GYSFLASH 50.12 FV Battery Stabilizer Instruction Manual

GYSFLASH 50.12 FV Battery Stabilizer Instruction Manual

SAFETY INSTRUCTIONS

This manual contains safety and operating instructions. Please read it carefully before using the device for the first time and keep it for future reference.
This machine should only be used for charging or power supply operations specified within the limits indicated on the machine and in the instruction manual. The operator must observe the safety precautions. In case of improper or unsafe use, the manufacturer cannot be held liable.
The device is destined to be used indoors. Must not be exposed to the rain.
This unit can be used by children aged 8 or over and by people with reduced physical, sensory or mental capabilities or lack of experience or knowledge, if they are properly monitored or if instructions for using the equipment have safely been read and potential risks understood.
Children must not play with the product. Cleaning and maintenance should not be performed by an unsupervised child.
Do not use to charge domestic batteries or non rechargeable batteries.
Do not use the charger if the mains cable or plug is damaged.
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 use on a frozen or damaged battery.
Do not cover the device.
Do not place the unit near a heat source or expose to prolonged high temperatures (above 60°C).
The operating mode of the automatic charger and the restrictions applicable to its use are explained later in this manual.

Fire and explosion risks!

• A battery can emit explosive gases when on charge.
• During the charge, the battery must be placed in a well ventilated area.
• Avoid flames and sparks. Do not smoke.
• Protect the electrical contact surfaces of the battery against short circuits.
  Do not leave a charging battery unattended for a long time.

Risk of acid dispersion!

• Wear protective goggles and gloves.
• In case of contact with the eyes or the skin, rinse immediately with water and see a medical doctor as soon as possible.

Connection / disconnection :

• Disconnect the power supply before plugging or unplugging the connections to/from the battery.
• Always ensure the Red clamp is connected to the «+» battery terminal first. If it is necessary to connect the black clamp to the vehicle chassis, make sure it is a safe distance from the battery and the fuel line. The charger must be connected to the mains.
• After charging, disconnect the charger from the mains, then disconnect the negative clamp from the car body and then disconnect the positive clamp from the battery, in this order

Connection :

• The charger must be connected to an earthed power supply.
• The connection to the power supply must be carried out in compliance with national standards

Maintenance :

• If the power supply cable is damaged, the replacement cable must be obtained from the manufacturer or its service team.
• Maintenance should only be carried out by a qualified person.
• Warning ! Always disconnect from the mains before performing maintenance on the device.
• The device does not require any specific maintenance.
• If the internal fuse is melted, it must be replaced by the manufacturer (GYS dedicated sales service) or by an equally qualified person to prevent any accidents.
• Do not use solvents or any agressive cleaning product
  

Regulations :

• The Machine is compliant with European directives.
• The declaration of conformity is available on our website.
• EAEC Conformity marking (Eurasian Economic Community).
• 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 Cم) CMIM) of conformity is available on our website (see cover page).

Waste management:

• This product should be disposed of at an appropriate recycling facility. Do not throw away in a household bin.

GENERAL DESCRIPTION

The GYSFLASH 50.12 FV provides a high powered stabilised power supply incorporating SMPS (Switch Mode Power Supply) technology. Designed to sustain 12V battery (liquid/AGM/gel) for vehicles during diagnostic work. This device will also ensure an ideal charging cycle for battery maintenance for the most modern vehicles and battery types. It can be fitted with cables up to 2x8m in 16mm². Changing charging cables requires recalibration (see page 18). It is considered a fixed device not a mobile product.

These devices have 5 modes including 2 that are hidden:

• Charge Mode: for charging lead (sealed, liquid, AGM…) or lithium (LiFePO4) starter batteries from 10 Ah to 600 Ah at 12V.
• Supply mode « Diag + »: GYSFLASH supply up to 50A to ensure compensation of current used by high-energy consumers (engine fan, window regulator, electronic suspension, etc). In this mode the voltage can be precisely adjusted.
• Supply mode « Showroom »: ensure current compensation when using electrical features of a demonstration vehicle (window regulator, heating, morrors, etc) enabling permanent display of the vehicle. In this mode the voltage can be precisely adjusted.
• « Change battery » mode: ensures a stabilised power supply to the vehicle during battery replacement to preserve memory settings. By default this mode is inactive and doesn’t appear in the mode list.
• « Power Supply » mode: This mode is intented for experimented user only. By default this mode is inactive and doesn’t appear in the mode list. This mode enables to use the charger as a powerful stabilised power supply with regulated voltage and adjustable maximum current.

This device has an automatic restart feature enabling in Charge, Showroom and Power Supply modes to automatically restart the device in case of power cut. The function «Lock Showroom», if activated, restricts the device to Showroom Mode only, to facilitate its use for vehicles demonstrators.

START UP

1. Connect the charger to the mains. With «Flexible Voltage» technology, this battery charger works on any voltage in the range 100V to 240V (50/60Hz).

2. Turn the switch to «ON». Within 3s the display will show «GYSFLASH 50.12 FV Vx.x»

3. Select the required mode. By default the charger will automatically select the last setting.

• The “Mode” key enables access to several menus : MODE Charge > Diag+ > Showroom (>Change Battery) (> Power Supply) *hidden by default.
• To access the “configuration” menu press the “mode” key for 3s : MODE 3 sec – Configuration

CHARGE MODE

This product will charge the battery safely even if the battery is still in the vehicle. Ensure that the correct sequences are followed.

Charge configuration :

Before starting to charge the battery, ensure that the charger has been correctly set (battery voltage, charging curve and battery capacity). Several charging curves are available

• Easy: simplified curve, suitable for every lead battery and which for it is not required to know the battery capacity. However for an optimized charge, it is recommended when possible to use the liquid or gel/AGM batteries charging curves.
• Liquid: charging curve for vented battery (lead, lead calcium, lead calcium-silver, etc). For this charging curve the battery capacity in Ah must be selected.
• Gel/AGM: charging curve for sealed battery (gel, maintenance free, AGM…). For this charging curve the battery capacity in Ah must be selected.
• LFP/LiFePO4: charging curve for LFP (Lithium Iron Phosphate) type lithium batteries. For this charging curve the battery capacity in Ah must be selected.
• Expert: charging curve type IUOIOU adjustable via the menu Expert configuration and intented for experimented user (see page 15). By default this curve is inactive and doesn’t appear in the curve list of the CHARGE mode.
  WARNING: According to the configuration of the expert curve (see page 19), it can be necessary to disconnect vehicle’s battery before starting the charge in order to protect the electronic of the vehicle.

CHARGE MODE CONFIGURATION DEPENDING ON THE BATTERY TYPE

Charging curves available if activated in
«Advanced Menu».

Charging curves available if activated in
«Advanced Menu».

Start up :

• Connect the clamps : red to the (+) and black to the (-) of the battery.
• Push the START/STOP key to start the charge.
• During the charge, the product alternates between displaying the progressing percentage of the charge, voltage, current, injected ampere hours and elapsed time.
• Push the START/STOP key again to stop the charge.

CHARGE MODE START UP

NB: When the charge ends (100%), if the battery remains connected the charger maintains the charge level of the battery by applying a floating voltage.
Precaution: Check the electrolyte level and fill if necessary before charging.
When charging on vehicle, it is recommended to reduce the electrical consumption of the vehicle to a minimum (switch off the lights, close the doors…) in order to do not disturb the charging process

DIAG+ MODE

On a stationary vehicle the GYSFLASH supplies up to 50A to test high-energy consumers: engine fan, window regulator, electronic suspension, etc… By supplying a steady voltage: – 12V to 14.8V

Voltage adjustment

It is possible to adjust the voltage in steps of 0.1V according to manufacturer’s specifications.

DIAG + MODE CONFIGURATION

Start up :

• Connect the clamps : red to the (+) and black to the (-) of the battery.
• Push the START/STOP key to start the mode.
• During use the current consumed and the instantaneous voltage are displayed.

DIAG+ MODE START UP

Precaution : If the screen displays a current greater than 10A, it indicates the battery is discharged. The device will start charging automatically. Check all electrical consumers are switched off on the vehicle. Wait until the current falls below 10A and then re-launch the diagnostic.

SHOWROOM MODE

On a stationary vehicle, the GYSFLASH supplies up to 50A to test high-energy consumers (engine fan, window regulator, electronic suspension, etc…) by supplying a steady voltage adjustable: – 12V to 14.8V

Volatage adjustment:

It is possible to adjust the voltage in steps of 0.1V according to manufacturer’s specifications

SHOWROOM MODE CONFIGURATION

Start up with battery :

• Connect the clamps : red to the (+) and black to the (-) of the battery.
• Push the START/STOP key to start themode.
• During use the current consumed and the instantaneous voltage are displayed.

SHOWROOM MODE START UP

Start without battery (not recommended)

It is possible to supply power to the vehicle without a battery by pushing the START/STOP key for 3 secondes. The screen will display “no battery” for 1 second before starting to supply the vehicle. Warning: polarity reversal can damage vehicle electronics.

Precaution :

If the screen displays a current higher than 10A, it indicates the battery is discharged. The device will start charging automatically. Check all electrical consumers are switched off on the vehicle. Wait until the current falls below 10A before using any electical functions of the car

CHANGE BATTERY MODE (OPTIONAL)

The GYSFLASH will maintain a stabilised power supply to the vehicle during battery replacement to preserve memory settings. By  default this mode is inactive and doesn’t appear in the mode list. It can be activated via the Advanced menu (see page 19).

Start up :

Connect :

1. Red clamp to the (+) of the battery / battery terminal, in such a way that the battery can be changed without disconnecting the clamp.
2. Black clamp to the vehicle chassis or earth.

• Press the START/STOP key to start the mode.
• During use, the current consumed and the instantaneous voltage are displayed.
• When changing the battery ensure the polarity is correct.While exchanging the batteries, be careful not to disconnect the charger clamps to avoid loss of electronic data.

CHANGE BATTERY START UP

Warning: polarity reversal can damage the vehicle electronics.

POWER SUPPLY MODE (OPTIONAL)

This mode is intended for expert users only. This mode enables the charger to be used as a stabilised power supply, with regulated voltage and adjustable maximum current. By default this mode is inactive and doesn’t appear in the mode list. It can be activated via the Advanced menu (see page 19).

Adjustment of the voltage regulation and current limitation :

The voltage regulation can be adjusted from 2V to 30V and the maximum current from 2A to 50A. For an adjustable voltage above 16V, the maximum current can be set up to 25A:

POWER SUPPLY MODE CONFIGURATION

Start up :

• Push the START/STOP key to start the mode.
• During use, the current consumed and the instantaneous voltage are displayed.

POWER SUPPLY START UP

NOTE: Unlike other modes, Power Supply mode, the charger does not compensate cables voltage drop. In this case, the voltage displayed on the screen corresponds to the output voltage of the charger (not the voltage on the clamps).

CONFIGURATION MENU

Access to configuration menu : MODE 3 sec – Mode To browse in the sub menu press the
«Select» key : SELECT languages > restart > lock showroom > cable check > ADVANCED MENU > Reset Memory

Sub menu :

• Languages :
  This menu enables to select the language (use the arrows to change the language).

• Automatic restart :
  Automatic restart only works with «Showroom», «Charge» and «Power Supply» mode. This feature enables charger to restart automatically and to restart charging after a cut in power. To activate the «Automatic restart» feature « Configuration | Restart : ON ».

• Lock Showroom :
  To lock the device in Showroom Mode (to avoid misuse). To activate the «Lock Showroom» feature « Configuration | Lock Showroom : Y ».

CONFIGURATION MODE

Shortcut to Lock Showroom :

The «Lock Showroom» feature can be activated without accessing the configuration menu.

• Turn OFF the device (main switch in the OFF position)

• Press MODE key MODE

• Turn ON the switch, while the MODE key is still pressed. The screen displays «GYSFLASH 50.12 FV Vx.x» for 3 seconds.

• Hold the MODE key until the creen displays «lock showroom: Y»

• Cables calibration :
  This mode must be used each time the cables are changed. The GYSFLASH can be fitted with cables up to 2x8m in 16mm².
  OK : The calibration was successful.
  FAIL : A problem occurred during the calibration. In this case, the calibration is reset to the factory setting. Check that the cables are in good condition and properly put in short-circuit and repeat the procedure.

• ADVANCED MENU (code 1-9-6-4) :
  This menu is intented for experimented user only. To access this menu, enter in the code above («Select» key to change the digit selection and «Start/Stop» key to confirm the code). For more details, see page 19.

• Reset Memory (code 1-9-6-4) :
  This menu is intented to factory reset the charger settings by entering the code above. Any personal parameters are deleted.

RESET MEMORY

DVANCED MENU

This menu controls the advanced parameters of the charger. To move from one parameter to another push the Select key :

SELECT: Activation «Change battery» > Activation «Power Supply» > Activation «Expert Curve» (> Adjusment of the «Expert Curve» parameters)

• CHANGE BATTERY mode activation: To activate the CHANGE BATTERY mode, select «ADVANCED MENU | Change bat: ON». Now this mode will be accessible from the mode list.
• POWER SUPPLY mode activation: To activate the POWER SUPPLY mode, select «ADVANCED MENU | Power Supply: ON». Now this mode will be accessible from the mode list.
• «EXPERT» curve activation: To activate the «RECOV» curve, select «ADVANCED MENU | Expert curve: ON». Now this curve will be available in the charging curves list from the CHARGE mode.
• Parameters adjustment of the «Expert» curve: If the charging curve is activated, the charging curve parameters can be adjusted (type IU0 I0 U):
  • Ucharge: Charge voltage adjustable from 12.0 to 16.0V (Step 7).
  • Icharge: Charging current adjustable from 10A to 200A per 100Ah of specified capacity (Step 6).
  • Urecovery: Recovery voltage adjustable up to 30.0V. If the value «OFF» is selected the recovery function is inactive (Step 2 and 4).
  • Ufloating: Floating voltage adjustment. If the value «OFF» is selected the floating function is inactive (Step 9).
  • Trecovery: Maximum time for shorted cells recovery, adjustable from 1h to 24h (Step 2).
  • Trefresh: Time for the refreshing phase adjustable from 1h to 12h. If the value «OFF» is selected, the refresh function is not activated (Step 8).
  • T desulfat: Maximum time adjustable from 1h to 24h of the desulfation phase (Step 4).
  • T ch_max: Maximum charging time (Step 7 and 6).
  • T ch_min: Minimum charging time (Step 7 and 6).
  • Urefresh: Maximum voltage during the cooling phase (Step 8).
  • OCP (Over Charge Protection): Maximum percentage of the nominal capacity which can be injected before the protection begins.

Warning: When charging in-situ, a «Urecovery» or «Urefresh» too high might damage the electronics of the vehicle. We advise NOT to adjust these settings above 15V.

To save and validate the new settings, select «ADVANCED MENU» | save? Yes» Push the «MODE» key to exit the «Configuration» menu.

ADVANCED MENU

Charging curve description (IU0I0U)

1. Battery analysis
2. Recovering damaged elements from an extended deep discharge
3. Sulphated battery test
4. Sulphated battery recovery
5. Checking the battery recovery
6. Battery charged to 80%
7. Battery charged to 95%
8. Battery cells refresh
9. Maintenance charge
10. Starts a charge cycle for maintaining performance = maintenance

PROTECTIONS

This device is protected against short-circuits and polarity inversions. It has an anti spark feature which prevents sparks whilst connecting the Gysflash to the battery. The Gysflash will not deliver current if there is no battery detected (no voltage in the clamps). The charger is fitted with an internal 80A fuse (ref. 054653), to protect against misuse.

TROUBLESHOOTING

1

| Screen flashing : « #error (+) <–>(-) » + alarm beep| The polarity has been reversed on the clamps| Connect the red clamp to the (+) and the black clamp to the (-) of the battery.
---|---|---|---

2

| Screen flashing : « #erreur U >Umax »  alarm beep| Battery voltage too high| Charger not suitable (ex: 24V battery instead of 12V battery).
3| Screen flashing : « #battery error » + alarm beep| Battery short- circuited or damaged| Change the battery.
Battery not connected or clamps in short-circuit| Check clamps connection.
6V Battery connected| Charger not suitable.
4| Screen flashing : « >50A » + alarm beep| Consumption exceeds the output of the charger| Turn off electrical consumers to reduce power demand
5| The GYSFLASH delivers a high cur- rent (greater than 10A) before the diagnostic tool has been activated.| Several consumers are active on the vehicle| GYSFLASH works to specification. Turn off consumers to check the battery is not too discharged (see cause n°2).
Battery discharged| Battery deeply discharged, the GYSFLASH delivers current to charge it. Wait until the output current is below 10A to start the diagnostic.
6| Displays for 1s : « no battery » + alarm beep| Showroom mode is working on « no battery »| Showroom without battery : GYSFLASH operating normally. To deactivate the “no battery” function, press the “START/STOP” key, and then press the “START/STOP” key again to start the Showroom mode with battery
7| The device is locked in Showroom mode| Lock Showroom active| Normal operation of GYSFLASH. Refer to configuration menu to deactivate this function.
8| Screen displays : « #error T(°C) » + alarm beep| Faulty fan| Contact your distributor.
Extended exposure to sunlight| Do not leave the device exposed to sunlight. Leave the device ON until the fault disappears. (The alarm beep can be stoppedPossibility to stop the alarm beep by pressing the START/STOP key).
9| Screen displays : « #error IHM » + alarm beep| Electronic fault| Contact your distributor
10| Screen displays : « #error fuse » + alarm beep| Mishandling| Internal fuse must be changed by a qualified person (ref. 054653 : 80A)
11| The device doesn’t display anything| Input fuse HS| Input fuse must be changed by a qualified person (temporised fuse 10A 5×20).
Faulty electrical network| Check the voltage of the electrical network is between 100V and 240V.

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.

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