PSW User Guide

The battery charges of the PSW series use high frequency technology, which enables them to be compact, light and efficient and to have a constant and repetitive behaviour. An inner microprocessor enables automatic recharging of batteries and stores the behaviour of the battery charger during its use.

This device has been developed for a professional use.

For best results and safety, the user is required to read, follow and keep these instructions carefully.

The manufacturer is not responsible for any damage due to improper use.

BATTERY

The battery voltage has to correspond to the PSW rated voltage (see rating data, for example 24V). A label on the PSW indicates the correct rechargeable battery type. Check that it matches the features of your battery. If necessary, it is possible to change the programming in order to adapt the PSW to your battery. Make contact with the supplier in order to carry out this change.

INSTALLATION

To ensure maximum safety, installation has to be carried out as indicated by the manufacturer. Any work on the charger must be carried out by qualified and authorized technical personnel. Never open the metal box: it is not necessary to get inside for installation.

WARNING: There is a risk of electric shock inside the box.

After unpacking be sure that the device is in perfect condition; in case of doubt, do not use and contact the supplier. It is better to install the PSW indoors, in a room free of humidity, acids or dust, with room temperature between 0 – 40°C. During use do not obstruct the ventilation holes. Any overheating of the PSW will reduce the output current; if overheating continues, charging will be stopped (see SPECIAL SIGNALS).

FIXED INSTALLATIONS: considering the small weight in order to avoid damage due to being dropped, we recommend fixing the PSW firmly to the wall. For fixing see Fig. 3.

ON BOARD INSTALLATION: fix the PSW horizontally in a well-protected area of the vehicle, which allows dissipation of the heat produced (FIF. 4). It is better to use vibration mounts. Connect the PSW cables directly to the battery poles; never use existing cables of the vehicle equipment.

Any non-compliance with this rule can cause malfunctioning or damage which cannot be attributed to the manufacturer.

More information is available in the ADDITIONAL FUNCTIONS section.

ELECTRICAL SUPPLY

Be sure the rating data of the battery charger is compatible with the mains power supply (single-phase, voltage, frequency, power). Plug into a socket equipped with protections that comply with local standard regulations. If you have to use an extension cable, contact the manufacturer for correct technical information. The replacement of the supply cable has to be carried out only by a qualified personnel.

BATTERY CONNECTION

Respect the polarity: red wire to + and black wire to -.

Incorrect connection does not cause any damage, but prevents the charging cycle from starting.

Do not use extension cables without manufacturer’s approval.

USE

Connect the battery and the power supply cable. LEDs light up for 2 seconds (PAN. 1), then only the CHARGE LED stays on (PAN. 2). If this does not happen, check the connection on the battery and supply. The PSW is unable to activate the charging if the voltage of the battery is lower than 1V/Cell (i.e., 12V for a 24V battery).

If everything is functioning properly the charger performs the whole charge and stops with the STOP LED illuminating (PAN. 3).

The time of charge depends on the discharge level, the battery type and the programmed charge cycle. For lead acid, gel or AGM batteries, 80% discharged, the whole recharge lasts 10-14 hours. For lead acid batteries it is possible to reduce the time to 7-8 hours by programming the fast cycle.

Shorter times are possible if the battery is less than 80% discharged.

Longer times are possible if the battery is more than 80% discharged.

SPECAIL SIGNALS

When the microprocessor detects a problem, it stops charging and signals this by flashing the two LEDs (PAN. 4).

The different possible problems are:

Overheating: the thermal conditions interrupt the current in order to avoid damage

Defective battery: the voltage trend shows a possible failure of the battery

Incorrect battery: the battery has a higher voltage than the charger (36V battery on a 24V charger).

In order to determine the king of problem it is necessary to read the internal PSW data memory (see DATA MEMORY section).

If the two LEDs remain lit (connecting the battery) (PAN. 8), means an internal problem has occurred. Only the manufacturer can solve this problem.

CHARGE INTERRUPTION

Power failures interrupt charging and all LEDs go out (PAN. 5); when the power supply is resumed charging starts again at the point it was interrupted. If charging has to be interrupted for any reason, switch off the PSW using the button provided and disconnect the battery.

To activate STOP, hold the button down until the STOP LED begins to flash (PAN. 6).

To interrupt the charge in the PSW is fitted on board, disconnect the mains supply and use the vehicle. Never disconnect the battery if the charge is supplying current, as the resulting spark could ignite the gases produced by the battery and cause an explosion.

For best charging, disconnect the battery only when the microprocessor indicates STOP (PAN. 3).

HOLDING

If you leave the PSW on line and connected even during long periods of inactivity, it is possible to maintain a 100% charge level.

At the end of a charge cycle (device indicating STOP – PAN. 3). The holding starts: when the battery voltage falls under a minimum level, the PSW goes into operation and supplies a small current in order to let the battery voltage reach a maximum level and then it stops. These charging pulses can be repeated indefinitely when necessary. The length of each pulse and the time between pulses depends on the battery condition. During charging pulses the display indicates STOP (PAN. 3).

If charging is interrupted by the pushbutton (PAN. 6), holding does not start.

We advise not to leave the PSW connected to the battery without mains supply for more than one week. Without mains supply, the PSW absorbs energy from the battery and may cause its total discharge,

DATA MEMORY

The internal microprocessor can store a remarkable quantity of information throughout the life of the PSW. This information can be read only through the suitable terminal (MUTLIPROGRAMMER) connected to the programming connector shown in Fig. 2.

Contact the supplier for purchase of a MUTLIPROGRAMMER-CLIENT.

Reading this information helps detect the problems and their cause.

It will be easily understood whether they are caused be a malfunction of the charger of the battery. It is also possibly to understand whether the problems are caused by the non-compliance of the user with the rules. Be particularly careful when reading the user’s handbooks.

ADDITIONAL FUNCTIONS

This section contains directions for the PSW when fitted on board.

When the PSW is assembled on board, the LEDs are often not visible.

It is possible to add am optional external display (VISLED) in order to place the control LEDs in a visible area. Ask your supplier for this and connect it to the auxiliary connector indicated in Fig. 1.

The PSW has two auxiliary contacts, which must be correctly connected to the vehicle equipment, with following functions:

Mains presence: the contact is normally closed; it opens when the PSW is supplied for charging. It has to stop the vehicle during the charging phases (contacts 1 and 7 of the auxiliary connector to be seen in Fig. 1);

Discharged battery: the contact is normally closed; it opens when the battery voltage is lower than the programmed value. It has to stop the vehicle when the battery has exhausted 80% of its energy (contacts 3 and 5 of the auxiliary connector to be seen in Fig. 1).

When the PSW operates on a discharged battery, it illuminates the BLOCK LED (only visible on the outer display VISLED) and it stops the vehicle.

In order to remove this block it is necessary to carry out a complete recharge.

The PSW will signal to the user when the technical maintenance is due. When this happens, the two LEDs flash alternately (PAN. 7). Make contact with the supplier.

GENERAL RECOMMENDATIONS

Do not let the battery run down completely (maximum 80%): it will last longer. Keep the battery contacts free of oxidation. Keep the charging area well ventilated.

MAINTENANCE

Keep the fan and the ventilation holes clean. To clean the outside, use a damp cloth, Use only original spare parts.

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