High Efficiency Intelligent Charger 01

Product Name: High Efficiency Intelligent Charger 01 Principle: LLC Resonant Charging Type: Electric Charger Type: Lithium Ion Battery Charger Input Voltage: 85~265VAC Rated Power: 3.3kw Origin: China Product Description High Efficiency Intelligent ChargerUser Manual Ver.1.5.3Table Of ContentsI.Product Overview.. 1II.Safety Instructions 2III.Preventing Leakage and Fire. 31.Correct use of Breakers, Sockets and Cables 32.Correct Use of Input Connections 43.Charging Environment Requirements 4IV.Regularly Maintenance. 5IV.Product Models 5V.Technical Specifications 6VI.parts list 7VII.Input and output interface. 8VIII.Charging Indicator Information Description. 10IX. Methods of Operation. 12X. Appearance and Installation Dimensions 13XI.Faults & solutions 14 I Product OverviewThe 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 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 InstructionsPlease 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 2.5mm2 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 2.5mm2 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 Fire1. 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 2.5mm2.(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 2.5mm2.(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 (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 2.5mm2.(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 Models1. Available Product Models CH4100-4830,CH4100-4835,CH4100-4840 CH4100-6025, CH4100-6030,CH4100-6035CH4100-6425, CH4100-6430,CH4100-6435CH4100-7220, CH4100-7225,CH4100-7230CH4100-8015, CH4100-8020,CH4100-8025CH4100-8415, CH4100-8420,CH4100-8425CH4100-9615, CH4100-9620,CH4100-9625CH4100-14410, CH4100-14415Note: Portable versions are available for above models, these models will be ended with a structure code 'B' such as 'CH4100-4825B'.V Technical SpecificationsRated input voltage: 220Vac 50/60HzInput 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 DescriptionMaxim output voltage: 140%UnRated output current (Ir): See Model DescriptionVoltage regulation accuracy: ≤ 0.5%Current regulation accuracy: ≤ 2%Conversion efficiency: ≥ 95% @ 220Vac input, full power outputProtection class: IP66Audible Noise: ≤ 40dBSeismic rating: Designed according to IEC60335-2-29-2004-Part.21Working temperature: -25~55 degree Celsius (Note: models whose output power greater than 2KW will ensure 2KW output at 60 degree Celsius. )Storage temperature: - 40~80 degree CelsiusRecognition certificates: CE SGSVI parts listA AC input Cables B DC output cables C Signal CablesD Charging indicator E Mounting plate F ShellG Cooling fan and fan coverVII Input and output interfaceInput CablesTerminal ModelDJ7031-4.8-11 Direction of view: form the cables to terminal.Terminal Model for matchingDJ7031-4.8-21Needle No.Wire ColorWire core diameterDescription1#brown2.5 mm2L--Live wire2#blue2.5 mm2N--Neutral wire3#Yellow and green2.5 mm2PE--Protective grounding wireOutput CablesTerminal ModelSB50Needle No.Wire ColorWire core diameterDescription+red6 mm2Output positive pole-black6 mm2Output negative poleSignal CablesNeedle No.Wire ColorWire core diameterDescriptionNeedle No.1#brown2#BlueDJ7031Y-2.3-21external LED indicator interfaceDJ7031Y-2.3-113#yellow4#purpleDJ7021-1.5-21Battery Temperature sensor interfaceDJ7021-1.5-115#white6#pinkDJ7043-2-21Serial communicationinterfaceDJ7043-2-117#Yellow and green8#Blue and white9#Green and white10#orangeDJ7021-2-11Forbidden signal interface(normal close)DJ7021-2-2111#greyWire core diameter0.5 mm2 for all Signal wiresSignal Cables Terminal DiagramDirection of view: form the cables to terminal.DJ7021-2-21DJ7021-1.5-11DJ7031Y-2.3-11DJ7043-2-11VIII Charging Indicator Information DescriptionThe 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.LED Indicator Information DescriptionI. Charging Process Information1Low battery powerR---2Battery charge lower than 80%R-3Battery charge between 80%--90%Y-4Battery charge between 90%--100%G-5Full chargeNormal process of chargingcontinuous Green lightBattery temperature sensor faultGreen light (3S) Yellow light (0.3s)II. Alarm Information1Battery Not connectedR-G---2Charger over-temperature protectionR-G-Y---3Input fault protectionR-G-Y-Y---4Charging timeoutR-G-Y-Y-Y---5Battery OverheatingR-G-Y-Y-Y-Y---6Pre-Charge timeoutR-G-Y-Y-Y-Y-Y---7Internal temperature sensor faultR-G-Y-Y-Y-Y-Y-Y---8Output voltage feedback faultR-G-Y-Y-Y-Y-Y-Y -Y---9Low 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-yellowIX 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 DimensionsIf cables of the charger need to be bended, the length from bending place to the shell should not be less than 50 mm (as shown in Figure).Leave at least 50mm away from cooling fan of the charger to other obstructions to improve heat radiating of the charger (as shown in Figure).XI Faults & solutionsIf your charger can not work correctly, you can refer to table belowFault PhenomenonAnalysisSolutionsBattery temperatureSensor FaultExternal battery temperature sensor is fault or not connectedCheck sensor connection or change a new oneBattery not connectedBattery is not connected or reverse connectedCheck and connect the battery correctlyOver-temperatureprotectionCharging environment temperature is too high; cooling fan is fault;air vents are obstructedPlace the charger in lower temperature environments and recharge;Check whether cooling fan is fault or air vents are obstructed Input fault protectionPoor contact of charger's input side ; Charger is brokenIf no poor contact phenomenon occurs, please contact usCharging timeoutBattery is damaged or agingCheck and replace batteryBattery OverheatingBattery is damaged or agingCheck and replace batteryPre-charge timeoutBattery is damaged or agingCheck and replace batteryInternal temperaturesensor faultCharger is broken insidePlease contact usOutput voltagefeedback faultCharger is broken insidePlease contact us"Full Power "aftershort chargingBattery 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 chargedBattery temperature becomes more than 50ºC and produces a lot of bubblesBattery is aging ;Battery voltage is lower than the nominal voltage of the chargerCheck the battery, and replace bad battery; Reselect charger that match battery voltage level .Low battery capacity after fully chargingBattery is agingReplace the batteryCables are too long or too thin Between the charger and batteryresume The output cables back to initial stateCharging time becomes too short or too longBattery is agingReplace the batteryCharger overheating protectionCheck if there are foreign matters around the fan and remove themCheck whether the cooling fan is working correctly, or contact us to replace the fan.LED indicator lights but no chargingConnectors are not connected firmly, or the polarity is reversed; Battery is disconnectedConnect all connectors correctly and rechargeBattery is brokenReplace new batteryLED indicator doesn't lightAC input is not connected firmlyCheck AC power supply and chargers' input cablesCharger is broken insidePlease contact usIf your charger still cannot work correctly after above treatment, please record the state of the fault phenomenon and charging indicator information, then contact us.