SAMLEX WSC-1250 Smart Battery Charger User Manual

SAMLEX WSC-1250 Smart Battery Charger

General safety and Installation instructions

Operate the device safely

Warning! Failure to observe this instruction can cause material damage, device malfunction, or danger of bodily injuries. Fundamental safety measures should be observed when using electrical equipment to avoid the danger of:

• Electric shock
• Fire hazard
• Injury

Safety instructions when installing the device

• Handle the batteries with care; they contain strong acids.
• Avoid contact with the battery fluid agent.
• If come in contact with battery fluid, one should rinse the affected parts of the body or clothing with plenty of cold water and seek medical attention immediately.
• Be sure that the device has a firm foundation.
• Do NOT use sharp or hard objects to clean the device; doing so may cause device damage.

Electrical cables
If cables have to be fed through metal walls or other walls with sharp edges, use ducts or wire bushings to prevent damage.

• Lay the cables so that other people will NOT trip over them.
• Do NOT lay cables which are loose or bent next to electrically conductive materials.
• Do NOT pull the cables.
• Fasten the cables properly.
• Lay the cables so that they cannot be easily damaged
• Always use sockets that are grounded and secured by earth leakage circuit breaker.
• Only a specialist should make the electrical connections.
• Do NOT lay the 115V/230V line and the 12V DC in the SAME cable duct!
• Keep to the indicated minimum cable cross-section.

Installation on boats

• Incorrect use or installation of the charger on boat may lead to corrosion of the boat. Please allow qualified personnel to perform the installation of the charger.

WARNING
Please read carefully about the following precautions. Damages caused by failure to follow the instructions below will NOT be covered by warranty.

• Use the charger only as intended.
• Do NOT operate the charger if the housing or the cables are damaged.
• The charger may NOT be used to charge any other type of batteries than the ones indicated.
• Do NOT operate the device in a damp or wet environment.
• Do NOT charge a frozen battery; there is the danger of explosion.
• Keep this charger in a safe place, out of reach of children.
• Only qualified personnel who are familiar with the risks involved and the relevant regulations should carry out maintenance or repair work.
• The device must be fixed and installed in such a way that it will NOT fall over or fall down.

Applications and Descriptions

The chargers regenerate power or recharge mobile batteries used onboard vehicles or boats. The charger can continuously charge supply batteries or starter batteries, enabling the batteries to maintain at a high capacity level. The charger can be used for charging three types of batteries:

• Gel / AGM batteries
• Lead-acid starter batteries
• Maintenance-free batteries

Please inquire your battery supplier about the maximum capacities of your lead-acid batteries. The charger is equipped with a polarity protection; this prevents the charger from being damaged in case of incorrect polarity. An optional temperature sensor, (Figure 9 Temperature Sensor TF-100) that is connected at the battery being charged protects the battery against damage cause by varying outside temperature by adapting the charging voltage of the temperature to the battery. Please connect two ends of Figure 9 Temperature Sensor TF-100 on – one end to “TEMP” socket on front panel and another end to the battery. An optional remote control (Figure 10 Remote Controller RC-600) can be obtained in order to provide remote access to the charger.

Introduction of the unit variants

The 4-stage battery charger can deliver different unit variants. It can charge batteries up to the specified battery capacity as indicated in the specification section. Regarding the identifi-cation of the specification of your unit, please see the model number on the type plate.

Front view Model-No.: WSC-1250 and WSC-2425

No. Description

1. “TEMP” connection for temperature sensor (accessory TF-100)
2. “REMOTE” connection for remote control (accessory RC-600)
3. Switch field S1 for the selection of the charging voltage, charging time limitation and power supply mode (see also Figure 8 Switch)
4. “STATUS” LED
5. “E.Q.” equalization LED
6. On/Off switch S2 for half power mode
7. Switch S3 for equalization on only
8. “+” (plus) DC output terminal for the supply battery
9. “-” (minus) DC output terminal for the supply battery
10. Connection for AC input 100~240 volts voltage
11. Plug holder

Rear view

No. Description

1. Ventilation outlet
2. Power switch

Accessories

Temperature Sensor TF-100
The temperature sensor (Figure 9 Temperature Sensor TF-100) measures the temperature of the battery or the environment around the battery and transfers the data to the charger. With deviating temperatures, the charging voltage increases and decreases accordingly.

Functions

• The temperature sensor transmits the battery temperature to the charger.
• The charging voltage is adjusted according to the temperature measured.

Installation

• Lay the cables from the batteries to the charger.
• Connect the temperature sensor to the “TEMP” socket of the charger.
• Connect the temperature sensor to the negative pole of the battery, or use a double-sided adhesive tape to attach the sensor to the top of the battery or in the vicinity of the battery (see Figure 15 Temperature Sensor Setup)

Note The length of TF-100 cable is 5M.

Remote Controller RC-600
Figure 10 Remote Controller RC-600.

Functions

• Switch the charger ON and OFF.
• Half power mode ON / OFF.
• Equalization ON.
• Status monitoring.

Note
Attach the remote control at a well accessible place to ensure easy access of the charger.
Be careful when attaching the remote control, for wiring harnesses, cables and other components that are in the assembly range could be damaged in the process!

Installation

• Ensure approximately 49mm width, 49mm height and 23mm depth for the take-up of the remote controller (see Figure 11 Remote Controller RC-600).
• Connect the remote control to the charger. The connection cable is equipped with two equivalent modular plugs.
• Place the remote control into the opening created. Secure the remote control with screws on the upper and bottom margin of the faceplate – use the available drills.

Note
The length of RC-600 cable is 10M.
Note
The power switch at the unit must be switched ON, so that the unit can be switched ON and OFF with the remote control.

Remote Controller RC-601D
The remote controller RC-601D,

Functions

• Switch the charger ON and OFF.
• Half power mode ON / OFF.
• Equalization ON.
• Display real-time information and settings.

Note The power switch at the charger must be switched ON, so that the charger can be switched ON and OFF by the RC-601D remote controller.
Caution! Be careful when attaching the remote control, for wiring harnesses, cables and other components that are in the assembly range could be damaged in the process!

Installation

• Connect this remote controller to the “REMOTE” socket of the charger (See Figure 14 Making Connections (RC-601D)).
• Ensure approximately 80mm width, 72mm height and 28mm depth for the take-up of the remote controller.
• Connect the remote controller to the charger. The connection cable is equipped with two equivalent modular plugs.
• Place the remote controller into the opening created. Secure the remote controller with screws on the upper and bottom margin of the faceplate – use the available drills.

Note The length of RC-601D cable is 10M.

Mounting of Battery Charger
For mounting battery charger on wall or flat places please refer from Figure 3 WSC-1250 / WSC-2425 Charger Top View regarding the size of housing and the location of mounting holes for your installation.

Making Connections

• Place the charger in a dry, cool, clean, and ventilated space.
• Set the power switch to “0” (off) and pull out the main plug before connection or disconnecting the direct current connection.
• Connect the “-“(minus) battery pole with a connecting cable with the”-“(minus) terminal at the charger (see Figure 5 Making Connections).
• Connect the “+”(plus) battery pole with the connecting cable with the “+”(plus) terminal at the charger (see Figure 5 Making Connections).
• Lay the cables from the batteries to the charger.
• Fold the cable ends with the multicore cable ends.
• Supply the cable with a fork connection for an ideal connection with the terminal (see Figure 7 Fork).

Ensure correct polarity of the battery and the battery charger, otherwise the internal flat-pin terminal will trigger with the wrong polarity.

Warning! Batteries with cell connection may NOT be charged. Explosive gases could result from battery overheating.
Note Only use cables with the designated wire cross sections to connect the charger to the battery.

Settings

Charging voltage setting
The switch field S1 can be used to select the charging voltage, equalization voltage, charging time and the operation mode of this charger (see Figure 8 Switch).
Warning! Please follow the table below to ensure correct operation of the charger Settings for the charging voltage for WSC-1250 and WSC-2425:

• Table 8-1 Switch Configure Charging Voltage****
  Switch 1| Switch 2| I phase voltage| Uo phase voltage| U phase voltage
  ---|---|---|---|---
  OFF| OFF| 13.5V/27.0V| 14.0V/28.0V| 13.5V/27.0V
  OFF| ON| 13.5V/27.0V| 14.4V/28.8V| 13.5V/27.0V
  ON| OFF| 13.8V/27.6V| 14.4V/28.8V| 13.8V/27.6V
  ON| ON| 13.8V/27.6V| 14.8V/29.6V| 13.8V/27.6V
• Table 8-2 Switch Configure Equalize Voltage****
  Switch 3| Equalization voltage
  ---|---
  OFF| Same as Uo phase voltage
  ON| 15.5V/31.0V
• Table 8-3 Switch Configure Power/Charger Mode****
  Switch 4| Operation mode
  ---|---
  OFF| Battery charger
  ON| Power supply 13.2V/26.4V
• Table 8-4 Switch Configure Uo Phase Time Limit****
  Switch 5| Switch 6| Charging time
  ---|---|---
  ON| OFF| 4 hours
  OFF| ON| 6 hours
  ON| ON| 8 hours
  OFF| OFF| Unlimited

Half power mode setting
When the switch S2 “HALF POWER” is pushed, the output power will reduce to half of the chargers’ amp rating and the “STATUS” LED will flash. The switch S2 is a kind of no memory switch. That means “ON/OFF” status cannot be identified from the switch. To enter and exit the “HALF POWER” mode by turns, please push the switch S2. The “HALF POWER” mode can be told from flashing “STATUS” LED. Due to the fan speed is adjusted according to the function of the load and the temperature inside the charger, when “HALF POWER” mode is on, the fan speed will be slowed down and become silent because of output current reducing to half the charger amp rating.

Note

1. The half power mode can be set only when equalization function is NOT activated or the charger is NOT in the power supply mode. (see Table 8-5 VOID Setting table for pushing switch on front panel)
2. Please refer to section 9.4 to understand the function of fan speed.

Equalization setting
When the switch S3 “E.Q.” is pushed, the function of equalization is activated and the “E.Q.” LED will light RED. Whenever the function of equalization is activated, it only can be cancelled by turning off the charger.

Note
The equalization function can be set only when the charger is NOT in the half power mode and NOT in the power supply mode. (See Table 8-5 VOID Setting table for pushing switch on front panel).

VOID setting table
To avoid the void setting, please refer to Table 8-5 VOID Setting table for pushing switch on front panel.

lights)

| VOID| Enter “HALF POWER” (“STATUS” LED flashing)| VOID
S3 “E.Q.” pushed| VOID| VOID| Equalization (“E.Q.” LED lights Red)| VOID

Using the Charger

Charging characteristic
The charging characteristic is generally designated as a modified IUoU characteristic.

1. I phase (bulk)
   The “STATUS” LED constantly lights Red. In the first stage of the charging process, the depleted battery is charged with a constant current until the battery voltage reaches I phase setting voltage (13.5V/27.0V or 13.8V/27.6V). When the battery reaches this voltage level, the charging current gradually drops. When the current drops down to 80%, the charger switches over to Uo phase setting voltage (14.0V/28.0V or 14.4V/28.8V or 14.8V/29.6V). Typically the battery is charged to 70-80% of its capacity.

2. Uo phase (absorption)
   The “STATUS” LED constantly lights Orange. This main charging phase could be set to the maximum of 4/6/8 hours or unlimited, and the current rises again to its maximum value. The current remains constant as long as the battery voltage is below Uo phase setting voltage (14.0V/28.0V or 14.4V/28.8V or 14.8V/29.6V). After reaching the setting voltage, it remains constant. However, the current drops again. Within this main charging phase, the battery is charged to 95% of its capacity.
   Note The charging voltage and the period for the main charging phase (Uo phase) can be selected using the switch field S1.

3. U phase (float)
   The “STATUS” LED constantly lights Green. If the current decreases to 10% or under the rated current or if the time limit of 4/6/8 hours is exceeded, then the charger switches over to economy charging (13.5V/27.0V or 13.8V/27.6V).
   Note Batteries may be charged separately from each other if the chargers have double charging or three-fold charging connections. The outputs are separated internally by diodes, thus the weaker battery will be always first charged to the charging level of the stronger battery.
   Attention The maximum battery capacity should NOT exceed the specified capacity, otherwise the functions of the individual charging phases could be influenced.

4. 8-day conditioning
   If the battery charger stays at U phase for 8 days, it will switch back to 3-stage charging IUoU, and stay at Uo phase for 60 minutes to revive the battery.
   Note

5. 8-day conditioning will be terminated whenever equalization function or half power mode is activated.

6. When the charger is in the equalization stage or half power mode, 8-day conditioning will NOT be triggered.

7. Equalization
   The function of equalization could be activated as long as the battery charger is NOT in the half power mode or power supply mode. The function of equalization will be activated only when the battery is charged and stays in Uo phase with < 25% of Full load current. The battery charger will charge the battery 3 hours with equalization setting voltage (15.5V or Uo phase setting voltage) and half of rated current.

Note Once the equalization function is activated, it can only be cancelled by turning off the battery charger.

Using the remote controller RC-600
There are three buttons and four LEDs on RC-600 (see Figure 10 Remote Controller RC-600).

• ON/OFF button to switch the charger ON and OFF
• Half Power button to enter/exit “HALF POWER” mode
• Equalization button to activate the function of equalization
• Bulk LED to indicate the charging stage of I phase
• Absorption LED to indicate the charging stage of Uo phase
• Floating LED to indicate the charging stage of U phase
• Equalization LED to indicate the function of equalization is activated

To avoid the VOID setting from the remote control, please refer to Table 9-1 VOID Setting.

Table 9-1 VOID Setting table for pressing button on remote controller

VOID
“ON/OFF” pressed| Stand by (“STATUS” LED slowly flashing Red)| Stand by (“STATUS” LED slowly flashing Red)| Stand by (“STATUS” LED slowly flashing Red)| Stand by (“STATUS” LED slowly flashing Red)

Note

• The power switch at the unit must be switched ON, so that the unit can be switched ON and OFF with the remote control.
• The “ON/OFF” button on the RC-600 should be pressed for 2 seconds to switch OFF the battery charger, and 0.5 second to turn ON.

Units with Temperature Sensor TF-100
A temperature sensor (Figure 9 Temperature Sensor TF-100) can be connected in order to provide the optimum charging functioning. The charging voltages, as can be seen from the following diagrams, vary, depending on the battery temperature.

Note

• The temperature sensor is only working in I, Uo and U phases.
• The output voltage is adjusted according to the function -25mV/°C for WSC-1250 and -50mV/°C for WSC-2425. However, the maximum output voltage is 15V/30V, and the minimum is 13.2V/26.4V.
• When the battery temperature detected via TF-100 reaches 55°C, the charger will stop the charging process (“E.Q.” LED flashing Red and “STATUS” LED lights Orange), and auto recover when temperature drops to 45°C.

Fan Speed
The fan speed is adjusted according to the load and the temperature inside the charger. When the load is over 70% of the chargers’ amp rating, the fan will turn in 100% speed. If the load is below 70% of the chargers’ amp rating, the fan speed will be determined according to the temperature inside the charger. When the temperature goes up, the fan will start turning with temperature 45°C, and reach 100% speed with temperature 65°C. When the temperature goes down, the fan will slow down the turning speed with temperature 60°C, and stop turning with temperature 40°C.

Functional check
The status LED in the front of the unit can be used to check the status of the charging process.
Note The optional remote controller can also be used to check the status of the charging process. The LEDs on the remote controller indicate different charging phases with their colors respectively.

Table 9-2 Normal Functional Check Table

activated
Red, constantly lit| Green, constantly lit| U phase, Equalization is activated
Red, constantly lit|  | Equalization is executed
 | Red, flashing| I phase, half power
 | Orange, flashing| Uo phase, half power
 | Green, flashing| U phase, half power
 | Green, double flashing| Power supply mode
 | Red, slowly flashing| Stand-by mode (RC-600/RC-601D)

Trouble Shootings

The battery voltage would NOT increase after charging

• If possible, measure with a suitable multi-meter during the charging to verify if the voltage at the battery terminals increases.
• Determine whether the terminals are connected properly to the battery poles. Clean the battery poles if necessary to ensure better connection.

The battery is NOT fully charged after a charging time about 20 hours
Disconnect the power to the charger. Remove the battery from the charging terminals and wait for a few minutes. Then, measure the voltage at the battery terminals with the multi-meter.

• 12V battery
  If the multi-meter displays a voltage of 10V or less, this indicates that the battery is defective and can not be charged any longer.

• 24V battery
  If the multi-meter indicates a voltage of 20V or below, allow the battery be checked by a specialist, if necessary dispose of the battery.

The battery discharges after a short period of time without usage
Measure the voltage at the battery terminals with a suitable multi-meter. If the multi-meter indicates a voltage below 12V of a 12V battery or a voltage below 24V of a 24V battery, then the battery is too weak to retain the charge.

Please refer to the following table for other trouble shootings
Table 10-1 Abnormal Functional Check Table

charging (TF-100)
Red, flashing| Red, flashing| Fan abnormal
Red, flashing| Orange, flashing| TF-100 connected to the remote socket
Red, flashing| Green, flashing| Charger overheated (>100°C), stop charging
Red, flashing| Red and green by turns| Charging voltage too high and shut down
Red, flashing| Orange and green by turns| Charging current too high and shut down
Red, flashing| Red and orange by turns| Defective fuse or reverse- polarity
Red, flashing for 10 seconds|  | Void setting

Specifications

EN 60335-2-29
EMC Standard| EMI: EN 55014-1
EMI: EN 61000-3-2
EMI: EN 61000-3-3
EMS: EN 55014-2
IEC 61000-4-2,3,4,5,6,11
Protective devices| Short circuit protection
Over voltage protection
Over current protection
Battery charger over temperature
Battery over temperature

Declaration of Conformity

For the following equipment :

• Product Name: SMART BATTERY CHARGER
• Model No.: WSC-1250 and WSC-2425
• Trade Name:
• Applicant: SAMLEX EUROPE B. V.
• Address: ARIS VAN BROEKWEG 15, 1507 BA ZAANDAM THE NETHERLANDS
  Is herewith confirmed to comply with the EMC requirements set out in the Directive 2014/30/EU and LVD requirements set out in the Directive 2014/35/EU of the European Parliament and of the Council of April 20, 2016 on the approximation of the laws of the Member States relating to electromagnetic compatibility and EC Low Voltage Directive. For the evaluation regarding the electromagnetic interference, the following EMC standards were applied:

EMI: Class A
EN55014-1:2006+A2:2011 EN61000-3-2:2006+A1:2009+A2:2009 EN61000-3-3:2013
LVD:
EN60335-1:2012+A11
EN60335-2-26:2004+A2:2010

EMS:
EN55014-2:1197+A2:2008 EN61000-4-2:2009 EN61000-4-3:2006+A2:2010 EN61000-4-4:2012 EN61000-4-5:2014 EN61000-4-6:2014 EN61000-4-11:2004

The following manufacturer/importer is responsible for this declaration:

www.samlex.com 
www.samlex-solar.com

References

• Samlex Europe manufactures and distributes power conversion products to more than 90 countries worldwide.
• Samlex Europe manufactures and distributes power conversion products to more than 90 countries worldwide.

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