Testing a forklift or industrial battery charger without taking a battery out of service calls for an electronic load that behaves like a battery at the charger's voltage and absorbs its full current. The ACBX does exactly that: it simulates a 12, 24, 36, 48, 72 or 80 V battery with fine voltage adjustment, absorbs up to 200 A with an adjustable limit, works at constant voltage and constant current with a high-frequency IGBT regulator and traces the charger's real charging curve in 1 minute; it can also discharge batteries above 24 V.
Testing the operation and performance of truck loaders has been a constant problem for the technical services of these equipments. To be able to perform this test they must have at least one battery. This is a problem if the technician has to test the chargers while the trucks are in service.
Furthermore, using a battery makes it impossible to test the full charge curve quickly, and it is complicated to adjust the discharge options and check all functions under different working conditions. The equipment is an electronic device, designed to test battery chargers of any voltage and power. It simulates the behaviour of a battery during the charging process and allows the technician the possibility to check the performance of any charger in a fast, safe and accurate way. The equipment eliminates the need to connect a battery to the charger in order to test it; it is simple and flexible. It can also be used to discharge batteries (over 24V) and for other purposes. On the front panel of the equipment you can find the following items:-Digital Voltmeter-Analogic Amperemeter-Test Voltage Selector (12-24-36-48-72-80 V)-Voltage Fine Tuning Potentiometer -Current Selection Potentiometer (0-200A)
High frequency IGBT regulator, which allows the equipment to work with constant current and voltage.
Robust construction for maximum reliability in all industrial applications.
Compact and portable design. With wheels for easy movement.
Intelligent protection system (includes soft start protection against polarity reversal and overheating)
Programmable digital panel, controlled by microprocessor.
It can be used to test chargers of any type of current and voltage. It can be used to discharge batteries of any voltage and capacity (over 24V).
Digital voltmeter and analog ammeter
CEcCSAus Certificate
The usual way to use the equipment when testing a charger is as follows:
The user selects the battery voltage to be simulated, using the appropriate potentiometer, while the digital display shows the current value. An independent potentiometer is available to select the maximum current that the equipment can absorb.
The user connects the charger to be tested to the input of the equipment. The charger controller will detect that a battery is connected and start the charging process;
The equipment keeps the voltage constant at the selected value, while the analog ammeter indicates the current supplied by the charger. If the current tends to exceed the set maximum value, the equipment increases the voltage to limit the current.
The user can modify the current and voltage freely, in order to simulate the behaviour under any load conditions. It is possible to get the real curve of the charger in 1 minute.
Special features, for maximum reliability and flexibility.
Self-testing of power electronic circuits under load, with automatic stop in case of failure.
Thermal protection of all electronic components and the resistor bank: in case of overtemperature (e.g. problems with fans or blocked air ducts) the device switches to stand-by mode.
Double casing for maximum thermal insulation: during operation, the external part of the casing is kept at a low temperature (maximum temperature rise <10 °C).
Hard wheels, with ball bearings, metal frame and rubber covers.
ACBX key data
- Simulated battery voltages: 12, 24, 36, 48, 72 and 80 V by selector, with a fine-adjustment potentiometer; the value is read on the ACBX digital voltmeter.
- Current: limit adjustable from 0 to 200 A with an independent potentiometer; the current delivered by the charger is read on the analog ammeter.
- Regulation: high-frequency IGBT regulator for constant-voltage and constant-current operation; if the current tends to exceed the set limit, the ACBX raises the voltage to limit it.
- Charging curve: voltage and current can be changed freely to simulate any charging condition, and the charger's real curve is obtained in 1 minute.
- Battery discharge: the ACBX also discharges batteries above 24 V of any capacity.
- Protection: soft start, reverse-polarity and overheating protection; self-test of the power circuits with automatic stop on failure, and stand-by mode if the components or the resistor bank overheat.
- Supply and construction: single-phase 85-135 or 180-250 V AC, 50/60 Hz, 250 W maximum power; 325 x 630 x 570 mm (570 mm high), 2 mm steel cabinet with double casing (outer temperature rise below 10 °C), forced ventilation and 4 wheels.
- Certification: CE and cCSAus.
Frequently asked questions
Can I test a forklift charger without connecting a battery?
Yes. The ACBX simulates a battery: the charger controller detects that a battery is connected and starts charging, while the ACBX holds the selected voltage, from 12 to 80 V, and absorbs up to 200 A. Chargers can be tested while the forklifts stay in service, and their real curve is obtained in 1 minute.
Can the ACBX also discharge batteries?
Yes. It discharges batteries above 24 V of any capacity, with the current limit set on the potentiometer up to 200 A and the current read on the analog ammeter.
