Operating Instructions

Charger LGW 22406 A.S.T. Leistungselektronik GmbH

_______________________________________________________________________

Charger

LGW 22406

OPERATING INSTRUCTIONS

Version 04/05 Subject to technical modifications

A.S.T. Leistungselektronik GmbH Brook-Taylor-Str. 10, D- 12489 Berlin T:++49 / 30 / 63925700 Fax: ++49 / 30 / 6392 5709
www.astle.de
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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________

TABLE OF CONTENTS

0 General………………………………………………..3

1 Safety Guidelines……………………….……………4

2 Technical Data……………………………………….6

3 Charging characteristic………………………………7

4 Charge level indications……………………………..8

5 Battery test…………………………………………….9

6 Battery temperature control………………………..10

7 Specification of signal outputs……………………..10

8 Report signals………………………………………..11

9 Connection diagram…………………… ………….12

10 Dimensions…………………………………………..13

11 Mounting……………………………………… ……14

12 Electrical Installation………………………………..14

13 Error signals………………………………………….15

14 Automatic error acknowledgement………………..16

15 Repair………………………………………………...17

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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________

0 General

The present operating instructions have been created with utmost care and have
extensively been tested several times. For reasons of clarity, neither all detailed
information about each product type nor each conceivable kind of installation,
operation or maintenance could be taken into account.

We also point out that the content of the operating instructions is not part of or
modifies an older or existing agreement, confirmation or legal relationship. All
obligations of the manufacturer arise from the respective purchase agreement which
also contains the complete and only valid warranty regulations. Considering the
operation instructions neither extends nor restricts these contractual warranty
specifications.

The manufacturer reserves the right to correct or to change the content and the
product specifications and omissions without prior notice. He is not liable for
damages, injuries or expenses due to above mentioned reasons.

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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________

1 Safety Guidelines

Intended conditions of use

The devices are electrical components intended to be installed in
electrical installations or machines. The devices' availability is
limited and they are exclusively intended for professional use in
terms of the standard EN 61000-3-2. The commissioning and the
start-up are prohibited until the machine or plant was deemed to
conform to the EC machine guideline 98/37/EEC and EN 60204.

ATTENTION, Danger to life:

If there are reasons to suspect that a safe operation is no longer
possible, the device has to be shut down and must be prevented
against unintentional operation.
It can be assumed that safe operation is no longer possible
• if the device shows visible damages.
• if the device is no longer working.
• after prolonged storage under unfavorable conditions.
• after severe transport stresses.

ATTENTION:
Prior to installation or commissioning, these operating instructions
must be carefully read by qualified personnel familiar with electric
traction equipment. Mishandling can lead to personal injuries and/or
property damage. The installation and the commissioning may only be
performed by qualified personnel.

ATTENTION, Danger to life:

Electrical devices are not fail-safe in principle.
The output voltage reaches values requiring protection against
accidental contact.
The user is responsible for ensuring that, in case the device breaks
down, the plant will be transferred into a safe state, since otherwise
personal injuries and/or property damage can occur.

NOTICE:
The trouble-free and safe operation of the charger requires proper
transport, professional storage, installation and mounting as well as
careful operation and maintenance.

ATTENTION:
The device contains electrostatic sensitive devices (ESD). The
relevant treatment instructions shall be observed.

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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________

BEFORE EACH MANIPULATION, THE DEVICE MUST BE

DISCONNECTED FROM THE POWER SUPPLY AND THE
BATTERY. AFTER A WAITING PERIOD OF APPROX. 5 MINUTES,
WHEN THE INTERMEDIATE CIRCUIT CAPACITORS HAVE BEEN
DISCHARGED AND HAVE A RESIDUAL VOLTAGE OF LESS THAN
50 V, WORK ON THE DEVICE MAY BE CARRIED OUT. BETWEEN
DISCONNECTING THE DEVICE FROM THE MAIN POWER
SUPPLY AND RECONNECTING THE SUPPLY VOLTAGE, A
WAITING TIME TARGET OF 1 MINUTE MUST BE MET.

THE GALVANIC ISOLATION BETWEEN POWER SIDE AND

CONTROL SIDE DOES NOT CORRESPOND TO THE VDE
REGULATION FOR SAFETY EXTRA-LOW VOLTAGE (SELV).

THERE IS NO GALVANIC ISOLATION BETWEEN INPUT AND

OUTPUT.

THE LEAKAGE CURRENT CAN BE ≥ 3,5 mA. ACCORDING TO

VDE 160, A FIXED CONNECTION FOR THE GROUND WIRE MUST
THEREFORE BE PROVIDED.

DO NOT TRY TO CHECK THE DIELECTRIC STRENGTH OF THE

CHARGER. DO NOT DISCONNECT ITS CONNECTIONS BEFORE
AN ISOLATION TEST OF THE PLANT HAS BEEN PERFORMED.

During the electrical installation, the general installation rules

must be followed:

-VDE 0100
Regulations for the erection of power installations with nominal
voltages below 1000 V.

VDE 0113
Regulations for the electrical equipment of machines.

VDE 0160
Electronic equipment for use in heavy current installations.

If there are special fields of application, other regulations must be

followed if necessary.
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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________

2 Technical Data

LGW 22406 ID 01 LGW 22406 ID 02

Nominal battery voltage 264 V 432 V
Battery type LC-P127R2P LC-P127R2P
Panasonic Panasonic
Sealed Sealed
Lead-acid battery Lead-acid battery
Number of cells 132 216
Nominal input voltage 357 V DC 565 V DC
Input voltage range 274 to 715 V DC 442 to 715 V DC
Surge protection 715 to 900 V for 2 s 715 to 900 V for 2 s
without destruction without destruction
Stand by power <6W <6W
Output voltage range 230 to 330 V DC 345 to 540 V DC
Temperature compensation - 396 mV / K - 648 mV / K
Nominal output current 0,7 A 0,7 A

Dimension 350 x 124 x 56

Protection class IP 20
Cooling Natural convection
Thermal contact of the cooling plate with the
switch cabinet housing required
Operating temperature range - 25 to + 55 °C
Storage temperature range - 25 to 70 °C
Relative Humidity Annual average < 75 %
30 days a year continuous 95 %
light condensation permissible
Shock and vibration IEC 61373

Output voltage maximum input voltage –5 V.

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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________

3 Charging characteristic

U/I

CI CU CU
Charging phase 1 Charging phase 2 Charging phase 3

I1
U1
U2

t
5 hours maximum Without time limit

LGW 22406 ID 01 LGW 22406 ID 02

Charging 1 2 3 1 2 3
phase
Type CI CU CU CI CU CU

Voltage limits [V]

330 303,6 540 496,8
@+20°C 1) @+20°C 1) @+20°C 1) @+20°C 1)
Current limits [A] 0,7 max. 0,7 A max. 0,7 A 0,7 max. 0,7 A max. 0,7 A
Charging phase max. 5 h ∞ max. 5 h ∞
timet [h]
Charging capacity max. 240 max. 400
[W]

1)
Temperature compensation (–3mV x number of cells)/K between 0 and 50 °C.

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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________

4 Charging level indications

Charging 1 2 3
phase
LED 1 2Hz 0 1Hz
LED 2 0 2Hz 1Hz
MK_BE 1 1 1
MK_BA 1 1 1
MK_BT 1 1 1

The charge level indication works only if all signal contacts are closed.

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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________

5 Battery test

When connected, the charger conducts a battery test without load resistance. The
charging will begin if a battery is connected and if the battery voltage is higher than
the battery test switch-on voltage and lower than the emergency switch-off voltage.
The battery test with loading is carried out every 120 min unless there is an error
condition and unless the battery temperature exceeds 50°C.

Battery voltage

U1
U2
U3

t
Battery current

I1

I2

L1: 1Hz L1: on t

L2: 2Hz L2: on

I3

Charging phase Charging pause 30 sec Battery test 5 sec I-charge U-Charge

I1 : Charging current in phase I

I2 : Charging current in phase U
I3 : Discharging current during battery test (load current)

LGW 22406 ID 01 LGW22406 ID 02

Battery test switch-on voltage 225 V 365 V
Battery failure at Ubatt < 255 V < 418 V
Load resistance 188 Ohm 272 Ohm

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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________

6 Battery temperature control

The scope of supply of the charger includes a battery temperature sensor. The
sensor's connecting cable must be electrically connected to the appropriate labeled
contacts of the Interface plug-in connector. The battery temperature sensor must be
attached directly to the battery. A good thermal connection with the battery ensures
accurate functioning.

The following battery conditions are monitored:

− Insufficient temperature: at temperatures below 0°C, the signal contact battery

temperature opens; the charging continues
− Excess temperature: at temperatures above 40°C, the signal contact battery
temperature opens; the charging continues until 50°C

At battery temperatures above 20°C, the final charge voltage is corrected in a

temperature-dependent manner with (-3mV x number of cells) / K. If the battery
temperature exceeds 50°C, the charging is stopped and the operation report is
opened.

7 Specification of signal outputs

The signal outputs are switched via solid state relays.

Loading capacity 50 V DC, 100 mA

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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________

8 Report signals

State Operation report Battery o.k. Battery temperature

No voltage Open Open Open

Ue 274V to 715V (ID 01) Depending on the Depending on the

Closed
Ue 442V to 715V (ID 02) operating state operating state

Ue 200V to 274V (ID 01) Depending on the Depending on the

Open
operating state operating state
Ue 200V to 442V (ID 02)

Ue < 200V Open Open Open

Depending on the Depending on the

Ue > 715V Open
operating state operating state
Depending on the Depending on the
Excess device temperature Open
operating state operating state
Depending on the
Battery temperature > 50°C Open Open
operating state

Internal error Open Open Open

Battery voltage < 255V

during discharge (ID 01) Depending on the Depending on the
Open
Battery voltage < 418V operating state operating state
during discharge (ID 02)
Battery voltage
255 to 330V (ID 01) Depending on the Depending on the
Closed
Batteriespannung operating state operating state
418 bis 540V (ID 02)
Depending on the Abhängig vom
Battery temperature < 0°C Betriebszustand Open
operating state
Battery temperature 0 to Depending on the Abhängig vom
Betriebszustand Closed
40°C operating state
Depending on the Abhängig vom
Battery temperature > 40°C Betriebszustand Open
operating state
Battery test switch-on
voltage < 225V (ID 01) Depending on the Depending on the
Open
Battery test switch-on operating state operating state
voltage < 365V (ID 02)

The reports are available approx. 10 s after switching on the operating voltage
following the conclusion of the internal start-up routines.
For the charger LGW 22406 ID 01, the error report for MK_BE, resulting from the
input voltage, the device temperature or the battery temperature, is being delayed by
5 sec if the error occurs permanently during this period.
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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________

9 Connection diagram

PE-
Connection

+ Input voltage

Minus voltage

+ Output voltage

Minus voltage
Battery temperature sensor

Signal contact ready

Signal contact battery

Signal contact battery temperature

Service connector

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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________

10 Dimensions

Necessary accuracy of the

M6 mounting bolts to each other: ±
0.4

Screw locking: disk with

detent edge disk SKS6
Tightening torque: 9 ± 1.5 Nm

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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________

11 Mounting

The charger has to be fixed with 4 screws M6 on the mounting plate of a control
cabinet. The mounting plate is used for taking away power dissipation. Sufficient
thermal contact to the mounting plate of the control cabinet must be provided.

12 Electrical installation

After mounting the device, installation of protective earth conductor and power
terminals must be carried out in a voltage-free state. The battery temperature sensor
cable must be connected to the corresponding connections of the Interface plug-in
connector.

Control and signal lines must be shielded and, as far as possible, laid separately
from DC, mains and battery cables.

The device must be protected at the output and input by the operator. Fuse 10 A
slow each.

Cable cross-sections:

Protective earth conductor 2.5 mm² Cu

Power terminals 2.5 mm² Cu
Control lines max. 1.5 mm² Cu

After applying the operating voltage, the charger starts independently without
further starting signal.

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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________

13 Error signals

Type of error LED 1

Input voltage too low Flashing 4 times

Input voltage too high Flashing 3 times

Device temperature or
Flashing 6 times
battery temperature too high

internal device error Flashing 12 or 15 times

Error reports are only displayed when signal contact MK_BE is open. For the charger
LGW 22406 ID 01, an error is only signaled once the error is present permanently for
5 s. The minimum input voltage for this function is 200 V.

14 Automatic error acknowledgement

The following errors are acknowledged automatically and the charging process is
restarted once the error cause has been remedied:

− Input voltage below minimum input voltage

The following errors are acknowledged automatically, and the charging process is
restarted once the error cause has been remedied:

− Input voltage > 715 V

− Excess device temperature
− Battery temperature > 50°C

The error report Battery ok is reset once a successful battery test has been carried
out.

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Operating Instructions
Charger LGW 22406 A.S.T. Leistungselektronik GmbH
_______________________________________________________________________

15 Repair

Prior to delivery, all devices undergo a precise functional testing. It is ensured that
only faultless devices are delivered. If a defect should occur nevertheless, please
send the device to the following address:

A.S.T. Leistungselektronik GmbH

Brook-Taylor-Str. 10
D-12489 Berlin

Tel. +49(0)30 6392 5700

Fax. +49(0)30 6392 5709

We ask for the following information: - application description

- failure description
- connection diagram

If one of the devices presents a defect, please do not try to repair the device by
yourself; please consult our service.

Subject to technical modifications

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