The Bassi Labs MVD Battery Charger is a sophisticated power conversion system designed for charging various types of batteries, including flooded lead-acid, GEL, AGM, and others, with a capacity range from 5Ah to 2500Ah. This charger incorporates advanced technology to ensure efficient and safe operation, featuring a hybrid system that combines a special isolation transformer with line frequency multiplication and a high-frequency switchmode converter based on IGBT technology. This design provides high electrical efficiency, near unity power factor, and very low output current ripple, making it suitable for multi-voltage, multi-current, and multi-application use.
Function Description:
The MVD Battery Charger operates by converting AC input into a regulated DC output suitable for battery charging. The system comprises a transformer, rectifier, chopper, and an IGBT Charge Controller, all managed by a microprocessor-based electronic board. The transformer reduces the AC input voltage, and the rectifier converts it to an unregulated DC voltage. The chopper, operating at high frequency, regulates the output voltage and current to the desired values, generating a perfectly constant output current with negligible ripple. The IGBT Charge Controller is the main control unit, managing the entire charge process. It includes a user interface (display, LEDs, and keyboard), a charge program memory (where all programmed parameters are saved), and a charge data logger (where the charge history is saved). A Power Regulation Board controls all power components and receives command signals from the IGBT Charge Controller, generating the high-frequency PWM control signal that drives the IGBT regulator.
The charger supports various charging programs, including IUIa, IUIU2, I1+I2+I3+I4+I5+I6, Voltage Refresh, and Voltage Refresh - Limited Current, each tailored for specific battery types and charging requirements. These programs allow for precise control over charging current, voltage, and duration, ensuring optimal battery health and longevity. The user can select from a range of programmable values for maximum voltage, maximum temperature, cable section, cable length, and language.
Important Technical Specifications:
- Battery Types: Flooded Lead Acid, GEL, AGM.
- Battery Capacity: 5Ah to 2500Ah.
- Input Voltage: Configurable for 208/240 VAC or 480 VAC (three-phase models).
- Operating Temperature: 0°C to 50°C.
- Storage Temperature: -20°C to 60°C.
- Relative Humidity: Less than 78%.
- Display: 2x20 character dot matrix display with four colored LEDs for status indication.
- Control Panel: Flat membrane keyboard for programming and data review.
- Communication: Equipped with a Communication Card for fleet management systems (DoctorFleet.com) and an Expanded Data-Logger Card with USB connection (optional).
- Safety Features: Anti-Arcing protection, reverse polarity protection, emergency stop, AC input black-out protection, and various alarm messages for abnormal conditions.
Usage Features:
The MVD Battery Charger is designed for user-friendly operation with a clear display and intuitive controls.
- Programming: Users can program the charger by accessing the "User Programming Mode" with a password. This mode allows modification of various parameters such as maximum voltage, temperature compensation, cable section, cable length, and language. The charger supports multiple steps (up to 6) for each program, allowing for complex charging profiles.
- Startup Sequence: The charger initiates with a main switch, followed by an automatic test of control circuits. The display shows "BASSI CHARGER MVD," "SYSTEM CHECK PLEASE WAIT," and "SYSTEM READY" before displaying current voltage, ampere-hour, and program number.
- Charge Cycle: Once connected to the battery, the charger displays the battery voltage, ampere-hour, and program number. The charging process begins by pressing the UP and DOWN buttons simultaneously. During the charge cycle, the display shows real-time information such as battery voltage, charging current, time of charge, and capacity returned.
- History Log (Optional): The charger stores a log of the last 250 charge cycles, which can be accessed via the display. Each record includes the number of the cycle, battery voltage at connection, battery voltage at the end of the charge, and the start date and time of the charge. This data can also be downloaded through DoctorFleet.com for comprehensive fleet management.
- Charge Termination Codes: The charger provides various codes indicating why a charge cycle terminated, such as "CHARGE COMPLETED," "MANUAL STOP," "BATTERY DISCONNECTED," and "EMERGENCY STOP."
- LED State Indicators: The charger uses a series of green and yellow LEDs to indicate the current state of the charge cycle. For example, a blinking first green light indicates "STEP CURRENT CONSTAT [I=K]," a blinking second green light indicates "STEP VOLTAGE CONSTAT [V=K]," and blinking first and second green lights indicate "STEP PAUSE / COOLING [PAU]." A fixed yellow LED indicates that the MVD auto limit the current.
- Manual Stop/Restart: Users can manually stop the charge process by pressing the UP pushbutton for five seconds. The charger can be restarted by pressing the UP button for five seconds.
- Desulphation/Recovery Function: The charger includes a desulphation/recovery function for overdischarged or unused batteries. This function can be activated and monitored via the display, showing the desulphation time and current.
Maintenance Features:
The MVD Battery Charger is designed for reliability and ease of maintenance, with several features to ensure long-term performance.
- Safety Precautions: The manual emphasizes critical safety precautions, including proper installation by qualified personnel, avoiding electric shock, ensuring adequate ventilation, using non-flammable materials, and checking cables and accessories regularly.
- AC Input Connection: The charger requires an adequate cable and plug, with disconnect switch and fuses. The AC input wires must be connected to the AC INPUT TERMINAL BLOCK, located on the internal panel, under the AC input contactor. Wires should be tightened with proper torque.
- AC Input Voltage Selection: The charger supports three-phase models configured for 208/240 VAC or 480 VAC. The selection is made using the appropriate terminal block and by adjusting the auxiliary transformer. Proper selection involves disconnecting the charger, removing plastic protection, removing three metal bars, placing metal bars in the required position, tightening nuts, applying plastic protection, and connecting the charger to the main supply. An important warning advises remembering to set BOTH the three metal bars AND the input wire on the Auxiliary Transformer, as incorrect settings can damage the charger.
- Temperature Compensation: The charger can be equipped with an optional battery temperature probe to dynamically adjust the charge voltage, compensating for the effect of temperature on the electrolyte. This feature is ENABLED or DISABLED via programming.
- Error Messages and Alarms: The charger provides various error messages and alarms to indicate abnormal conditions, such as "ERROR SETTING" for incorrect program parameters, "MAX VOLTAGE" or "TEMPERATURE TOO HIGH" if limits are exceeded, "BATTERY VOLTAGE TOO HIGH" if the battery voltage is higher than a maximum threshold, "AC INPUT BLACK OUT" if there is a power outage, and "REVERSE POLARITY PROTECTION" if batteries are connected with reverse polarity. An alarm will cause the input contactors to open, a buzzer to beep, and the display to show the cause of the alarm, with red LEDs blinking.
- Warranty: The manual states that any modification applied without written authorization of the manufacturer may generate unsafe operating conditions and will void the warranty.
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