Green Energy GECI Black Diamond Charger User Manual

Green Energy GECI Black Diamond Charger

GECI™ BLACK DIAMOND CHARGER USER’S MANUAL

PLEASE READ CAREFULLY BEFORE OPERATING THE CHARGER OR BATTERY.

1. Installation and Service operations can be done by qualified personnel only.

2.  To prevent the risk of electric shock, don’t touch uninsulated portions of the Black Diamond Charger and the Battery.

3. Remove AC input before to disconnect the battery.

4. The charger is suitable for indoor installation, in ambients with abundant ventilation.

5. Don’t use the charger near flammable materials.

6. DO NOT obstruct the ventilation slots and leave sufficient free space around the unit.

7. DO NOT expose the charger to liquids or excessive dust.

8. Check the conditions of cables and accessories on a regular basis, and replace them immediately if they get damaged.

9. DO NOT extend the battery cables. Replace them, if necessary, with cables of the same type, length, section and insulation as the original ones.

10. During the installation of the charger, make sure to connect the EARTH conductor properly,
    and respect all the applicable Safety Standards.

11.  DO NOT modify any part of the charger. Any modification, applied without written authorization of the manufacturer, may generate unsafe operating conditions and will void the warranty.

GECI™ BLACK DIAMOND CHARGER DESCRIPTION

The Black Diamond Charger is suitable to charge lead-acid motive batteries.
The operation is completely automatic, and it’s managed by a microprocessor control system, composed by a Main Control Board, installed inside of the charger, and an optional wireless Battery Identification Module (WBM), that is permanently connected to the battery.

The AR-TOP has two, selectable charging curves (Wa and WSa).

Wa: typical charge time 10-12 hours typical start rate 15-18% of the battery capacity C/5
WSa: typical charge time 7-8 hours typical start rate 23-26% of the battery capacity C/5
The power conversion system of the Black Diamond and its optimized charging algorithm help to reduce the charging factor to the minimum value, so the duration of the overcharge/gassing phase and the average temperature of the battery are minimized.
The Black Diamond Charger is equipped with a built-in Real-Time Clock, which allows the user to program the desired start time of the day, the full charge time window and to schedule the weekly equalize cycles.
It is possible to connect the charger to the Fleet Management System DoctorFleet.com, which allows to monitor, program and configure the complete fleet through a WEB based interface, at any time of the day and from anywhere in the World, to send automatic messages by email in case of problems.
The Black Diamond charger features an extensive set of advanced functionalities, including an automatic algorithm for
the compensation of the voltage drop of the charging leads. These functionalities are programmable through an Advanced Configuration Menu. Please call your service technician for more details.
The operation is completely automatic, and it’s managed by a microprocessor based control system, composed by a Main Control Board, installed inside of the charger, and an optional wireless Battery Identification Module (WBM), that is permanently connected to the battery.

GECI™ BLACK DIAMOND CHARGER INSTALLATION

CONDITIONS OF USE:

• Temperature (operation): from 0°C to 50°C.
• Temperature (storage): from –20°C to 60°C.
• Relative Humidity: less than 75 %.

> >ATTENTION!<<<
The Black Diamond Charger can be installed by qualified personnel only. It’s recommended to control that the AC input voltage available at the installation site has the right value, and that the power available is sufficient. The nominal AC input voltages that the charger can accept, and maximum input current and power are reported on the nameplate of the unit.
In order to prevent fires or electrical shock, don’t expose the Black Diamond Charger to rain or excessive humidity.
Don’t use the Black Diamond Charger near flammable gas, because it contains components (contactors) that may generate sparks during their normal operation.
Don’t open the cabinet of the charger. Only qualified personnel can service the unit.
Allow adequate air flow inside of the unit, in order to prevent excessive heat buildup.
Don’t install the unit near materials that may obstruct the air passages, near devices that may generate heat, under the direct sunlight or in presence of excessive dust or mechanical vibration.

CONNECTION OF THE AC INPUT:
The charger must be connected to the AC input using an adequate cable a g, with disconnect switch and fuses. The AC input wires have to be connected to the AC INPUT TERMINAL BLOCK, that is located on the internal panel, just under the AC input contactor. Make sure to tighten the terminal block screws with the proper torque, and pull each wire separately in order to verify that they are mounted properly.

AC INPUT VOLTAGE SELECTION 208/
The three-phase models may be configured for 208/ This selection can be done using the AC INPUT VOLTAGE PRESET BOARD of the internal panel, near the terminal blocks for the A C input  connection of the AUXILIARY TRANSFORMER.

• Disconnect the charger from main supply and battery.
• Remove the plastic protection over the AC INPUT VOLTAGE PRESET BOARD
• Remove the three metal bars.
• Place the metal bars in the required position, with ref to the following pictures.
• Tighten the nuts with the proper torque.
• Apply the plastic protection.
• Connect the charger to main supply.

**AC INPUT VOLTAGE SETTINGS

ATTENTION!<<<
**The proper setting of the power transformer taps is very important for the correct operation of the BLACK Diamond chargers.

The POWER TRANSFORMER TAPS and the label with the list of the NOMINAL voltages that are available are located on the internal panel, in a central position. Depending on the charger model, the number of available taps may range from 3 to 5.
The following table is referred to the 3 taps version.

SINGLE PHASE

• 208-240VAC
• 1x 240 VAC
• 1x 220 VAC
• 1x 208 VAC

TWO PHASE

• 208-240-480VAC
• 3x 240 VAC — 3x 490 VAC
• 3x 220 VAC — 3x 480 VAC
• 3x 208 VAC — 3x 460 VAC

THREE PHASE

• 600VAC
• 3x 610 VAC
• 3x 600 VAC
• 3x 575 VAC
•  Using an adequate AC-voltmeter, measure the value of the REAL AC input voltage available at the mounting location of the charger.
• Identify which of the NOMINAL voltage values is closest to the REAL measured value.
•  For the singlephase units, the wires to be moved are the TWO that are connected to the AC contactor, marked with the letter “A”.
•  For the threephase units, the wires to be moved are the THREE that are connected to the AC contactors, marked with the letters “A”, “B” and “C”.

GECI™ BLACK DIAMOND CHARGER

PRELIMINARY CONTROLS
Before to proceed with the programming sequence and before to connect a battery, make sure that the GECI™ Black Diamond Charger has been installed by a qualified electrician, according with the instructions reported in this manual. Before to use the charger, it’s necessary to control that the ventilation slots are not obstructed, and that all the safety precautions reported in this manual are respected.

GECI™ BLA CHARGER PROGRAMMING

GECI™ BLACK DIAMOND CHARGER STARTUP SEQUENCE

Turn on the charger by moving the main switch to position “1”.
The charger will perform an automatic test of the control circuits, and will wait for a random delay on start.
The display will visualize the following messages.

> >ATTENTION!<<<
Before to program the charger, disconnect the battery. This condition is necessary in order to activate the User Programming Mode. Only expert users should modify the settings of the charger.

GECI™ BLACK DIAMOND CHARGER ACTIVATE PROGRAM MODE

HOW TO ACTIVATE USER PROGRAMMING MODE

• Press the button DOWN and keep it pressed The display will show the message: EDIT PASSWORD
• Enter the Password UP-DOWN-UP-DOWN-UP The display will show the message: EDIT PASSWORD

PARAMETER 9 AND 10: EQUALIZE TIME WINDOW
Programmable values: Any day, from 00.00 to 23:59
Default value: From SATURDAY at 12.00 to SUNDAY at 22.00
NOTE: These parameters set a time window during the week in which the charger is allowed to fully charge and Equalize the battery. It’s recommended to set a minimum Equalize time of 12 hours after the normal completion of the charge cycle.

PARAMETER 11: WBM ENABLE
Programmable values: Enabled, Disabled, Optional
Default value: Disabled
NOTE: This parameter sets the operation of the charger with the Wireless Battery Identification module WBM (optional). Three different operating modes are selectable.
Enabled: When a battery is connected, the charger establishes a communication with the WBM and uses the information stored into the WBM to optimize the charge cycle.
Only batteries with WBM installed and properly configured will be charged!
Disabled: The communication of the charger with WBMs is disabled, and any battery (with correct voltage) will be charged. Optional: When a battery is connected, the charger tries to establish a communication with the WBM.
If a WBM is found, it’s used to optimize the charge cycle and to add the battery ID tag on the charge history log.
If a WBM is not found, the battery will be charged anyway.

PARAMETER 12: WIRED IP ADDRESS RS-485
Programmable values: 1 to 254
Default value: 1
NOTE: This parameter sets the IP address of the charger, when it’s connected to a wired DoctorFleet.com management network.

PARAMETER 13: RESET WIRELESS
Programmable values: Disabled / Try Search.NET
Default value: Disabled
NOTE: This parameter is used during the setup procedure of a wireless DoctorFleet.com management network.

PARAMETER 14: TEST WIRELESS
Programmable values: Disabled / Try Send Test.
Default value: Disabled
NOTE: This parameter is used during the setup procedure of a wireless DoctorFleet.com management network.

GECI™ BLACK DIAMOND CHARGER OPERATION

CONNECTION OF THE BATTERY, AUTOMATIC START
Connect the Battery to the charger, using a connector of adequate size. When the battery is correctly connected, the charger visualizes the following message: BATTERY CONNECTION

WIRELESS CONNECTION TO BATTERY IDENTIFICATION MODULE (OPTIONAL)
If the Battery Identification Module is enabled, a few seconds after the connection of the battery, the charger will try to establish a wireless connection. And the display will visualize the message: SEARCHING
When the wireless connection is active the charger is ready to start the charging cycle. The display visualizes the message:SEARCHING
At this point, the battery information are transferred to the charger and are visualized on the display. The charger is now ready to start. Depending on the programmed start time window (Parameter 8), the charger may enter in stand-by mode, and the display visualizes the message: CONNECTED
Where (hh.mm)A represents the real time at that moment, and (hh.mm)B represents the programmed start time. When the charge begins, the display visualizes the message: TO CHARGE

BATTERY VOLTAGE TOO HIGH
If the battery voltage is higher than a maximum threshold, the charge will not start and the display visualizes the message: BATTERY VOLTAGE TOO LOW
If this message appears, it’s recommended to verify that the nominal battery voltage matches the nominal voltage of the charger. Probably a wrong battery has been connected.

BATTERY VOLTAGE TOO LOW
If the battery voltage is lower than a minimum threshold, the charge will not start and the display visualizes the message: If this message appears, it’s recommended to verify that the nominal battery voltage matches the nominal voltage of the charger. Probably a wrong battery has been connected.
It’s also possible that the battery has been deeply discharged, bringing the voltage below the minimum value required for the automatic start the charge. In this case, it’s possible to start the charge manually, by pushing the button DOWN for 5 seconds.

EMERGENCY STOP
If the battery doesn’t reach the gassing voltage within a predetermined time, the charger will suspend the charge, and it will visualize the message: In this case, the charge cannot proceed, and it’s necessary to disconnect the battery. It’s recommended to control the battery for damaged cells.

AC INPUT BLACK OUT
If there is a black-out of the AC input, while the charge is in progress, the charger will shut down, while the charge parameters will remain in memory. When the AC input will be recovered, the charger will restart the charge cycle automatically, and the display will show the message:

OVERCURRENT PROTECTION
If the AC input voltage is abnormally high and/or the AC input adjustments have not been done correctly (See Chapter “INSTALLATION”), the charging current may reach an excessive value. In this case, the charger will suspend the charge, and the display will visualize the message:
The charge will not proceed, and it’s necessary to disconnect the battery.
It’s recommended to control the AC input connections of the charger, as explained in Chapter 3 “INSTALLATION”.
It’s recommended to verify the condition of the battery, as it may have one or more cells in short circuit.

AUTOMATIC STOP
The charger shuts down automatically when the charge is correctly complete, and it will visualize the message:
At this time it’s possible to disconnect the battery.

EQUALIZE CYCLE – AUTOMATIC (CLOCK MODE)
At the end of the charge, if the battery is left connected to the charger for a sufficient time, the charger activates the
Equalize cycle automatically, based upon the programmed schedule.
If the charge cycle ends outside of the programmed Equalize time window, the charger remains in stand-by mode, and the display shows the message:
Where DAY and TIME represent the beginning of the programmed Equalize time window.

EQUALIZE CYCLE – MANUAL
During the charging of the battery the operator can scroll the menu of the display, and he can force a EQ manual cycle at the end of this cycle

DESULFATION
The operator can every time interrupt the standard charging and enable with a easy procedure a special desulfation cycle. During the charging the operator can press Enter few seconds and the display shows a desulfation menu, in this menu the operator can select the time during of desulfation and the type of restart of desulfation, in fact sometimes it is strategic important to complete a standard charging after a completed desulfation cycle.

REFRESH-MAINTENANCE
This function is useful to keep the battery in perfect condition when it’s not used for an long period (weeks, months, …). It is sufficient to leave the battery connected to the charger. After a normal termination of the charge and the equalize cycle, the control board will activate the charger automatically for 15 minutes of refresh charge every day. While the charger waits before to activate a Refresh cycle, the display shows the messages:

• Battery Voltage [Volt]
•  Nr of Refresh cycles already given to the battery
• Total Time of Charge [hours.minutes]
• Total Capacity Returned [Ah]

PROGRAMMING HARDWARE RULES

During installation and programming activity it is necessary to ensure that the position of the battery power cables and charger cables are correct.
As illustrated below, it is important that the cables are not overlapping or entwined in the cables of another battery. the position As illustrated below, it is important that the cables are not overlapping or entwined in the cables of another battery. Failure to comply with these instructions may disturb occurs the charger will generate the following alarm.

GECI BLACK DIAMOND CHARGER

ENERGY METERING AND HISTORY LOG

The internal memory of the BLACK DIAMOND charger contains a log of the last

200 charge cycles. More than 50 meters of the 50 most recent cycles can be log can be accessed and downloaded through Recent cycles, it’s sufficient to scroll the menu buttons, and to press ENTER for 3 seconds in order to access the database. The results of each   cycle are represented on two pages. Use the UP-DOWN buttons to scroll between each record.

CHARGE TERMINATION CODES

GROUP 1: CHARGE COMPLETED

• 00 Battery modules recognized. Start charging.

• 01 Charge completed successfully.

• 02 Charge completed successfully.
  Equalize NOT executed because battery was disconnected.

• 03 Charge completed successfully.
  Equalize started but not completed, because battery was disconnected during the cool-down time before the Equalize cycle.

• 04 Charge completed successfully.
  Equalize started but not completed, because battery was disconnected while the Equalize was in progress.

• 05 Charge completed successfully. Over range maximum time during pulsed

• 06 Desulphation cycle completed successfully.

• 07 Charge completed successfully. Equalize completed successfully. Refresh-Cycle NOT executed because battery was disconnected.

• 08 Charge completed successfully. Equalize completed successfully.
  Refresh-CyclRefresh-Cycle completed successfully.e started but not completed, because battery was disconnected while the Refresh was in progress.
  Refresh-Cycle completed successfully.

• 09 Charge completed successfully. Equalize completed successfully.
  Refresh-Cycle completed successfully.

• 10 Gassing voltage reached successfully.
  Full charge NOT executed because time window Disabled.

• 12 Charge completed successfully. Equalize completed successfully.

GROUP 2: MANUAL STOP

• 11 Charge stopped manually, during a generic cooling state
• 20 Charge stopped manually, before to reach the gassing voltage.
• 21 Charge stopped manually, during the finishing charge.
• 22 Charge stopped manually, during eq.
• 23 Charge stopped manually, during refresh.
• 24 Charge stopped manually, during desulphation.

GROUP 3: BATTERY DISCONNECTED

• 30 The battery has been disconnected before the begin of the charge, while the charger was waiting for the programmed
  Start Time window.

• 31 The battery has been disconnected during the first part of the charge, before to reach the gassing voltage.

• 32 Successful Opportunity charging cycle.
  The battery reached the gassing point, the charger entered in stand-by mode waiting for the Full Charge/Overcharge
  time window, and at that point the battery has been disconnected.

• 33 The battery has been disconnected during the finishing charge, while it was cooling between two charging pulses.

• 34 The battery has been disconnected during the finishing charge, while it was receiving a charging pulse.

• 36 Charge never started.
  The battery has been disconnected while the charger was trying to establish a wireless connection with the Battery
  Identification Module (WBM).

• 37 Charge never started.
  The battery has been disconnected while the charger was communicating with the Battery Identification Module (WBM).

• 38 Desulphation cycle NOT completed.
  The battery has been immediately disconnected, at the beginning of the Desulphation cycle

• 39 Desulphation cycle NOT completed.
  The battery has been immediately disconnected, before to complete the programming of theDesulphation cycle.

• 40 Desulphation cycle NOT completed.
  The battery has been disconnected while the Desulphation cycle was in progress.

GROUP 4: EMERGENCY STOP

• 60 Emergency Stop!
  Maximum voltage limit exceeded during first part of the charge, before to reach the gassing voltage.

• 61 Emergency Stop!
  Maximum voltage exceeded during the finishing charge.

• 62 Emergency Stop!
  Maximum voltage exceeded during the equalize cycle.

• 63 Emergency Stop!
  Gassing voltage not reached within the predetermined time limit.

• 64 Charge never started.
  Battery voltage was too LOW

• 65 Charge never started.
  Battery voltage was too HIGH

• 66 Emergency Stop!
  Maximum Current Limit Exceeded.

• 67 Emergency Stop!
  Maximum voltage exceeded during the refresh cycle.

• 68 Emergency Stop!
  Maximum temperature exceeded before to reach the gassing voltage.

• 69 Emergency Stop!
  Maximum temperature exceeded during the finishing charge.

• 70 Emergency Stop!
  Maximum temperature exceeded during the equalize cycle.

• 71 Emergency Stop!
  Maximum temperature exceeded during the refresh cycle.
  72 Emergency Stop!
  When a battery is connected, the WBM communicate that the voltage of battery is not compatible with this charger

• 76 Emergency Stop!
  Maximum temperature exceeded during desulphation.

GROUP 5: WARNING MESSAGES

• 80 Maximum finishing charge time (safety timer) exceeded. Charge termination criteria (dV/dt) not reached.
• 82 The battery has been disconnected while the charge was in progress, in a generic state.
• 83 Output fuse blown.
• 85 Communication problem with Wireless Battery Module.
• 99 Black out of the AC input.

WARRANTY

GECI™ BLACK DIAMOND CHARGER
Green Energy Concepts, Inc. (hereinafter called “GECI”) warrants that each new and unused GECI battery charger, power supply or converter (hereinafter called “equipment”) manufactured and supplied by it is of good workmanship and is free from any inherent mechanical defects, provided that (1) the product is installed and operated in accordance with generally accepted industrial standards and in accordance with the printed instructions of GECI, (2) the product is used under normal conditions for which designed, (3) the product is not subjected to misuse, negligence or accident, and (4) the product receives proper care, protection and maintenance under supervision of competent personnel. This warranty is subject to the following provisions:

1. PRODUCTS AND PARTS WARRANTED. Subject to the exceptions listed below each GECI equipment is warranted for a period of three (3) years from the date of its shipment, provided the charger is used in accordance with GECI’s published performance rating or the unit involved. The Warranty covers parts, components and/or assemblies supplied completely free of charge but does not extend to labor, service, interventions and or any other costs whatsoever related to fixing defective chargers and/or parts. The conditions of this parts warranty are as follows:
   • Primary switch contacts, fuses, bulbs and filters are not warranted unless found to be defective prior to use.
   • Power transformers of 60Hz chargers are warranted for ten (10) years after GECI’s shipment of the unit(s).
   • The charger brand names that are warranted under this document are the Green, Red, Black and Orange Diamond.
   • The Blue Diamond is handled separately and is not part of this warranty agreement.
2. COMMENCEMENT OF WARRANTY TIME PERIODS. The warranty periods shall commence on the date of shipment by GECI.
3. PERSONS COVERED BY WARRANTY. This warranty is extended by GECI only to the purchaser of new equipment from GECI or one of its authorized distributors. The products purchased under this agreement shall be used exclusively by the buyer and its employees and by no other persons, and therefore there shall be no third party beneficiary of this warranty.
4. LIMITATION OF REMEDY. The existence of claimed defects in any product covered by this warranty is subject to GECI’s factory inspection and judgment. GECI liability is limited to repair of any defects found by GECI to exist or, at GECI’s option, the replacement of the defective equipment, F.O.B. factory after the defective product has been returned by the purchaser at its expense to GECI’s shipping place. Replacement and exchange parts will be warranted for the remainder of the original warranty or for a period of ninety (90) days, whichever is greater. GECI and its authorized distributors or dealers shall not be liable for direct or indirect, special or consequential damages in excess of such repair or replacement. In no event shall the purchaser be entitled to recover for contingent expenses resulting from, but not limited to, telephone calls, telegrams, travel expenses, lodging, duties and taxes, labor, rental or replacement equipment, loss of business or profits or other commercial losses.
5. USE OF DEFECTIVE PRODUCTS. Continued use of GECI equipment after discovery of a defect voids all warranties.
6. ALTERED EQUIPMENT. Except as authorized in writing, the warranty specified does not cover any equipment that has been altered by any party other than GECI.
   EXCEPT AS STATED ABOVE, ALL OTHER WARRANTIES AND CONDITIONS, WHETHER EXPRESSED OR IMPLIED,
   INCLUDING IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY
   EXCLUDED. BASSI NEITHER ASSUMES NOR AUTHORIZES ANY PERSONS TO ASSUME FOR BASSI ANY OTHER
   LIABILITY IN CONNECTION WITH THE SALE OR USE OF THE GOODS SOLD, AND THERE ARE NO ORAL AGREEMENTS
   OR WARRANTIES COLLATERAL TO OR AFFECTING THIS WRITTEN WARRANTY.

References

• DoctorFleet.com is for sale | HugeDomains
• Green Energy Concepts (GECI) - GECI Green Energy Concepts, Inc

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