CURTIS 240V Single Phase Concerto Star Battery Charger Instruction Manual

Concerto Star
Battery Charger
Single-Phase 240V
Manual

VERSION WITH NEW ELECTRONIC CARD PBM750 rev.2 – SW 2.2

INSTALLATION AND OPERATING INSTRUCTIONS

Single-phase 240 Volt Supply
The CURTIS Concerto battery charger, manufactured by PBM S.r.l., carries the “CE” mark as required by the European Directives:

• *89/336/EEC ( Electromagnetic Compatibility )
• *73/23/EEC ( Low Voltage )

Important: read the instructions carefully before connecting the charger to the mains and before operating.

INSTALLATION AND SAFETY WARNINGS

Read the manual carefully before connecting charger to mains and battery.

• Skilled and authorised personnel only shall be allowed to open the charger.
• Before setting the charger at work, the insulation of mains connection cable and battery connection connectors has to be checked.
• The electrical appliances have to be operated by skilled personnel only.
• Disconnect from mains before connecting or disconnecting battery.
• WARNING: Batteries produce explosive gases while being charged, therefore there must be neither flames nor sparks near the charger while it is in operation. Keep the charger far away from other appliances, which may endanger people and objects.
• The charger contains electric components, which may produce voltaic arcs and sparks, therefore if it is used in a closed environment it has to be installed in a proper site. The standard charger (IP 20) is to be used in closed and ventilated environments only and not exposed to rain nor splashed with water. It has to be positioned onto solid and levelled floors, far away from dust, water, heating and moisture. The charger has not to be positioned onto supports and/or shelves of wood or other inflammable materials. Do not stack materials near the charger and do not place any objects or fluid containers on the top of the charger.
• Ensure that an adequate earth connection is made to prevent risks of electrocution. The charger has to be connected to a mains supply of standards corresponding to the power of the charger and has to be protected through an adequate electrical device conforming to European Standards (fuses or automatic cut-outs – use Category D breakers). The protection must be at least 10% higher than the power absorption of the device; furthermore the device has to be protected from a too high contact voltage, according to the provisions by local Authorities.
• It is recommended to use bipolar standard connectors which do not allow a polarity reversal on battery; check the proper connection of cables in the contacts of the connectors (bad conditions of the connectors due to the oxidation of the electrical contact may produce dangers like sparks or fires).
• Do not use additional cables to prolong the existing electrical connections.
• Check regularly the condition of the battery. It is recommended to use batteries in good state.
• Do not tamper with the charger and in particular the safety systems.
• Problems in the electrical components have to be removed by skilled personnel only. Defective parts have to be replaced with other components with the same features and have to be authorised by the manufacturer.
• Check regularly all internal electrical connections. Make sure that cables and terminals have not been damaged by overheating due to bad contacts; remove dust (in particular from the contactor and the mobile parts).
• The Curtis battery chargers do not need any special maintenance, apart from the usual cleaning which has to be performed regularly depending on the installation site. Before cleaning the charger, disconnect it from mains and battery.

MAINS SUPPLY 240-Volt (single-phase)

• Connect the charger to a suitable rated mains supply. See rating label on side of charger for details. The equipment must be earthed.
• Single phase chargers are pre-set for 240 volt operation.
• Should the mains voltage differ from the rated value, the charger transformer tappings on the terminal board should be adjusted to suit. The auxiliary transformer must also be adjusted on the single phase equipment.
• The mains supply should allow for a 20% safety margin above the rated input for the charger to allow for potential overloads. As chargers present an inductive load to the mains, the supply should be protected by either slow acting class 4 or class D magnetic breakers or thermal circuit breakers or motor start fuses.

DC CONNECTION

• Connect the DC output cables of the charger to the appropriate style DC connector ensuring correct polarity is maintained and the charger is correctly matched to the battery.

MAINTENANCE

• As with all chargers, an excessive build up of dust may create a fire hazard. It is therefore advised that the charger should be “blown-out” with an air line or equivalent at least once a year.
• Servicing and/or repairs should only be carried out by Curtis approved service engineers.

CHARGING PROCESS (standard configuration)

• Once mains and battery connections have been performed, the card performs a lighting test of all LED’s. Then the green “BATTERY CONNECTED” LED remains lit (constant).
• In the standard configuration the “AUTOSTART” function is enabled (as default setting): the charger begins automatically charging 5 seconds after connection to battery. The Autostart stage is indicated by the blinking of the green “END OF CHARGING” LED, red “SAFETY TIMER” LED, and yellow “EQUALIZING CHARGE” LED.
• If the Autostart function is disabled, press the GREEN button to start the charging process. The green LED (“CHARGING”) begins blinking, and it will blink for the whole charging process. To stop charging, press the GREEN button again.
• After the initial charge stage, depending on the discharge rate of the battery, and provided that the average cell voltage has reached 2.4 V/cell (adjustable value), the yellow “FINAL CHARGE” LED will light up on the front control panel. Then an electronic timer starts counting down the last three hours of final charge.
• When the final charge time (adjustable value) has elapsed, the charger stops automatically and the green “END OF CHARGING” LED lights up.
• If the operator disconnects charger from battery during the charge process, the battery charger stops the charging process and signals a fault by means of the yellow LD4 LED blinking. On connecting the battery to the charger, the card resets and starts the charging process again. If the same battery is reconnected to the charger, the charger will disregard any final charge, which it might have previously started (beginning from SW 2.1b).

EQUALIZING CHARGE

• The equalizing charge (see the corresponding yellow LED always lit) is an optional function with a default factory setting. To disable it, contact the service engineers.
• The equalizing charge will start automatically after each normal charging cycle, but it can also be deactivated by software (see the functions of the SW1 DIP switches).
• After the normal charge a pause will take place (T. Pause = 60 min) after which Equalizing will be performed (for a Teq time = 45 h).
•  Equalizing is made up of an Np amount (= 3) of Neq (= 5) pulse packages, each of which consists of charges (T.ON = 12 min) and pauses (T. OFF = 48 min).
• The above mentioned pulse packages alternate with pauses (Ts = 15h).
• These pulses are performed during the Active cycle (=45h), followed by a Stop cycle (=120h).
• This equalizing system has no time limits and stops on battery disconnection. The system is very useful during holidays and week-ends, since it makes it possible to keep battery charged while preventing overcharging, overheating, and/or water consumption.

SPECIAL FUNCTIONS

The new Curtis Concerto charger with microprocessor card features special functions which can be selected by the operator, depending on his/her own needs, by means of the jumpers on the PBM750 electronic card, according to the following description:

Jumper
code| Function| Function description
---|---|---
Without jumper| With jumper
TV| Quick test| Normal times| Accelerated times
CF4| Final charge time| 3-h final charge time| 4-h final charge time
AS5| Standard Autostart| Manual start| Autostart after 5 sec
A3H| Delayed Autostart| Autostart after 3 h
CPR| Proportional charge| Proportional  charge not enabled| proportionalcharge enabled
CIllh| Safety timer| Safety timer set at 9h| Safety timer set at 11 h
CEQ| Equalizing charge| Not programmed| Programmed

The PBM750 rev2 card features an additional jumper (J3) with the function described below:

| | Function description
---|---|---
Jumper code| Function| REG*| FIX
J3| Setting of the gassing voltage| Threshold adjustable bymeans of a trimmer| Fix threshold preset between 2.37 and 2.43V/cell

• = default programming
  PLEASE NOTE: Before inserting jumpers to achieve the above-mentioned functions, disconnect charger from battery, otherwise the microprocessor will not accept the settings performed.
  The above configuration has to be performed by skilled personnel only.

SAFETY DEVICES

• DC output fuse, protection against battery polarity reversals and/or overloads.
• Control card protection fuse.

GUARANTEE

• The charger is guaranteed for 5 years from the date of dispatch against all proven defects in components, assembly and construction.
• Any incorrect installation or incorrect use of the equipment will invalidate the guarantee, as does any unauthorised tampering.
• In case of difficulties please contact Curtis Instruments.

For further assistance or information on the full range of Curtis products please contact:

Curtis Instruments (UK) Limited
5 Upper Priory Street
Northampton
NN1 2PT
Tel: +44 (0) 1604 629755
E-mail: e-mail@curtisinst.co.uk
Fax: +44 (0) 1604 629876
Web site: www.curtisinst.com
Three-Phase 420V
Manual
Concerto ( Star)
Battery Charger

VERSION WITH NEW ELECTRONIC CARD PBM750 rev.6 – SW 3.0

INSTALLATION AND OPERATING INSTRUCTIONS

The CURTIS Concerto battery charger, manufactured by PBM S.r.l., carries the “CE” mark as required by the European Directives:

Low Voltage Directive 2014/35/UE
– EMC Directive 2014/30/UE
– RoHS III Directive 2011/65/UE amended by Commission Delegated Directive 2015/863/UE

The CURTIS Concerto battery charger, manufactured by PBM S.r.l., carries the “UKCA”
marking as required by the GB regulations and designates standards:

• S.I. 2016 No. 1101 “The Electrical Equipment (Safety) Regulations 2016”*

•  S.I. 2016 No. 1091 “The Electromagnetic Compatibility Regulations 2016”*

• S.I. 2021 No. 422 “The Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment (Amendment) Regulations 2021”

• Amended by The Product Safety and Metrology etc. (Amendment etc.) (EU Exit) Regulations 2019
  Important: read the instructions carefully before connecting the charger to the mains and before operating.

“STAR” battery charger

VERSION: THREE-PHASE
USER MANUAL
INSTALLATION / USE / OPERATION

To use the charger, you have to abide by safety prescriptions contained in laws and regulations and in provisions made by Local Authorities.
User obligations: conforming to the operating instructions, the “user” is any natural or juridical person using directly P.B.M. battery chargers. The “user” will be responsible for the installation site of the charger, according to the instructions given below.

 INSTALLATION AND SAFETY INSTRUCTIONS

READ THE INSTRUCTIONS CAREFULLY before connecting charger to mains and battery.

• Skilled and authorised personnel only shall be allowed to open the charger.

•  Before setting the charger at work, the insulation of mains connection cable and battery connection connectors has to be checked.

• Disconnect from mains before connecting or disconnecting battery.

• BE CAREFUL!! Batteries produce explosive gases while being charged, therefore avoid flames and sparks and smoking near the charger while it is in operation.

• BE CAREFUL!! The charger contains electrical/electronic components which may produce voltaic arcs and sparks, therefore if it is used in a closed environment it has to be installed in a proper site, is to be used in closed and ventilated environments only and not exposed to rain nor splashed with water. It has to be positioned onto solid and flat floors, far away from dust, water, heating, and moisture. The charger has not to be positioned onto supports and/or shelves made of wood or other
  inflammable materials.

• Ensure that an adequate earth connection is made to prevent risks of electrocution. The charger has to be connected to a mains supply of standards corresponding to the power of the charger and has to be protected through an adequate electrical device (fuse or automatic cut-out) complying with European Standards. The protection needs minimum a 10% higher setting than the mains input of the charger (as shown on the rating plate of the charger).

• P.B.M. battery chargers do not need any special maintenance, apart from the usual cleaning which has to be performed regularly depending on the installation site. Before cleaning the charger, disconnect it from mains and battery.

CONNECTION TO MAINS

It is essential to connect the charger to a mains supply corresponding to the power of the battery charger installed and equipped with protection fuses (s. the values on the rating plate).
In case of connection to a power supply protected by Automatic Circuit Breaker, use only SWITCHES with D or K curve.
Make sure to earth the charger properly.
The charger is pre-set for a THREE-PHASE 420V AC mains voltage.
Should the charger be set for a three-phase mains supply of 240V AC:

• perform voltage adjustments on the terminal board
• retap taps on the auxiliary transformer (TA)
• replace mains fuses installing the suitable ones on the external panel

ADJUSTMENT TO MAINS VOLTAGE

During installation, or after changing installation site, it is advisable to check the actual value of the mains voltage present at the installation site of the charger. If it is too high or too low compared to the rated values, problems due to drops or increases in the charging current might arise.
The charger is usually pre-set for a 420V AC ± 5% or a 240V AC ± 5% mains voltage. Check mains voltage and, if required, adjust the connection of mains voltage to the transformer by means of the adjusting terminal board on the transformer. The above adjustment has to be performed by skilled personnel only.

CONNECTION TO BATTERY

We advise the use of bipolar standard connectors which do not allow reverse polarity on battery.
Check also cable connection in the connector contacts.
The above check has to be performed by skilled personnel only.

CHARGING PROCESS (standard configuration)

• Once mains and battery connections have been performed, the card performs a lighting test of all LED’s. Then the green “BATTERY CONNECTED” LED remains lit (constant).
• In the standard configuration the “AUTOSTART” function is enabled (as default setting): the charger begins automatically charging 5 seconds after connection to battery. The Autostart stage is indicated by the blinking of the green “END OF CHARGING” LED, red “SAFETY TIMER” LED, and yellow “EQUALIZING CHARGE” LED.
• If the Autostart function is disabled, press the GREEN button to start the charging process. The green LED (“CHARGING”) begins blinking, and it will blink for the whole charging process. To stop charging, press the GREEN button again.
• After the initial charge stage, depending on the discharge rate of the battery, and provided that the average cell voltage has reached 2.4 V/cell (adjustable value), the yellow “FINAL CHARGE” LED will light up on the front control panel. Then an electronic timer starts counting down the last three hours of final charge.
• When the final charge time (adjustable value) has elapsed, the charger stops automatically and the green “END OF CHARGING” LED lights up.
• If the operator disconnects charger from battery during a charging process, the battery charger stops temporarily the charging process and signals a fault by means of the yellow LD4 LED blinking. On connecting again a battery to the charger, the card resets and starts the charging process again. If the same battery is connected again to the charger, the charger will disregard any final charge, which it might have begun previously (beginning from SW 2.1b)

EQUALIZING CHARGE

• The equalizing charge (see the corresponding yellow LED always lit) is an optional function with a default factory setting. To disable it, contact the service engineers.
• The equalizing charge will start automatically after each normal charging cycle, but it can also be deactivated by software (see the functions of the SW1 DIP switches).
• After the normal charge a pause will take place (T. Pause = 60 min) after which Equalizing will be performed (for a Teq time = 45 h).
• Equalizing is made up of an Np amount (= 3) of Neq (= 5) pulse packages, each of which consists of charges (T.ON = 12 min) and pauses (T. OFF = 48 min).
• The above mentioned pulse packages alternate with pauses (Ts = 15h).
• These pulses are performed during the Active cycle (=45h), followed by a Stop cycle (=120h).
• This equalizing system has no time limits and stops on battery disconnection. The system is very useful during holidays and week-ends, since it makes it possible to keep battery charged while preventing overcharging, overheating, and/or water consumption.
• This equalizing system has no time limits and stops on battery disconnection. The system is very useful during holidays and week-ends, since it makes it possible to keep battery charged while preventing overcharging, overheating, and/or water consumption.

EQUALIZING CHARGE
The new Curtis Concerto charger with microprocessor card features special functions which can be selected by the operator, depending on his/her own needs, by means of the jumpers on the PBM750 electronic card, according to the following description:

Jumper

code

| Function| Function description
---|---|---
Without jumper| With jumper
TV| Quick test| Normal times| Accelerated times
CF4| Final charge time| 3-h final charge time| 4-h final charge time
AS5| Standard Autostart| Manual start| Autostart after 5 sec
A3H| Delayed Autostart| Autostart after 3 h
CPR| Proportional charge| Proportional charge not enabled| Proportional charge enabled
CIllh| Safety timer| Safety timer set at 9h| Safety timer set at 11 h
CEQ| Equalizing charge| Not programmed| Programmed

The PBM750 rev2 card features an additional jumper (J3) with the function described below:

| | Function description
---|---|---
Jumper code| Function| REG*| FIX
J3| Setting of the gassing voltage| Threshold adjustable bymeans of a trimmer| Fix threshold preset between 2.37 and 2.43V/cell

• = default programming
  PLEASE NOTE: Before inserting jumpers to achieve the above-mentioned functions, disconnect charger from battery, otherwise the microprocessor will not accept the settings performed.
  The above configuration has to be performed by skilled personnel only.

SAFETY DEVICES

• DC output fuse, protection against battery polarity reversals and/or overloads.
• Control card protection fuse.

GUARANTEE

• The charger is guaranteed for 5 years from the date of dispatch against all proven defects in components, assembly and construction.
• Any incorrect installation or incorrect use of the equipment will invalidate the guarantee, as does any unauthorised tampering.
• In case of difficulties please contact Curtis Instruments.

For further assistance or information on the full range of Curtis products please contact:
Curtis Instruments (UK) Limited
5 Upper Priory Street

Northampton
NN1 2PT
Tel: +44 (0) 1604 629755
E-mail: e-mail@curtisinst.co.uk
Fax: +44 (0) 1604 629876
Web site: www.curtisinst.com

Instructions for disposal

The European directive on the disposal of electrical and electronic equipment (WEEE, 2012/19/EU) has been implemented with the law on electrical and electronic equipment. All P.B.M. battery chargers are subject to WEEE and are marked with the symbol of a crossed-out dustbin. This symbol indicates that the product must not be disposed of with household waste. P.B.M. is registered with the Italian authority ERION Professional with registration number IT20080000012397 disposal of used electrical and electronic equipment (implemented in the countries of the European Union and in other European countries with a special collection system for these devices). The symbol on the device or its packaging indicates that this product must not be treated as normal household waste, but must be delivered to a collection point for the recycling of electrical and electronic equipment. By disposing of this product correctly, you help protect the environment and the health of those around you. Incorrect disposal endangers the environment and health. Recycling of materials helps reduce the consumption of raw materials. For more information on recycling this product, contact your local authorities, municipal waste disposal service or the shop where you purchased the product.

References

• Curtis Instruments, Inc. | World leading electric vehicle technology, integrated EV systems and engineering support.

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