tbs electronics OC12-90 Professional Programmable Battery Chargers Le manuel du propriétaire

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Le manuel du propriétaire
Professional programmable battery chargers
Omnicharge
OC12-90 (12V/90A)
OC24-50 (24V/50A)
OC24-80 (24V/80A)
OC48-40 (48V/40A)
Owner’s manual
Gebruiksaanwijzing
Bedienerhandbuch
Mode d’emploi
Manual del propietario
TBS ELECTRONICS BV
De Marowijne 3, 1689AR, Zwaag, The Netherlands
http://www.tbs-electronics.com
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Notice of Copyright
Omnicharge OC40-90 battery charger owner’s manual © 2015-2022 TBS Electronics BV. All
rights reserved. No part of this document may be reproduced in any form or disclosed to
third parties without the express written permission of TBS Electronics BV, De Marowijne 3,
1689AR, Zwaag, The Netherlands. TBS Electronics BV reserves the right to revise this
document and to periodically make changes to the content hereof without obligation or
organization of such revisions or changes, unless required to do so by prior arrangement.
Exclusions for documentation and product usage
UNLESS SPECIFICALLY AGREED TO IN WRITING, TBS ELECTRONICS BV (“TBS”) :
1. MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY
TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER
DOCUMENTATION
2. ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES,
WHETHER SPECIAL, DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT
ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION
WILL BE ENTIRELY AT THE USER’S RISK
3. REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH OR
DUTCH, ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE
TRANSLATION, THE ACCURACY CANNOT BE GUARANTEED.
4. MAKES NO WARRANTY, EITHER EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED
TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE, REGARDING THESE TBS PRODUCTS AND MAKES SUCH TBS PRODUCTS
AVAILABLE SOLELY ON AN “AS IS” BASIS.
5. SHALL IN NO EVENT BE LIABLE TO ANYONE FOR SPECIAL, COLLATERAL, INCIDENTAL, OR
CONSEQUENTIAL DAMAGES IN CONNECTION WITH OR ARISING OUT OF PURCHASE OR
USE OF THESE TBS PRODUCTS. THE SOLE AND EXCLUSIVE LIABILITY TO TBS, REGARDLESS
OF THE FORM OF ACTION, SHALL NOT EXCEED THE PURCHASE PRICE OF THE TBS
PRODUCTS DESCRIBED HERE IN.
Document name, date and part number
OC40-90 Manual Rev2endfs”, May 2022, 201476
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English
Page 4
Nederlands
Pagina 25
Deutsch
Seite 46
Francais
Page 67
Español
Página 88
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TABLE OF CONTENTS
1. INTRODUCTION ...................................................................................................................... 5
2. INSTALLATION ........................................................................................................................ 6
2.1 Unpacking .................................................................................................................... 6
2.2 Mounting ..................................................................................................................... 6
2.3 Accessing the connection compartment ..................................................................... 7
2.4 Wiring details ............................................................................................................... 8
2.4.1 Control board connections and settings ................................................................ 10
2.4.2 Bottom side connections ....................................................................................... 11
2.5 Parallel operation ...................................................................................................... 11
3. CONFIGURING THE BATTERY CHARGER ............................................................................... 12
3.1 Selecting the correct charge program ....................................................................... 12
3.2 Charge programs explained ....................................................................................... 14
4. GENERAL OPERATION........................................................................................................... 16
4.1 Omnicharge display and control overview ................................................................ 16
4.2 Charging batteries ..................................................................................................... 17
4.3 Equalizing a flooded battery ...................................................................................... 18
5. TROUBLESHOOTING GUIDELINE .......................................................................................... 19
6. TECHNICAL SPECIFICATIONS ................................................................................................ 22
7. WARRANTY CONDITIONS ..................................................................................................... 23
8. DECLARATION OF CONFORMITY .......................................................................................... 24
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1. INTRODUCTION
Thank you for purchasing a TBS Electronics (TBS) Omnicharge battery charger. Please read
this owner’s manual for information about using the product correctly and safely. Keep this
owner’s manual and all other included documentation close to the product for future
reference. For the most recent manual revision, please check the downloads section on our
website.
The purpose of this owner’s manual is to provide explanations and procedures for installing,
configuring and operating the battery charger. The installation instructions are intended for
installers that should have knowledge and experience in installing electrical equipment,
knowledge of the applicable installation codes, and awareness of the hazards involved in
performing electrical work and how to reduce those hazards.
WARNING
Before proceeding with this owner’s manual, please make sure you have carefully read the
enclosed safety flyer!
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2. INSTALLATION
2.1 Unpacking
The charger package should contain the following items :
- Battery charger
- Wall bracket
- Battery temperature sensor (3m)
- Owner’s manual
- Safety flyer
- Charger warning stickers
- 2x M8 crimp terminals
- 7x mounting screws
!
CAUTION
After unpacking, check if the product shows any mechanical damage. Never use the product
when the enclosure shows any visual damage caused by harsh handling, or when it has
been dropped accidentally. Contact your local supplier for further information.
2.2 Mounting
Please see the image below for the mounting method.
The image on the next page shows the mutual distances of the drilling holes.
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!
CAUTION
Keep a clear space of at least 10 cm around this product for cooling purposes! Always
mount this product in an upright position. Floormounting is allowed as well, provided that
all 7 screws are used to secure the enclosure.
WARNING
To reduce the risk of explosion, never use this product in locations where there is danger of
gas- or dust explosions or where ignition protected equipment is mandatory. Never install
the charger directly on top of the battery or vice-versa.
2.3 Accessing the connection compartment
To access the connection compartment, remove the
two screws indicated on the left and slide the red
connection compartment cover downwards.
Never operate this product without having the cover
re-installed!
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2.4 Wiring details
Please see the image below for the wiring details.
Please consult the following table to determine the correct battery cable and fuse size
for each model. Using a smaller cable size or a longer cable will cause additional losses
and may result in improperly charged batteries. Fire and burning hazards are present if
the battery cables are insufficiently sized for the expected current. Battery cable
lengths longer than 6 meters, are not recommended.
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Model
Cable size
(length ≤ 3 m)
Cable size
(length = 3 to 6m)
Battery fuse
(quick type)
OC12-90
35mm2 (AWG2)
50mm2 (AWG0)
100-120Amp
OC24-50
25mm2 (AWG3)
35mm2 (AWG2)
60-80Amp
OC24-80
35mm2 (AWG2)
50mm2 (AWG0)
100-120Amp
OC48-40
25mm2 (AWG3)
35mm2 (AWG2)
50-70Amp
The AC input must be protected by an earth leakage circuit breaker with overcurrent
protection (RCBO), that can withstand the maximum nominal current consumption
from the charger without tripping. All AC wiring must be sized accordingly. Please
consult the following table to determine the correct AC wiring and RCBO sizes :
Model
AC wiring size / RCBO size
(220-240VAC)
AC wiring size / RCBO size
(100-120VAC)
OC12-90
1.5mm2 (AWG15) / 8A (30mA)
2.5mm2 (AWG13) / 16A (30mA)
OC24-50
1.5mm2 (AWG15) / 10A (30mA)
4mm2 (AWG11) / 20A (30mA)
OC24-80
2.5mm2 (AWG13) / 16A (30mA)
-
OC48-40
2.5mm2 (AWG13) / 16A (30mA)
-
Please make sure that the information in this table is in accordance to all locally
applicable electrical regulations.
Up to 3 battery banks can be connected to the charger. Each output can supply the full
rated charging current. The total charging current of all 3 outputs combined, will never
exceed the maximum rated charging current. All 3 outputs are isolated from each
other by highly efficient active rectifiers.
WARNING
The schematic above shows a typical standalone installation. No guarantees are given on
the compliance of any local electrical regulations. Please make sure that the complete
installation is made in accordance to all locally applicable electrical regulations.
WARNING
This Class I product must be earthed! Always connect the PE wire or chassis ground screw at
the bottom of the enclosure to your central ground (vehicle chassis, grounding system of
your boat etc.)
!
CAUTION
Always connect the negative (-) cable directly on the negative terminal of the battery, or on
the “loadside” of a current shunt. Always keep positive and negative cables close to each
other to minimize electromagnetic fields. Double check for correct polarity, before
connecting the battery cables to the battery! Wrong polarity may damage the charger.
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!
CAUTION
Please feed all connection compartment wiring through the rubber grommets and plastic
gland.
2.4.1 Control board connections and settings
The following image shows the control board connections and switch options.
Master/slave switch position. This switch must be set to ‘MASTER’ when a single
charger is installed. The ‘SLAVE’ setting is only relevant for parallel charger systems.
5 pole screw terminal block. The first three positions are connected to the normally
open, normally closed and common contacts of the internal alarm relay. This relay
will be activated when the charger shuts down into an error mode. When the error
condition has been cleared, this relay will de-activate again. Please make sure not to
exceed the maximum relay contact rating of 60V and 5A to avoid damaging the relay
or PCB.
On the 4th and 5th position of the screw terminal, an external switch can be connected
to remotely turn the charger on and off. This switch can be located up to 50 meters
away from the charger. It is advised to use a wire size of 1mm2 (AWG17) for the
remote switch connection. For the remote switch, any single pole switch can be used.
Only a low power signal must be switched on this line.
Remote bypass switch position. When a remote switch is connected to the 5 pole
screw terminal block, the remote bypass switch must be set to OFF. When no remote
switch is used, the remote bypass switch must be set to ON.
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2.4.2 Bottom side connections
Please see the next image for the bottom side connections.
2.5 Parallel operation
Up to 6 battery chargers of the same model can be connected in parallel, in order to reach
very high charge current levels. This manual will not show any connection or operation
details for paralleled charger systems. Such details are explained in the documentation that
is included with the optional Omnicharge XL Parallel Kit (art.# 5029950)”.
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3. CONFIGURING THE BATTERY CHARGER
3.1 Selecting the correct charge program
The image in chapter 2.4 showed the location of the rotary selector, which is used to select
the desired charge program. The charge program selection depends on the type of battery
that needs to be charged. Each battery type has its own typical bulk and float charge
voltages. When your battery type or optimal charging voltages are still not available in the
standard list, you can select rotary position ‘0’ and setup the battery charger using the TBS
Dashboard for Windows software. This software is included in the optional TBSLink to USB
Communication Kit (art.# 5092120), which also contains an isolated interface box required to
connect the Omnicharge to a PC. Using TBS Dashboard, all available parameters can be
edited, and it is also possible to edit or create your own battery charge programs.
!
CAUTION
Invalid battery type settings can cause serious damage to your batteries and/or connected
battery loads. Always consult your battery’s documentation for the correct charge voltage
settings.
In de following table, all settings are explained.
Selector
position
Battery
type
Voltage (12V / 24V / 48V) and maximum timer settings
Position 0
Custom
(empty
from
factory)
The voltage settings for this position are empty. Connect the
charger to a PC running TBS Dashboard and create a custom
charge program to save on this position. If not, the charger will
return a battery error when the selector is set to ‘0’.
Position 1
Flooded
(factory
default
setting)
Absorption voltage = 14.40V / 28.80V / 57.60V
Float voltage = 13.50V / 27.00V / 54.00V
Equalize voltage = 15.80V / 31.60V / 63.20V
Max. bulk time = 8hrs
Max. absorption time = 4hrs
Position 2
GEL
Absorption voltage = 14.20V / 28.40V / 56.80V
Float voltage = 13.50V / 27.00V / 54.00V
Equalize voltage = equalize not available
Max. bulk time = 8hrs
Max. absorption time = 4hrs
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Position 3
AGM
(also for
Optima
SpiralCell)
Absorption voltage = 14.70V / 29.40V / 58.80V
Float voltage = 13.65V / 27.30V / 54.60V
Equalize voltage = 15.50V / 31.00V / 62.00V
Max. bulk time = 8hrs
Max. absorption time = 4hrs
Position 4
Lead
Calcium
Absorption voltage = 14.80V / 29.60V / 59.20V
Float voltage = 13.50V / 27.00V / 54.00V
Equalize voltage = 15.80V / 31.60V / 63.20V
Max. bulk time = 16hrs
Max. absorption time = 8hrs
Position 5
LiFePO4
Absorption voltage = 14.40V / 28.80V / 57.60V
Float voltage = 13.80V / 27.60V / 55.20V
Equalize voltage = equalize not available
Max. bulk time = 12hrs
Max. absorption time = 12hrs
Position 6
Empty
Reserved for future use.
If selected anyway, the charger will return a battery error.
Position 7
Empty
Reserved for future use.
If selected anyway, the charger will return a battery error.
Position 8
Empty
Reserved for future use.
If selected anyway, the charger will return a battery error.
Position 9
Empty
Reserved for future use.
If selected anyway, the charger will return a battery error.
This manual will only describe the rotary selector settings. Configuration by TBS Dashboard
will be explained in the TBS Dashboard manual that comes with the TBSLink to USB
Communication Kit.
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3.2 Charge programs explained
Most standard selectable charge programs, perform a four stage IUoUoP charging process
comprising of a “Bulk” , an “Absorption”, a “Float” and a “Pulse” stage. The image below
visualizes the four stage charging process (for typical 48V voltage values, please multiply the
24V values by 2):
In the Bulk stage, the charger delivers full output current and typically returns approximately
80% of charge back into the battery once the absorption voltage is reached. During this
stage, indicators 3d and 3c (see frontpanel image in chapter 4.1) will be lit depending on the
Bulk charge progress.
When the absorption voltage has been reached, the Absorption stage will be entered and
indicator 3b will be lit. This stage will return the final 20% of charge to the battery. The
output voltage is kept at a constant level and the charge current decreases as a function of
the battery's state of charge. When the charge current has dropped below a certain value or
when the maximum absorption timer has been expired, the Float stage will be entered.
Indicator 3a will be lit and an acoustical message will sound, indicating that the battery is
full. In this stage the battery voltage will be held constant at a safe level for the battery. It
will maintain the battery in optimal condition for as long as the battery remains connected
to the activated charger. Connected battery loads will be directly powered by the charger
up to the charger's maximum output current level. When even more current is drawn, the
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battery must supply this which results in a declining battery voltage. At a certain battery
voltage level, the charger jumps back to the Bulk stage and will finalize a complete four stage
charging process again, once the battery load consumption has dropped below the charger's
maximum output current level.
The fourth stage called “Pulse”, will perform a short refresh charge of approximately 1 hour
each 7 days while the charger operates in the Float stage. This will keep the battery in
optimal condition while prolonging it's lifetime. The battery can remain connected to the
activated charger continuously, without risk of overcharging.
When the battery temperature sensor is installed, the charger automatically compensates
the charge voltages against battery temperature. This means that the charge voltages are
slightly increased at lower temperatures and decreased at higher temperatures (-30mV/°C
for 12V chargers, -60mV/°C for 24V chargers and -120mV/°C for 48V chargers). This way,
overcharging is prevented which prolongs your battery's lifetime. A connected battery
temperature sensor also enables the battery temperature protection, which stops the
charging process when the battery's temperature is below -20°C or above +50°C.
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4. GENERAL OPERATION
4.1 Omnicharge display and control overview
See the next image for an overview of all LED indicators on the Omnicharge frontpanel, as
well as the location of the main switch.
The frontpanel can be divided into four sections :
Output current bar. Indicates the percentage of total delivered charging current.
Mode indicator. Indicates the operating mode of the battery charger
Indicator mode
Description
Continuous green
Power on, normal mode
Flashing red (1 flash per sec.)
Battery error
A battery error can appear for several reasons. These are :
battery voltage is too low (too deeply discharged) or too
high and battery temperature is too low or too high (only
available when battery temperature sensor is connected).
The charger will not restart automatically in battery error
mode, except when this error was generated due to a too
low battery voltage or a too low battery temperature.
Flashing red (2 flashes per sec.)
High/low AC input voltage
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Flashing red (3 flashes per sec.)
High charger temperature
The charger automatically restarts when the temperature
is below an acceptable level.
Flashing red (4 flashes per sec.)
Charger error (return for service)
Charge status bar. Gives a rough indication of the charging progress, see below :
LED 3a : 100% full (ready)
LED 3b : 80% full
LED 3c : 50% full
LED 3d : empty
Power on, off, charger only switch.
Switch position
Description
“0”
Charger off
When the switch is in position “0”, it does not interrupt
any internal AC or DC sources. This means that there are
still lethal voltages present inside the charger! In position
“0”, the charger will still consume a small amount of AC
current.
“I”
Charger on in automatic charging mode
“II”
Charger on in forced float mode
In this mode, the output voltage of the charger is set
constantly to the float voltage (value is depending on
selected battery type) while being able to deliver full
rated output current. Since no automatic charging
programs are activated in this mode, it can be used for
constant voltage charging or operating the charger as a
battery buffered power supply.
4.2 Charging batteries
!
CAUTION
Before you start to charge batteries, read all enclosed safety instructions and warnings
while following all safety precautions about working with batteries.
The list below globally describes the steps to follow for charging batteries :
1. Push the charger switch in the “O” (Off) position and disconnect the AC supply to the
charger
2. If possible disconnect or switch off all loads from the battery
3. Connect the battery to the charger
4. Switch on the AC supply and activate the charger by pushing the charger switch in the
“I” (power on) position. After a two tone beep, the charger will start the charging proces.
5. After charging is completed, push the charger switch in position “O” and switch off the
AC supply again, before disconnecting the battery. Or, keep all connections and the
charger switch position untouched and just re-connect all battery loads.
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4.3 Equalizing a flooded battery
If you are using a lead acid battery, an occasional equalization charge cycle may
be recommended by the manufacturer. This might also be true when the battery
has been very deeply discharged or often charged inadequately. During equalization, the
battery will be charged up to approx. 15.5V (31V for 24V and 62V for 48V models) at a
reduced output current level. Before starting an equalization charge cycle, the following
caution statements must be read carefully :
!
CAUTION
Equalization should only be performed on a lead acid battery type that supports this
process. Therefore the Omnicharge only allows equalization when the battery type rotary
selector is set to Flooded, AGM or Lead Calcium. Other battery types like GEL or Lithium will
be damaged by this process. Please be aware that not all AGM and Lead Calcium battery
manufacturers allow an equalization process. Always follow the battery manufacturer's
instructions when equalizing batteries.
During equalization, the battery generates explosive gasses. Follow all the battery safety
precautions enclosed with your Omnicharge. Ventilate the area around the battery
sufficiently and ensure that there are no sources of flames or sparks in the vicinity.
Disconnect all loads connected to the battery during equalization. The voltage applied to
the battery during this process may be above safe levels for some loads.
The Omnicharge cannot automatically determine when to stop the equalization of a
battery. The user must monitor the battery’s specific gravity throughout this process to
determine the end of the equalization cycle. The internal 1 hours time-out timer of your
charger is only intended as a safety feature, but may not be sufficiently short to prevent
battery damage. Therefore, equalizing a battery is always a process that must continuously
be supervised by the user.
As explained earlier, the Omnicharge will only allow equalization when the battery type
rotary selector is set to a battery type that may allow an equalization cycle. Besides this, the
charger also needs to have a full charge cycle completed and must operate in the Float
stage. When these two conditions are met, the equalization charge mode can be activated
by pressing the recessed pushbutton on the bottom side of the unit (see image in chapter
2.4.2) for 3 seconds, until all charge status indicators start flashing.
The Omnicharge battery charger will allow a maximum equalization time of 1 hour before it
automatically jumps back to the Float stage. If the specific gravity of each cell does not
match the battery manufacturer's specifications yet, you can initiate a new 1 hour
equalization cycle by pressing the pushbutton for 3 seconds again. Always keep on checking
the specific gravity of each cell repeatedly during the equalization process. When these
values are correct, you can manually exit the equalization process by pressing the recessed
pushbutton once. The battery charger will then return to the Float stage.
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5. TROUBLESHOOTING GUIDELINE
Please see the table below if you experience any problems with the Omnicharge battery
charger and/or the installation.
Problem
Possible cause
Remedy
Omnicharge is not working at
all.
Main switch in Off (0)
position.
Push the power switch in the
‘I’ or ‘II’ position.
AC input voltage is out of
range or not available.
Make sure the AC input
voltage is available and
within the operating range of
the charger.
Remote switch or TBS
Remote Control has
deactivated the charger.
Activate the charger
remotely or check if the
remote bypass switch is set
correctly.
Poor contact between the
charger battery wires and
the battery terminals.
Clean battery terminals or
charger wire contacts.
Tighten battery terminal
screws.
Blown DC fuse.
Check battery fuse or
internal charger output fuse
(located on charger PCB).
Very poor battery condition.
Replace battery.
The battery is not being
charged up to it’s maximum
capacity.
Incorrect absorption charge
voltage setting.
Check the battery type
selector for correct settings.
Or adjust the absorption
voltage using TBS Dashboard.
Incorrect charge current
setting.
Adjust the charge current
using the Universal Remote
Control or TBS Dashboard.
Typically, the charge current
should be set to 10%-20% of
the total battery capacity
Too much voltage loss in
battery cables and/or
connections.
Make sure that the battery
cables have a large enough
diameter. Check if all DC
connections are solidly
made.
Additional battery loads are
consuming too much current
during charging.
Turn-off or disconnect all
battery loads.
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tbs electronics OC12-90 Professional Programmable Battery Chargers Le manuel du propriétaire

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Le manuel du propriétaire