Battery Iindicates that the battery is not accepting charge (Please check with

battery manefacturer) or the LMP charger and the battery are not
The battery performance is highly dependent upon the condition of the matched.
battery. It is therefore of vital importance to the operation of the vehicle Description of Operation Control Wiring
that the battery is maintained well.The battery should be fully charged 1. Ensure that the battery is suitably matched to the charger output
every day, before the start of work. The following routine checks are specification.2. Connect the battery to the charger.
recommended for a better life of the battery. 3. Switch on the charger, then the POWER ON lamp will light and
During periods of prolonged storage, the batteries will need POWER LED will come ON.
to be fully charged. If a battery is left in discharged state, sulphating takes 4. The charger will run a self test program - all the LED’s will come ON
place on and within the plates. This condition is not reversible and will one by one and go OFF.
cause permanent damage to the battery. The charged battery should be 5. After ensuring that the AC input supply is healthy, the charger will
disconnected from any circuit that could discharge the battery. For on- check whether the battery voltage lies within 1.2V / cell and 2.90V/cell, If
board and out board chargers, disconnect the charging harness from the so, Charging will comence and CHARGING LED will come ON.
receptacle. The batteries must be cleaned and all deposits neutralised 6. During charging, LED display is illuminated it indicates the % rated
and removed from the battery tray to prevent discharge. The batteries charging current and the charging begins with constant current mode.
should be tested or recharged at thirty days interval. 7. “80% CHARGED” Amber LED will come on when the battery voltage
Electrolyte level has reached 2.40V / cell. At this point the constant current mode will
Check at least once a week that the electrolyte level is at the correct level. change to taper mode. The charge controller will taper battery current
The electrolyte specific gravity at 25° C is shown below for the corresponding while the voltage builds up naturally. The finishing current will be 40%
state of discharge of starting current at 2.7V / cell.
Remaining battery Specific gravity 8. The controller evaluates the state of the charge in the post gassing
capacity in g / cm3 period by the dv/dt method. When the voltage is found to be constant
100 % 1.290 within a specified window for a period of time, the controller terminates
75 % 1.240 the charging.
50 % 1.180 9. In the charged condition “ CHARGED” LED will illuminate.
20 % 1.150 10. The charging is now complete. The charger should be switched OFF
Refilling before disconnecting the battery.
Only distilled water should be used for refilling. Refilling should be 11. If the battery is fully charged and is not required for immediate
undertaken only after the charging has been completed. This is because service, leave the battery connected to the charger with the switch ON.
the electrolyte tends to expand during charging and will otherwise run The charger wil deliver Refreshing charge at regular itervals (10 minutes
over. for every 6 hours) to maintain the battery in a fully charged condition.
Cleaning The CHARGING LED flashes to indicate that the charger is performing
The battery surface must be kept clean. Remove any spilt electrolyte REFRESH charging.
using cloth with dissolved soda or ammonia and rinse with water. No dust
and dirt must be allowed to deposit on the battery surface. They may carry HF1 Charger
so-called leak currents between the poles of the element.
Battery Poles Operator controls and Indications
Maintain clean battery surface and remove any sulphate deposits by
filing. Such deposits may result in considerable loss of voltage. Grease Power on Switch
the poles with acid-free grease and always ensure that the cable terminals This switch isolates the power to the control circuit.
are tightened securely to the battery poles. LED Descriptions
Charging / Refreshing
Battery Charger
Charging - This LED will come ON after 3 seconds delay.Charging has now
The battery charger is for charging traction batteries only. The charger is started.
electronically protected against over current, short circuit and reverse
battery connection. The charging profile is constant current followed by a Refreshing - This LED flashes to indicate that the charger is performing
forced taper with dv/dt sensing to evaluate the 100% charged condition. REFRESHING charge.
80% Charged / Override
Technical information 80% charged - The LeD will come ON when the battery is approximately
Input Voltage/Frequency 230V +10%/-15%, 50Hz 80% charged.
Charging Time 8Hrs for a 80% discharged
C-5 Battery This LED will also on when battery received 7 hours voltage did not reach
Battery operating temp. 0° to 40°C 2.40V/cell within this period, the charger switched to taper mode.
Relative Humidity 90% Override - The LED flashes. This indicates that the battery is not accepting
Installation and Commissioning chare or that the HF1 charger and the battery Ah capacity is not matched.
Receiving Charger Charged / Equalising
When received, the charger should be unpacked and checked for any Charged - LED comes fully charged.
transit damage. Check/tighten the mounting bolts of the main transformer. Equalising - Flashing Green LED indicate charger in equalising mode.
Location of Charger DC Fault / Over temperature
1. No battery connected or battery connector not matched properly or
Install the charger in a cool, dry, well ventilated location away from corrosive battery voltage does not fall within 1.80V/cell and 2.90V/cell
fumes and steamy atmospheres. Allow 200mm free space on all sides for 2. The same DC fault indication will come on when battery connected in
proper ventilation. Sl.No Colour Code Wire Colour Description
reverse or if the outputs DC fuse blow.
Over temperature - The yellow will be ON if the charger is over the 1 01 Red & Yellow Switch With KeyInput
LMP1 Charger limits. 2 02 Red Switch With Key Output
Operator controls and Indications AC Fault 3 03 Red & Green Parking Brake Output
The Red LED will come ON if
Rocker Switch The mains AC supply below 170V AC or above 265V AC. 4 04 Yellow & Green Brake Micro Switch Output
This switch isolates the power to the control circuit. The charger will stop charging automatically when the AC supply in 5 05 Orange Main Contactor Output
LED Indications between limits.
There are two sets of LEDs. 6 06 White Reverse
PCB Fault
CHARGER STATUS : This indicates the charging status. This LED will come ON in case of electronics failure or if AC 7 07 White & Black Forward
AMPS : This set of 5 LED’s Indicates the % rated Charging current. voltage is below 150V ac. 8 08 Red & Black Hall Signal
Charger Status LED’s Operation 9 09 Blue & White Speed Seneor(Hall -ve)
Power ON The charger has two modes of operations Normal mode and Equalising
Put the Rocker switch ON. The POWER ON LED will come ON and all 10 10 Yellow & Red Speed Sensor(Hall +ve)
mode.
the other LED’s will come ON and go OFF. This is a SELF TEST for the Normal mode 11 11 Black & Red Pot High
PCB. 1. Put switch in normal condition. 12 12 White & Red Pot Wiper
Charging / Refreshing 2. Connect charger charging plug to vehicle battery plug.
The GREEN LED will come ON after 3 seconds delay. Charging has now 13 13 Black Pot Low
3. Put the MCB on front panal charging to vehicle battery plug.
started. The set of 5 LED’s indicates the CHARGING CURRENT. The 4. Charging will start after5-8 secs. In this time a self check will be done. 14 14 Red & Blue Mode Select Switch
Charger will charge even if the battery is deeply discharged (1.2V/cell). 5. Charging will end with the green LED ON. 15 15 Blue B(-ve)
If no battery or wrong voltage battery or very deeply discharged battery Equalising mode 16 16 Green & Black Charger Plug Output(48v)
(below 1.2V/cell) is connected charging will not start. Refreshing LED 1. Put switch in equalising position.
will flash when charger is delivering a refreshing charge at periodic 2. Charging will start and complete. Green LED will come ON. then
17 17 Yellow 12V (+ve)
intervals. equalising will start. 18 18 Green Horn
80% Charged / DC Fault 3. Green LED will be flashing when equalising is in progress. 19 19 Grey Head Light
The AMBER LED will come ON when the battery voltage reaches 2.4V /
cell.
20 20 White & Green Brake Indication
Maintenance
This means the battery is approximately 80% charged. The charge 1. Put it in safe, ventilative, clean and no drenching place. 21 21 Yellow & White Beacon
controller will now start tapering the battery current. This LED will flash 2. Don’t open the case when charging. 22 22 Yellow & Blue Flasher Output
(DC FAULT) if battery voltage is below 1.2V / cell or wrong polarity. 3. Don’t open the case except professionl workers. 23 23 Brown & White Turn Indicator Left
Charged / Override 4. Packaged putting when long time not used.
The RED LED will come ON when the battery is 100% charged. The 5. During recharging, super-voltage or sub-voltage, i.e. voltage range is 24 24 Brown & Green Turn Indicator Right
LMP will automatically stop the charging. The battery is now ready for out of 185V~255V for 220V,323V~437V for 380V. In protection status,
use. fault light would signal the user. Charging would auto-continue when
This RED LED will Flash (OVERRIDE) if 100% charged condition is not voltage was back in the working range.
reached within the 6 hours after 80% CHARGED is reached. This

Page 4 JUNE-2010 JUNE-2010 For prompt service, please mention the correct part numbers in all your enquiries. Page 13