regulations for the erection of power installations with nominal voltages below 1000 V. VDE 0113 Regulations for the electrical equipment of machines. VDE 0160 Electronic equipment for use in heavy current installations. If there are special fields of application, other regulations must be followed if necessary. 5

Operating Instructions

Charger LGW 22406

A.S.T. Leistungselektronik GmbH _______________________________________________________________________

2 Technical Data LGW 22406 ID 01 264 V

LGW 22406 ID 02 432 V

Number of cells

LC-P127R2P Panasonic Sealed Lead-acid battery 132

LC-P127R2P Panasonic Sealed Lead-acid battery 216

Nominal input voltage

357 V DC

565 V DC

Input voltage range

274 to 715 V DC

442 to 715 V DC

Surge protection Stand by power

715 to 900 V for 2 s without destruction