Ch4100 Series High Efficiency Intelligent Charger Thunderstruck User Manual Ver. 1.03

CH4100 Series High Efficiency Intelligent Charger
ThunderStruck User Manual Ver. 1.03

Table Of Contents
I. Product Overview
II. Safety
III. Preventing Leakage and Fire
1.Correct use of Breakers, Sockets and Cables
2. Correct Use of Input Connections
3. Charging Environment Requirements
IV. Regular Maintenance
V. Technical Specifications
VI. Parts List
VII. LED Charge Light Information
VIII. Appearance and Installation Dimensions
IX. Connections and Wiring
X. Faults & Solutions

I Product Overview
The CH4100 series high efficiency intelligent charger is designed to charge traction
batteries of electric vehicles. This series of products adopt the most advanced technologies such
as LLC resonant, active power factor correction, microcomputer measurement and control,
digital adjusting, and extremely water resistant technology. Its features include: wide input
voltage range, high input power factor that significantly reduces the input current as well as heat
generated from the input cable, and Low harmonic current that reduces interference to other
electric equipment. Full range soft switching is used to achieve high conversion efficiency and
very little electromagnetic interference. The charger is designed according to IP66 protection
grade and is highly water resistant. It is also small in size, lightweight, quiet, beautiful, simple to
install and of course easy operation and maintenance.
The charger uses microcomputer measurements and control technology, the embedded
CPU can accurately detect battery voltage and charge current.
The charger has temperature compensation functions, as well as automatic shut down
after being fully charged. Reverse battery connection protection as well as output short circuit
protection, AC input under voltage protection, and overheating protection . These functions help
to ensure safe and reliable use.
II Safety
1. Please do not disassemble the charger; this may cause electric shock or other injuries.
2. If the charger needs to be connected to an AC power supply with extension cables, please
make sure that the extension cable can withstand the maximum input current (GB 2.5mm2
copper core cable is recommended to be used), and limit the extension cable length within 10m.
3. Don’t place the charger where it can get wet, this may cause damage to the charger as
well as electric shock to the operator.
4. The charger’s DC output plug should be connected reliably to the socket, if they are
damaged or loose, please replace them immediately, otherwise it will cause overheating in the
plug position, and can even cause fire.
5. If the charger produces any abnormal sound or smell while on, please unplug the
power immediately and contact the service department. Do not attempt to open the charger case.
6. Make sure that all air vents are unobstructed to prevent charger overheating. Do not place
the charger near a heat source; the charger should be left with enough space to ensure proper
ventilation.
7. Please disconnect the charger's AC input power if you need to move it.
8. Make sure that AC power supply voltage matches chargers’ input voltage. For inquiries,
please contact your supplier or local power Supply Corporation.
9. Battery voltage and the nominal voltage of the charger must be matched or it
could damage both the charger and the batteries.
10. To avoid damage to the charger’s cables, do not pull, twist or shake the cables or the
connection terminals. If the cable is worn, please replace it immediately.
III Preventing Leakage and Fire
1. Correct use of Breakers, Sockets and Cables
1. Use copper core cables with flame-retardant jackets. The cables’ core diameter must be at
least 2.5mm in diameter.
2. Prevent plugs, sockets from coming in contact with water.
Note: According to statistics, 80% of electric car fires occur during charging. The main reasons
for this include insufficient core diameter, size of cables, poor quality plugs and sockets, poor
contact of plugs and sockets, poor flame-retardant sheath or shells of breakers, plugs and sockets
and so on.
2. Correct Use of Input Connections
Make sure that the plug is clean, undamaged and free of dirt before charging.
3. Charging Environment Requirements
Have it be spacious and away from flammable materials. Avoid mounting/placing the charging
plugs, charging cables or the charger itself on car cabs, synthetic seats and other flammable
objects.
4. Lithium Safety
A lithium battery pack should have a battery management system to ensure safe charging. A
battery pack with no BMS can be a very dangerous thing. We are not responsible for damage to
batteries due to using a charger with no BMS.
Most prismatic lithium batteries should be contained in a manner that prevents them from
swelling during charging and discharging. Consult your battery manufacturer’s recommendation
for the best way to package your cells.
IV Regular Maintenance
1. Check the J1772 Socket regularly for corrosion or other conduction inhibitors. Poor contact
may result in overheating and burning inside the socket, which although unlikely could cause
fire.
2. Make sure to use a charger that has a dedicated breaker and wire running to it.
3. Make sure that the charger’s shell and cooling fan are free of debris and dirt.
V Technical Specifications
Rated input voltage: 220VAC 50/60Hz
Input voltage range: 85~265VAC (Note: When the Input voltage is lower than 185VAC, the
output power will be limited to 1.5KW)
Power Factor: ≥ 0.99 @ 220VAC input, full power output;
Total Harmonic Current: ≤ 5% @ 220VAC input, full power output;
Nominal output voltage: 144V
Maxim output voltage: 180V
Rated output current: 15A
Voltage regulation accuracy: ≤ 0.5%
Current regulation accuracy: ≤ 2%
Conversion efficiency: ≥ 95% @ 220VAC input, full power output
Protection class: IP66
Audible Noise: ≤ 40dB
Seismic rating: Designed according to IEC60335-2-29-2004-Part.21
Working temperature: -25~55°C (Note: models whose output power greater than 2KW
Storage temperature: - 40~80°C
Recognition certificates: CE SGS will ensure 2KW output at 60°C. )
VI Parts List
A - AC Input Cables
B - DC Output Cables
C - Signal Cables
D - Charging Indicator E Mounting plate F Shell
G - Cooling Fan and Fan Cover
VII LED Charge Light Information
When... Then...
Green Light Flashing It is Charging Normally
Flashing Yellow, Red and Green in Various Charging has recently stopped or has a
Orders Fault with Charger or Batteries. Contact
Thunderstruck-ev.com.
VIII Appearance and Installation Dimensions
Do not bend the wires coming out of the charger until they have at least 50mm of space from
where they enter the shell of the charger.
Insure that there is a 50mm gap above the charger to allow for proper ventilation.
IX Connections and Wiring
Input Cables
Note: The Yellow and Pink wires are not used, Refer to the EVCC Manual for more details on
EVCC wiring.
Output Cables
X Faults and Solutions
If your charger is not working correctly, you can refer to the table below:
Fault Analysis Solutions

Battery temperature External battery temperature Check sensor connection or change a
Sensor Fault sensor is fault or not connected new one
Battery not Battery is not connected or Check and connect the battery
connected reverse connected correctly
Charging environment Place the charger in lower
Over-Temperature temperature is too high; cooling temperature environments and retry;
Protection fan is fault; air vents are Check whether cooling fan is at fault
obstructed or air vents are obstructed
Poor contact of charger’s input If no poor contact phenomenon
Input fault protection
side; Charger is broken occurs, please contact us
Charging timeout Battery is damaged or aging Check and replace battery
Battery Overheating Battery is damaged or aging Check and replace battery
Internal temperature
Charger is broken inside Please contact us
Sensor fault
Output voltage
Feedback fault
Battery is broken;
Check whether the battery is
“Full Power ”after Poor contact between charger and
damaged; battery connecting cables
Short charging battery;
are firm ; the battery is fully charged
Battery has been fully charged;
Battery temperature Battery is aging; Check the battery, and replace bad
becomes more than Battery voltage is lower than the battery; Reselect charger that match
50°C nominal voltage of the charger battery voltage level .
Battery is aging Replace the battery
Low battery capacity
Cables are too long or too thin Reduce the output cables back to
after full charge
Between the charger and battery initial length
Battery is aging Replace the battery
Check if there are foreign matters
Charging time
around the fan and remove them
becomes too short or
Charger overheating protection Check whether the cooling fan is
too long
working correctly, or contact us to
replace the fan.
Connectors are not connected
Connect all connectors correctly and
firmly, or the polarity is reversed;
LED indicator lights recharge
Battery is disconnected
but no charging
Replace your battery with a new
Battery is broken
battery
Check AC power supply and
LED indicator AC input is not connected firmly
chargers’ input cables
doesn’t light
If your charger still does not work correctly after referencing the above list, please record the
state of the fault and charge indicator information, then contact us.

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CH4100 Series High Efficiency Intelligent Charger

ThunderStruck User Manual Ver. 1.03

III. Preventing Leakage and Fire

1.Correct use of Breakers, Sockets and Cables

2. Correct Use of Input Connections

3. Charging Environment Requirements

IV. Regular Maintenance

VI. Parts List

VII. LED Charge Light Information

VIII. Appearance and Installation Dimensions

IX. Connections and Wiring

X. Faults & Solutions

VII LED Charge Light Information

Green Light Flashing It is Charging Normally

Fault Analysis Solutions

Charging timeout Battery is damaged or aging Check and replace battery

Battery Overheating Battery is damaged or aging Check and replace battery

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