KGCFS BATTERY PLATES FORMATION CHARGER/DISCHARGER OPERATION MANUAL JL [ANGSU JINFAN POWER TECHNOLOGY CO.LTD TEL:0086-512-58591431 FAX:0086-512-58591435 E-MAIL:UUJINFAN@PUBLICI.SZ.COM HTTP:/WWW.JSJE.COM.CN Te 58591431 E-mail: ulinfin@oubli.szcn Fax: 0086-512-58591435 Web: hnpi/wwrw si. Com onuC-KGCFS Battery formation chargerdischarger operation manual 1 Warranty announcement Jinfan Power Co., Lid guarantees that there will be not any defect of materials and craft of ur equipment within one year period since shipment if the equipment is applied fully according to technical requirement, otherwise, Jinfan will futfil free reparation and replacement for its customer. The customer can contact Jinfan's after-sale service department or their local office for reparation’and replacement. But Jinfan will not be responsible for any damages caused by customers’ disobeying operation manners or other indirect or special reasons. The following will not be within the warranty range 1, poor-quality fuse or common fuse replacing semi-conductor fuse cause damages to - power components or other components. 2, damages caused by thunder-stroke 3, damages caused by corrosion of acid mist 4, temperature or humidity severely exceeds regulated technical index 5, electricity grid severely exceeds regulated technical index 6, damages from artifical or indirect foreign or special reasons 7, damages of delicate parts during the process of proper operation such as semi-conductor fuse. 8, other new functions customers want but not ordered with supplier at the beginning. Safety notes: + When the equipment is in operation, please don’t open the door of cabinet for electric shock. When you open the cabinet door, please keep the cabinet off electricity, otherwise itis easy for you to contact the high-voltage terminals and thus suffer electric shock accident. Even if the cabinet is off electricity, if not for necessary maintenance, reparation or replacement of broken fuse, please don't open the cabinet door, because high voltage from connected batteries can also cause electric shock. + For replacement of damaged parts or periodic maintenance, be sure to disconnect the electricity and confirm that the batteries have also been disconnected, use universal meter to make sure there is no high-voltage currently, Replacing easily-damaged parts or periodic maintenance should be done by professional technicians, don’t operate high-powered switch by wet hand to avoid electric shock. + "Power cables should be laid out properly, see to that power cables don't receive outside force, otherwise the insulation layer will be injured, so that short circuit, leak “Te: 0086-512-58163383 58591431 Fax: 0086-512-58591435 E-mail: wulinfan@publicszca Web: hep/www jsif Com enuC-KGCFS Battery formation chargerdischarger operation manual 2 electricity and electric shock will be caused. Notes) * Ratings of input cable of power and output cable of battery should conform with requirements to prevent overload of cable, insufficient charge and discharge failure. Please make sure polarity of cables connecting batteries should conform with that of output terminals of equipment, incorrect connection will make charge and discharge reverse, even lead to battery's explode or crack + When'the power is on or within a short period of time after the power is off, please don't carry out reparation, because some components inside the cabinet have very high temperature, which will possibly lead to burns, Catalogue Chapter 1... ‘General introduction Chapter2 “Technical specification Chapter 3. System principle Chapter 4. Application method Chapter 6... Problems solving Chapteré. Equipment maintenance - Attached drawing: schematic diagram of plate formation charger/discharger Principle of control-pane! Chapter 1 General introduction This equipment is for formation of lead-acid battery and alkaline battery and dump timed charge of battery group, discharge power retums to electricity grid. The structure of this cabinet is very compact, each microprocessor controlling one channel, very easy to operate. Installation structure takes drawer module for easy installation and reparation, appearance orderly and beautiful This equipment has single-step control and computer completely automatic control. For automatic control the program can be preset by control-panel of equipment, or by master computer's software. For single-step control, can enter control-voltage, control-current, contro-time in advance and microprocessor can supervise the operation of equipment of each single step. Besides many channels of one equipment can be networked, different equipments can also be networked for easy center control. 58591431 Fax: 0086-512-58591435 Web: up/www jsf Com on Te EsHC-KGCFS Batery formation charge/discharge operation manual 3 Chapter 2 Technical specification 1. Working conditions: Input Ac: 3 phase, 4 wires Ac380V, 50Hz Tolerance of input voltage: +10%, -5%, input power should at least be AC360V for output of standard load. Environment temperature: 1~40°C Environment humidity: below 90% Latitude height: lower than 1000m 2. Functions specifications, Control mode: can set &control craft, having automatic and single-step control function ‘Working mode: constant current charge, constant-vottage with current-limited charge, constant-current with voltage-limited discharge, reverse charge, static and cycle ete. Protection: protection for over current, over voltage, broken current, data restoration for power off, automatic operation recovery when power on, protection for over-high temperature. Record: step shift according to time, voltage, Ah and can record data at preset time. Rectifying mode: 3 phase fully controlled bridge rectifying mode Cooling mode: cool down naturally or by electric fan Dc input voltage: 0~rated voltage(300V,320V, 340V,350V) Deinputcurrent.0~rated current (3A, 5A, 6A, 8.54,10A, 12A, 15A, 30A, 50A,100A, 150A, 200A, 300A,350A,400A,500A) continuously work. Accuracy of current and voltage:<#0.5% ratings Accuracy of time: <308/24h Description of working mode Constant current charge: set current for charge, shift qualification has time, voltage and capacity totally 3 modes. Constant voltage with current limited charge: set control current and control voltage, shift qualification has time and capacity two modes Constant current with voltage discharge: set current for discharge, shift qualification has time, voltage and capacity, Reverse charge: this control mode is only used for plate formation, it equals to time-fx constant current discharge, it need only to set control current and the qualified time for shift, while the other two qualifications are ZERO, the controller will discharge the battery with constant current according to the preset control current until this step-has operated for a period of time that has been set and go to the next working step. Cycle: set beginning step for cycle and times of cycle, please note that a cycle can't be cycled. Static: output of controller is Zero, contactor for charge/discharge is open for a period of time which has been set before until itis the time for enter next step. “Tel: 0086-512-58163383 58591431, Fax: 0086-512-58591435 E-mail: wuinfan@publicszcn Web: tpi/sw jsf. Com enHC-KGCFS Battery formation chargeridischarge operation mana 4 Chapter 3 System principle 1. Composition of system ue-KGCFS battery charger/discharger can be used for battery formation and plate formation, each equipment can be controlled separately, or many equipments can be networked to a PC through COM port to realize center control and data processing Master computer ¢ Adapter fecifying controller Batteries} "2. Working principle ©-KGCFS takes microprocessor as the core for control and rectifying controller for controlling charge and discharge. Automatic multi-step charge and discharge can be realized. Working mode, current, voltage and time can be used as the qualification for shift of each working step. The microprocessor can make records of operative data according to qualification for recording required by working craft, and timely exchange data with master computer. ‘The composition of charger/discharger power system: ‘Tel: 0086-512-58163383 58591431 Fax: 0086-512-58591435 E-mail: ujinfin@public zen Web: hap jf Com enC-KGCFS Battery formation charger/discharger operation manual s ‘Communication 1 i Lig [ votage | cones caret mie | seg] | TP | regutaor [7] wa reulaor viaser [SCR | I i ole it ‘Change current ! | F j r Change voltage ! i i i I | chargeischarge HY cht iJ controt T] wich 7 qi \ 9 3 2 ul Chart 2 “Mainly include communication part, function displaying, voltage/current contro! and charge/discharge control besides microprocessor. Microprocessor accepts working craft from master computer, according to craft control current, voltage and time ete. Microprocessor output IG( Rated current) and VG{Rated voltage) to rectifying control panel, and rectifying control panel will according to IG and VG output signals. Microprocessor outputs charge/discharge signal to control contactor status, thus complete change between charge and discharge. Reetifying control penel( ) according to parameters set through Microprocessor outputs, coresponding current and voltage, and after completing processing these parameters feedback to microprocessor, thus microprocessor realize closed-circuit control. See chart 2 to get rough idea about rectifying control panel. Reectifying control panel according to charge/discharge signals to control contactor status, thus complete conversion between charge and discharge; at the same time charge and discharger signal makes it possible that protection module MOD can control the other channels and complete the process of charge/discharge Tet 0086-512-58163383 Sas9143t Fax: 0086-512-58591435 Email: wuinfn@publesen Web: pve jl Com onC-KGCFS Batter formation charge/discharge operation manual 6 Chapter 4 Application method 1. safety notes for installation Please keep the equipment in vertical direction when moving or carrying ‘Make sure that the place for installation can bear the weight of the equipment Please install equipments where it will not easily come across severe shaking ‘Avoid installation of equipments in battery formation area to prevent corrosion from acid Avoid high temperature and high humidity working environment. Input cable and electricity grid must be able to support the normal operation of equipment's full load 2. Installation introduction Open the wooden carton and carefully move the cabinet out and check the nameplate to confirm the model conform to order, and the cabinet should not have obvious damage. . Check all components and wires are not loose after transportation; there should be not problem of short circuit. Equipment should be installed vertically, the biggest declination angle can only be 5. there should be @ area around the equipment for cooling atmosphere to enter from downside and exhaust from the top. ‘There should be an empty room about 0.5m around the equipment, there should be very good environment for ventilation, the environmental temperature will affect the equipments lifespan very much, the temperature have to be between 0-40°C, please ‘make sure to avoid high temperature, high humiaity and can't be installed where it is very easy tobe shunned by sunshine According to provided electric principle chart, select proper input and output wire. Based on provided power parameters, make sure that electricity grid have enough input power. Connect 3 phase power to QF, static line N, grounding line PE, input wire and input power Circuit don't need any contactor with fuse or fuse itset. Connect communication cable, communication box and computer. 2. operation of panel 2.1 introduction of panel operation voltage meter, current meter displays the actually output value of voltage and current. Indication lights indicate power status, operation status and, mal-function status. Panel of plate formation charger/discharger Output voltage output current Power Charge Discharge Malfunction ° ° ° ° Tel; 0086-512-58163383 58591431 ax: 0086-512-58591835 E-mail: walinfan@nublicszen Web: http si Com onuC-KGCFS Battery formation charperGischarger operation manual 1 Stop Normal Reverse Se Eiecees Run Com. Err ChDch NT. A VT ik Worki Start Sap mote isp Pause ; (v) Step 3.2 Explanation of panel keys of yc-2000S Names. Function - ‘Step 1. when microprocessor is of waiting status, press this key to set working craft 2. "when the microprocessor is editing working craft, if the current parameters has been set property, press this key to go to the next step editing 3. when the microprocessor is editing working craft, if ‘stop’ has been selected( digitally displayed as ‘End’ and lighting), press this key to confirm that the current manual editing craft has been completed (digitally displayed as ‘End’ but not lighting, : ‘when manual editing craft has been completed, together with ( ¥ Step) key, operator can view and mend previously set parameters of each step. ‘Working mode 4, when the microprocessor is in operation, press this key can change displaying accuracy (automatically restore in 30 seconds) 2. When the microprocessor is eciting working craft manually, press this key to press this key to select working mode (charge, discharge, static, stop). Set Display “.when the microprocessor is in operation, press this Key for change of display ‘among current, voltage and time. 2. when the microprocessor is editing working oraft, press this key to for change of display of contro! parameters that that you want to set( control-current, control-voltage, conversion-voltage, conversion-time. Tel: 0086-512-58163383, 58591431 Fax: 0086-512-58591435 E-mail: uulinfan@oublis.szen Web: Insp/rww jsf. Com onC-KGCES Plate formation charger/dscharger operation manual 8 Step 7. when the microprocessor is editing working craft, together with (Step), press this key to mend the step No. of the current working craft. 2. when microprocessor is of waiting status, press this key to set the working craft for a single step, when step is displayed as ‘db’. if you start the operation immediately after ‘Setting completes, the microprocessor will carry out the single-step working craft but will not remember it, the single-step working craft has to be set each time. 1. when the microprocessor is editing working craft, press this key to modify the current parameters’ value (control-current, control-voltage, conversion-voltage, conversion-time., equals to + 2. when the microprocessor is editing working crafi, press this key to modify the current parameters’ value (control-current, control-voltage, conversion-voltage, conversion-time., equals to ~ 1. when the microprocessor is in operation, press this key to stop and restore’ operation 1. when the microprocessor is in operation, press this key for at least 2 seconds to stop operation. 2.- when the microprocessor is editing working craft, if the editing has been completed, press this key to exit from editing craft and returns to ‘wait status. Explanation of Digital display on The fist two digits display step No. db represent single step ES-ES 3] The equipment is of wating status FAUS ‘The equipmentis paused sToP The equipments of stopped’ status oe When time indicator is on, represent time, the former 2 digits is hour, the later is minutes Evi The equipments of broken current En? ‘The equipment is of over-high current En3 The equipments of leak current Era The equipments of over-high voltage. ‘et 0086-512-58163385 seso1aat Fax: 0086-512-58591435 E-mail: wuinfan@public.szen Web: _itpi/www jst Com cnuC-KGCFS Battery formation chargerdischarger operation manual 9 Ens Working craft has some mistake. For automatic operation suggests that working craft lost or checking error, need master computer to resend craft En ‘There are no craft stored in Microprocessor, need master computer to resend, when you can't start the automatic craft by operating on the Er panel. When operator is setting craft manually, wam of a mistake in the setting 3.4 Explanation of indication light Indicator of run: when the microprocessor is in operation, it will be on. Indicator of communication: when the microprocessor is exchanging data with master ‘computer, it will be on. Indicator of charge, discharge and static: 1. when the microprocessor is running, represent the current working mode 2. when the microprocessor is editing craft manually, the indication will flash at a frequency each time/s indicating the current control mode for the craft. Indicator of current, voltage and time 1. when the microprocessor is running, indicating the current real-time data(current AV.T) 2. when the microprocessor is editing craft manually, the indication will flash at a frequency each time/s , indicating the current control mode for the craft. Ifthe a channel is charging batteries, the indicated the voltage data is control-voltage, namely the value of constant voltage, if the current working mode is discharging, this value is conversion-voltage for discharge.) 3.5 Editing craft through panel, example illustration (1) when the microprocessor is of ‘wait’ status, dis-}-F-—-—] the front two digits display the step, the later four digits display status (error) or data (ourrent, voltage, time) (2) at most 30 steps can be set through the panel, also single step operation can be set. {3)edit multi-step working craft through panel First: begin to set working craft Press [Step a! display [o; | cone ‘Shows that the microprocessor comes to the state of editing working craft, the [01 represents the step No., Among [C***) , the first digit represents working mode, C represents charge, F discharge, J static, press [working mode to select. Tel 0086-512-58163383 58591481 Fax: 0086-512-58591435 E-mail: winfin@publicszcn ‘Web: bupivnww jsf Com onC-KGCFS Battery formation chargerdischerger operation manual 10 Second: set control mode of step 1 Re-press [working mode) , displays [01) [F*##m [Ot] [u*J—ml ot J TF" |—m 101) [-End-) —® [01] [ow] Select charge/discharge mode, totally 4 modes, C represents charge, F discharge, Jstatic, [-End | represents complete. The later [*** suggests different current or voltage value, if the current indication lights, the three digits represent control-current, so the ‘same for the voltage and time. Third: set control current, control voltage and control time. Re-press [Set—display) When the current indicator is on, through [ A J[ ¥ Jto mend the control current, which is the constant value for charge. The unit is A (Ampere) When the voltage indicator is on, through [ & JI ¥ to mend the control voltage, which is a constant voltage control value, for discharge the value is control value for the ‘completion of discharge craft. The unit is V (Volt) When the time indicator is on, through [ 4 ['¥J to mend the control current, which The unit is **hour**minute. Forth: set working craft of step 2 Press [Step a, display [02] [-End|he [02] represents the step No, is 2, then just repeat the same editing ways for editing step 1 to individually set the control mode ‘and current, voltage and time Butwhen pressing [Step a , if [-Err] has been displayed, that shows there is ‘something wrong with the currently set working parameters, for example, the time has been set as zero or the current has set as zero. Fifth, set working craft of step 3 Press [Step a , display 03) [-End] According the above methods, enter the working parameters of step 3 to step 30. Press [Step A] ,Re-press [working mode] to display [04) [-End] Press [Stop] to display [~] [—J , that means that the system has exit from the status of editing craft to ‘wait’ status. (4), set single-step working craft. When the microprocessor is of ‘wait’ status, press [Step V, display [dbJ[C***], Which means that the microprocessor has entered the status of editing working craft, [db ‘shows that the working craft contains only one single step, other parameters needed can be entered just the same as the above method. After the setting ends, press [start-pause | key to start the single-step operation (6) Run working craft ‘When the microprocessor is of ‘wait’ status, it is displayed as [—) [——J press [start-pause key, the equipment will begin to run according to the ready working craf, if its displayed as [01] [C—J , it means it begin to run the firs step, then the second, then the third just this way. ‘Tel: 0086-51 38591431 Fax: 0086-512-58591435 E-mail ulinfangipublie.z en Web: p/w jaf. Com cnuC-KGCFS Battery formation charger/discharger operation manual n (6) pause/restore operation ‘When the microprocessor is of ‘wait’ status, press ['start~pause , itis displayed as [01 | fc***] , that means the microprocessor is paused temporarily, if the operator press the key again, the microprocessor will run again (7) stop the operation When the operation is going on, press ['stop] for 2 seconds above, it will be displayed as [01 | [ stop) , that means the microprocessor has been stopped. After that the display will be [-) [—] , which means the operation has entered ‘wait’ status. (8) set communication address ‘When the microprocessor is of ‘wait’ status, press [a] [| at the same time, it will be displayedas [| [-001),so [-001! suggests that communication address of the current circuits 1, operator can press [a J or [VJ to change.. after the change has completed, press [working mode) to confirm. (9). Set rated current.( which has been set ready before shipment) ‘When the microprocessor is of ‘wait’ status, press [ J [stop at the same time, it will be displayed as [| [-005) ,so [-001! suggests that the current of the specified circuit is 5A, operator can press [4] or [VJ to change. after the change has completed, press [working mode] to confirm. (10). Set rated voltage.( which has been set ready before shipment) ‘When the microprocessor is of ‘wait status, press_[ a | [stop at the same time, it will be displayed as [| [-320] ,so [-320| suggests that voltage of the current circuit is320V, operator can press [A] or [¥! to change.. after the change has completed, press Tworking mode) to confirm. 4, preliminary regulation ‘Series-connect two lamps of 200W for output to measure the input power cable, switch on QF, QF1, QF2. Press [Start-Pause! key, the equipment will begin to operate according to the preset working craft, measure the output voltage, make sure that for charging the At of the output polarity should be positive, and B to be negative, for discharging A+ should be negative, B- to be negative. The output voltage should be rated value plus 10V Take away the lamps and series-connect current meter for output, observe the operatin and make sure that each circuit should conform to equipment’s requirements. Disconnect the current meter, connect batteries, the required voltage of battery should be 60% that of rated value, send the working orders and observe the operation of the equipment. Please see below chart for output polarity(for measurement, the value is between At and B-) Character status [At Be charge | + Resistance load(lamp) | discharge | - Charge |* : Batteries load discharge | + = “et 0086-512-58163383 58591481 Fax: 0086-512-58591435 E-mail: uujinfan@publicszcn Web: htpiwww jsf Com enHC-KGCFS Battery formation charger/discharger operation manual R 4. Normal operation Confirm the polarity of batteries, connect them Edit the required working craft, press [ Start-pause| to send orders. Observe the displayed data for 20 minutes, make sure that the polarity of batteries is right, for charging the current should rise smoothly, for discharging the voltage should decline smoothly, for the first charge or discharge of battery, should check that the batteries are really being charged or discharged, if any abnormal phenomenon appears, check the equipment and output wires and also the polarity connection of batteries. When the equipment is running, should pay attention to that current, voltage and time should conform to craft's requirement. 6, Operated by supervision software UC-KGCFS Formation Charger ischarger, ‘Communication port . ee mx Computer (connected to above box by the cable) Cycle communication box After the above devices have been connected ready, switch on the electricity, set the address for each circuit.( refer to operation explanation of panel). Start the master computer to install software. 2. Installation of software Software requirements: PC above586, minimum 32M memory, color display screen, ‘two COM port, WINSX/2000/XP. “el: 0086-512-58163383 38591431 Fax: 0086-512-58591435 E-mail: wulinfan@pubicszen Web: htp/www jsf Com enuC-KGCFS Battery formation charge/discharge operation manval B First, insert the soft disk with installation program into the driver, open the disk and execute the Setup. Exe document of the installation file, according to the dialogue box install the program in a certain directory, after completion, the system will automatically generate a uC-2000S icon on the desk of the computer, which means that the installation has been properly completed. 3. Operation of the software (1) start the software Double click the:C-2000S icon on the desk of the computer, for the first operation of this software, the system will remind you of the setting of communication address, the ‘operation should fil in the required parameters. Double click the fast-icon of charge/discharge supervision system on the desk of Window or Battery supervision system in the menu—start, the below supervision interface will be displayed: Chart 5 Supervision display Chart 6 Tool bar (2) click ‘edit craft in the too! bar, then set the required steps needed for working craft, finally save the working craft in hard disk. Tel: 0086-512-58163383, 58591431 Fax: 0086-512-58591435 E-mail: wuinfan@public.szcn ‘Wed: htpfworw ji Com onHC-KGCFS Batery formation charge/discharge operation manual 4 Chart 7 Working craft edit window: The implication of the parameters in the working craft editing form (chart 7) 1) step: step sequence No. 2) working mode: decide how this step should work, select one of them. 3) Control current: the control current for charge or discharge of this step, unit is ampere A). 4) Scopet/Scope2: pulse scope value of pulse charge, unit is ampere (A) 5) Pulse width 1/ pulse width 2: pulse width value of pulse charge, unit is second (S) 6) Control voltage (V): The control voltage of the current working step. 7) Conversion voltage (V): for charge the voltage of the current working step should be - less than conversion voltage, when the voltage has reached the conversion voltage Point, the current step will be stopped, and the next step will begin to work. 8) Conversion time (h: m): when the running time of the current step is longer than this value, this conversion qualification will go into effect. 8) Conversio’ Ah: the Ah value of the current step is lower than this value, when it has reached this value, this step will stop, and the next step will begin to work... for discharge, the value of the current step is higher than the conversion Ah, but when the value has declined to the conversion Ah, the current step will stop, and the next step will begin. 10) Record-interval (h: m ): for the current step the data will be recorded at such intervals. Parameters needed for different steps when editing working craft. 1) static: conversion time, record interval 2) Charge: control current, control voltage, conversion voltage, conversion time, conversion Ah, record interval. 3) Discharge: contro! current, conversion voltage, conversion time, conversion Ah, record interval 4) Set capacity: Conversion Ah 5) Cycle begin: no parameters 6) Cycle: cycle times 7) End: no parameters After completing editing a step, can go on to edit the next step, at most can edit 30 steps, the last step should be End. Save steps If the computer reminds of an error for saving working craft, please check and mend, then save again, Tel 0086-512-38163363 58591831 Fax: 0086-512-58591435 E-mail: wlinfin@nublicszen Web: huptwww ji Com enuC-KOCFS Battery formation charger/discharger operation manual 15 (3) run the working craft click ‘run’ in operation column, dialogue box of sending working craft will be popped Up, select working craft and click send, then the charger/discharge will begin to work. Chart 8 Chart 9, Chartt0 ‘Tel 0086-512-58163383 58591431 Fax: 0086:512-58591435, E-mail: uuiinfan@oublic sen Web: pw sf. Com enuC-KGCFS Battery formation chargeridischarger operation manual 16 ‘Supervision: ‘The operator can make such operations as: start, pause, restore, stop, next step, Upper circuit, next circuit, track and scan, “Change step", it has two modes: one is double-click a certain step in the craft form, ©. with mouse double-click the 4th step of the currently running crafi( supposed there exists the 4th step), the circuit will change to carry out the 4th then, The other is directly click [next step] in the dialogue box, a message box as shown by Chart 10 will be popped up, click [confirm the circuit will change to the next step just following the current one to work(supposed that the currently running step is not Tend) ‘The application method of other buttons in the dialogue box “Former step" single-click this button to check the data of former step. “Next step" single-click this button to check the data of next step. “Track” single-click this button to collect data of the currently running circuit “Scan’ single-click this button to cancel “track”, visit to all circuits will be restored. Chapter 5 Problems solving 1. Phenomena of maifunetion and solving manners When your equipment suffers malfunctions, first please check the following items, if the Problems still can't be ridden, please get in contact with us or our local office in your area. Phenomena causes solving manners When started to run, | controlled circuit the equipment comes | 1.improper contact of contactor or | 1.Check contactor aits ‘across matfunctions | damaged contactor cause broken a as broken current, circuit eee over current, leak 2.fuse broken 2.Check fuse current or over ‘3.damaged breaker cause leak e fe ress ‘S.check breaker 4.Check wiring status of inside and fasten change mal-functional components. 4.Loose wire causes broken circuit ‘Tei: 0086-512-38163383 58591431 Fax: 0086-512-58591435 E-mail: wuiinfan@public sen Web: hutp/worw jj Com enC-KGCES Batery formation chargeldscherger operation manuel n control board ‘.wire not connected properly Check connecting wire 2.Microprocessor malfunction change microprocessor 3.main circuit board malfunction change main circuit board outside 1.broken output wire 2.overvoltage of battery 4.check wire 2.decrease batteries in series Circuit breaker automatically switch off after its being tumed on ‘low-speed fuse cause damage to silicon controlled of MCCB 2.breaker damaged ‘use recommended fuse by manufacturer and change silicon controlled of control board 2.change breaker Circuit breaker automatically switch off during the process, of proper running “leak phase of input power 2 connect wire without shutting down the power after wire breaks 3.output wire improperly connected ‘1.check input power 2.pause operation before connecting wire S.upgrade connecting wire no output current ‘T.broken output wire 1.check output wire while there is 2.leak phase of input power 2.check three phase wire displayed voltage —_| 3,fuse melt to broken status 3.change fuse 4.microprocesor malfunction 4.change microprocessor S.main control board maifunction _| S.change main control board output current and | improper contact of output wire | 7.check connecting wire voltage fluctuate in a 2.check air switch and Rca Bleck phisee of NEMLAC RON 'Sctcly hat 3.net voltage too low(below 340V) | 3.upgrade electricity net 4.400 high voltage of battery 4.decrease batteries in series ‘S.microprocessor malfunction 5.change microprocessor 6.main control board malfunction 6.change main control board output current can't reach rated value ‘.voltage of net low(below360V) 2.battery voltage too high S.control board of loses ratings. joprocessor 4.main control board malfunction 5.leak phase of input electricity net ‘upgrade electricity net 2.decrease series-connected batteries 3.by master computer reset equipment ratings 4.check pulse transformer of main control board and silicon controlled 5.check electricity net Fuse broken ‘Tel 0086-512-58163383 E-mail: uulinfan@oublicszsn 1.sudden output short circuit 2.connect wire while the power is on ‘58591431 Fax: 0086-512-58591435 1 .becareful to avoid 2.becareful to avoid Web: hepi/www jsf Com.cnuC-KGCFS Battery formation charger/discharger operation manual 18 net (below 340V) 4.clectricity net voltage too low S.electricity countdown of electricity | 3.pause before electricity countdown 4.upgrade electricity net alarm for equipment | 4.High temperature of surrounding | 1.control environment overheat environment matfunction 2.cooling fan inside cabinet temperature to be below 40°C 2.change cooling fan can't be networked for | 4.communication adapter ‘communication malfunction communication cable 4.change adapter 2.computer system malfunction 2.reinstall system 3.connection problem of ‘3.check connection of ‘communication cable ‘cooling fan too much dust malfunction too much noise of fan ide cabinet, and | clear up dust and change _ cooling fan Chapter 6 Equipment maintenance 1. Daily and periodic examination ‘This charger/discharger is a solid state equipment which takes semiconductor as the core, daily and periodic examination of the equipment must be carried out because its working environment Will inevitably do harm to the lifespan, such as acid mist, temperature, humidity, dust, dirty and shaking. Note: before maintenance, the power and AC output must be switched off to avoid electric shock. content Remarks ‘Charge/discharge properly Charge/discharge at rated current Installation environment Items for daily | Cooling fan examination | indicator Display of V&A Working craft ‘Abnormal sound Visual examination Visual examination Visual examination Measure Careful attention in operation Attention in operation Overheat or color change Visual examination ‘Conductor , insulation material Fast fuse “Tel: 0086-512-58163383 58591 Fax: 0086-512-58591435 E-mail: yuiinfan@publicszen ‘Web: htp/iworw jeff Com en1uC-KGCFS Battery formation chargeridscharger operation manual 19 lead Visual examination Terminals Visual examination Items for Wire insulation material Visual examination periodic Dust inside cabinet Visual examination examination | Display of current Measure with standard current Display of voltage Measure with standard voltage Conversion contactor for Charge/ Discharge/ works reliably Check in operation and replace Spare parts replacement for cooling | timely fan: 1—2year Check and replace. Fast fuse replacement should take the same model or the models recommended by manufacturer. 2. Control board 2.1 Principle drawing of control board and components( see attached 1,2) 2.2 Explanation of control board X1: connection port for signal wire, square wire connects control board. X1:3: control signal for charge X1:4: control signal for discharge 1:15: feedback signal of battery's voltage X1:28: feedback signal of current X1:21: control signal for charge voltage X1:22: control signal for charge current X2: input and output connection port of main circuit X2:1,2,3: U,V, W_ 3 phase input wires X2: 4,5 : DC output wire X3: output conneetion port of controlled-circuit X3, 1: BE feedback signal wire of voltage X3, 2: CH Charge signal output X3, 3: N the public port of charge/discharge signals X3, 4: DC discharge signal output Potentiometer RP1: regulation potentiometer for current feedback RP2: regulation potentiometer for voltage feedback RP9: zero setting for current feedback Test prod UF test prod: Measure the voltage value after the battery's voltage has been changed({ull scale is 4V). IF test prod: Measure the voltage value after the current has been changed(full scale is 4) Tel: 0086-512-58163383 58591431 Fax: 0086-512-58591435 E-mail; wulinfan@oublicszen Web: tpunww jsf Com.enC-KGCFS Bartery formation charger/discharger operation manual 20 silicon controlled KP1-KP6: for regulation and output Resistance: R82: for sampling current R81, R83: for sampling voltage R26: Voltage controt-ring proportional resistance C11: Voltage controt-ring integral capacitor R46: current control-ring proportional resistance C24: current control-ring integral capacitor Integrate circuit N1,.N2, NG: operation magnifier N3, N4, NS: integrate circuit controlled trigger NB: magnified integrate circuit by pulse MOD: Circuit specially developed by Jinfan 2.3 Regulation explanation of main control board. When output éurrent or voltage can't reach the maximum value, i is necessary to make adjustment to current and voltage. Adjust the highest current: connect the current meter in series, set 5% rated current to operate, when display has become stable regulate RP to make the output current reach Setvalue. Set 100% rated value to operate, when display has become stable regulate RP1 to make output current reach set-value. ‘Adjust the highest voltage: connect two lamps of 200W in series for output, set 100% rated voltage to operate, when display has become stable regulate RP2 to make the output voltage reach set-value. 2.4 Microprocessor control board Location illustration Control wire connection port 2X1: Control wire connection port, 26 cores square wire X2: Control wire connection port, 26 cores square wire X3: Communication port, 10 cores square wire Potentiometer \W1: Regulation of voltage signal (clockwise for voltage uprising) ‘Wa: adjust of current signal (clockwise for voltage uprising) 2.5 adjustment for control board display When there is a deviation of output current or voltage, user has to adjust the current or voltage by himself. ‘Adjust current: connect the current meter in series, set 0-100% rated current to operate, Tel: 0086-512-58163383 58591431 Fax: 0086-512-58591435 E-mail: wiinfin@publiesz.en Web: hutp/anww jf. Com enHC-KGCFS Battery formation charger/discharger operation manual 2 when display has become stable regulate W2 to make the output current equal to actual value. ‘Adjust voltage: connect two lamps of 200W in series for output, set 0-100% rated voltage to operate, when display has become stable regulate W1 to make the output voltage equal to actual value. Tet 0086-512-58163383 58591431 Fax: 0086-512-58591435 E-mail wulinfin@oublic sen Web: rp ef, Commlol-ttin-ooar Wola NOWI3NNOD CTs ZHOS AOSE gE IndNt OV