B AT T E R Y C H AR G E R

BATTERY CHARGER

NG5 NG7 NG9

Installation and User Manual

Battery charger NG5-7-9

ATTENTION: To reduce the risk of electric shock, do not remove cover. Refer servicing to qualified service personnel. Disconnect the mains supply before connecting or disconnecting the links to the battery. Read the Instruction Manual carefully before use. Verify that the selected charge curve is suitable for the type of battery You have to re-charge.

Explanation of Graphical Symbols: The lightning flash with arrowhead symbol, within an equilateral triangle, is intended to alert the user to the presence of uninsulated dangerous voltage within the equipments enclosure; that may be of sufficient magnitude to constitute a risk of electric shock to persons.

The exclamation point within an equilateral triangle is intended to alert the user to the presence of important operating and maintenance (servicing) instructions in the literature accompanying the equipment.

This product is covered by warranty. The relative warranty certificate is attached to the Instructions Manual. If the Manual is not provided with this certificate, please ask your retailer for a copy. For further references, please write the serial number in the proper space: Serial No. _____________________

Information contained in this Manual relates to ZIVAN S.r.l. property which reserves the right to supply for the exclusive use of customers. No other use is allowed without a written authorization supplied by ZIVAN S.r.l. ZIVAN S.r.l. will be not responsible for inaccuracies contained in this manual due to print or translation errors. ZIVAN S.r.l. has the right to make changes or improvements, also for the user interest, without prejudicing the essential characteristic of operation and safety. Copyright 2003 by ZIVAN S.r.l. First Edition
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Installation and safety instructions

Battery charger NG5-7-9 has been designed to provide safety and reliable. It is necessary to observe the following precautions in order to avoid damage to persons and to the battery charger: Read the installation instructions contained in this Manual carefully. For further information put the Manual in a proper place. Fix the battery charger to a stable surface through the appropriate holes inserted on the fixing flanges. In case of installation on a vehicle it is advisable to use antivibration supports. Preferably the charger should be installed in the vertical position with the fan facing up. The horizontal installation is allowed. Never install in the vertical position with the fan facing down. Ensure all ventilation ports are not obstructed, to avoid the overheating. Do not put the battery charger near heat sources. Make sure that free space around the battery charger is sufficient to provide adequate ventilation and an easy access to cables sockets. Protect the battery charger from ingress of water. Do not pour liquids inside the case. Verify that the available supply voltage corresponds to the voltage that is stated on the battery charger name plate. In case of doubt, consult a retailer or local Electric Supply Authority. For safety and electromagnetic compatibility, the battery charger has a 3-prong plug as a safety feature, and it will only fit into an earthed outlet. If you can not plug it in, chances are you have an older, non-earthed outlet; contact an electrician to have the outlet replaced. Do not use an adapter to defeat the earthing. To avoid damaging the power cord, do not put anything on it or place it where it will be walked on. If the cord becomes damaged or frayed, replace it immediately. If you are using an extension cord or power strip, make sure that the total of the amperes required by all the equipment on the extension is less than the extensions rating. Disconnect the mains supply (turn off the switch) before connecting or disconnecting the links to the battery. To recharge Lead Acid batteries: WARNING: Explosive Gas Avoid flames and sparks. The battery must be positioned in a correctly cooled place. Do not use to charge batteries installed on board of thermal engine cars. Avoid recharging of non-rechargeable batteries. Verify that the nominal voltage of the battery to be re-charged corresponds to the voltage stated on the battery charger name plate. Verify that the selected charging curve is suitable for the type of battery to be re-charged. In case of doubt, consult Your retailer. ZIVAN S.r.l. will not accept any responsibility in case of mistaken choice of the charging curve that may cause irreversible damage to the battery. In order to avoid voltage drop, thereby assuring 100% charge at the battery, the output cables must be as short as possible, and the diameter must be adequate for the output current. Do not try to service the battery charger yourself. Opening the cover may expose you to shocks or other hazards. If the battery charger does not work correctly or if it has been damaged, unplugged it immediately from the supply socket and from the battery socket and contact a retailer.

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Operating principle
The battery charger considerably affects battery life and performances, which is the main part of every electric vehicle. A non controlled traditional battery charger (rectifier) provides a simple direct AC/DC conversion.

i i i

AC DC

Batteria

Disadvantages of this solution are: Low efficiency Large physical size Long charge times Charge depends on changes in the mains supply (with overcharge danger in the final charge phase)

In modern battery chargers these disadvantages are solved with an indirect AC/DC conversion, by passing through an intermediate DC/DC conversion. This is the usual method of operation for the SMPS (Switching Mode Power i Supply) at high power. This solution i AC DC gives a good performance for minimum Batteria v costs and physical dimensions using i DC DC switches more faster and powerful (modern technology).

The main advantages of this solution are: High efficiency Reduced dimensions Short charge times Charge independent from the changes of the mains supply Electronic control that provides the desired charge curve The advent of electrical problems (due to commutation) has imposed the introduction of adequate filtering to satisfy requirements of EMC 89/336/EEC directive for electromagnetic compatibility.

Block Diagram
R S T E F0 F1 F2 EMI FILTER RECTIFIER AND FILTER POWER STAGE RECTIFIER AND FILTER EMI FILTER F4

RECTIFIER AND FILTER

CONTROL LOGIC

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Battery charger NG5-7-9

Charging Level Indicator

100% 80% START 80%

RED LED shows that the battery is in the initial charging phase. YELLOW LED shows that the battery charger has reached 80% of charge. GREEN LED shows that the battery has reached 100% of charge. Further information can be found in the description of the Charging Curve.

Line Alarm Indicator

LINE ALARM

This RED LED turns on when there is a phase missing on the mains. In this situation the battery charger will not operate and the charging level indicator changes to yellow. (Check mains and input fuses).

Alarms (Two-tone audible message)

An two-tone audible message and the flashing LED shows that an Alarm situation has occurred: Condition Audible message + RED flash Audible message + YELLOW flash Alarm Type Battery Presence Thermal Sensor Description (Action) Battery disconnected or not in conformity. (Verify the connection and the nominal voltage). The thermal sensor is disconnected during the recharge or it is out working range. (Verify the connection of the sensor and measure the temperature of the battery). Phase 1 and/or Phase 2 have a duration in excess of the maximal allowed. (Verify the battery capacity). Loss of output Current control. (Failure of the control logic). Loss of output Voltage control. (Battery disconnected or failure of the control logic). An unavailable configuration has been selected (Verify the selectors position) Overheating of semiconductors. (Verify the fan operation).

Audible message + GREEN flash Audible message + RED-YELLOW flash Audible message + RED-GREEN flash Audible message + YELLOW -GREEN flash Audible message + RED-YELLOW-GREEN flash

Timeout Battery Current Battery Voltage Selection Thermal

When there is an alarm the battery charger stops supplying current.

Thermal Sensor and/or External Indicator

Thermal Sensor and External Indicator are Options that have to be connected to the 5 poles socket 180. Unless otherwise stated, the compensation of the Battery Voltage in function of the temperature of the Thermal Sensor is of -5mV/C for battery cell. The control range of the Thermal Sensor goes from -20C to +50C. The External Indicator reflects exactly the LED Indicator which is placed on the equipment. Further information can be found in the description of the Charging Curve. D01274-00 5

Battery charger NG5-7-9

Auxiliary Contacts
AUX1
NC C NO

AUX2
NC C NO

Technical Features: changeovers contacts 0,3A 125VAC 0,3A 110VDC 1A 30VDC Connector: faston 6,3 0,8 mm

Unless otherwise stated, the auxiliary contacts provide the following functions: Section AUX1 Function Mains Presence Description When the equipment is switched on, the contact Normally Open (NO) CLOSES and instead the contact Normally Closed (NC) OPENS. When the Stop Phase or the No Stop Phase is reached, the contact Normally Open (NO) CLOSES and instead the contact Normally Closed (NC) OPENS.

AUX2

End of charge or Trickle Phase

LED Bar Graph and Digital Instrument

100%

50%

CURRENT

The LED Bar Graph is an Option that shows a percentage indication of output current in comparison with its max. value. The Digital Instrument indicates the output tension expressed in Volt (V) and the output current expressed in Ampre (A). The corresponding unit of measure of the visualised numbers is indicated by the LED V or A. By means of the MODE button, it is possible to select A or V to be visualised. N.B. The instrument indicates by -L0 the output tensions, which are inferior to the nominal value of the battery.

V A
V A

LINE ALARM

MODE

Battery
A battery is characterised by two sizes: tension and capacity. Tension: Each element has a nominal tension, which depends on the type of battery (no matter what size). In order to reach higher tension, many elements are connected in series, so creating a BATTERY of elements. The number of elements is calculated by dividing the nominal tension of the battery for the tension of each single element in the table: Nominal Tension 2 V/cell 1,2 V/cell 1,2 V/cell 1,714 V/cell

Type
Pb NiCd NiMH NiZn

Capacity: It is the quantity of electric charge that the batteries can supply to an external circuit before the tension decreases under the final limit value and it is obtained by multiplying the intensity of the discharging current I, expressed in ampere (A), for the discharging time t expressed in hours (h): C = I x t. The traction battery capacity is normally referred to the discharging system of 5h: C5 = I x 5h. The capacity values that can be recharged by the battery chargers can be found in the description of the Charging Curve (this value is not present in the curves able to charge any capacity).

:
This device is in conformity with the Low Voltage directive 73/23/EEC and EMC directive 89/336/EEC and their further modifications.
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Battery charger NG5-7-9

Mechanical dimension

270

470

130 105

550

N.B. All dimensions are expressed in mm.

Drilling details
260

16

UP
518 550

Advised Installation

N.B. All dimensions are expressed in mm.

16 70 130 70

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TECHNICAL FEATURES
Ta=25C unless otherwise specified

Mains side
Description Supply Voltage Three-phase Frequency Absorbed Maximum Current per phase Inrush Current Power Factor Absorbed Minimum Power Absorbed Maximum Power Symbol Vin f Ifmax P = Pmax Test Condition Value and/or Range 400 15% 50 60 10 (NG5) 14 (NG7) 18 (NG9) < 2,35 0,72 < 10 5 (NG5) 7 (NG7) 9( NG9) Unit Veff Hz Aeff

cos Pinmin Pinmax

Vin=400Veff P = Pmax End of charge P = Pmax

A W kW

Battery side
Description Output current Maximum output current Output current ripple Absorbed current Output voltage Constant output voltage Thermal compensation of output voltage Operating range of Temperature Sensor Output voltage ripple Maximum power supplied Symbol I I1 Ia U U1 dU1/dT Phase 2 Phase 2 U = U1 U = U1, I = I1 Phase 1 I = I1 Equipment turned off Test Condition Value and/or Range See curve See curve < 5% < 0,5 See curve See curve -5 from -20 to +50 < 1% 4350 (NG5) 6100 (NG7) 7830 (NG9) Depend on the model (>0,2) Unit A mA V
mV / (Ccell)

T
Pmax

C W

Output capacity

mF

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General
Description Operating range of temperature Maximum relative humidity Switching frequency Efficiency Maximum size Weight Enclosure class Symbol Test Condition At each operation condition Without connecting cable Without connecting cable Value and/or Range from -20 to +50 90% 25 5% > 87% 550270120 9 IP20 Unit C kHz mm kg -

T
RH fc abc -

Protection and Safety

Description Insulation Insulation Insulation Leakage current Input fuses Symbol IL F0-F1-F2 Test Condition Mains to Battery side Mains side to Earth Battery side to Earth Supplied equipment Inside the equipment Value and/or Range 1250 500 500 <1 20 (NG5) 20 (NG7) 25 (NG9) Output fuse Minimum output voltage of operation (Battery Detector) Maximum output voltage Reverse output polarity F4 Um Inside the equipment Equipment turn on Phase 3 (IUIa - IUIUo) At the connection to the Battery Ta=55C
EN60335-1, EN60335-2-29 EN55014-1, EN61000-3-3 EN55014-2, EN61000-4-2 EN61000-4-4, EN61000-4-5 EN61000-4-6, EN61000-4-11

Unit VAC VDC VDC mA A

about 1,2I1 1,5 See curve Protection provided by fuse F4 100 -

A V/cell V -

Thermal protection of semiconductors (Temperature of Thermal Alarm) Safety Requirements (Rules) EMC Requirements (Rules)

C -

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Battery charger NG5-7-9 Design, production and sale: ZIVAN SRL Via della Costituzione, 36 42028 Poviglio (RE) ITALIA Tel. +39 0522 960593 Fax +39 0522 967417 info@zivan.it

SALES OFFICES
ITALY ZAPI SPA Via Parma, 59 42028 Poviglio (RE) Tel. +39 0522 960050 Fax +39 0522 960259 info@zapispa.it SLOVENIA/CROATIA PROTEUS ELECTRIC SRL Via di Noghere, 94/1 34147 Muggia Aquilina (TS) Tel. +39 040 232188-232388 Fax +39 040 232440 U.S.A. ELECTRIC CONVERSIONS 215, 14th Sreet Sacramento CA 95814 Tel. 916- 441-4161 Fax 916- 444-8190 elcon@jps.net SPAIN JZ RECIELCA S.L. C / Progrs, 2-A. Gav 08850 Barcelona Tel. +34 93 6382383 Fax +34 93 6383166 jz.administra@terra.es GREECE START Industrial Batteries 7-9 Agiou Filippou Street 18540 Piraeus Tel. +301 4179 951 Fax +301 4179 950 startbatteries@ath.forthnet.gr FRANCE URMA SARL 30, Rue de Morvan Silic 503 94623 Rungis Cedex Tel. +33 1 45609477 Fax +33 1 46750871 urma@wanadoo.fr HOLLAND SPI Special Product for Industry Vlijtseweg 232 7317 AN Apeldoorn Tel. +31 55 5211111 Fax +31 55 5222366 GERMANY ATECH Antriebstechnik GmbH Gewerbepark Lindach D7 84489 Burghausen Tel. +49 8677 98090 Fax +49 8677 980920 info@atech-antriebstechnik.de SWEDEN ETP KRAFTELEKTRONIK AB Jrningen, 15 43323 Partille Tel. +46 31 440715 Fax +46 31 449720 battman@etpab.se CHINA CNEEC N 1 Lianhuahe Hutong Beijing 100036 Tel. +86 10 63403913 Fax +86 10 63261083 zhoux@cneec.com.cn SWITZERLAND ASMO ENGINEERING AG Glashtte, 58 CH 4229 Beinwil (SO) Tel. +41 61 3136400 Fax +41 61 3136401 asmokarts@datacomm.ch UNITED KINGDOM EZ ELECTROFIT ZAPI LTD Unit 2 - Halesfield 17 - Telford Shropshire TF7 4PW Tel. +44 1 952 582482 Fax +44 1 952 581377 SPAIN VARELEC SCCL c / Lope de Vega 10-12 Bajos 08005 Barcelona Tel. +34 93 3032565 Fax +34 93 3032565 varelec@teleline.es BELGIUM BATTERY SUPPLIES n.v. Lindestraat, 89A 8790 Waregem Tel. +32 56 617977 Fax +32 56 617955 battery.supplies@skynet.be

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Electric Conversions Distributor of ZIVAN Battery Chargers 215 14th Street, Sacramento CA 95814 Tel. 916-441-4161 Fax 916-444-8190 E-mail: elcon@jps.net Web: www.zivanusa.com
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