mantenedores de beteria serie 9000

DEEP SEA ELECTRONICS

DSEEXTRA

DSE9000 battery chargers

Author : Anthony Manton

COMPLEX SOLUTIONS MADE SIMPLE


2 057-085 DSE9000 battery charger manual ISSUE8.1

Deep Sea Electronics Plc Highfield House Hunmanby North Yorkshire YO14 0PH ENGLAND

Sales Tel: +44 (0) 1723 890099 Sales Fax: +44 (0) 1723 893303

E-mail : [email protected] Website : www.deepseaplc.com

057-085 DSE9000 battery charger operator manual

Deep Sea Electronics Plc All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means or other) without the written permission of the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Act 1988. Applications for the copyright holders written permission to reproduce any part of this publication should be addressed to Deep Sea Electronics Plc at the address above.

Any reference to trademarked product names used within this publication is owned by their respective companies.

Deep Sea Electronics Plc reserves the right to change the contents of this document without prior notice.

Amendments since last publication

Amd. No. Comments 1 Added Efficiency curve of 2A charger 2 Updated specs table of 3.7A charger 3 Added 5A DSE9255 charger and 9250-002 277V input charger 4 Added DSE9155 30V 2A charger (Issue7) 5 Added 10A charger (Issue8) 6 Added Indication (LED) for 10A chargers (Issue 8.1)

Typeface : The typeface used in this document is Arial. Care should be taken not to mistake the upper case letter I with the numeral 1. The numeral 1 has a top serif to avoid this confusion.


057-085 DSE9000 battery charger manual ISSUE8.1 3

1 INTRODUCTION .............................................................................................. 4 2 SPECIFICATIONS............................................................................................ 4

2.1 PART NUMBERING ........................................................................................................ 4 2.1.1 PROTECTION .......................................................................................................... 5 2.1.2 CHARGE FAILURE OUTPUT .................................................................................... 5

2.2 COMMON ELECTRICAL SPECIFICATIONS .................................................................... 5 2.3 OUTPUT SPECIFICATIONS............................................................................................ 6

2.3.1 DSE9130 12V 5A ..................................................................................................... 6 2.3.2 DSE9140 12V 10A.................................................................................................... 7 2.3.3 DSE9150 12V 2A ..................................................................................................... 8 2.3.4 DSE9155 30V 2A ..................................................................................................... 9 2.3.5 DSE9250 24V 3.7A ................................................................................................. 10 2.3.6 DSE9255 24V 5A ................................................................................................... 11 2.3.7 DSE9260 24V 10A.................................................................................................. 12

2.4 DIMENSIONS AND MOUNTING .................................................................................... 13 2.4.1 DSE9130 12V 5A ................................................................................................... 13 2.4.2 DSE9150 12V 2A ................................................................................................... 14 2.4.3 DSE9140 12V 10A.................................................................................................. 15 2.4.4 DSE9155 30V 2A ................................................................................................... 16 2.4.5 DSE9250 24V 3.7A ................................................................................................. 17 2.4.6 DSE9255 24V 5A ................................................................................................... 18 2.4.7 DSE9260 24V 10A.................................................................................................. 19

2.5 APPLICABLE STANDARDS ......................................................................................... 20

3 INSTALLATION ............................................................................................. 21 3.1 BATTERY SUITABILITY ............................................................................................... 21 3.2 USER CONNECTIONS ................................................................................................. 21

3.2.1 DSE9130 12V 5A ................................................................................................... 21 3.2.2 DSE9140 12V 10A.................................................................................................. 22 3.2.3 DSE9150 12V 2A ................................................................................................... 22 3.2.4 DSE9155 30V 2A ................................................................................................... 23 3.2.5 DSE9250 24V 3.7A ................................................................................................. 23 3.2.6 DSE9255 24V 5A ................................................................................................... 24 3.2.7 DSE9260 24V 10A.................................................................................................. 24

3.3 TYPICAL WIRING DIAGRAM ........................................................................................ 25

4 OPERATION .................................................................................................. 26 4.1.1 INDICATIONS ........................................................................................................ 26 4.1.2 OPERATING MODES ............................................................................................. 28 4.1.3 PSU MODE ............................................................................................................ 28 4.1.4 CHARGE MODE .................................................................................................... 28 4.1.5 BOOST MODE ....................................................................................................... 29

5 FAULT DIAGNOSIS ....................................................................................... 30 6 MAINTENANCE, SPARES, REPAIR AND SERVICING .................................. 30 7 WARRANTY .................................................................................................. 30 8 DISPOSAL ..................................................................................................... 30

8.1 WEEE (WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT) .................................. 30 8.2 ROHS (RESTRICTION OF HAZARDOUS SUBSTANCES .............................................. 30



1 INTRODUCTION

This document details the installation requirements of the DSE9000 series range of battery chargers part of the DSEExtra range of ancilliary modules. The manual forms part of the product and should be kept for the entire life of the product. If the product is passed or supplied to another party, ensure that this document is passed to them for reference purposes. This is not a controlled document. You will not be automatically informed of updates. Any future updates of this document will be added to the DSE website at www.deepseaplc.com

2 SPECIFICATIONS

2.1 PART NUMBERING

9130 - 001 - 00

* DSE9150 12V 2A only available in Variant -00 (13.7V for lead acid batteries)

** For variant 03 (For other battery types), the float voltage can be adjusted between 12.5V and 15V for DSE9130 12V 5A chargers (25V - 30V for DSE9250 24V 3.7A chargers). This change must be made at the DSE factory. Ensure the correct variant (and float voltage if applicable) is specified on ordering. Consult your battery manufacturer for further details of required float voltage.

NOTE : This document DOES NOT contain details of the older DSE9210 and DSE9240 battery chargers. For further details of these units, please visit www.deepseaplc.com or contact Deep Sea Electronics.

Product type Variant

Hardware revision

Revision 1 001

For lead acid batteries 12V charger set to 13.7V 24V charger set to 27.4V

00

For 9 or 18 cell NICAD batteries* 12V charger set to 13.0V 24V charger set to 26.0V

01

For 10 or 20 cell NICAD batteries* 12V charger set to 14.5V 24V charger set to 29.0V

02

For other battery types* Specify required float voltage on ordering**

03

DSE 9130 12V 5A 9130

DSE 9150 12V 2A 9150

DSE 9250 24V 3.7A 9250

DSE 9255 24V 5A 9255

9250 24V 3.7A 277V nominal AC input 002

9155 DSE 9155 30V 2A

9140 DSE 9140 12V 10A

DSE 9260 24V 10A 9260



2.1.1 PROTECTION

Current limit to charger specification (2A, 3.7A, or 5A depending upon charger model) Short circuit protection. Charger automatically restarts operation after the fault is removed. Reverse battery polarity protection. Charger automatically restarts operation after the fault is

removed.

2.1.2 CHARGE FAILURE OUTPUT (Not applicable to DSE9150 12V 2A)

Charge failure determination The charge fail circuit will operate upon failure of the AC input or if the output voltage drops below approximately 6V

Charge failure relay rating 3A DC resistive, 30V maximum

2.2 COMMON ELECTRICAL SPECIFICATIONS

Parameter Min Nominal Max Input Voltage (V) DSE9130 12V 5A DSE9150 12V 2A DSE9140 12V 10A

90V 90V 90V

110V-277V 110V-240V 110V-240V

304V 250V 305V

DSE9155 30V 2A 85V 110V-240V 265V DSE9250 24V 3.7A (9250-001-xx) DSE9250 24V 3.7A (9250-002-xx) DSE9255 24V 5A DSE9260 24V 10A

90V 90V 90V 90V

110V-240V 110V-277V 110V-277V 110V-240V

265V 305V 305V 305V

Operating Temperature -30C -22F

55C 131F

Input frequency (Hz) 48Hz 64Hz Output ripple and noise 9140 & 9260

1% Vo 2% Vo

Load regulation 9140 & 9260

1% Vo 2% Vo

Line regulation



2.3 OUTPUT SPECIFICATIONS

2.3.1 DSE9130 12V 5A

Parameter Min Nominal Max Comments Output Voltage (12 V DC battery) 12.5V 13.7V 15.0V Specify float voltage on

ordering. Output Charging Current (A) 0A 5A 5.5A Current limit threshold (A) 5A 5.3A 5.5A Recovery from current limit (A) 5A Full load AC input current (A) 1.5A With output at 13.7V DC AC Input Inrush (10ms) current (A) 20A

0.8

0.82

0.84

0.86

0.88

0.9

0.92

85 110 230 260

Effic

ien

cy %

Input Voltage (V)

DSE9130 Efficiency Curve at 5A

Efficiency Curve



2.3.2 DSE9140 12V 10A

Parameter Min Nominal Max Comments Output Voltage (12V DC Battery) 12V 13.7V 15V Output Charging Current (A)

10A 11A Current limit threshold (A) 10A

11A Recovery from current limit (A) 10A

11A

Full load AC input current (A)

3.1A

At Vin=85V, Vo=13.7V, Io=10Amp

Full load AC input current (A)

1.3A

At Vin=230V, Vo=13.7V Io=10Amp

AC Input Inrush (10ms) current (A)

60A

For 10ms

0.78

0.79

0.8

0.81

0.82

0.83

0.84

0.85

0.86

0.87

85 110 230 260

Effic

ien

cy %

Input Voltage (V)


Efficiency Curve at 10A



2.3.3 DSE9150 12V 2A

Parameter Min Nominal Max Comments Output Voltage (12 V DC Battery) 12.5V 13.7V 13.7V Float voltage not adjustable Output Charging Current (A) 0A 2A 2.5A Current limit threshold (A) 2A 2.3A 2.5A Recovery from current limit (A) 2A Full load AC input current (A) 0.7A With output at 13.7V DC AC Input Inrush (10ms) current (A) 10A

74

76

78

80

82

84

86

88

90

85 110 230 250

Effic

ien

cy %

Input Voltage (V)


Efficiency Curve



2.3.4 DSE9155 30V 2A

Parameter Min Nominal Max Comments Output Voltage (30 V DC Battery) 28.0V 34.3V 34.5 Output Charging Current (A) 0A 2.2A 3A Current limit threshold (A) 2A 2.2A 3A Recovery from current limit (A) 2A Full load AC input current (A) 2A AC Input Inrush (10ms) current (A) 30A

0.78

0.8

0.82

0.84

0.86

0.88

0.9

0.92

0.94

85 110 230 260

Effic

ien

cy %

Input Voltage (V)


Efficiency Curve



2.3.5 DSE9250 24V 3.7A

Parameter Min Nominal Max Comments Output Voltage (24 V DC Battery) 25.0V 27.4V 30.0V Specify float voltage on

ordering. Output Charging Current (A) 0A 3.7A 4A Current limit threshold (A) 3.6A 3.75A 4A Recovery from current limit (A) 3.6A Full load AC input current (A) 2A With output at 27.6V DC AC Input Inrush (10ms) current (A) 30A

0.8

0.82

0.84

0.86

0.88

0.9

0.92

85 110 230 260

Effic

ien

cy %

Input Voltage (V)

DSE9250 Efficiency Curve at 3.7A

Efficiency Curve



2.3.6 DSE9255 24V 5A

Parameter Min Nominal Max Comments Output Voltage (24 V DC Battery) 25.0V 27.4V 30.0V Specify float voltage on

ordering. Output Charging Current (A) 0A 5A Current limit threshold (A) 5A 5.3A 6A Recovery from current limit (A) 5A 5.2A Full load AC input current (A) 0.65A 2.7A With output at 27.6V DC AC Input Inrush (10ms) current (A) 30A

0.8

0.82

0.84

0.86

0.88

0.9

0.92

0.94

85 110 230 260

Effic

ien

cy %

Input Voltage (V)





2.3.7 DSE9260 24V 10A

Parameter Min Nominal Max Comments Output Voltage (12V DC Battery) 26V 27.6V 29V Output Charging Current (A) 10A 11A Current limit threshold (A) 10A 11A Recovery from current limit (A) 9.5A 10A 11A Full load AC input current (A) 2.2A At Vin=230V, Vo=27.6V,

Io=10Amp Full load AC input current (A) 5.8A At Vin=85V, Vo=27.6V,

Io=10Amp AC Input Inrush (10ms) current (A) 60A For 10ms

0.78

0.8

0.82

0.84

0.86

0.88

0.9

0.92

0.94

85 110 230 265

Effic

ien

cy %

Input Voltage (V)





2.4 DIMENSIONS AND MOUNTING

2.4.1 DSE9130 12V 5A

Overall size 136.48mm x 140.41mm x 63.40mm 5.37 x 5.53 x 2.5

Weight 0.5kg Mounting type DIN rail or chassis mounting Din rail type EN 50022 35mm type only Mounting holes Suitable for M4 Mounting hole centres 119.36mm x 128.36mm

4.7 x 5.05

Dimensions in mm unless stated



2.4.2 DSE9150 12V 2A

Overall size 108.03mm x 101.10mm x 48.6mm (4.25 x 3.98 x 1.91)

Weight 0.16kg Mounting type DIN rail or chassis mounting Din rail type EN 50022 35mm type only Mounting holes Suitable for M4 Mounting hole centres 91mm x 89mm

4.25 x 3.51




2.4.3 DSE9140 12V 10A

Overall size 152mm x 188mm x 2.44mm (6 x 7.4x 2.44)


(5.59 x 5.0) 30mm (1.18) from top and bottom edges 5mm (1.97) from left and right edges.

Input voltage (nominal) 110V-277V Input voltage (absolute range)

90V-305V

Charge failure relay rating 3A DC resistive 30V maximum

Operating Temperature -30C to 55C (-22F to 131F)


6 in 2.44 in 7.

4 in



2.4.4 DSE9155 30V 2A



4.7 x 5.05




2.4.5 DSE9250 24V 3.7A



4.7 x 5.05




2.4.6 DSE9255 24V 5A



4.7 x 5.05




2.4.7 DSE9260 24V 10A

Overall size 152mm x 188mm x 2.44mm (6 x 7.4x 2.44)


(5.59 x 5.0) 30mm (1.18) from top and bottom edges 5mm (1.97) from left and right edges.

Input voltage (nominal) 110V-277V Input voltage (absolute range)

90V-305V

Charge failure relay rating 3A DC resistive 30V maximum

Operating Temperature -30C to 55C (-22F to 131F)


6 in 2.44 in

7.4

in



2.5 APPLICABLE STANDARDS

BS 4884-1 This document conforms to BS4884-1 1992 Specification for presentation of essential information.

BS 4884-2 This document conforms to BS4884-2 1993 Guide to content. BS 4884-3 This document conforms to BS4884-3 1993 Guide to presentation. BS EN 60068-2-1 (Minimum temperature) -30C (-22F) BS EN 60068-2-2 (Maximum temperature) +55C (131F) BS EN 60950 Safety of information technology equipment, including electrical

business equipment. BS EN 61000-6-2 EMC Generic Immunity Standard (Industrial). BS EN 61000-6-4 EMC Generic Emission Standard (Industrial). BS EN 60529 (Degrees of protection provided by enclosures)

IP21.

UL508 NEMA rating enclosure type 1 (indoor use only).

In line with our policy of continual development, Deep Sea Electronics, reserve the right to change specification without notice.



3 INSTALLATION

The DSE9000 battery charger is designed to mounted within a control panel, on the panel DIN rail utilising the integral mounts or on a chassis utilising the mounting holes. For dimension and mounting details, see the section entitled Specification, Dimensions elsewhere in this document.

The DSE9000 battery charger is fit-and-forget. It can be permanently connected to the supply and the load, with no requirement to disable the charger during times of heavy load (such as engine cranking).

3.1 BATTERY SUITABILITY

The standard charger is factory set by DSE to suit Lead Acid batteries but can be adjusted at the time of ordering to suit other battery types. Care should be taken to ensure the batteries connected to the charger are of the correct technology to suit the setting of the charger. For details of other supported battery types and float voltages see the section entitled Specifications, Part Numbering elsewhere in this document.

3.2 USER CONNECTIONS

Connection type Screw terminal, rising clamp, no internal spring Min cable size 0.5mm (AWG 22) Max cable size 2.5mm (AWG 10) Recommended AC fuses DSE9130 12V 5A charger DSE9150 12V 2A charger DSE9140 12V 10A DSE9155 30V 2A charger

DSE9250-001 24V 3.7A charger DSE9250-002 24V 3.7A 277V input charger DSE9255 24V 5A charger DSE9260 24V 10A

2.0A anti-surge 1.5A anti-surge N/A (Internally fitted) 2.5A anti-surge

2.5A anti-surge 2.5A anti-surge 3.5A anti-surge N/A (Internally fitted)

Recommended cable size Refer to tables below

3.2.1 DSE9130 12V 5A

Connector A

Terminal Function Recommended size -OP Load negative 1mm (AWG 16) Battery negative terminal +OP Load Positive 1mm (AWG 16) Battery positive terminal

BOOST Boost mode 0.5 mm (AWG 22) Connect together for boost operation BOOST Boost mode 0.5 mm (AWG 22) CF Charge failure relay 0.5 mm (AWG 22) Closes under charge fail conditions CF Charge failure relay 0.5 mm (AWG 22)

Connector B

Terminal Function Recommended size

Earth 1mm (AWG 16) N AC Neutral 1mm (AWG 16) L AC Live 1mm (AWG 16)

NOTE : The DSE9000 series battery charger should only be used to charge one battery bank at a time. It is not recommended to parallel batteries as the tolerance of the batteries leads to imbalance in their charging.



3.2.2 DSE9140 12V 10A

Connector A



Connector B



3.2.3 DSE9150 12V 2A

Connector A

Terminal Function Recommended size NC Not Connected Do not connect -OP Load negative 1mm (AWG 16) Battery negative terminal +OP Load Positive 1mm (AWG 16) Battery positive terminal

Connector B





3.2.4 DSE9155 30V 2A

Connector A



Connector B



3.2.5 DSE9250 24V 3.7A

Connector A



Connector B





3.2.6 DSE9255 24V 5A

Connector A



Connector B



3.2.7 DSE9260 24V 10A

Connector A



Connector B





3.3 TYPICAL WIRING DIAGRAM

Charger type Recommended AC fuse DSE9130 12V 5A 2.0A anti-surge DSE9150 12V 2A 1.5A anti-surge DSE9140 12V 10A N/A (Internally fitted) DSE9155 30V 2A 2.5A anti-surge DSE9250 24V 3.7A 2.5A anti-surge DSE9255 24V 5A 3.5A anti-surge DSE9260 24V 10A N/A (Internally fitted)

x

BOOST not available on DSE9150 12V 2A DSE9155 30V 2A

CF not available on DSE9150 12V 2A



4 OPERATION

4.1.1 INDICATIONS

DSE 9130, DSE9155, DSE9250, DSE9255, DSE9150

DSE9130 12V 5A DSE9155 30V 2A

DSE9250 24V 3.7A DSE9255 24V 5A

DSE9150 12V 2A

LED Indications

Function Colour Action Charger Status Red Off when AC supply is not present or output volts are too low.

Steady during normal operation with AC supply above minimum operating voltage.

Flashing when connected to an operating charging alternator. Pulsing during overload conditions.

DANGER OF DEATH : LIVE PARTS exist within the DSE9000 enclosure. The enclosure cover must not be removed.

Charger Status Charger Status



DSE9140, DSE9260

DSE9140 12V 10A DSE9260 24V 10A

LED indications Function LED Action Charger Status Red 1) Off when AC supply is not present or output voltage is too low

2) Steady during normal operation with AC supply above minimum operating voltage 3) Flashing when connected to an operating charging alternator

Short circuit and reverse polarity indication

Green 1) Off when AC supply is not present or output voltage is too low 2) Steady during normal operation with AC supply above minimum operating voltage 3) Flashing during short circuit or reverse polarity conditions

Charger Status LEDs (Red and Green)



4.1.2 OPERATING MODES

The DSE9000 series of battery chargers can be used as a battery charger, DC power supply, or both at the same time. For instance, the units can be used to power the generator control panels and charge the panel batteries or starter batteries at the same time.

With no AC input to the charger, the Charge fail relay will be closed. This can be used to provide indication of charger failure which operates upon mains supply AC supply failure or battery charging failure. When a suitable AC supply is connected, operation of the unit will depend upon the load connected to the units output terminals :

Battery connected The charging operation will begin (Charge mode) No Battery connected The output voltage will be enabled. (PSU mode) Reverse connected battery The charger will remain in charge fail mode. Short circuit The charger will remain in charge fail mode.

4.1.3 PSU MODE

If no battery is connected to the output terminals, the DSE9000 battery charger will operate as a DC power supply only, current limit is factory set. See the section entitled Specification elsewhere in this manual for output specifications.

4.1.4 CHARGE MODE

Constant Voltage The DSE9000 battery charger operates in Constant voltage current limited mode. The charger output voltage is maintained at a constant level to allow the battery to charge while the load does not exceed the maximum rating of the charger. Once the battery is fully charged, the DSE9000 battery charger will switch to ECO-POWER mode. This is a low power use standby mode.

Current Limit If the load on the battery charger (battery charge demand+standing load) exceeds the maximum current rating of the charger, the charging current is limited to the maximum rating of the charger and the voltage is reduced. The voltage will rise to the rated voltage again once the load drops below the maximum rating of the charger.

Charging time Charge time is often of little consequence when the battery is used in a standby operation. An example of this is when the battery is used to supply the starting system of a diesel generator. During normal operation, the battery is at full capacity and the battery charger is used to maintain the float voltage of the battery. The battery is only drained when the generator is called to start. As the generator has a DC charging alternator fitted, the battery is quickly recharged when the generator is running. Should the generator stop before the battery is fully recharged, the DSE9000 will continue to recharge the battery until it is fully charged.

Typically a battery will charge from flat to 80% capacity in 16hrs when when charged at C/10. For example charging a 50Ah battery for 16hrs at 5A will charge the battery to 80% of its full capacity. Remember to take into account any other standing load such as control panel requirements when calculating how much power is left to charge the battery.



4.1.5 BOOST MODE (Not applicable to DSE9150 12V 2A or DSE9155 30V 2A)

Boost mode is operated by connecting the BOOST terminals together (for instance with an external switch or timer circuit). This will raise the battery charger floating voltage by 0.8V DC.

CAUTION : Boost mode is intended for equalisation of the cells in lead acid batteries and should not be operated when the battery charger is connected to other battery types or when the charger is used as a power supply only. If in doubt, consult your battery manufacturer.



5 FAULT DIAGNOSIS

Nature of problem Suggestion The charger is not operating Check that the incoming AC supply is correctly connected and within

limits and check the integrity of any external fuse that may be fitted.

Ensure the charger is not being operated above the maximum temperature specification.

Charge fail relay continuously operated

Check the connected load of the charger is not reverse connected or short circuit.

Batteries fail to charge Check the batteries using the battery manufacturers recommendations.

Charge time is too long Typically a battery will charge from flat to 80% capacity in 16hrs when when charged at C/10. For example charging a 50Ah battery for 16hrs at 5A will charge the battery to 80% of its full capacity. Remember to take into account any other standing load such as control panel requirements when calculating how much power is left to charge the battery.

6 MAINTENANCE, SPARES, REPAIR AND SERVICING

The DSE9000 battery chargers is designed to be Fit and Forget. As such, there are no user serviceable parts. In the case of malfunction you should contact your original equipment supplier (OEM).

7 WARRANTY

DSE provides limited warranty to the equipment purchaser at the point of sale. For full details of any applicable warranty, you are referred to your original equipment supplier (OEM).

8 DISPOSAL

8.1 WEEE (WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT)

Directive 2002/96/EC If you use electrical and electronic equipment you must store, collect, treat, recycle and dispose of WEEE separately from your other waste.

8.2 ROHS (RESTRICTION OF HAZARDOUS SUBSTANCES

Directive 2002/95/EC:2006 To remove specified hazardous substances (Lead, Mercury, Hexavalent Chromium, Cadmium, PBB & PBDEs)

Exemption Note: Category 9. (Monitoring & Control Instruments) as defined in Annex 1B of the WEEE directive will be exempt from the RoHS legislation. This was confirmed in the August 2005 UKs Department of Trade and Industry RoHS REGULATIONS Guide (Para 11).

Despite this exemption DSE has been carefully removing all non RoHS compliant components from our supply chain and products. When this is completed a Lead Free & RoHS compatible manufacturing process will be phased into DSE production.

This is a process that is almost complete and is being phased through different product groups.

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