EN Version 1.2 2023.

06

ATTENTION
This Instruction provides information covering installation, parameter,trouble shooting
and maintenance.
In order to ensure the correct installation and operation of this charger please read
the instructions carefully before installation, and properly keep the manual for future

LITHIUM BATTERY CHARGER

reference

SPECIAL NOTICE
USER MANUAL • Unauthorized conversion or reproduction of all or any part of this manual is
prohibited.
• The contents of this manual are subject to change without notice.
• lf any error or omission is found in the instructions,please contact our distributor.
• Please keep the charger serial number and nameplate properly to ensure you can
enjoy a better afterservice

※ Thanks for choosing our charger!

※ Please read “User Manual” before you operate the charger. POWER YOUR BUSINESS
-I-
CONTENT SUMMARY OF PRODUCTS

This series of high frequency chargers is equipped with high conversion

efficiency, high precision of voltage stabilization and current stabilization,
and low ripple of output current Owing to the high frequency technology,
Summary of Products 1
the charger has the characteristics of saving electricity, easy control,
Mechanical Properties 2
adjustable and wide range,compact size and lightweight.
Product View 2
Electrical Parameters 4
The charger is mainly composed of rectifier filter circuit,high frequency
Operation Instructions 6
switiching inverter circuit,PWM control circuit,output rectifier wave circuit,
Installation and Startup 7
reverse protection,short circuit protection,hardware protection circuit and
Maintenance 8
auxiliary power source circuit.
Fault List and Troubleshooting 8

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MECHANICAL PROPERTIES PRODUCT VIEW

Dimension and weight of the product are shown in below table. 400±2.5 3000±5.0 200±2.5

Model Weight(kg) Dimension(mm) Cooling Mode Suitable Iocation

24V100A 11 400×170×370 Forced air Indoor 3000±5.0

390±2.5
24V150A-220 26 380×330×475 Forced air Indoor

48V100A 17 398×200×390 Forced air Indoor

80V65A 17 398×200×390 Forced air Indoor

48V200A-220 46 380×440×625 Forced air Indoor

TYPE II
48V250A-220 55 380×440×795 Forced air Indoor
Applicable Model 48V100A 80V65A
48V150A 40 380×440×625 Forced air Indoor
330±2.5
48V200A 40 380×440×625 Forced air Indoor 380±2.5 3000±5.0 270±2.5

48V250A 46 380×440×625 Forced air Indoor

80V100A 40 380×440×625 Forced air Indoor

80V150A 46 380×440×625 Forced air Indoor

475±2.5
80V200A 46 380×440×625 Forced air Indoor

80V250A 55 380×440×795 Forced air Indoor

3000±5.0

PRODUCT VIEW TYPE III

Applicable Model 24V150A-220

440±2.5
400±2.5 3000±5.0 170±2.5 3000±5.0 380±2.5 380±2.5

3000±5.0
370±2.5

625±2.5
TYPE I 3000±5.0

Applicable Model 24V100A

TYPE IV
48V200A-220V 48V150A 48V200A 48V250A
Applicable Model
80V100A 80V150A 80V200A

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 PRODUCT VIEW ELECTRICAL PARAMETERS

440±2.5
3000±5.0 380±2.5 380±2.5
Model 48V100A 48V150A 48V200A
Rated input voltage AC380V±15% Three phase four wire
Rated frequency 50/60Hz
Power factor ≥ 0.99
Input power ≤ 5.2KW ≤ 8KW ≤ 10.5KW
Conversion efficiency ≥ 0.92
Rated output voltage 48V

795±2.5
Rated output current 100A 150A 200A
Rated output power 4.8KW 7.2KW 9.6KW
DC output voltage 18VDC~65VDC
Output plug GB125A / 250A ; REMA DIN 160A / 320A (Male or Female plug,optiona)
Cooling mode Air cooling
Working temperature -20°C~50°C
Working humidity 0%~95%
3000±5.0
IP Rating IP20
Noise <65dB
TYPE V Altitude <2000M

Applicable Model 48V250A-220V 80V250A

Model 48V250A 80V65A 80V100A

Rated input voltage AC380V±15% Three phase four wire
ELECTRICAL PARAMETERS Rated frequency 50/60Hz
Power factor ≥ 0.99
Model 24V100A 24V150A 48V200A-220 48V250A-220 Input power ≤ 13KW ≤ 8KW ≤ 8.7KW
Rated input voltage AC220V±15% Single Phase 220V AC220V±15% Three phase four wire Conversion efficiency ≥ 0.92
Rated frequency 50/60Hz Rated output voltage 48V 80V
Power factor ≥ 0.99 Rated output current 250A 65A 100A
Input power ≤ 2.6KW ≤ 3.9KW ≤ 10.5KW ≤ 13KW Rated output power 12KW 5.2KW 8KW
Conversion efficiency ≥ 0.92 DC output voltage 18VDC~65VDC 30VDC~100VDC
Rated output voltage 24V 48V Output plug GB125A / 250A ; REMA DIN 160A / 320A (Male or Female plug,optiona)
Rated output current 100A 150A 200A 200A Cooling mode Air cooling
Rated output power 2.4KW 3.6KW 9.6KW 12KW Working temperature -20°C~50°C
DC output voltage 10VDC~32VDC 18VDC~65VDC Working humidity 0%~95%
Output plug GB125A / 250A ; REMA DIN 160A / 320A (Male or Female plug,optiona) IP Rating IP20
Cooling mode Air cooling Noise <65dB
Working temperature -20°C~50°C Altitude <2000M
Working humidity 0%~95%
IP Rating IP20
Noise <65dB
Altitude <2000M

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 ELECTRICAL PARAMETERS • Second screen display

Status Charging Temp:Cell temperature

Model 80V150A 80V200A 80V250A Temp ℃ Voltage: Cell voltage

Voltage V SOC:Battery capacity
Rated input voltage AC380V±15% Three phase four wire
SOC %
Rated frequency 50/60Hz
Power factor ≥ 0.99
• Third screen display
Input power ≤ 13KW ≤ 17.5KW ≤ 21.7KW
Conversion efficiency ≥ 0.92
Status Charging B Current :Output current of charger MODULE B
Rated output voltage 80V
B Current A A Current :Output current of charger MODULE A
Rated output current 150A 200A 250A
A Current A C Current:Output current of charger MODULE C
Rated output power 12KW 16KW 20KW
C Current A
DC output voltage 30VDC~100VDC
Output plug GB250A ; REMA DIN 320A (Male or Female plug,optiona)
• Fourth screen display
Cooling mode Air cooling
Working temperature -20°C~50°C
Status Charging Voltage :Current battery voltage
Working humidity 0%~95%
Voltage V Time :charge time
IP Rating IP20
Time M Current:Charger output current
Noise <65dB
Current A
Altitude <2000M
※ For special working condition, please communicate with us before placing the order.

INSTALLATION AND STARTUP

OPERATION INSTRUCTIONS
Installation external wiring and Air switch minimum requirements for AC input power.


Charging preparation


• Please check appearance including the charger, cables and plugs. Model Section area of Input wirings(mm²) Air Switch
• Please make sure the AC input terminal and DC output terminal are connected in place and
24V100A 2×2.5mm²+1×2.5mm² [ L+N+PE ] 32A-2P
that they are not loose.
• Make sure the air switch is in the right state. 24V150A-220 2×4mm²+1×4mm² [ L+N+PE ] 32A-2P
• Power on the charger,self-checking will be initiated automatically. 48V200A-220 3×6mm²+1×6mm² [ Three Phase+PE ] 63A-3P

Charging operation steps 48V250A-220 3×10mm²+1×10mm² [ Three Phase+PE ] 63A-3P
• Make sure the plug and your hands are dry before operation. 48V100A 3×2.5mm²+1×2.5mm² [ Three Phase+PE ] 32A-3P
• Turn off the forklift and the power on the battery. 48V150A 3×4mm²+1×4mm² [ Three Phase+PE ] 32A-3P
• Connect the charge plugs of charger with the battery.
48V200A 3×6mm²+1×6mm² [ Three Phase+PE ] 32A-3P
• Charging always starts automatically after connecting to battery,and the charger indicator is
flashing at the same time. 48V250A 3×6mm²+1×6mm² [ Three Phase+PE ] 63A-3P
• If an error occurs during charging,press 'Pause’to stop charging until solve it. 80V65A 3×2.5mm²+1×2.5mm² [ Three Phase+PE ] 32A-3P
• The charger will automatically stop charging when battery is fully charged. Otherwise the 80V100A 3×4mm²+1×4mm² [ Three Phase+PE ] 32A-3P
charger indicator is always On.
80V150A 3×6mm²+1×6mm² [ Three Phase+PE ] 63A-3P
• If you want to use the forklift during the charging,press 'Pauseto stop charging before
disconnecting the plugs. 80V200A 3×6mm²+1×6mm² [ Three Phase+PE ] 63A-3P
80V250A 3×10mm²+1×10mm² [ Three Phase+PE ] 63A-3P
LCD display description


• First screen display

Installation Environment Requirements


No rain/water, no direct exposure to sun light, far from heat source.

Status Charging REQA: Charge current set by battery BMS
REQA A REQV: Charging voltage set by battery BMS Free of dust. corrosive gases,flammable gases, oily mildew,steam, dripping
REQV V water, etc Indoor is better.
FLAMMABLE

Voltage: Current battery voltage

GAS

Voltage V ≥200mm Leave more than 200 mm space around.

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 MAINTENANCE
In order to increase the service life, please clean the dust of the air inlet every
month(adjust direction according to environmental condition), so as to cool down
the machine well.

FAULTS LIST AND TROUBLESHOOTING

NO. Faults on display Description Troubleshooting

The input voltage is higher Stop charging and check:

1 Fault UVP
than the allowable value. if the AC input voitage meets 380V +10%.

The AC input three-phase Stop charging and check if the AC input

2 Fault IPC
power is missing one phase three phase power is correct

The fan is faulty. Stop charging and check:

3 FAN Fault
Check the fan. Check whether the fan is stuck.

Stop charging and check:

Output undervoltage Output voltage is below
4 1. Right charger for right battery.
protection allowable value.
2. The output voltage of the charger.

Stop charging and check:

Output overcurrent Output current is higher 1. The output current settings of the charger.
5
protection than allowable value. 2. Whether the output gun is damaged.
3. If the connection is normal.

Stop charging and check:

POWER YOUR BUSINESS
The charger temperature 1.Check whether the fan is stuck.
6 Fault OTP
is too high. 2.Check whether the heat dissipation air
duct of the charger is shielded.

Stop charging and check:

Battery disconnection Charger Output Line Not 1.The charging gun is not connected well.
7
protection Connected to Battery. 2. The CAN communication line is not
connected well.

Interruption of communication Stop charging and check whether the CAN

8 BMS Fault
between charger and BMS communication line is not connected well

Stop charaina and check whether there is

Output Short Circuit Output positive and negative
9 short circuit to ground or between positive
Protection pole short connection
and negative poles.

Stop charging and check the positive and

Battery Back Positive and negative are
10 negative poles of the charging gun and
Connection Protection reversed
the battery

※ Note: Please contact us if the above treatments can’t solve the failure

Printed in China
-8- 2023.06