BC1216
BC1225
BC1235
BC2416
BC2425
BC2450
BC2465
Acculader
Battery charger
Batterieladegerät
Chargeur de batterie
Bedieningshandleiding en
installatie instructies
Operation manual and
installation instructions
Bedienungshandbuch und
Installationsvorschriften
Manuel d’utilisation et
instructions d’installation
3
8
13
18
Copyright © 2001 Vetus den Ouden n.v. Schiedam Holland
Contents
Preface............................................................ 8
1 Information for the user ................................. 8
1.1 Purpose of the manual .................................. 8
1.2 Symbols ......................................................... 8
2 For your safety ............................................... 8
2.1 General remarks ............................................ 8
2.2 Use for correct purpose ................................ 9
2.3 Authorised operators ..................................... 9
2.4 Industrial use ................................................. 9
3 Design ............................................................ 9
4 Installation and commissioning .................... 9
4.1 Installation ...................................................... 9
4.2 Power-supply connection .............................. 9
4.2.1 Power failure .................................................. 9
4.3 Battery connection ...................................... 10
4.4 On-Board-Version ........................................ 10
5 Operation ..................................................... 10
5.1 Function of the LEDs ................................... 10
5.2 Button .................................................. 11
6 Troubleshooting ........................................... 11
7 Technical data .............................................. 12
9 Disposal ........................................................12
10 Charging programs ..................................... 12
Inhaltsverzeichnis
Vorwort ......................................................... 13
1 Benutzerinformationen .................................13
1.1 Zweck des Handbuchs .................................13
1.2 Symbolerklärung ..........................................13
2 Zu Ihrer Sicherheit ........................................13
2.1 Allgemeines ..................................................13
2.2 Bestimmungsgemäße Verwendung .............14
2.3 Zugelassene Bediener ..................................14
2.4 Im gewerblichen Einsatz ..............................14
3 Aufbau ...........................................................14
4 Aufstellung und Inbetriebnahme ..................14
4.1 Aufstellung ....................................................14
4.2 Netzanschluß ................................................14
4.2.1 Netzausfall ....................................................14
4.3 Batterieanschluß ...........................................15
4.4 On-Board-Version ..........................................15
5 Bedienung ....................................................15
5.1 Funktion der Leuchtdioden ..........................15
5.2 Taster ....................................................16
6 Störungen und Fehlersuche .........................16
7 Technische Daten .........................................17
9 Entsorgung ...................................................17
10 Ladeprogramme ...........................................17
Sommaire
Avant-propos ............................................... 18
1 Informations pour l’utilisateur ...................... 18
1.1 Objet du manuel d’utilisation ...................... 18
1.2 Explication des symboles ........................... 18
2 Pour votre sécurité ...................................... 18
2.1 Généralités ................................................... 18
2.2 Exploitation conforme à l’application .......... 19
2.3 Opérateurs autorisés ................................... 19
2.4 En exploitation commerciale ....................... 19
3 Conception .................................................. 19
4 Installation et mise en service ..................... 19
4.1 Installation .................................................... 19
4.2 Raccordement au secteur ........................... 19
4.2.1 Défaut d’alimentation .................................. 19
4.3 Raccordement de la batterie ....................... 20
4.4 Version on-board ......................................... 20
5 Commande .................................................. 20
5.1 Signification des diodes lumineuses .......... 20
5.2 Touche ......................................................... 21
6 Défauts et recherche des défauts ............... 21
7 Caractéristiques techniques ........................ 22
9 Mise au rebut ............................................... 22
10 Programmes de charge .............................. 22
Inhoud
Voorwoord ..................................................... 3
1 Gebruikersinformatie ..................................... 3
1.1 Doel van het handboek ................................. 3
1.2 Verklaring van de symbolen .......................... 3
2 Voor uw eigen veiligheid ............................... 3
2.1 Algemeen ....................................................... 3
2.2 Bedoeld gebruik ............................................ 4
2.3 Geautoriseerde bediener ................................4
2.4 Bij commercieel gebruik .............................. 4
3 Opbouw ......................................................... 4
4 Opstellen en in gebruik nemen ..................... 4
4.1 Opstellen ........................................................ 4
4.2 Netaansluiting ................................................ 4
4.2.1 Stroomuitval ................................................... 4
4.3 Accu-aansluiting ............................................ 5
4.4 Aan-boord-uitvoering ......................................5
5 Bediening ....................................................... 5
5.1 Functie van de lichtgevende dioden ............. 5
5.2 Toets .................................................... 6
6 Storingen en opsporen van fouten ............... 6
7 Technische gegevens .................................... 7
9 Afvoer ............................................................. 7
10 Laadprogramma’s ......................................... 7
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8
9.0112
Battery charger type BC1216, BC1225, BC1235, BC2416, BC2425, BC2450, BC2465
Preface
These operating instructions are intended to assure the correct
and safe operation of the Battery Charger. In order to work safe-
ly, avoid unnecessary downtime and increase the reliability and
lifespan of the Battery Charger, study these instructions careful-
ly and follow them at all times.
1 Information for the user
1.1 Purpose of the manual
These operating instructions contain information essential for
the correct operation of Chargers of the BC12xx and BC24xx
series. To assure correct and safe operation of the Battery
Chargers, study these instructions carefully and follow them at
all times. This will help to avoid:
• danger to the units,
• danger to the user
• downtime
and
• increase the reliability and lifespan of the Charger.
In the following instructions, the Chargers of this product series
BC12xx and BC24xx are referred to as ‘Charger’.
The operating instructions must be read and observed by all
persons involved in operating or working with the Charger.
Before switching the Charger on for the first time, read all the
chapters of these instructions carefully, paying particular atten-
tion to the details given.
When the unit is in industrial use, the safety guidelines, stan-
dards and legislation in force at the place or in the country of
use must also be observed, and standard procedures of good
working practice followed.
For further information not contained in these instructions, con-
sult the specialist personnel of the manufacturer or supplier.
1.2 Symbols
The Charger has been designed and produced in accordance
with generally accepted rules and the current state of the art. To
assure the safety of the user, additional notes on safety appear
in the text. The safety of the user in working with the Charger
can be guaranteed only when these notes are read and com-
plied with.
It is occasionally necessary to emphasise certain passages.
Passages marked for special emphasis have various meanings.
Note!
Indicates a remark which makes working with the
Charger considerably easier!
Caution!
Indicates a remark which draws attention to potential
danger for the Charger.
Warning!
Indicates a remark which draws attention to potential
danger to persons.
2 For your safety
2.1 General remarks
Warning!
The Charger has dangerous levels of voltage!
The Charger should be opened and repaired by quali-
fied electricians only.
Before opening the Charger, disconnect it from the
power supply and the lead-acid accumulator.
If the Charger is being used for industrial purposes, the follow-
ing accident-prevention regulations or relevant local and nation-
al regulations must be read and complied with in addition to
these operating instructions:
• ‘General Regulations’ VBG 1
• ‘Electric Equipment and Materials’, VBG 4
and
• Supervisory and reporting duties regarding any special fea-
tures of the operation in question (e.g. organisation of work,
procedures, personnel etc.)
The user of the Charger is responsible for ensuring that these
regulations are posted in a suitable position or are available
for consultation at any time.
Note!
In cases where safety regulations have been ignored or
9.0112
9
Battery charger type BC1216, BC1225, BC1235, BC2416, BC2425, BC2450, BC2465
ENGLISH
neglected when working with the Charger, the manu-
facturer or supplier will accept no liability for injury or
damage. In addition, such damage is no longer cov-
ered by the manufacturer’s guarantee.
2.2 Use for correct purpose
The Charger is intended only for re-charging lead-acid accu-
mulators. Depending on the previously set charging program, it
can also be used for wet-cell batteries and sealed maintenance-
free traction batteries.
The unit can also be used for charging wet-cell batteries and
sealed maintenance-free traction batteries. Always observe the
instructions provided by the battery manufacturer.
The Charger is not suitable for accumulators or non-
rechargeable batteries of any other type!
The use of the unit for any other purpose is incorrect and con-
sequently prohibited. The operator of the Charger alone is
responsible for any damage occurring under such circum-
stances.
The use of the unit for its correct purpose includes compliance
with these operating instructions.
The Charger should be used only in technically perfect condi-
tion. The user must be constantly aware of potential danger and
safety procedures. Any faults, malfunctions or damage (espe-
cially those which may involve a risk to the safety of the opera-
tor of the Charger) must be corrected immediately. In case of
faults or malfunctions affecting its safety, the Charger must be
taken out of service immediately and reported to the supervisor
in charge or other responsible person or department.
2.3 Authorised operators
No person is authorised to operate the unit unless he has read
and understood the operating instructions.
Adjustments (e.g. voltage adjustment) or repairs (e.g. replace-
ment of the DC fuse) should be carried out only by a qualified
electrician.
2.4 Industrial use
If the Charger TEBECHOP Traction is in use for industrial pur-
poses, the following also applies:
The operator must have undergone special instruction or train-
ing to familiarise himself with the charging and handling of lead-
acid accumulators. Such tasks should be performed only by
authorised personnel.
For safety reasons, it is prohibited to make changes or modifi-
cations to the unit. Always observe the protective earthing.
3 Design
The unit comprises a controllable high-frequency power unit,
microprocessor-controlled charging electronics and an operat-
ing and indicating panel with buttons and 4 LEDs.
The individual components are accomodated in a sturdy hous-
ing of steel sheeting. Cables are installed for connection to the
battery and power supply.
Note!
Always observe the power-supply data given on the
machine plate! The machine plate is located at the rear
of the unit.
4 Installation and commissioning
4.1 Installation
The unit should be used only in enclosed rooms. The place of
erection resp. the mounting room should be selected to ensure
that the ventilation openings are not covered and that the cur-
rent of cooling air is not obstructed. The unit must not be
installed or mounted close to radiators or other sources of heat.
It should also be ensured that no corrosive gases, e.g. acid
fumes, conductive dust etc. can penetrate the interior of the
unit. The protective system of the charger is IP 20.
4.2 Power-supply connection
The power-supply voltage and frequency must comply with the
data on the machine plate.
The unit must be protected against excessive contact voltage in
accordance with the regulations of the local electricity supplier.
The power supply fuse should be selected in line with the
following table:
Either gL fuses or automatic circuit breakers with B- or C- char-
acteristics are suitable for use.
4.2.1 Power failure
The unit starts a new charging process after every disruption in
the power supply lasting longer than 20 ms.
Rated current Mains fuse
0 - 6 A 6 A gL
6 - 10 A 10 A gL
10 - 16 A 16 A gL
10
9.0112
Battery charger type BC1216, BC1225, BC1235, BC2416, BC2425, BC2450, BC2465
4.3 Battery connection
Before connecting the battery cable, ensure that the battery
voltage complies with the data on the machine plate.
Observe the manufacturer’s instructions with regard to
the assignment of battery to charging unit!
Caution!
The charging unit must be correctly connected!
Connect the unit as follows:
1. red cable (+ terminal) to + terminal of battery, and
2. black cable (- terminal to - terminal of battery
or
insert the charging plug in the the appropriate socket of
the battery cable if the unit is fitted with a charging
plug.
4.4 On-Board-Version
In the on-board version the unit is mounted in a wall cabinet.
Furthermore the following options are included:
a) Protection against start (break of the driving motor) during
the charging process. The change-over contact can be
looped in the traction control circuit and is engaged as fol-
lows:
green = COM (common)
brown = N.C. (normally closed; break-contact)
white = N.O. (normally open; make-contact)
contact rating: max. 60V/2A/120W
The relay remains energized as long as the unit is switched
on and mains voltage is present.
b) Printed-board coating (the printed boards are coated with a
plastic cover to avoid malfunctions caused by humidity).
c) Mechanics have been shock and vibration tested.
5 Operation
When the battery is connected, the charging process begins
automatically. The program set is indicated for approx. 10 secs.
by the LEDs flashing. The LEDs which indicate the various
charging programs are given in table 3 of the appendix.
When the battery is fully charged, the charging process is also
ended automatically.
If the charging process is interrupted manually before comple-
tion, the unit must be switched off at switch before disconnect-
ing the battery.
Fig. 1: Operating and indicating panel
5.1 Function of the LEDs
The functions of the unit are indicated by four LEDs:
Table 1: Function of the LEDs
LED ‘charge’ (yellow)
glows during the main and gassing charge
phases
flashes during the equalising charge and
the second U-constant phase
(charge programs 7 and 15 only) in
combination with LED ‘charge
ended’
LED ‘charge ended’ (green)
glows after completion of charging
LED ‘Fault’ (red)
glows on failure of microprocessor-con-
trolled charging-electronics
flashes in steps of 2 seconds
after forced switchover to gassing
charge
flashes in steps of 4 seconds
in case of overtemperature discon-
nection
LED ‘maintenance-free’ (yellow)
glows, if the unit is set for programming
maintenance-free sealed batteries
(pre-set for programs 2 - 6 and 10-
14, for no. 7 and 15 as required)
Caution: maintenance-free batteries
must not be charged if the LED does
not glow!
9.0112
11
Battery charger type BC1216, BC1225, BC1235, BC2416, BC2425, BC2450, BC2465
5.2 Button
The button is used for interrupting the charge. When it is
pressed again, the unit continues charging.
Caution!
If the battery has to be disconnected during the charg-
ing process, the button must first be pressed.
6 Troubleshooting
The charging process can only begin if:
a) the Charger is connected to the power supply,
b) the battery is correctly connected to the unit,
c) the battery voltage is at least 9 V
d) the button has not been pressed.
For further notes on correcting faults and malfunctions, see
table 2.
Table 2: Troubleshooting
ENGLISH
Fault
No LED indication
Battery is not fully charged!
LED ‘Fault’ flashes in steps of 2 sec-
onds, other LEDs work normally
LED ‘Fault’ flashes in steps of 4 sec-
onds,other LEDs dark
LED ‘Fault’ glows continuously
Cause
Charge interrupted by pressing button
Power-supply failure
No battery voltage
DC fuse failed
Switchover to ‘Gassing charge’ by safe-
ty-timer function
Overtemperature
Failure of microprocessor-controlled
charge electronics
Check/Remedy
Continue charge by pressing button
again
Check power supply!
If o.k. contact Customer Service
Check charging cable, plug etc.
Contact Customer Service
Check allocation of battery capacity to
rated power of charging unit!
Check amount of power supply!
Undervoltage?
Check ventilation.
Make the charger cool out..
Battery defective?
Extract power plug and re-insert (reset).
If LED continues to glow, contact
Customer Service
12
9.0112
Battery charger type BC1216, BC1225, BC1235, BC2416, BC2425, BC2450, BC2465
ENGLISH
7 Technical data
Mains voltage : 230 V ( ± 10%, 47 - 63 Hz
Output voltage : see machine plate
Output current : see machine plate
Charging program : see section 10 of operating
instructions
Temperature range : 0 - 40°C
Protective system : IP 21
Length of power cable : 1900 mm
Dimensions (w x h x d) / Weight
BC1216 / BC2416 : 28 x 18 x 8 cm / 3.5 kg
BC1225 / BC2425 : 28 x 18 x 8 cm / 3.5 kg
BC1235 : 28 x 18 x 8 cm / 5.5 kg
BC2450 : 34 x 22 x 110 cm / 7.5 kg
BC2465 : 39 x 22 x 11 cm / 8.5 kg
The units comply with the following regulations:
EN 60335-2-29 Safety
EN 55014-1 EMV
EN 55014-2 EMV
EN 61000-4-4 EMV
EN 50 082-2 Noise immunity for industrial use
EN 50 081-1 Noise output for residential, business,
industrial areas
and small workshops
EN 60 146 part 1-1 Semiconductors, current rectifiers
IEC 68-2-6 Shock and vibration (only applicable for
on-board-version)
IEC 68-2-29 Shock and vibration (only applicable for
on-board-version)
We reserve the right to make changes as required.
1 Wet battery (100 % In)
2 Dryflex GiV/PzV (100 % In)
3 Supra F GiV (100 % In)
4 Dryfit-GiV Batterie (100 % In)
5 Dryfit PzV Batterie (100 % In)
6 Champion (100 % In)
7 WUoU (100 % In)
9 Wet battery (80 % In)
10 Dryflex GiV/PzV (80 % In)
11 Supra F GiV (80 % In)
12 Dryfit-GiV Batterie (80 % In)
13 Dryfit PzV Batterie (80 % In)
14 Champion (80 % In)
15 WUoU (80 % In)
‘yellow’ / charging ⊗−⊗−⊗−⊗⊗−⊗−⊗−⊗
‘green’ / charged −⊗⊗− −⊗⊗−⊗⊗− −⊗⊗
‘red’ / failure − − − ⊗⊗⊗⊗ − − − ⊗⊗⊗⊗
‘yellow’ / maintenace free −−−−−−−⊗⊗⊗⊗⊗⊗⊗
LED
Charging program /
Battery type
9 Disposal
When disposing of the Charger TEBECHOP Traction , always
observe the local regulations.
Note!
The Charger contains electrolytic condensors and
semiconductor components. The Charger should be
disposed of in such a way that no environmental dam-
age is caused.
The packaging material used for the Charger must be
separated before disposal. Paper, cardboard and plas-
tic materials should be recycled.
10 Charging programs
Table 3 indicates for which charging program your Charger
TEBECHOP Traction is set. The charging program is indicated
automatically for 10 secs. by flashing diodes at the start of the
charging process.
You can find the number of the adjusted charging program on
a label near the machine plate.
Table 3: Charging programs
Symbols: ‘
⊗‘ - LED flashes
‘
−’ - LED off
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9.0112
23
Battery charger type BC1216, BC1225, BC1235, BC2416, BC2425, BC2450, BC2465
Acculader Totale lengte plus- en minkabel Draaddoorsnede
Battery charger Total length of positive and negative cables Wire size
Batterieladegerät Gesamtlänge des Plus- und Minuskabels Leiterquerschnitt
Chargeur de batterie Longeur totale des câbles pos. et neg. Diamètre du fil
Cargador de batería Largo total de los cables positivo y negativo Diámetro de hilo
Caricabatterie Lunghezza totale cavo positivi e negativi Diametro del filo
BC1216 0 - 10 m 0 - 47 ft 6 mm
2
AWG 8
BC1225 0 - 11 m 0 - 48 ft 10 mm
2
AWG 6
BC1235 0 - 12 m 0 - 34 ft 16 mm
2
AWG 6
BC2416 0 - 20 m 0 - 94 ft 6 mm
2
AWG 8
BC2425 0 - 22 m 0 - 95 ft 10 mm
2
AWG 6
BC2450 0 - 27 m 0 - 76 ft 25 mm
2
AWG 4
BC2465 0 - 21 m 0 - 58 ft 25 mm
2
AWG 4
Draadkeuzetabel
Wire size selection table
Drahtwahltafel
Tableau de selection de fils
Tabla de selección de hilos
Tabella di selezione dei cavi
FOKKERSTRAAT 571 - 3125 BD SCHIEDAM - HOLLAND - TEL.: +31 10 4377700
TELEX: 23470 - TELEFAX: +31 10 4152634 - 4153249 - 4372673 - 4621286
Printed in the Netherlands
9.0112 I.BC1665 08-01
/