GYS 15.24 PL-E Battery Charger Instructions

: June 15, 2024
: GYS

Table of Contents

SAFETY INSTRUCTIONS
GENERAL DESCRIPTION
CONNECTION AND WIRING
CABLE CALIBRATION
CHARGE MODES
TROUBLESHOOTING, CAUSES, SOLUTIONS
WARRANTY
TECHNICAL TABLE
MECHANICAL DRAWINGS
Documents / Resources
- Read User Manual Online (PDF format)
- Download This Manual (PDF format)

GYSFLASH
15.24 PL-E ****

SAFETY INSTRUCTIONS

This manual includes guidelines on the operation of your device and the precautions to follow for your own safety. Ensure it is read carefully before first use and keep it handy for future reference.
This device should only be used for charging and within the limits indicated on the device and in the manual. The safety instructions must be followed. In case of improper or unsafe use, the manufacturer cannot be held responsible
Device suitable for indoor use only. Do not expose to rain or excessive moisture.
This device may be used by children from age 8 and by persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge, provided that they are under supervision or have been told how to use the device safely and are aware of the potential risks. Children must not use the device as a plaything. Cleaning and servicing tasks may not be carried out by children unless they are supervised.
Do not use for charging non-rechargeable batteries Do not use any charger other than the one supplied with the machine to charge the batteries.
Do not use the device if the charging cable appears to be damaged or assembled incorrectly in order to avoid any risk of short circuiting the battery.
Never charge a frozen or damaged battery.
Do not cover the device.
Do not place the device near a fire or subject it to heat or to longterm temperatures exceeding 50°C The electrical installation must include a way to disconnect the appliance from the supply network after installation.
Disconnection can be achieved by providing an accessible socket outlet or by incorporating an omnipolar switch in the fixed lines according to the installation rules.
The electrical installation of the charger must be carried out by a qualified person.
The automatic mode of operation and usage restrictions are explained below in these operating instructions.
Risk of explosion and fire!
A battery being charged can emit explosive gas.

During the charge, the battery must be placed in a well ventilated area.
Avoid flames and sparks. Do not smoke.
Protect the electrical contacts of the battery against shortcircuiting.

Connection / disconnection:

Disconnect the power supply before connecting/disconnecting the device to/from the battery.
The terminal of the battery that is not connected to the car frame must be connected first. The other connection must be made on the car frame, far from the battery and the fuel line.
The battery charger must be connected to the power supply network.
After the starting/charging process, disconnect the booster/ battery charger from the power supply network and remove the connector from the car frame and then the connector from the battery, in this order.

Connection:

This device must be connected to an earthed power supply
Connection to the mains must be made according to the national installation regulations.

Maintenance:

If the power supply cable is damaged, it must be replaced by the manufacturer, its service agent or an equally qualified person.
Service should be performed by a qualified person
Warning! Always remove the power plug from the wall socket before carrying out any work on the device.
Under no circumstances should solvents or other aggressive cleaning agents be used.
Clean the device’s surfaces with a soft, dry cloth.

Regulations:

The device complies with European Directive.
The certificate of compliance is available on our website.
EAC conformity mark (Eurasian Economic Commission)
**** Equipment in compliance with British requirements. The British Declaration of Conformity is available on our website (see home page).
Equipment in conformity with Moroccan standards.
The declaration C م (CMIM) of conformity is available on our website (see cover page).

Disposal:

This product should be disposed of at an appropriate recycling facility. Do not dispose of in domestic waste.

GENERAL DESCRIPTION

GYSFLASH 15.24 PL-E is an on-board charger designed for charging traction batteries used in forklifts or floor scrubbers, utility batteries found in the navy, lorries or buses and batteries for electromobility transport vehicles (bicycles, scooters, golf cars,…). Suitable to charge most of lead (Liquid/Gel, AGM) and Lithium batteries (LiFePO5, Lithium-Ion…).
This charger is perfectly suited for charging and maintenance of:

24 V Liquid/Gel-AGM lead batteries (12 cells in series) from 30 Ah to 240 Ah.
LFP batteries 24V (8 elements in series) from 15 Ah to 240 Ah.
24 V Li-ion batteries (7 cells in series) from 15 Ah to 240 Ah.

CONNECTION AND WIRING

Connections	Wiring
Type	Section
A

1.LIVE
2.NEUTRAL
3.Not Connected
4.EARTH
Order No. Connector Mirth Electronik 691344510004| HO5RN-F or equivalent| mini : 3G0.75 mm²
maxi : 3G2.5 mm2
B| | 24 V BATTERY CONNECTION
1.SIGNAL mains presence (+24/50mA)
2.NEGATIVE CONNECTION -24 V
3.POSITIVE CONNECTION +24 V : ****
Order No. Connector Mirth Electronik 691344510003| H01V-K or equivalent| Battery (2/3)
2.5 mm²or AWG14
Signal (1)
maxi 2.5 mm2

Crimp the appropriate wiring sleeves 1 for the cross-section of each cable.
Screw the sleeves onto the connector following the connection diagrams for connectors A and B (above).
Clip the connectors into their sockets on the board.
Pass the cables through the rubber cable glands 2 and plug them into the sheet metal.
Attach the flanges 3 in such a way that the wired parts inside the housing are never under tension (screws M3x20 – TORX 10).

CABLE CALIBRATION

Procedure for calibrating the charging cables of the device, so that the charger optimally compensates for the voltage drop due to the cables. It is strongly recommended to perform this procedure each time the cables are modified or changed.

Enter one of the lead charging modes.
Short-circuit the 2 clamps of the cable (do not short-circuit a battery).
Unplug the product from the mains and wait until the charger switches off.
Press and hold button while plugging in the mains socket until indicator or lights up.
– lit: Calibration has been performed correctly.
– Light on: calibration failed, disconnect the power plug and repeat the procedure.
Unplug the mains plug until the charger switches off.

CHARGE MODES

To change the charging mode settings:

Unlock the charger by pressing the button for 3 seconds .
Select the mode by pressing the button again .
Lock the mode by pressing the button again for 3 seconds (or wait 10 seconds without pressing the button).

Lead Liquid/Gel (28.6 V/15 A) charging mode:
Mode designed for the recharge of 24V lead/GEL batteries from 30 Ah to 240 Ah. 7-step automatic charging cycle.
Lead Liquid/Gel-Traction (28.8 V/15 A) charging mode:
Mode designed for charging 24V lead/liquid traction batteries from 30 Ah to 240 Ah. 7-step automatic charging cycle.
Lead AGM (29.4 V/15 A) charging mode:
Mode designed for the recharge of 24 V lead/AGM batteries from 30 Ah to 240 Ah. 7-step automatic charging cycle.
Lead AGM-Traction (29.4 V/15 A) charging mode:
Mode designed for charging 24 V lead/AGM-traction batteries from 30 Ah to 240 Ah. 7-step automatic charging cycle.
Lithium Iron Phosphate charging mode (28.8 V/15 A):
Mode for charging 24 V lithium LiFePO4 batteries from 15 Ah to 240 Ah. 6-step automatic charging cycle.
Charging mode Lithium-ion (29.1 V/15 A) :
Mode for charging 24V lithium-ion batteries from 15Ah to 240Ah. 6-step automatic charging cycle.
Some Lithium batteries incorporate a UVP protection (Under Voltage Protection) which disconnects the battery in case of deep discharge. This protection prevents the charger from detecting the battery. In order for the Gysflash 15.24 PL-E to be able to charge the battery, it is necessary to deactivate the UVP protection. To do this, set the charger to Lithium charging mode, unplug the charger until the product turns off. Press and hold button while plugging in the product’s power outlet. The charger will then deactivate the UVP protection and automatically start charging.
Caution: In case of UVP protection of a lithium battery, remove all consumers on the battery before activating the UVP Wake up.

Load curve Lead:
The GYSFLASH 15.24 PL-E incorporates an advanced 6 (or 7) step charging curve that guarantees the optimal performance of your battery. This automatic charging curve is adapted to all types of lead-acid batteries (liquid and AGM) in order to guarantee an optimal charge level of your battery. This curve is perfectly compatible with the presence of consumers on the battery.
Lithium charging curve :
The GYSFLASH 15.24 PL-E uses an advanced 6-step lithium charging curve that ensures optimal battery performance. This automatic charging curve is adapted to all types of Lithium batteries to ensure an optimal charge level of your battery. This curve is perfectly compatible with the presence of consumers on the battery.

Step 1 : Analysis
Analysis of the battery condition (charge level, inversion, polarity, wrong battery connected, etc).
Step 2 : Recovery (6 A)
Recovering damaged elements after deep and prolonged discharge.
Step 3 : Desulfation (15.8 V)
Battery desulfation algorithm.
Step 4 : Charge (15 A)
Fast charging at maximum current up to 80% of the charge level

Liquid/Gel	AGM	Liquid/Gel – Traction	AGM – Traction
28.6 V	29.4 V	28.8 V	29.4 V

Step 5 : Absorption
Charge under constant voltage to bring the charge level to 100%

Liquid/Gel	AGM	Liquid/Gel – Traction	AGM – Traction
28.6 V	29.4 V	28.8 V	29.4 V

Step 6 : Traction (31 V)
If the traction option has been selected, the charger will then inject an additional current to create gas to mix the electrolyte and recondition the battery cells. During this phase, the battery may lose a bit of water.
Step 7 : Floating (27 V)
Maintains the battery charge level at its maximum level.

Lithium charging curve :
The GYSFLASH 15.24 PL-E uses an advanced 6-step lithium charging curve that ensures optimal battery performance. This automatic charging curve is adapted to all types of Lithium batteries to ensure an optimal charge level of your battery. This curve is perfectly compatible with the presence of consumers on the battery. Step 1 : Analysis
Analysis of the battery condition (charge level, inversion, polarity, wrong battery connected, etc).
Step 2 : Charge (15 A)
Fast charging at maximum current up to U1LiFePO4| Li-ion
---|---
27.6 V| 28.7 V

Step 4 : Complement
Progressive increase of the voltage at reduced current to reach U2 of the charge level.

LiFePO4	Li-ion
28.8 V	29.1 V

Step 5 : Equalization / Balancing
Balancing the battery cells.
Step 6 : Floating
Maintains the battery charge level at its maximum level with a maintenance charge every 2 months.

Protections :
The GYSFLASH 15.24 PL-E has comprehensive safety features to protect it against short-circuits and polarity reversals. It has an anti-sparks feature which prevents sparks whilst connecting the device to the battery. This charger has double insulation and is safe to use with the battery in situ as it will protect the vehicle’s on-board electronics.

The GYSFLASH 15.24 PL-E is fitted with an integrated temperature probe that ensures that the charging current is adapted to the ambient temperature, for an optimal charging performance.

TROUBLESHOOTING, CAUSES, SOLUTIONS

| Troubleshooting| Causes| Solutions
---|---|---|---
1| Indicator flashes.| •Polarity reversal
•Battery voltage is too high
•Battery in short-circuit| •Check that the charging cables are properly connected.
•Check that it is a 24V battery.
2| The indicator is on.| •Charge failure, battery non recoverable.| •Change the battery and press the mode button to restart a charge
3| The indicator light remains on even after pressing mode button .| Thermal protection| Ambient temperature is too high (>50°C), cool the room and let the charger cool down.

WARRANTY

The warranty covers faulty workmanship for 2 years from the date of purchase (parts and labour).
The warranty does not cover:

Transit damage.
Normal wear of parts (eg. : cables, clamps, etc..).
Damages due to misuse (power supply error, dropping of equipment, disassembling).
Environment related failures (pollution, rust, dust).

In case of failure, return the unit to your distributor together with:
– The proof of purchase (receipt etc …)
– A description of the fault reported.