DOC: CA10-CL20-UM_X_28MAR11.doc
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Table of Contents:
Read Me First 3 Whats in the box? 4 Understanding the Label 4 Frequently Asked Questions 5 Functional Description of the Charger Features 6 Output Characteristics 7 CONNECTIONS TO THE CHARGER DC Output 8 Universal AC Input 9 Fan Connection (Air-Cooled) 10 CAN Communications 11 Ground Lug 12 COOLING Air-Cooled Chargers 12 Liquid-Cooled Chargers 12 INTERNAL MODULE DESCRIPTION Single Unit Charger 13 Manual Operation 13 Staged Charging 13 BMS Controlled 13 Paralleling of Chargers 13 CA10x03 and CL20x03 PRODUCT FAMILY Air-Cooled 15 Liquid-Cooled 18 CABLE DIAGRAMS AC Input Cable 21 DC Output Cable 21 Pump/LED Cable 22 Communications Cable 22 Block Diagram 23 Specifications 24
AC Input 25 Controls Input 25 DC Output (208VAC input or above) 25 Low Voltage Output Range 1 units (CA10L03, CL20L03) 25 High Voltage Output Range 2 units (CA10H03, CL20H03) 25 Power Limits 26 Battery Voltage Compensation 26 Output General 27 Protection Features 27 LED Indicator Function 27 Environmental 28 Computer Interface 28 Software Install 29 Installing the Lawicel CAN-USB Adapter 29 Installing the PEAK PCAN USBCAN Adapter 34 Installing the Current Ways VIP Control Software GUI Setup and Connections 34 Current Ways VIP Control Software GUI Operation with Charger 39 Stage Charging Setup 40 Battery Management System Interface 41 Updating the Internal Charger Control Firmware 41 SAE J1772 Control of Charger 41 MECHANICAL OUTLINE DRAWINGS Air-Cooled Charger 42 Liquid-Cooled Charger 43
This manual is copyright and wholly owned by Current Ways Inc. and is for the exclusive use of its customers. Any other use of this manual must be by expressed written permission of Current Ways Inc. Current Ways Inc. 10221 Buena Vista Ave. Santee, CA 92017 USA 619-596-3984 www.CurrentWays.comCurrent Ways Inc. reserves the right to alter product offerings and specifications at any time without notice, and is not responsible for typographical or graphical errors that may appear in this document. Copyright 2011 Current Ways, Inc. All rights reserved. PLUGIN TO THE POWER is a U.S. registered trademark/service mark, and an EU registered logo mark of Current Ways, Inc. All other products or services mentioned are the trademarks, service marks, registered trademarks or registered service marks of their respective owners. Current Ways has several patent applications filed.
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SECTION 1 - READ ME FIRST: Congratulations and Thank you for your purchase of the Current Ways Inc. BC-Series of IP67 fully sealed, output isolated electric vehicle battery charger. The Current Ways design and production team has spared no effort to make this battery charger system a feature packed worldclass product with high performance and high efficiency at a competitive price. To fully utilize the features and to operate the unit safely, please read this entire manual before installing or applying power to the charger.
WARNING: TRACTION DRIVE BATTERY VOLTAGES AND CURRENTS ARE LETHAL! FAILURE TO COMPLY WITH THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH. DO NOT REMOVE ANY OF THE COVERS ON THE CHARGER. DOING SO WILL EXPOSE POTENTIALLY LETHAL VOLTAGES AND VOID THE WARRANTY. THERE ARE NO FIELD SERVICEABLE PARTS INSIDE. END USER IS REQUIRED TO INSTALL FUSES ON THE DC OUTPUT CABLE, BOTH POSITIVE AND NEGATIVE, AS CLOSE TO THE BATTERIES AS POSSIBLE. REFER TO THE USER MANUAL FOR RECOMMENDED FUSE SIZES. TRACTION DRIVE BATTERY VOLTAGES AND CURRENTS ARE LETHAL! ALTHOUGH THE CONNECTOR SYSTEM UTILIZED IS CONSIDERED FINGER SAFE, THE USER MUST DISCONNECT THE BATTERY BEFORE TOUCHING OR REMOVING THE BATTERY FUSES OR REMOVING THE DC OUTPUT CABLE FROM THE CHARGER. FAILING TO HEED THIS WARNING MAY RESULT IN INJURY OR DEATH. IMPROPER SETUP AND USE OF THIS CHARGER CAN RESULT IN DAMAGE TO THE BATTERY AND OTHER ASSOCIATED SYSTEM. CURRENT WAYS WILL NOT BE RESPONSIBLE FOR IMPROPER USE OF THIS DEVICE.
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The Current Ways BC-Series of high voltage traction battery chargers are designed with safety first in mind. Lethal voltages exist on the input and output connectors, cables, and batteries in typical systems. To fully utilize all the safety and operational features of the charger, please carefully read all the operation instructions described in this manual, and retain this manual for future reference. Updated manuals and other related documents can always be downloaded from the Current Ways website www.CurrentWays.com.WHATS IN THE BOX: Besides the charger, cables that were ordered with the charger, a CD ROM with this manual and the VIP Control Software for operation of the charger, and other options will be contained within the shipping container.
UNDERSTANDING THE LABEL: The charger has a detailed label with the various particulars for the model printed upon it. A brief guide to reading this label follows:
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Frequently Asked Questions: 1. The charger will operate out of the box only with one industry standard BMS protocol; all other modes of operation require setup and/or control by the Current Ways VIP Control Software GUI program supplied. Read this manual in its entirety before operating or applying power to the charger. 2. Verify your batterys charging requirements and setup the charger appropriately. Never exceed your batterys maximum charging voltage. Current Ways is not responsible for any battery or system damage due to improper use of the charger. 3. All connectors must be present for the charger to operate, as there are interlocks in the AC Input, DC Output, CAN Communications, and Fan/Pump/LED connectors. 4. The charger can be mounted in any plane as long as fresh cooling air can enter and exit (60 CFM) from the air cooled model, and sufficient cooling liquid (4 liters/min) is circulated through the liquid cooled model. 5. The charger exterior will become warm during operation. In the case of a failure in the coolant system, the charger will become very hot and could possibly cause burns if touched. Keep hands and materials away from the charger when in operation 6. The charger does not have internal DC output fuses. Proper installation of appropriate output fuses is required for safe operation. 7. If you are unsure of any point of the installation and use, please contact the factory for assistance before installing or operating this charger. 8. Do not remove any covers or panels on the unit under any circumstances. There are no user serviceable parts inside. Opening the unit will expose potentially lethal voltages and will also result in damaging the IP67 seals voiding the warranty. 9. Do not connect the unit to AC mains until a thorough inspection of the battery and control connections has been done. Battery voltages are lethal and Current Ways will not be responsible for any negligent use or damage. 10. Never operate the unit without appropriate grounding / earthing connections. 11. Use a GFI device in the AC mains to the charger. 12. Never overload the AC mains connection as this is a fire danger. 13. Always use appropriately sized AC mains conductors to the charger to prevent poor operation and fire danger. 14. Disconnect the charger from the AC mains when not in use. 15. If you are ever unsure of anything regarding the proper use of the charger, consult the factory before making a potentially damaging error!
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SECTION 2 Functional Descriptions of Charger Features
ENCLOSURE: The case of the BC-Series battery charger is sealed against the elements and is rated for IP67 operation; it is resistant to immersion in water to one meter for one half hour, so the unit can be mounted in relatively unprotected areas of the vehicle. All case components, connectors, fans, hardware, etc. are rated for temporary water immersion without water ingress to the electronics inside. The internal design is extremely shock and vibration resistant, with all components of substantial mass or thermal characteristics being fully supported and thermally connected to either the air or liquid cooled heatsinks, depending on the model. The CA10 model is air cooled (the fans are electrically isolated and immersable), and the CL20 model is liquid cooled (use of an aluminum compatible 50/50 water/glycol coolant mix is required).
MOUNTING: Six M6-1 machine threaded bosses are installed on the charger for mounting the unit to a flat surface within the vehicle or externally. For the air cooled versions, these bosses are on the electronics module cover:
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For the liquid cooled unit, the six M6 bosses are installed on the baseplate of the heatsink:
The length of the M6-1xN screws should be chosen so that between 4 and 6 mm of the screw tip protrudes into the mounting surface of the charger. An optionally available mounting plate can be attached using these bosses and to create a flanged style mounting system if desired. See the product family section in this manual for more detailed mounting drawings. Note: Do not exceed the recommended screw protrusion depth into the mounting bosses. Exceeding the recommended depth could cause breakthrough in the bosses that would compromise the watertight rating of the charger, or could potentially cause damage to the mounting point. OUTPUT CHARACTERISTICS: The BC-Series battery charger is capable of 3kW of constant output power in two voltage ranges; either 112-225V (Low range) or 225-450V (High range). The output range is selected at order time by indicating L or H in the 5th position of the model number - CA10L03 and CL20L03 models are internally set for the Low range, and the CA10H03 and CL20H03 are internally set for the High range. Output current below 112V on the low range is automatically restricted to 27A maximum down to near zero volts of output, and on the high range below 225V the current is automatically restricted to 13.5A maximum also down to near zero volts of output.
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CONNECTIONS TO THE CHARGER; DC OUTPUT: DC output is via a 2 pin Tyco 280 automotive style sealed interlocked touchproof connector on the I/O panel. The separately ordered DC output cables P/N 056156 have shielded conductors (at chassis potential), safety orange in color. The DC output cable must be plugged into the charger for operation. Interlocks built into the DC output cable connector and the two circular control connectors require that all be present for the charger to operate.
DC Cable Wiring Breakout; Black BATTERY NEGATIVE, Red BATTERY POSITIVE, Sheilds CHASSIS / EARTH Use of a disconnecting contactor to the battery is highly recommended, so that the charger is isolated from the battery during drive time. The DC output connector is interlocked, so upon removal, the power output stage of the charger is disabled. Bleed down of the internal output storage capacitors upon removal of the connector from the chassis meets UL2202 specifications. External DC fuses must be used in each lead to the storage battery these fuses must be located as close to the battery as possible to protect battery and charger in case of a short in the DC output cabling or a reversed polarity connection. A reverse polarity diode is installed internally to the charger, and will cause the external output fuses to blow should the charger be connected reverse polarity. There are no internal output fuses within the charger. Fuses should be rated for DC operation at 600V - type KLKD is highly recommended, but others are available with similar ratings. Amperage ratings of 30A for the low voltage range unit and 15A for the high voltage range unit are recommended. If paralleled chargers are used, it is highly recommended that each DC output cable be used with a set of fuses at the battery, as shown in the illustration below:
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Typical Output Fuse Wiring with Three Paralleled Chargers CONNECTIONS TO THE CHARGER; UNIVERSAL AC INPUT: AC input is via a 3 pin Tyco 280 automotive style sealed touchproof connector on the I/O panel. The separately ordered AC input cable P/N 056155 is shielded (chassis connected) and safety orange in color. Standard line colors are marked on the cable; black for line hot, white for line neutral or second hot, and green for earth/chassis. The user must connect an appropriate AC plug to the cable. The charger has internal 20A input fuses on both sides of the line, and these fuses will not blow during normal operation, and are present to protect against some sort of catastrophic internal failure. These fuses are NOT field replaceable. If the fuses clear, the charger must be returned to factory for repair
AC Wiring Breakout; Black LINE, 2/White NEUTRAL/LINE, 1/Green EARTH, Sheild CHASSIS / EARTH The AC input voltage range is nominally 100 to 240VAC single phase, 50-60 Hz. The AC input module is power factor corrected (PFC) to present a minimum of harmonic energy to the power source for lowest noise and lowest interference with nearby electrical equipment and the best power efficiency. The PFC function is extremely good, with total harmonic distortion typically less than 3%, and power factor typically greater than 0.99.
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Input current is automatically limited to 12A at power up and when the input voltage is below approximately 150VAC; this is so that the unit can be used with a standard 115VAC 60Hz 15A wall socket. Output power will be automatically controlled to limit the input current to this level. The maximum output power that is typically available when operating on nominal 120VAC lines is between 1000 and 1200W. A brown-out condition, where the line dips below 100VAC will result in the charger reducing its power to keep the current at or below 12A. An automatic fault reset will occur every 30 minutes of operation to correct for any line (or load) abnormalities that cause a power output decrease such as this. The user can change the below 150VAC input setting of 12A to a maximum of 16A when a 20A 115VAC nominal line connector is available. Doing this will allow higher output from a nominal 120VAC 20A outlet of between 1300 and 1500W. This change is accomplished by selecting a setting option on the available VIP Control program GUI. This must only be done if the outlet is rated for and has circuit breaker protection for 20A. When the AC input voltage is above approximately 150V, the input current is automatically restricted to 16A, so the full power benefit of a nominal 208 or 230VAC 20A source can be used. The full 3kW of output power is available when the AC line is above 208VAC. Below that, the unit will automatically reduce output power slightly to maintain the input current to 16A (depending on line voltage). In the case of a fault, a brown out or a black out condition that causes the charger to disable its output, the charger will attempt to restart every 30 minutes. This automatic timed retry applies to any fault; output, input, thermal, etc. On the occurrence of a fault, the charger will reduce power or disable its output, wait the 30 minute interval, and try again. If the causal fault has been cleared, charging at the original parameters will resume. This feature may prevent a minor fault event which causes the charger to shut down and potentially leaving the user stranded with a discharged battery, by attempting to restart the charge cycle. CONNECTIONS TO THE CHARGER; FAN CONNECTOR (AIR COOLED): The connector panel houses a 5 pin female contact connector for the function of +12V out to fans (or cooling liquid pump control), external status indicating LED, and interlock function. Current Ways cables must be used to preserve the warranty. Please consult the factory for details on custom cable configurations to meet your specific requirement. Using cables other than those supplied by Current Ways will compromise the IP67 rating, voiding the warranty.
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Pin 1 has a +12V chassis referenced output capable of up to 1A (not for general purpose, this is an isolated current limited output). Pin 2 is a switched return for the thermostatically controlled fan function, described elsewhere. Pin 3 is a controlled return for an external LED for charger status indication, described elsewhere. This external LED can be powered by the Pin 1 12V source, or an external source of 12V. Pins 4 and 5 are for interlock function CONNECTIONS TO THE CHARGER; COMMUNICATIONS CONNECTOR: The connector panel houses a 9 pin male contact connector for the function of CAN communications, status relay contacts, J1772 pilot tone and proximity connections, and interlock. Current Ways cables must be used to preserve the warranty. Please consult the factory for details on custom cable configurations to meet your specific requirement. Using cables other than those supplied by Current Ways will compromise the IP67 rating, voiding the warranty.
CAN Communications Cable 056160 CAN communications signals are on Pin 1 for CAN + (high) and Pin 2 for CAN (low). These signals are electrically isolated from chassis and all other signals within the charger. The CAN interface complies with the current CAN 2.0 B, 500 kHz communications standards. Other bit rates can be programmed if desired via the available VIP Control software interface. Note that no CAN terminating resistances have been placed within the charger. The choice of terminating resistor location can be very sensitive and is installation dependent, and may require some experimentation on the part of the user. Typically a 120 ohm terminating resistor should be placed at the last physical location of CAN connections in a string of devices on the bus. An isolated 2A rated normally open relay closure is available on Pins 3 and 4. These are cold relay contacts only they do not supply power. They can be used to control an external 12V source feeding for example a master BMS or other devices. These relay contacts close upon booting up of the internal microprocessor after AC power is applied, and stay closed as long as
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the charger is available and ready to charge. The contacts will open during a delayed charging start, as with programmed time of day charging (for example when a delay of charging is desired until cheaper time of day electric rates is available). Pins 5, 6, and 7 are related to SAE J1772 charging station controls. Pin 5 is the pilot tone input. Pin 6 is the pilot tone and proximity signal return (chassis connected). Pin 7 is the proximity signal input. A full functional description of these signals is described elsewhere in this manual, and also in the SAE publication for J1772 Standards dated January 2010. Pins 8 and 9 are for interlock function and the mating connector must have an internal jumper between the two pins. CONNECTIONS TO THE CHARGER; GROUNDING LUG: A M4-.7 threaded stud is on the connector panel that must be used to securely connect the chassis of the charger to the frame of the vehicle or service earth, depending on where the charger is installed. COOLING Air Cooled Chargers: The CA10x03 units are air cooled by means of internal fans impinging forced air upon a finned heatsink. Two fans mounted on the heatsink need a source of free air; mounting the unit in a closed space will result in overheating and poor functional performance. Allow free space of at least 6 inches on both the inlet (connector side) and outlet of the heatsink. The fans are protected against water splash or immersion, but care must be used to protect them against dirt or other solids clogging the heatsink. Operation up to 65C ambient air is possible; but best performance will be obtained by significantly lower temperatures for inlet air. The built in fans are thermostatically controlled and will activate when the chargers internal temperatures are approximately 45C. No user interaction is required, other than to make sure that fresh air is available and the inlet and outlet for the fans and heatsink are not blocked. COOLING Liquid Cooled Chargers: The CL20x03 units are liquid cooled by means of forced liquid through the cold plate. A 50/50 mix of aluminum compatible anti-freeze and water should be used; plain water will cause contaminant buildup within the cold plate. Approximately 4 liters per minute of flow is needed for best cooling and low pressure drop across the cold plate. With this flow rate, there will be approximately 3psi pressure drop across the cold plate during operation; the maximum inlet pressure must be limited to 15 PSI. Fittings are supplied to attach standard 3/8 rubber hose for inlet and outlet cooling liquid. Due to the high efficiency of the liquid cooling system, operation is possible with up to 75C ambient inlet cooling liquid temperature. Note: the maximum static inlet pressure must be limited to 15 PSI. This is to preserve the integrity of the seals in the cold plate and internally to the charger. The Pump/LED accessory cable P/N 056158 allows for use of 12V external pump (with 1A max current draw) to be powered by the charger. This external pump will be thermostatically controlled by the charger; whenever the internal temperature of the charger approaches 45C, the 12V return on the pump cable will connected to the 12V return, turning on the pump. If your particular pump requires more than 1A, the pump output from the charger can be used to activate 12 of 43
an external relay, effectively thermostatically controlling the external pump. See the Pump/LED cable drawing for connection details later in this manual. INTERNAL MODULE DESCRIPTIONS: A pair of functional modules, one for the AC input or PFC, one for the DC output or DCDC converter, is utilized within the charger. All components of mass are potted, clamped, or otherwise secured to the baseplate for rigidity, shock and vibration tolerance. All connectors must be in place for the charger to operate via an interlock system built into each connector. SINGLE UNIT OPERATION: A single 3kW charger is a complete high voltage charging system and can be vehicle or externally mounted for operation with a traction battery. All connections must be made as described. The charger is controlled by the CAN bus interface. See other sections of this manual for the messaging information needed to program a controller. Convenient manual, automatic stage charging, and BMS control options are standard in the chargers control programming, and can be setup and monitored via the available Windows based VIP Control software program from Current Ways. MANUAL OPERATION: Fully manual operation is setup and controlled via the VIP program. It is a graphically based user interface program, and allows full control and monitoring of the charger parameters. Voltage, current, power, enable/disable, charge progress and fault reporting, as well as time of day and a few other features are available on the on the GUI screen. STAGED CHARGING: This mode is setup via the available Windows based VIP Control GUI program to set up the storage batterys charging characteristics. Duration in stage, voltage, current, power, charging stage rests, time of start, time of completion, etc. can be programmed in up to 5 complete charging stages. This feature is most useful where a BMS system is not utilized, such as with flooded cell based or AGM style battery systems, as well as other battery technologies. BATTERY MANAGEMENT SYSTEM (BMS) CONTROLLED: The BMS (utilizing LHVs published CAN message protocols) is in full control of the charger voltage and current settings at all times. The BMS monitors and understands each cell state and commands the charger to output the appropriate current levels to properly charge the battery in bulk, equalization, or balancing modes. Several popular BMS technologies are supported, with and without the use of a master BMS system module. PARALLELING OF CHARGERS: The chargers are designed so that parallel operation for multiples of 3kW of output power is possible and simple to implement. Simple paralleling of the AC input connections, the DC output connections, the CAN + and CAN- connections is all that is physically required to put multiple units into parallel operation. Each unit is Voltage, Current, and Power controlled enabling this simple paralleling operation. Up to 20 chargers can be paralleled in this manner, for up to 60kW of charging power. In parallel operation, power up of the multiple units should be done simultaneously. The units will communicate with each other over the CAN bus, and one unit will assume the role of master, and the other units will become slaves. The master unit will then communicate with 13 of 43
the host, so the host essentially a single charger capable of the power levels of the paralleled units. The slave units will be in communication with the master, not the host, and will take commands directly from the master. When full power levels of the paralleled devices are demanded, all units will deliver power into the battery as classical current sources. When power levels less than the number of chargers is demanded, slaves will be shut down in sequence, to the point where only the master will deliver power if the demand is less than what one charger can deliver. This method of control has been implemented to maximize line power utilization efficiency. An example of this would be during full charge under BMS control (master and slaves delivering full power), then low power balancing (only master active and delivering low power). For AC power, each charger requires up to 16A for full power operation above 208VAC. Sizing of source, breakers and wiring must accommodate these current levels. Typical home installations will be single phase, in which case all line, neutral, and ground connections to each charger are simply paralleled (no diagram shown). Where available, 3 phase connections can be utilized. Some simplified typical 3 phase connections are shown below; note that most home (if 3 phase equipped) and commercial wiring utilizes Wye connections.
Three Chargers on Wye connection
Three Chargers on Delta connection
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SECTION 3 - CA10X03 and CL20X03 Product Family Air Cooled Version (CA10x03 models)
Front View
Connectors
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Front Dimensional View
Side Dimensional View
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Mounting
Pattern View
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Liquid Cooled Version (CL20x03 models)
Front View
Connectors
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Front Dimensional View
Top Dimensional View
Side Dimensional View
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Liquid Cooled Mounting View
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AC INPUT CABLE 056155
DC OUTPUT CABLE 056156
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PUMP/LED CABLE 056158
COMMUNICATIONS CABLE 056160
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J1772 CTRL CAN BUS, I2C BUS 4 AC CURR SNS AC VOLT SNS PFC T SNS DCDC T SNS 6
FAN/PUMP/LED CONN 056152 ISOLATION AND J1772 uP 4 30 PFC CTRL ENABLE / FEEDBACK DCDC CTRL
uP CTRL
5
COMMS CONN 056161 BIAS SUPPLY 8 4
9
AC INPUT CONN 056150 3
400V BUS
GATE CTRL/PRI I FB
400V FILT
PRI 1
CHARGER INTERNAL BLOCK DIAGRAMGATE DRIVE
PRI 2
23 of 432 PFC A CTRL PFC B CTRL AC LINE FILT/ 20A FUSES PFC BOOST STAGE
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DC-DC CONV STAGE DC OUTPUT CONN 056149 4
3
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SECTION 4 Specifications
WARNING: TRACTION DRIVE BATTERY VOLTAGES AND CURRENTS ARE LETHAL! FAILURE TO COMPLY WITH THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH. DO NOT REMOVE ANY OF THE COVERS ON THE CHARGER. DOING SO WILL EXPOSE POTENTIALLY LETHAL VOLTAGES AND VOID THE WARRANTY. THERE ARE NO FIELD SERVICEABLE PARTS INSIDE. END USER IS REQUIRED TO INSTALL FUSES ON THE DC OUTPUT CABLE, BOTH POSITIVE AND NEGATIVE, AS CLOSE TO THE BATTERIES AS POSSIBLE. REFER TO THE USER MANUAL FOR RECOMMENDED FUSE SIZES. TRACTION DRIVE BATTERY VOLTAGES AND CURRENTS ARE LETHAL! ALTHOUGH THE CONNECTOR SYSTEM UTILIZED IS CONSIDERED FINGER SAFE, THE USER MUST DISCONNECT THE BATTERY BEFORE TOUCHING OR REMOVING THE BATTERY FUSES OR REMOVING THE DC OUTPUT CABLE FROM THE CHARGER. FAILING TO HEED THIS WARNING MAY RESULT IN INJURY OR DEATH.
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AC Input: Voltage: 100-240VAC nominal line, single phase, 50 to 60Hz Current: 16A maximum >150VAC input, 12A maximum 0.97 at 1kW output Harmonics: designed to meet EN61000-3-2, FCC Part 15 Class B Efficiency: >90% at 3kW output; >85% at 1kW output Leakage current to chassis: 20mS above 90VAC Inrush current:
