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Charger
LGW 22406
OPERATING INSTRUCTIONS
A.S.T. Leistungselektronik GmbH Brook-Taylor-Str. 10, D- 12489 Berlin T:++49 / 30 / 63925700 Fax: ++49 / 30 / 6392 5709
www.astle.de
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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________
TABLE OF CONTENTS
0 General………………………………………………..3
1 Safety Guidelines……………………….……………4
2 Technical Data……………………………………….6
3 Charging characteristic………………………………7
5 Battery test…………………………………………….9
8 Report signals………………………………………..11
10 Dimensions…………………………………………..13
11 Mounting……………………………………… ……14
12 Electrical Installation………………………………..14
13 Error signals………………………………………….15
15 Repair………………………………………………...17
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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________
0 General
The present operating instructions have been created with utmost care and have
extensively been tested several times. For reasons of clarity, neither all detailed
information about each product type nor each conceivable kind of installation,
operation or maintenance could be taken into account.
We also point out that the content of the operating instructions is not part of or
modifies an older or existing agreement, confirmation or legal relationship. All
obligations of the manufacturer arise from the respective purchase agreement which
also contains the complete and only valid warranty regulations. Considering the
operation instructions neither extends nor restricts these contractual warranty
specifications.
The manufacturer reserves the right to correct or to change the content and the
product specifications and omissions without prior notice. He is not liable for
damages, injuries or expenses due to above mentioned reasons.
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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________
1 Safety Guidelines
ATTENTION:
Prior to installation or commissioning, these operating instructions
must be carefully read by qualified personnel familiar with electric
traction equipment. Mishandling can lead to personal injuries and/or
property damage. The installation and the commissioning may only be
performed by qualified personnel.
NOTICE:
The trouble-free and safe operation of the charger requires proper
transport, professional storage, installation and mounting as well as
careful operation and maintenance.
ATTENTION:
The device contains electrostatic sensitive devices (ESD). The
relevant treatment instructions shall be observed.
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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________
-VDE 0100
Regulations for the erection of power installations with nominal
voltages below 1000 V.
VDE 0113
Regulations for the electrical equipment of machines.
VDE 0160
Electronic equipment for use in heavy current installations.
2 Technical Data
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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________
3 Charging characteristic
U/I
CI CU CU
Charging phase 1 Charging phase 2 Charging phase 3
I1
U1
U2
t
5 hours maximum Without time limit
1)
Temperature compensation (–3mV x number of cells)/K between 0 and 50 °C.
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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________
Charging 1 2 3
phase
LED 1 2Hz 0 1Hz
LED 2 0 2Hz 1Hz
MK_BE 1 1 1
MK_BA 1 1 1
MK_BT 1 1 1
The charge level indication works only if all signal contacts are closed.
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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________
5 Battery test
When connected, the charger conducts a battery test without load resistance. The
charging will begin if a battery is connected and if the battery voltage is higher than
the battery test switch-on voltage and lower than the emergency switch-off voltage.
The battery test with loading is carried out every 120 min unless there is an error
condition and unless the battery temperature exceeds 50°C.
Battery voltage
U1
U2
U3
t
Battery current
I1
I2
I3
Charging phase Charging pause 30 sec Battery test 5 sec I-charge U-Charge
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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________
The scope of supply of the charger includes a battery temperature sensor. The
sensor's connecting cable must be electrically connected to the appropriate labeled
contacts of the Interface plug-in connector. The battery temperature sensor must be
attached directly to the battery. A good thermal connection with the battery ensures
accurate functioning.
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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________
8 Report signals
The reports are available approx. 10 s after switching on the operating voltage
following the conclusion of the internal start-up routines.
For the charger LGW 22406 ID 01, the error report for MK_BE, resulting from the
input voltage, the device temperature or the battery temperature, is being delayed by
5 sec if the error occurs permanently during this period.
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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________
9 Connection diagram
PE-
Connection
+ Input voltage
Minus voltage
+ Output voltage
Minus voltage
Battery temperature sensor
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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________
10 Dimensions
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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________
11 Mounting
The charger has to be fixed with 4 screws M6 on the mounting plate of a control
cabinet. The mounting plate is used for taking away power dissipation. Sufficient
thermal contact to the mounting plate of the control cabinet must be provided.
12 Electrical installation
After mounting the device, installation of protective earth conductor and power
terminals must be carried out in a voltage-free state. The battery temperature sensor
cable must be connected to the corresponding connections of the Interface plug-in
connector.
Control and signal lines must be shielded and, as far as possible, laid separately
from DC, mains and battery cables.
The device must be protected at the output and input by the operator. Fuse 10 A
slow each.
Cable cross-sections:
After applying the operating voltage, the charger starts independently without
further starting signal.
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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________
13 Error signals
Error reports are only displayed when signal contact MK_BE is open. For the charger
LGW 22406 ID 01, an error is only signaled once the error is present permanently for
5 s. The minimum input voltage for this function is 200 V.
The following errors are acknowledged automatically and the charging process is
restarted once the error cause has been remedied:
The following errors are acknowledged automatically, and the charging process is
restarted once the error cause has been remedied:
The error report Battery ok is reset once a successful battery test has been carried
out.
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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________
15 Repair
Prior to delivery, all devices undergo a precise functional testing. It is ensured that
only faultless devices are delivered. If a defect should occur nevertheless, please
send the device to the following address:
If one of the devices presents a defect, please do not try to repair the device by
yourself; please consult our service.
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