2019 08 06 Tricom FuturRF Servicemanual en

Service manual
FUTUR
Energy. Endurance. Power.

Service manual TriCOM FUTUR
Preface
Notes on the service manual
The safe operation of the charger requires knowledge that this instructions provides. The information thus
provided has been presented in a concise and well-structured form, with the sections, sub-sections and pages
being consecutively numbered.
This instruction documents chargers of the type TriCOM ® Futur. You can take the relevant data from the
"Technical information". Make sure when operating the charger and carrying out maintenance work that the
product description for the relevant charger is observed.
Our chargers are continually developed further. Please understand that we reserve the right to make changes
as to the shape, the design and the technology. It is therefore not possible to derive any claims regarding
certain properties of the charger from the content of these operating instructions.
2 Service manual TriCOM FUTUR

Table of Contents
1. General matters concerning these service manual 5
2. Safety 6
2.1 Explanation of signs and symbols ..................................................................................................... 6
2.2 Qualification of the personnel ............................................................................................................ 6
2.3 Intended use ..................................................................................................................................... 7
2.4 Safety instructions on trouble-shooting and maintenance ................................................................. 8
3. Components 10
3.1 Power module IEB770 EU ............................................................................................................... 10
3.2 Power module IEB770 US ............................................................................................................... 11
3.3 EC pump ......................................................................................................................................... 11
4. Housing options 12
4.1 Dimensions and housings ............................................................................................................... 12
4.2 Arrangement of the components in the charger .............................................................................. 14
4.2.1 Housing RF450 ............................................................................................................................... 14
4.2.2 Housing RF455 ............................................................................................................................... 15
4.2.3 Housing RF460 ............................................................................................................................... 16
4.2.4 Housing RF480 ............................................................................................................................... 16
4.2.5 Housing RF550 ............................................................................................................................... 17
4.2.6 Housing RF560 ............................................................................................................................... 18
4.2.7 Housing RF650 ............................................................................................................................... 19
4.2.8 Housing RF750 ............................................................................................................................... 20
4.2.9 Housing RF950 ............................................................................................................................... 21
4.2.10 Housing RF1250 ............................................................................................................................. 22
5. Charger settings 23
5.1 Setting the charging characteristic .................................................................................................. 23
5.2 Setting the service characteristic (formation, desulphation) ............................................................ 25
5.3 Expert Mode .................................................................................................................................... 26
5.3.1 Activate Expert Mode ...................................................................................................................... 26
5.3.2 Change charging parameters in Expert Mode ................................................................................. 27
5.4 Read out charging history ............................................................................................................... 29
5.5 Firmware update ............................................................................................................................. 30
6. Troubleshooting and correction 32
6.1 General procedure .......................................................................................................................... 32
6.2 Malfunctions and error messages ................................................................................................... 32
6.3 Error messages via the graphic display (touch screen) ................................................................... 34
6.4 Warnings ......................................................................................................................................... 35
6.5 Troubleshooting flowcharts ............................................................................................................. 35
6.5.1 Initial test ......................................................................................................................................... 36
6.5.2 Functional test ................................................................................................................................. 37
6.5.3 Module test ...................................................................................................................................... 38
6.5.4 Module replacement ........................................................................................................................ 39
Service manual TriCOM FUTUR 3

7. Repair measures 40
7.1 Module fuses ................................................................................................................................... 40
7.1.1 Fuse ratings on name plate ............................................................................................................. 40
7.1.2 Fuse ratings EU modules ................................................................................................................ 41
7.1.3 Fuse ratings US modules ................................................................................................................ 41
7.2 Operating and display unit .............................................................................................................. 41
7.2.1 Description of the operating and display unit .................................................................................. 42
7.2.2 Replace operating and display unit ................................................................................................. 42
7.3 Power modules ............................................................................................................................... 43
7.3.1 Nominal voltage of the power module ............................................................................................. 43
7.3.2 Check power modules ..................................................................................................................... 44
7.3.3 Replace power modules .................................................................................................................. 46
7.4 Processor card ................................................................................................................................ 50
7.5 Module fans ..................................................................................................................................... 51
7.5.1 Check module fan ........................................................................................................................... 51
7.5.2 Replace module fan ........................................................................................................................ 52
7.6 Control card for device options ........................................................................................................ 53
7.6.1 Check control card for device options ............................................................................................. 54
7.6.2 Replace control card for device options .......................................................................................... 54
7.7 Charging process with electrolyte circulation "EC" (O) .................................................................... 55
7.7.1 Check EC pump .............................................................................................................................. 55
7.7.2 Replace EC pump ........................................................................................................................... 56
7.8 Remote display (external display) (O) ............................................................................................. 56
7.8.1 Check remote display ...................................................................................................................... 57
7.8.2 Replace remote display ................................................................................................................... 57
7.9 Charging process with temperature compensation (O) ................................................................... 57
7.9.1 Check temperature sensor on the battery ....................................................................................... 58
7.9.2 Check temperature sensor in the charger ....................................................................................... 58
7.9.3 Replace temperature sensor on the battery .................................................................................... 59
7.9.4 Replace temperature sensor in the charger .................................................................................... 59
7.10 Aquamatic function (O) .................................................................................................................... 60
7.11 Pilot contact "Safety Disconnect" (O) .............................................................................................. 60
7.12 Li-Ion chargers ................................................................................................................................ 62
7.12.1 Check Li-Ion CAN interface ............................................................................................................. 62
7.12.2 Replace Li-Ion CAN interface .......................................................................................................... 62
7.12.3 Replace Li-Ion CAN wiring .............................................................................................................. 63
8. Maintenance 64
8.1 Cleaning, inspection and maintenance ........................................................................................... 64
8.2 Replace EC pump filter ................................................................................................................... 65
8.3 Spare parts ...................................................................................................................................... 66
8.4 Disposal .......................................................................................................................................... 66
9. Technical Information 67

1 General matters concerning these service
manual
These service manual are meant to facilitate the intended use and the safe operation of the chargers of the
type TriCOM ® Futur which are referred to hereinafter merely as charger.
The service manual is also intended to assist in checking and repairing the chargers.
The service manual must always be available and are to be kept close at hand in the vicinity of the charger.
The service manual needs to be read and applied by all persons commissioned to operate the charger. Apart
from actually operating the charger, this includes shipping, putting up, installing, maintaining and
disassembling it.
When being used for commercial purposes, not only these service manual are to be observed, but also the
directives, standards and laws for the safe and professional work that are applicable at the site of
deployment or in the country where the charger is used.
Further information in addition to these service manual can be obtained from the experts of the manufacturer
or from the supplier.
All documents are protected under the copyright law. Neither the documents as a whole nor extracts thereof
must be copied or passed on to any third parties without the consent of the owner. Nor is the usage of the
documents’ contents allowed, unless explicitly approved.
service manual TriCOM ® Futur Service manual TriCOM FUTUR 5

5
2 Safety
2.1 Explanation of signs and symbols
The charger has been manufactured in accordance with the generally recognized rules of sound engineering
practice. Additional safety instructions are given, in order to sufficiently ensure the personnel’s safety.
Sufficient safety can only be achieved and ensured, if these additional instructions are duly observed when
operating the charger.
Safety instructions and markings

Safety instructions and important explanations are marked (pursuant to EN 82079) as follows:
! Danger
Identifies an imminent dangerous situation! If not being avoided, it will result in death or severe injuries.
! Warning
Identifies a potentially dangerous situation! If not being avoided, it might result in death or severe injuries.
! Caution
Identifies a potentially dangerous situation! If not being avoided, it might result in slight or minor injuries.
Note
Identifies a potentially harmful situation (risk of property damage)! If not being avoided, the plant or an object
in its surroundings may get damaged.
The following symbols are used in the document:
ð stands in front of notes and explanations
¡ identifies the optional additional equipment
2.2 Qualification of the personnel

Only duly qualified personnel must operate the charger. The personnel’s responsibilities for operating,
installing and repairing the charger must be clearly and strictly separated.
! Warning
Warning against dangerous voltage!
The charger is an electrical appliance that conducts electricity, the current and voltage of which is
dangerous.
ð The charger must only be operated by duly qualified personnel.
ð Disconnect the power supply and, where applicable, the connection with the battery, before working on
the charger.
ð The charger must only be opened and repaired by duly qualified electricians.
Duly qualified personnel in accordance with these fundamental notes are persons who are familiar with:
- putting up and installing,
- commissioning,
- operating,
- shutting down and disassembling the charger
and have the required qualification for these jobs.
service manual TriCOM ® Futur 6

The charger must only be maintained by duly qualified and authorized electricians.
The manufacturer hereby points out that he cannot be held liable for any damage, breakdowns or
malfunctions caused by the non-observance of these service manual.
Commercial use
If the charger is used for commercial purposes, the following shall apply additionally:
- The operator must have been familiarized with the charging process of the batteries concerned and their
handling by having been given special instructions or by having attended training sessions.
- Only specialist personnel assigned to their job must work on the charger.
2.3 Intended use

The charger has exclusively been designed to charge a battery (rechargeable).
Depending on the charging parameters set, only batteries matching these pre-set parameters must be
charged. The charger is not suitable for charging non-rechargeable batteries.
At the operator’s request, the charger can be equipped with various types of charging plugs. The operator
shall:
- only use those charging plugs that are designed and specified for the appliance’s charging current and
for the battery voltage.
- exclude the connection of unsuitable battery types by mistake.
- The latter can be avoided by the color-coding or the mechanical coding of the charging plug.
Note
The regulations of the battery manufacturer shall be observed and complied with.
! Caution
It is the duty of the operator in the case of a charger with a subsequently modified charging program to
permanently indicate the matching battery type visibly on the outside of the housing!
! Danger
Danger of explosion when charging unsuitable or incorrectly set battery types!
Charging a battery that is not approved for this charger is prohibited. Moreover, the charging program set in
the charger and the battery type to be charged must be in conformity with each other. Failing to observe the
above instructions may damage both the charger and the battery. The battery can excessively emit gas, boil
off and even explode!
ð It must always be checked, whether the charger has been set for the battery type concerned. In cases
of doubt do get in touch with the competent specialists.
The intended use of the equipment requires that :
- the specification concerning the site of deployment (see section Safety instructions about putting up and
installing and section Requirements concerning the site of deployment),
- the details on the name plate (see section name plate),
- the Technical Information (see annex Technical Information)
are observed and complied with.

! Danger
There is a danger of severe personal injury and property damage caused by:
ð the improper use or the incorrect operation,
ð the unauthorized opening,
ð or the incorrect installation or the improper maintenance and repair of the charger.
All information about the intended use, the residual risk, the installation, the operation and the maintenance
as contained in this service manual must be observed and complied with.
The charger must only be used for applications described in this service manual and in the technical
specification and only with accessories or components recommended or approved by the manufacturer.
Any other use or any use beyond these limits is not deemed to be within the scope of the unit’s intended
use. The operator or user of the charger shall therefore be solely responsible for any resultant damage.
The charger must only be put into operation with the Directive (2014/30/EU) on Electromagnetic
Compatibility being observed.
2.4 Safety instructions on trouble-shooting and maintenance

Please observe the following notes:
ð Maintenance work must only be carried out in accordance with the instructions in this service document.
ð When working with batteries, personnel must not smoke or be near any naked flames. Flammable
substances or substances which might produce sparks must be kept at least 2 meters away from the
area in which batteries are charging. The room in which the charger is stored and operated must be
ventilated. Firefighting equipment must be kept at hand.
ð Only trained and qualified electricians may open the charger.
ð Even when the charger is switched off, some internal components are still live until the unit is
disconnected from the battery or from the mains.
ð The housing of the charger should only be opened 5 minutes after the unit is disconnected from the
battery and the mains. This will allow the capacitors to discharge.
ð Any tools to carry out work on the inside of the charger must be insulated.
ð All personnel involved in carrying out repair and maintenance work on the charger must be familiar with
first aid procedures in case of electrical accidents.
ð The local electricity provider's guidelines and other safety regulations must be observed!
ð The insulation resistance cannot be measured.
ð Use the differential current measuring method to measure the leakage current.
ð Carry out DGUV V3, TRBS 2131 and/or VDE 0701-0702 regulation checks on the charger (if
necessary) after completion of repair or maintenance.
ð Once all of the screws have been fitted to close the lid of the housing, the charger can be returned to
operation.
8 service manual TriCOM ® Futur

8
! Warning
dangerous.
the charger.
! Warning
ð Modifications, additions or conversions that may affect the safety must not be made without the
manufacturer’s approval! This shall also apply to the installation and setting of safety devices. Special
care shall be taken that spacings, clearances and air paths are not reduced.

9
3 Components
3.1 Power module IEB770 EU
Note
Depending on the power supply, different power modules can be installed. The IEB770 EU or the IEB770 US
module can be used. This has no influence on the housing (exception RF450, RF455, RF460 only for EU,
RF480 only for US).
The following drawing shows a single EU power module.
1 power module 9 minus pole of the battery connection

2 fan 10 plus pole of the battery connection
6 charging fuse 19 coding switch for the mechanical position of
the power module
7 mains fuse 20 CAN connection of the power module
8 fan connection and pilot contact 21 DSP card with CAN termination resistor
10service manual
Service TriCOM ® Futur
manual TriCOM FUTUR
10
3.2 Power module IEB770 US
Note
Depending on the power supply, different power modules can be installed. The IEB770 EU or the IEB770 US
module can be used. This has no influence on the housing (exception RF450, RF455, RF460 only for EU,
RF480 only for US).
The following drawing shows a single US power module.
1 power module 9 minus pole of the battery connection

2 fan 10 plus pole of the battery connection
6 charging fuse 19 coding switch for the mechanical position of
the power module
7 mains fuses 20 CAN connection of the power module
8 fan connection and pilot contact 21 DSP card with CAN termination resistor
3.3 EC pump
17 EC pump - controller card for the electrolyte circulation
service manual TriCOM ® Futur 11 Service manual TriCOM FUTUR 11

4 Housing options
Various housing variants are available for the installation of the power modules. Depending on the power
supply, different power modules can be installed. The IEB770 EU or the IEB770 US module can be used.
This has no influence on the housing (exception RF450, RF455, RF460 only for EU, RF480 only for US).
4.1 Dimensions and housings
Dimensions (in mm) [in inch] Weight (in kg) [in

Housing
Width Heigth Depth lbs]
RF450 (only EU) 430 [17.0] 270 [10.7] 125 [5.0] min. 12.0 [27]
RF455 (only EU) 430 [17.0] 430 [17.0] 170 [6.7] min. 13.5 [30]
RF460 (only EU) 290 [11.5] 550 [21.7] 100 [4.0] min. 12.5 [28]
RF480 (only US) 430 [17.0] 305 [12.1] 145 [5.8] min. 14.5 [32]
Example of the housing RF450
12service manual
manual TriCOM FUTUR
12
Dimensions (in mm) [in inch] Weight (in kg)
Housing
Width Height Depth [in lbs]
RF550 430 [17.0] 415 [16.4] 355 [14.0] min. 30.0 [67]
RF560 430 [17.0] 510 [20.1] 355 [14.0] min. 45.0 [100]
RF650 430 [17.0] 735 [29.0] 355 [14.0] min. 65.0 [144]
RF750 430 [17.0] 840 [33.1] 355 [14.0] min. 80.0 [177]
RF950 430 [17.0] 1015 [40.0] 355 [14.0] min. 89.0 [197]
RF1250 (standing device) 460 [18.2] 1300 [51.2] 550 [21.7] min. 127.0 [280]
Examples of housings RF560, RF650 and RF1250

13
4.2 Arrangement of the components in the charger
Depending on the device configuration, EU or US modules are installed. There are also versions with or
without graphic display or an EUW pump for electrolyte circulation in wet batteries.
The chargers can be installed as stand-alone or wall-mounted units, depending on the place of use. The
mains plugs and charging plugs are installed according to the customer's requirements. The same applies to
the color design of the housing.
The different housing variants are shown below as examples.
4.2.1 Housing RF450

This housing variant is only used for EU power modules.
1 power module 12 graphic display (touch screen)

3 charging cable 13 housing door (front)
4 mains cable with mains plug 15 feet
5 charging plug 16 processor card
11 LED display and USB unit
14service manual TriCOM ® Futur

14
4.2.2 Housing RF455
This housing variant is only used for EU power modules. An EC pump is installed in it.
1 power module 13 housing door (front)

3 charging cable 15 feete
4 mains cable with mains plug 16 processor card
5 charging plug 17 EC pump
11 LED display and USB unit 18 controller card for the electrolyte circulation
12 graphic display (touch screen)

4.2.3 Housing RF460
This housing variant is only used for EU power modules. It is specially designed as a slim stand-alone
device.
4.2.4 Housing RF480

This housing variant is only used for US power modules.
1 power module 11 LED display and USB unit

3 charging cable 12 graphic display (touch screen)
4 mains cable with mains plug 13 housing door (front)
5 charging plug 16 processor card
16service manual
manual TriCOM FUTUR
16
4.2.5 Housing RF550
1 power modules (3x) 14 housing door (side)

3 charging cable 15 feet
12 graphic display (touch screen) 21 mains terminal
13 housing door (front)

4.2.6 Housing RF560
1 power modules (4x) 14 housing door (side)

13 housing door (front)
18service manual
manual TriCOM FUTUR
18
4.2.7 Housing RF650
1 power modules (6x) 13 housing door (front)


4.2.8 Housing RF750

3 charging cable 16 processor card
4 mains cable with mains plug 17 EC pump
5 charging plug 18 controller card for the electrolyte circulation
11 LED display and USB unit 21 mains terminal
20service manual
manual TriCOM FUTUR
20
4.2.9 Housing RF950

3 charging cable 16 processor card
4 mains cable with mains plug 17 EC pump
5 charging plug 18 controller card for the electrolyte circulation
11 LED display and USB unit 21 mains terminal

4.2.10 Housing RF1250
RF1250 with 12 power modules
22service manual
manual TriCOM FUTUR
22
5 Charger settings
! Danger
Danger of explosion when charging unsuitable or incorrectly set battery types!
Charging a battery that is not approved for this charger is prohibited. Moreover, the charging program set in
the charger and the battery type to be charged must be in conformity with each other. Failing to observe the
above instructions may damage both the charger and the battery. The battery can excessively emit gas, boil
off and even explode!
ð It must always be checked, whether the charger has been set for the battery type concerned. In cases
of doubt do get in touch with the competent specialists.
Various charging settings are stored in the charger. The settings of different chargers may differ.
This depends on:
- customer
- charger type
- firmware version
- customer-specific special adjustment
The charging settings stored on the processor card are attached to the charger in the form of a characteristic
table and can be changed via the programming interface or via a USB firmware update.
The installed firmware is indicated on the name plate, as well as the installed software of the DSP card.
5.1 Setting the charging characteristic

Note
ð The set charging characteristic is indicated by rapid flashing of the LEDs (3 times per second).
ð All unused characteristic curve settings are indicated by slow flashing of the LEDs (once per second).
After changing the characteristic curve, the charger must be put back into operation and checked for fault-
free operation. In addition, it is recommended to read out the charger and to check the set charging
characteristic with the ConVision FileReader using the readout (see "Read out charging history").
Setting the charging characteristic for devices with graphic display
display in the start display and in the menu for setting the charging curve

Requirements:
- The charger is connected to the mains.
- Start display is active. No battery must be connected.
- The charger is equipped with a graphic display (touch screen).
Procedure:
- Press the characteristic number in the start display.
- Enter the service password.
- Use the arrow keys to select the desired setting. The parameters of the selected charging curve are
displayed on the right.
- Confirm the selection of the charging characteristic with "OK".
Setting the charging characteristic for devices without graphic display
operating and display unit without graphic display with pause button (below)
Requirements:
- No battery must be connected.
Procedure:
- Press the pause button for 3 seconds until the white LED goes out and then flashes briefly every 4
seconds.
- Press the pause button again for 10s to activate the programming mode.
- The LEDs flash rapidly in the currently set characteristic curve combination (4x per second).
- Press the pause button briefly until the corresponding combination of charging curves appears. The
decoding can be found in the characteristic table.
- Press and hold the pause button again until the LEDs flash rapidly (5s).
- The changed characteristic is activated.
- Press the Pause button between 1.5s and 3s to exit the programming mode.
- Briefly press the pause button to return the charger to standby mode.
24service manual
manual TriCOM FUTUR
24
flow chart for setting the charging characteristic without graphic display
5.2 Setting the service characteristic (formation, desulphation)

The formation or the desulphation can be activated, depending on the battery type (see table with
characteristic). If the desulphation/formation has been carried out properly, the charger will automatically
return to the standard setting of the relevant charging characteristic.
Formation charge
The formation characteristic serves the formation during the commissioning of new batteries: The battery will
be charged with an increased charging factor (1.3) during the first three charging cycles. The re-charging will
be extended, when at least 50 % of the battery’s rated capacity has been charged during the main charging
phase. The standard setting of the relevant charging characteristic will again be automatically activated after
three successful formation charges.
Desulphation
The desulphation characteristic is used for sulfated batteries to reduce/remove the sulfate layer. In doing so,
the battery will be charged with a constant current (of approx. 3 A/100 Ah) for 24 hours. After the end of the
desulphation charging, a charge with the standard setting of the relevant characteristic will be applied with a
delay of 30 min, so as to charge the battery to its full capacity.

Requirements:
- The charging characteristic with its charging function has been set in the charger.
- The battery voltage amounts to least 0.5 V/cell.
- The battery voltage does not exceed 2.4 V/cell.
- The charger is:
- in the stand-by mode (with the start display being active) or
- in the start phase of the charge (i.e. 5 sec before the charging starts).
Procedure:
- Press the pause key briefly.
- Select and activate the required service characteristic in the pull-down menu by pressing the pause button
for at least 5 sec.
- The selected service characteristic can be deactivated by also pressing the pause button for at least 5 sec.
- It is possible to always set only one service characteristic. Once a service characteristic has been
activated, it must first be deactivated, before another one can activated.
Service characteristic LED display Description

during the setting
Formation (O) Deactivated:
only for batteries of types PzS, LED <80 % is flashing slowly
GiV, PzV Activated:
No separate display while being LED <80 % is flashing rapidly
charged.
Desulphation (O) Deactivated:
only for batteries of the type LED <80 % is flashing slowly
PzS Activated:
The LED >80 % is flashing LED <80 % is flashing rapidly
during charging.
Setting the service characteristics via the graphic display (O)

The characteristics can also be set on the optional graphic display by pressing the service button. Following
that, the service characteristic concerned can be activated. The relevant function is indicated on the start
display of the graphic display ("*F" behind the set charging characteristic for the formation charge or "Desulf.
24h" instead of the set charging characteristic for an activated desulphation charge).
5.3 Expert Mode

If the battery charger contains the work function, it is possible to adjust the charger to the battery. So it is
possible to charge different wet and gel batteries with only one charger (only for wet and gel batteries, not
necessary for lithium batteries).
Furthermore different charging options can be activated.
5.3.1 Activate Expert Mode

Requirements:
- the charger must be switched on
26service manual
manual TriCOM FUTUR
26
- the battery is not connected with the charger.
Procedure:
- When pressing the button "work" on the touchscreen for more than 1 sec, the charger opens the
password protected menu.
- Type in the password 1234 (if four characters are requested) or 75019 (if five characters are requested).
- The work menu will be opened.
set battery
voltage and symbolic battery
charging current status
of the charger
button for
set charging
entering the work
characteristic
mode
set capacity
range
set battery type /
temperature
compensation (O)
5.3.2 Change charging parameters in Expert Mode

The following graphic shows the menu to change the charging parameters individually. The touch display
can be used to select and change the charging parameters directly. By pressing the up or down arrow keys,
the entries can be selected as well. The changes have to be done from the top to the bottom because there
can be dependencies between the several entries.
If the necessary changes are done, the arrow key to the right has to be pressed to save the changes. Finally
you have to confirm the changes to activate the parameters.
The following figure shows the menu in which the charging parameters can be set individually.
Battery type
The charging voltages are adjusted depending on the selected battery type.

The following battery types can be set:
- Flooded (PzS)
- Gel (PzV)
- Gel Bloc (GiV)
- AGM
Charging profile
The following charging profiles can be set, depending on the selected battery type:
- IUoU
- IUIoIa
- IUpuls
- Desulphation 24 hours
charging characteristic Flooded (PzS) Gel (PzV) Gel Bloc (GiV) AGM
IUoU X X X X
IUIoIa X X X -
X - - -
IUpuls
Desulphation 24 hours X - - -
Desulphation
The desulphation characteristic is used for sulfated batteries to reduce/remove the sulfate layer. In doing so,
the battery will be charged with a constant current (of approx. 3 A/100 Ah) for 24 hours. After the end of the
desulphation charging, a charge with the standard setting of the relevant characteristic will be applied with a
delay of 30 min, so as to charge the battery to its full capacity.

Battery voltage
The battery voltage can be adjusted in steps of 2V as well.
Battery capacity
The battery capacity can be set, too. Therefore a numeric keypad is shown to enter the capacity (in Ah) of
the battery to be charged.
Charging current
The charging current can be adjusted to the needs of the battery. The current can be set within a range of
8.0 to 20.0A/100Ah. In combination with the previously entered capacity of the battery, the maximum
charging current of the charger is calculated.
Battery temperature
For optimal results the battery temperature can be set. Depending on this temperature a compensation of
the charging characteristics will be performed. The default value is 30°C/86°F.
If the charger is equipped with the optional temperature sensor, this measured value will be used.
Electrolyte circulation
The electrolyte circulation can be activated/deactivated only for the battery type flooded (PzS). For further
information read the chapter containing the charger options.
Aquamatic function
The Aquamatic function can be activated/deactivated only for the battery type flooded (PzS). For further
information read the chapter containing the charger options.
Formation charge
The formation characteristic serves the formation during the commissioning of new batteries: The battery will
be charged with an increased charging factor (1.3) during the first three charging cycles. The re-charging will
be extended, when at least 50 % of the battery’s rated capacity has been charged during the main charging
phase. The standard setting of the relevant charging characteristic will again be automatically activated after
three successful formation charges.
The formation charge can be activated/deactivated only for the battery type flooded (PzS).
5.4 Read out charging history

The charger can be read out via the USB interface.
Requirements:
- Start display is active. No battery must be connected.
- A formatted USB stick is available.
If the USB stick is plugged into the USB interface on the charger when the start display is active, the data is
automatically exported to the main folder of the USB stick. A progress bar is displayed, which is hidden again
after the data has been read. In addition, an LED running light from top to bottom signals the writing process
on the USB stick. The USB stick can then be removed again.
The file name on the USB stick contains the serial number of the charger, the date and time of the readout
(e.g. "123456_20180220_123434.ieb770").

data export of the charging history to a USB stick
import of the exported charging history using ConVision FileReader
5.5 Firmware update

In addition to the programming interface, the processor card can also be updated with a firmware via the
USB interface.
Requirements:
- The charger is not connected to the mains.
- A formatted USB stick is available.
- The firmware file is stored in the main directory of the USB stick.
- The firmware file name is "image512.hex" (rename if necessary, upper/lower case is irrelevant).
Procedure:
- When the charger is switched off, plug the USB stick into the USB interface of the operating and display
unit.
- Connect the charger to the mains.
- The charger automatically updates the firmware if the above requirements are met.
- Updating is additionally indicated by an LED running light from bottom to top.
- After completion of the update (approx. 15-20s) a restart takes place. The display briefly turns white.
30service manual
manual TriCOM FUTUR
30
inserted USB stick with firmware when the charger is switched off
If the LED running light does not appear and the process only takes 1-2s, check whether:
- a USB stick is connected.
- the file is in the root directory.
- the file name is "image512.hex".
In the event of an error, use another USB stick if necessary.
Alternatively, the firmware update can also be triggered via the menu when the charger is switched on. To do
this, press the arrow on the right side of the screen. After typing in the password 1234 (for a 4-digit
password) or 75019 (US customers) respectively 14624 (EU customers) (both for a 5-digit password) the
process is triggered via the menu item "software update" when the USB stick is inserted. A battery must not
be connected. The rest of the procedure is identical to the above procedure.

6 Troubleshooting and correction
6.1 General procedure
The LEDs on the control and display unit give the operator a quick overview of the function of the battery
charger (see battery charger operating instructions).
The following devices may be useful for troubleshooting:
- Current clamp for direct current
- Multimeter with measuring tips
- USB stick for reading the charging history
- PC with software ConVision FileReader for the evaluation of the charging history
6.2 Malfunctions and error messages

The five LEDs of the operating and display unit indicate malfunctions and the status of the charger:
LED
Error group Description
display
battery fault
BAT
- incorrect battery voltage established
time or capacity fault

- preliminary charging takes too long (battery voltage <1.5 V/cell for longer
than 30 min)
TIME
- constant current phase (I1) is too long
- constant voltage phase (U1) is too long
- capacity monitoring has been triggered
system fault
SYSTEM - problem with the internal data bus
- module defective
external communications fault

COM
- communication with connected peripheral devices impaired
temperature fault
TEMP - internal temperature fault
- external temperature fault (optional)

32
The following table provides an overview over possible causes of faults and their rectification:
Error group Corrective measures
Starting point: the battery must be connected.
Check the battery allocation.
Check the battery’s polarity and correct it, if applicable.
Measure the battery voltage:
BAT - Battery voltage is under 0.5 V/cell.
- Raise the battery voltage with suitable measures above 0,5 V/cell.
Check the battery, whether there is an internal short circuit.
Check the output fuse of the appliance.
If the fault continues, do contact the service technician.
Check the battery allocation.
Check the battery itself.
- Battery too hot: if a battery defect can be excluded, continue the charging process after
a sufficient cooling down phase.
- Battery defective (e.g. internal short circuit).
- Battery was deeply discharged: re-start the charging process.
Compare the battery’s rated voltage and capacity with the setting in the charger.
- If there is no suitable setting for charging the battery, the charger cannot be used for
TIME this battery.
- If the battery capacity is only slightly higher (max. 25%) than stated on the charger, the
charging is possible to a limited extent, which cannot be recommended for a longer
period. Besides, you must expect the same error message every time you charge a
battery.
Check the preliminary charging current.
- If the measured current is clearly lower than the preliminary charging current specified
by the charging characteristic, there is a fault in the charger.
- If the fault re-occurs after 30 min., do get in touch with the service technician.
Disconnect the charger from the mains and re-start it after 1 min. in order to confirm the
fault.
Check the charger to identify the connection that may possibly be loose, after you have
SYSTEM disconnected charger and battery.
If the power module is defective, the defective module will be indicated, if the charger is
equipped with a display.
If the fault continues, do get in touch with the manufacturer of the charger.
COM Check the connected peripheral devices.
Check the connections between the peripheral devices and the charger.
TEMP Check the inlet and outlet air openings.
- The openings of the charger must not be obstructed.
- If dust filters have been installed, clean or replace them, if necessary.
- Select a site of deployment for the charger, where an unobstructed air flow is ensured.
- Maintain a sufficient distance to other chargers or heat sources.
- A too high ambient temperature may affect the charging process.
- Check the ventilators’ function during the charging process.
Check the battery itself.

33
Error group Corrective measures
- It must not be hot when being touched; if so, let it cool down.
If all these causes can be excluded, do get in touch with the service technician.
6.3 Error messages via the graphic display (touch screen)

The graphic display (touch screen) of the operating and display unit is used to indicate errors and the status
of the device. The error message is displayed in the middle of the screen, as shown in the figure below.
touch screen with error message (time error "Iconst")

Further error messages such as "Wrong battery", "CAN BUS error", "I2C BUS error", "SPI BUS2 error" or
"1Wire BUS error" are possible and are partly supplemented by equipment dependent error messages.
If a "Module error" occurs, it can be evaluated in a more detailed error display. The "Module error" error
message field on the touch screen must be pressed to do this. The status display of the modules then
opens. In addition to the mechanical position of the faulty modules, an error code and a short description
describe the problem.
touch screen with error message (module error)
touch screen with error message (details of the faulty modules)

6.4 Warnings
Warnings will not interrupt the charging process; they merely draw the user’s attention to that fact that there
is a problem which is affecting the charging process.
The following (and other) warnings may be received:
Behavior of the charger
LED display Warning Corrective measures
without interference
Check the connection of the
temperature sensor and
especially, whether it is
externally damaged. Inform
the manufacturer of the
The battery temperature can
charger, if necessary.
temperature sensor no longer be monitored.
Once the fault has been
defective or not A fixed battery temperature
rectified, the red LED will go
connected of 30° C will be set for the
out and the charging process
charger.
will again be adapted to the
x = flashing
current battery temperature.
If the fault continues, do get
in touch with the service
technician.
Check the hose connection
and make sure that the air
hose leading to the battery is
The charging process will be
properly connected.
continued without electrolyte
EC pump cannot Check, whether the air hose
circulation (EC), which
build up pressure is damaged and if so, get it
extends the charging time by
repaired.
up to three hours.
x = flashing If the fault continues, do get
in touch with the service
technician.
6.5 Troubleshooting flowcharts

The following flowcharts support you in the targeted troubleshooting and elimination of errors.
service manual TriCOM ® Futur 35 Service manual TriCOM FUTUR 35

6.5.1 Initial test
36service manual
manual TriCOM FUTUR
36
6.5.2 Functional test

6.5.3 Module test
38service manual
manual TriCOM FUTUR
38
6.5.4 Module replacement

7 Repair measures
7.1 Module fuses
! Warning
Before carrying out any work with the charger, the safety instructions in chapter "Safety" must be observed!
Note
All power modules are mechanically identical. A single power module is described as an example.
Requirements:
- Switch off the battery charger (pull out the mains plug).
- Disconnect the battery from the charger (unplug the charger plug).
- The housing of the battery charger should not be opened until 5 minutes after disconnecting the device
from the battery and mains. This will allow the capacitors to discharge.
- Remove the housing screws from the housing doors.
- Open the housing door to the side.
! Warning
Danger of short-circuit!
When opening the housing door, make sure that the earthing cable attached to it is not damaged or torn off
and that no screws etc. fall into the charger. Remove all metallic objects that have fallen into the charger!
Check/replace fuses
Procedure:
- Check the mains fuses of the power module.
- Check the charging fuse of the power module.
- Replace defective fuses with new, suitable fuses - see section "Fuse ratings EU modules" and "Fuse
ratings US modules".
Put the charger back into operation
Procedure:
- Check whether the connector plugs and screws have come loose. Tighten them if necessary.
- Close the housing doors and reattach them to the housing with the screws.
- Perform regulation tests on the charger (DGUV V3, TRBS 2131, VDE 0701-0702 as required).
- Put the battery charger back into operation and check that it operates correctly.
7.1.1 Fuse ratings on name plate

The fuse values for the mains and charge fuses are marked on the name plate of the charger and with
stickers on each module.
40service manual
manual TriCOM FUTUR
40
Name plate with fuse values
7.1.2 Fuse ratings EU modules
nominal voltage of the module mains fuses charge fuses

24V 1x25A 1x150A
48V 1x25A 1x100A
80V 1x25A 1x50A
120V 1x25A 1x50A
7.1.3 Fuse ratings US modules
nominal voltage of the module mains fuses charge fuses

24V 2x10A 1x150A
48V 2x10A 1x100A
80V 2x10A 1x50A
120V 2x10A 1x50A
7.2 Operating and display unit

! Warning

7.2.1 Description of the operating and display unit
An operating and display unit with five LED elements (of which one is a red/white dual LED), a USB
interface, a pause key and, depending on the design, the resistive 4.3-inch graphic display (optional) are
located on the front side of the charger.
Each component (LED card, USB card, graphic display) of the operating and display unit can be replaced
individually.
7.2.2 Replace operating and display unit

Requirements:
42service manual
manual TriCOM FUTUR
42
! Warning
Operating and display unit without graphic display

Procedure:
- If checking the cable contacts and replacing the cables does not help, remove the cables from the
operating and display unit.
- If you want to avoid replacing the complete housing door, remove the glued operating and display unit
from the housing door.
- Stick a new, functioning operating and display unit onto the housing door.
- If the LED card and/or USB card is defective, loosen the screws on the housing door and replace the
cards with new, functioning cards. Please note that the LED card with three yellow LEDs must also be
installed for the display with blue status symbols.
- Connect the cables to the processor card and to the operating and display unit.
- Check that the cables are correctly seated (note the orientation of the cables).
Operating and display unit with graphic display
Procedure:
- The working steps correspond to the operating and display unit without graphic display.
- If the graphic display as such is defective, loosen the screws that fix the graphic display to the door from
the inside.
- Remove the graphic display and replace it with a functioning graphic display and screw it back onto the
housing door.
- Connect the cables to the processor card and the graphic display.
- Check that the cables are correctly seated (note the orientation of the cables).
Procedure:
7.3 Power modules

! Warning
7.3.1 Nominal voltage of the power module

In addition to the subdivisions "EU" and "US", the power modules are also divided into four voltage classes.
24V, 48V, 80V and 120V. The voltage class is indicated on the nameplate of each power module.

Serial number and module variant
The following table shows the general assignment of the modules to the chargers:
Nominal voltage of the charger up to 24V up to 48V up to 80V up to 120V
Nominal voltage of the power 24V 48V 80V 120V
modules
Note
ð Due to special operating conditions or customer requirements, there may be deviations from the
assignment between charger and power modules. Therefore, the nominal voltage of a module to be
replaced must also be checked with the installed modules. These must always be identical.
7.3.2 Check power modules

When troubleshooting for the defective power module, the error messages via the graphic display and also
the LEDs of the DSP card on the modules can be helpful.
view into the opened charger with the module connections

close-up view of a power module
LED displays and set terminating resistor on the DSP card of a power module
Requirements:

! Warning
Procedure:
- Check the mains voltage (EU: 400V, US: 480V) connected to the power module.
- Check that all DSP BIAS LEDs of all modules are lit. For modules in which the LEDs do not light up,
check the fuses and replace them if necessary (see chapter "Module fuses").
- Switch off the battery charger (pull out the mains plug). Wait 5 minutes after disconnecting the mains
plug to allow the internal capacitors to discharge.
- Check the connection of the processor card to the power module (CAN connection cable), if necessary
ensure that the connection is fixed and correct.
- Replace the power module if none of the checked points could correct the error (see chapter "Replace
power module").
Procedure:
7.3.3 Replace power modules

! Warning
Note
All power modules are mechanically identical. A single power module is described as an example.
Requirements:
! Warning
- To remove a power module, the connections to the module must be disconnected (see "Check power
modules") to carefully remove the power modules out of the housing.

After testing and determining a defect (see "Module replacement") on a power module, it can be replaced
with little effort.
Note
ð The power module may only be replaced by a power module which is designed for the same nominal
voltage (see "Nominal voltage of the power module").
ð The nominal voltage of the new power module must match the nominal voltage of the installed power
module.
Charger with one power module
For a single-module charger, lift the power module upwards after loosening the additional screw (PE
connecting cable) in the bottom of the housing.
mounting position of a single-module charger
Note
Please observe the tightening torques of the screws, otherwise mechanical damage to the power modules
may occur!
Tighten the screws of the charging cable connected to the power module (M8) to 8 Nm.
Charger with more than one power module

For multi-modular chargers, the power modules are held in guide rails.

The individual steps for module replacement in a multi-modular charger are illustrated below:
open the front and side doors of the charger

disconnect mains input cable, CAN connection cable and battery connection.
Note
Please observe the tightening torques of the screws and nuts, otherwise mechanical damage to the power
modules may occur!
Tighten the screws on the battery busbar connected to the power modules (M6) to 4 Nm.
Tighten the nuts on the battery busbar to which the charging cable is attached (M8) to 12 Nm.

carefully pull out the module to the side
The module can then be reinstalled in reverse order. Make sure that the mechanical position on the power
module is set correctly (see "Module replacement") and that the screws and nuts are tightened correctly.

Procedure:
7.4 Processor card

The processor card serves as the central control unit in the battery charger and communicates via the CAN
interface with the power modules connected in series. The characteristic tables for charging the battery are
stored in the processor card. In the rear, there is a buffer battery for supplying the integrated real-time clock.
When connecting all connectors, make sure that they are correctly aligned, as indicated by the recesses in
the processor card.
50service manual
manual TriCOM FUTUR 50
Charging is indicated via the LED card and optionally via the graphic display (touch screen). The operating
and display unit on the housing door contains the pause button and the USB card. This enables the firmware
to be updated and the load history to be read out.
The other interfaces are listed in the following graphic:
Processor card with interfaces

A CAN connection to the power modules F UART connection
B Graphic display (touch screen) G CAN plug-in card
C LED card H programming interface
D 1-wire connection (temperature sensor I Expansion interface (e.g. for control cards for
battery, ID chip etc.) EC, Aquamatic)
E USB card
Optionally, a CAN box is connected to the expansion interface or a CAN plug-in card is mounted on the
processor card, which is used for communication with Li-Ion batteries.
7.5 Module fans

! Warning
7.5.1 Check module fan

Requirements:

! Warning
Procedure:
- Connect the charger to a (partially) discharged battery.
- The charger starts charging.
- The fans start with a delay (temperature-dependent after 5 to 10 minutes).
- The start of the fans can vary from module to module. However, both fans per module must function
perfectly in any case.
If a fan does not function properly, the following steps must be carried out:
- Check the wiring of the fan.
- Check the plug connection of the fan.
7.5.2 Replace module fan

Requirements:
! Warning
Procedure:
- Loosen the fan screws.
- Disconnect the fan plug from the power module.
- Replace the fan with a new, functional fan.
- Connect the fan to the power module (keep the previous installation direction!).
- Attach the screw fastening to the fans.
- Check fan.

module fans (screw fastening of the fans and plug connectors))
Procedure:
7.6 Control card for device options

If the charger has further device options, such as aquamatics or electrolyte circulation (EC), an additional
control card is installed. Depending on the housing variant, this can be found at different positions in the
housing.
Mounting position control card housing variant

Control card on the side of the cable outlet RF450, RF455, RF480
Control card in the lower part of the charger RF550, RF560, RF650, RF750, RF950
Control card near the processor card RF1250
Below is the wiring diagram as well as the equipment variant of the control card with EC:
Circuit diagram and photo of a control card with electrolyte circulation (EC)
service manual TriCOM ® Futur

53
A Connector X1 Supply voltage 230V E Slot X12 Aquamatic
B Fuse control card (1A) F Plug connection to the processor card
C Connector X11 Electrolyte circulation (EC) G Slot X13 for optional function
D Plug EC pressure switch H Slot X14 for optional function
Depending on the equipment of the charger, up to two further functions can be switched optionally in
addition to EUW and Aquamatik. The control card is equipped with a 1A fuse (a maximum of 5A can be
switched).
7.6.1 Check control card for device options

Requirements:
! Warning
Procedure:
- Check wiring.
- Check fuse (1A) on control card.
7.6.2 Replace control card for device options

Requirements:
! Warning

Procedure:
- Disconnect the wiring.
- Remove defective control card.
- Install the new control card in the charger and connect the wiring.
Procedure:
7.7 Charging process with electrolyte circulation "EC" (O)

Note
When the EC pump is switched on, the blue LED "AIR" on the operating and display unit will light. The
proper operation of the electrolyte circulation (EC) will be monitored with a potential-free pressure switch in
the pump housing.
If the charger notes a drop in pressure while charging, the charging process will be continued with a charging
factor of 1.20, with the blue LED "AIR" on the operating and display unit flashing. The relevant operating
status will continue to be indicated by the LEDs.
The battery will continue to be charged with the original charging factor, if the drop in pressure has been
eliminated within the first hour of charging.
When charging with electrolyte circulation, the following needs to be observed:
ð The EC pump must not be operated without counter pressure.
ð Put the charger in such a position that the in-built EC pump is located at least 0.5 m above the battery
to be charged.
ð If an error message is indicated (i.e. the blue LED "AIR" is flashing), charge the battery without
electrolyte circulation to its full capacity. When the charging process is prematurely interrupted, the
battery will not be sufficiently charged, so its available capacity will be reduced.
The pump can only be re-started after the battery has been disconnected.
7.7.1 Check EC pump

! Warning
Requirements:

55
! Warning
Procedure:
- Check the wiring of the EC pump and control cards.
- Check fuses and replace if necessary.
- Connect the charger to the battery.
- Measure the voltage at the EC pump plug directly after connecting the battery charger to the battery.
7.7.2 Replace EC pump

Requirements:
! Warning
Procedure:
- Loosen the nuts from the pump holder.
- Remove the pump holder with the EC pump from the housing.
- Mark and disconnect the EC pump lines.
- Remove the air hose.
- Remove the EC pump from the pump holder.
Procedure:
7.8 Remote display (external display) (O)

As an option, the charger can be equipped with an externally installed remote display instead of the one that
is usually installed in the housing door. The LED display will always be installed by default.

56
The remote display is connected with the charger by way of an external cable (D-Sub) and provides a
graphic image of the LED display on the right-hand side of the screen, in addition to the usual display of the
charging process. Also a button for activating the pause mode is integrated in the remote display.
graphic display in the housing of the remote display
7.8.1 Check remote display

Procedure:
- Check external wiring.
- Disconnect external wiring.
- Open the remote display.
- Check internal wiring and repair if necessary.
7.8.2 Replace remote display

Requirements:
Procedure:
- Disconnect the wiring of the defective remote display.
- Connect the new remote display.
Procedure:
7.9 Charging process with temperature compensation (O)

Note
ð Apart from the temperature sensor itself, the charging software must be suitable for being used together
with a temperature sensor.

When temperature compensation is used during the charging process, the charging voltage will be adjusted
to the measured battery temperature with the help of an external temperature sensor. If the battery’s
maximum temperature is exceeded, the charger will indicate a fault (see section "Malfunctions and error
messages") and interrupt the charging process.
Depending on the battery type used, the set maximum temperatures differ as follows:
- wet-cell battery: 60°C
- gel battery: 50°C
If the charger is unable to establish a connection with the temperature sensor, a warning will be issued (see
section "Warnings"), although the charging will continue.
7.9.1 Check temperature sensor on the battery

Procedure:
- Check wiring.
- Check auxiliary contacts in charging plug.
- Check temperature sensor for external damage.
7.9.2 Check temperature sensor in the charger

Requirements:
! Warning

Procedure:
- Check internal wiring.
- Check the plug connection of the temperature sensor for correct seating and slightly bend the contacts if
necessary to ensure a better hold.
processor card without and with attached wiring to the temperature sensor
7.9.3 Replace temperature sensor on the battery

Requirements:
- Make sure the battery is voltage-free.
Procedure:
- Open the battery plug.
- Change the temperature sensor.
7.9.4 Replace temperature sensor in the charger

Requirements:
! Warning
Procedure:
- Disconnect the temperature cabling from the processor card.
- Remove the cable from the plug socket.
- Replace temperature sensor.

7.10 Aquamatic function (O)
The optional aquamatic function of the TriCOM ® Futur charger is intended to control an automatic water
refilling system, which is used to set the battery’s nominal electrolyte level automatically. The charging gas
will disappear through the degassing opening of the stoppers. The valve in the stoppers, together with the
floater and the floater rods, will control the refilling process with regard to the water quantity. The water
pressure at the valve will make sure that the inflow of the water is stopped and that the valve is safely
closed.
The automatic water refilling system can be controlled in various ways:
- by a potential-free closing contact
- by a voltage of 230 V AC
- by a voltage of 12 V DC
Note
Connection pressure/falling water
The water refilling system must be operated in such a way that the water pipe is under a pressure of
between 0.3 and 1.8 bar. The installation height of the storage tank depends on the type of the water refilling
system employed.
The following shall be observed in this respect:
- Control via an immersion pump: The immersion pump will generate the required filling pressure. There
must be no difference in height between the storage tank and the battery’s standing area.
- Control via valves without immersion pump: The lower edge of the storage tank must be located least 3
m above the upper edge of the battery, so that the necessary filling pressure can be achieved.
Functionality of the automatic water refilling system
Requirements:
- The battery is connected with the automatic water refilling system "Aquamatic".
- The charger must be equipped with the aquamatic function.
- The charger must be connected with the battery.
- The charging process can be started.
Procedure:
- A relay contact for controlling the automatic water refilling system will be activated cyclically 10 min
before the end of the re-charging process at the following intervals:
- switched on for 25 sec -> water inflow to the battery open
- switched off for 5 sec -> water inflow to the battery blocked
7.11 Pilot contact "Safety Disconnect" (O)

The pilot contact is an auxiliary contact which closes lagging when inserting the charging plug and it
activates the advanced opening when the plug is pulled out. The advanced opening of the pilot contact will
automatically stop the charging process, so that the charging current doesn't flow anymore. This will prevent
the formation of sparks when the battery is separated from the charger.

power module with the plug-in jumper inserted
The pilot contact is connected to the module (for chargers with two modules at the upper module, with three
or more modules always at the 3rd module) and connected to the charger's charger plug. In the case of
multi-modular chargers, the remaining modules are fitted with a jumper. The pilot contact in the battery plug
then closes the pilot contacts in the charger and charging can be started. For chargers without this option,
jumpers are installed on all modules.
Check pilot contact

Note
If the pilot contact is defective, the charger cannot start charging.
Requirements:
! Warning
Procedure:
- Check the wiring of the pilot contact from the charger to the battery plug.
- Check jumpers for tight fit and contact.
- Check bridge in battery plug (disconnect plug from power supply).
- If the pilot contact cannot be repaired on site, a jumper can be attached to the module so that the charge
can still be started.
service manual TriCOM ® Futur

61
7.12 Li-Ion chargers
Chargers intended for charging Li-Ion batteries communicate with the BMS (Battery Management System) of
the Li-Ion battery via a separate CAN communication interface. For this purpose, either a CAN box is
mounted on the expansion interface of the processor card, or a CAN plug-in card is mounted directly on the
processor card (see "Processor card").
CAN box or CAN plug-in card for communication with the BMS of the Li-Ion battery
7.12.1 Check Li-Ion CAN interface

Requirements:
! Warning
Procedure:
- Check internal wiring and plug connection.
- Check external wiring.
- Check the plug connection in the charging plug.
7.12.2 Replace Li-Ion CAN interface

Requirements:
62service manual
manual TriCOM FUTUR
62
! Warning
Procedure:
- Remove the defective CAN unit from the processor card.
- Connect the new CAN unit to the processor board.
Procedure:
7.12.3 Replace Li-Ion CAN wiring

Requirements:
! Warning
Procedure:
- Remove the wiring of the CAN unit.
- Install new wiring. Pay attention to the assignment of the wires ("CAN Low" bottom left and "CAN High"
top right).
Procedure:

63
8 Maintenance
8.1 Cleaning, inspection and maintenance
The battery charger’s professional and thorough maintenance is important, so that its safe use can be
ensured. If the regular maintenance jobs are not carried out, the charger may develop malfunctions that pose
a danger to people and the charger’s operation.
Check before commencing each charging operation, whether:
ð the connection with the mains is undamaged,
ð the housing is free from damage,
ð the insulation of the charging cables and that of the connection cables with the mains does not show
signs of damage,
ð the charging plug is undamaged, and
ð all screwed connections are tight.
Note
A charger’s general conditions of use will have a considerable effect on the wear and tear of those
components that require maintenance. The maintenance intervals referred to herein are based on normal
operating conditions.
ð More unfavorable operating conditions, such as heavy contamination with dust or severe temperature
fluctuations, require that the maintenance intervals are reasonably shortened.
ð Remove dust or dirt on the charger with a dry cloth.
Note
The heat sink in the charger is forced-air ventilated, so that the air is not channeled directly across the
electronic components. It is nevertheless possible that dust gets into the charger. The maintenance intervals
referred to herein are based on normal operating conditions.
ð The room, in which the charger is located, must be ventilated.
ð Keep the room, in which the charger is located, clean and tidy.
ð Check the inside of the charger at least every half year to identify any contamination and clean the
appliance. Work inside the charger must only be carried out by duly qualified electricians.
ð More unfavorable operating conditions, such as heavy contamination with dust or severe temperature
fluctuations, require that the maintenance intervals are reasonably shortened.
! Warning
dangerous.
the charger.
! Warning
64service manual
manual TriCOM FUTUR
64
Carry out maintenance work
Requirements:
! Warning
Procedure:
- Clean the charger with dry compressed air. Keep a distance of at least 20 cm from the components to
avoid damage. Fix the fans during cleaning.
- Check the fan for ease of movement and replace if necessary.
- Remove dust or dirt on the charger with a dry cloth.
- Check the housing for visible damage.
- Check the insulation of the charging cable and the mains cable for external damage. Repair or replace
defective parts.
- Check the charging and mains plugs for external damage. Repair or replace defective parts.
Procedure:
8.2 Replace EC pump filter

Note
For chargers with an EC pump, the air filter should be changed annually. This maintenance interval value
refers to normal operating conditions. If the charger operates under difficult conditions, e.g. in areas with
excessive dust pollution or strong temperature fluctuations, these maintenance intervals should be
shortened.
Requirements:

! Warning
Procedure:
- Disconnect all wiring from the EC pump.
- Remove the EC pump from the housing.
- Remove the EC pump from the mounting plate by removing the screws from below.
- Carefully remove the EC pump.
- Loosen the air filter on the underside of the EC pump.
- Change the filter and tighten it again.
- Mount the EC pump again on the mounting plate and install it back into the housing.
Procedure:
8.3 Spare parts

If spare parts are required, please contact the manufacturer or supplier and state the charger data from the
name plate.
8.4 Disposal
Once the charger is permanently taken out of service, the laws and regulations for the disposal applicable at
that point in time shall be observed.
More detailed information can be obtained from specialist disposal firms or from the competent authorities.
Note
Electronic scrap contains various plastic, metal and heavy metal components which pose a high danger
potential for the environment.
ð Collect and dispose of electronic scrap separately from household refuse or commercial waste.
ð Deliver electronic scrap to your company’s internal disposal department, if there is one, which will see that
the scrap is passed on the relevant specialist disposal firms.
The packaging of the charger shall be disposed of separately. Paper, cardboard and plastic can be recycled.

9 Technical Information
Appliance series TriCOM ® Futur
Appliance number. see name plate
Charging characteristic see technical data sheet
Temperature range 0°C – 40°C [32°F – 104°F]
Rated input frequency 47 – 63 Hz
Degree of protection see technical data sheet
Housing see dimensions and housings
2014/35/EU – Low Voltage Directive
2014/30/EU – EMC Directive
Directive (EU)
2011/65/EU – RoHS
Detailed information can be found in the Declaration of Conformity.
UL 1564 – Standard for Industrial Battery Chargers
Standard (US)
Detailed information can be found in the Declaration of Conformity.

Dated August 2019 – We reserve the right to make changes without notice

2019 08 06 Tricom FuturRF Servicemanual en

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

2019 08 06 Tricom FuturRF Servicemanual en

Uploaded by

Copyright:

Available Formats

Service manual

Energy. Endurance. Power.

2 Service manual TriCOM FUTUR

Service manual TriCOM FUTUR 3

4 Service manual TriCOM FUTUR

service manual TriCOM ® Futur Service manual TriCOM FUTUR 5

Safety instructions and markings

2.2 Qualification of the personnel

service manual TriCOM ® Futur 6

2.3 Intended use

service manual TriCOM ® Futur 7

2.4 Safety instructions on trouble-shooting and maintenance

8 service manual TriCOM ® Futur

service manual TriCOM ® Futur Service manual TriCOM FUTUR 9

1 power module 9 minus pole of the battery connection

1 power module 9 minus pole of the battery connection

17 EC pump - controller card for the electrolyte circulation

service manual TriCOM ® Futur 11 Service manual TriCOM FUTUR 11

4.1 Dimensions and housings

Dimensions (in mm) [in inch] Weight (in kg) [in

Example of the housing RF450

Examples of housings RF560, RF650 and RF1250

service manual TriCOM ® Futur Service manual TriCOM FUTUR 13

4.2.1 Housing RF450

1 power module 12 graphic display (touch screen)

14service manual TriCOM ® Futur

1 power module 13 housing door (front)

Service manual TriCOM FUTUR 15

4.2.4 Housing RF480

1 power module 11 LED display and USB unit

1 power modules (3x) 14 housing door (side)

Service manual TriCOM FUTUR 17

1 power modules (4x) 14 housing door (side)

1 power modules (6x) 13 housing door (front)

service manual TriCOM ® Futur 19

1 power modules (7x) 13 housing door (front)

1 power modules (9x) 13 housing door (front)

service manual TriCOM ® Futur 21

RF1250 with 12 power modules

5.1 Setting the charging characteristic

Setting the charging characteristic for devices with graphic display

service manual TriCOM ® Futur 23

5.2 Setting the service characteristic (formation, desulphation)

Service manual TriCOM FUTUR 25

Service characteristic LED display Description

Setting the service characteristics via the graphic display (O)

5.3 Expert Mode

5.3.1 Activate Expert Mode

5.3.2 Change charging parameters in Expert Mode

Service manual TriCOM FUTUR 27

28 Service manual TriCOM FUTUR

5.4 Read out charging history

service manual TriCOM ® Futur 29

import of the exported charging history using ConVision FileReader

5.5 Firmware update

service manual TriCOM ® Futur 31

6.2 Malfunctions and error messages

time or capacity fault

external communications fault

32service manual TriCOM ® Futur

service manual TriCOM ® Futur Service manual TriCOM FUTUR 33

6.3 Error messages via the graphic display (touch screen)

touch screen with error message (time error "Iconst")