Gysflash 8.48 Pl-E - Welding machine GYS - Free user manual and instructions

USER MANUAL Gysflash 8.48 Pl-E GYS

Line drawing of a rectangular electronic enclosure with ventilation slots and mounting tabs (no text or symbols)

FR	02-06 / 37-44
EN	07-11 / 37-44
DE	12-16 / 37-44
ES	17-21 / 37-44
RU	22-26 / 37-44
NL	27-31 / 37-44
IT	32-36 / 37-44

GYSFLASH 8.48 PL-E

DESCRIPTION GÉNÉRALE

Liquide/Gel	AGM	Liquide/Gel-Traction AGM-Traction
57.2 V	58.8 V	57.6 V	58.8 V

Liquide/Gel	AGM	Liquide/Gel-Traction AGM-Traction
57.2 V	58.8 V 57.6 V	58.8 V

Étape 1 : Analyse

ANOMALIES, CAUSES, REMÈDES

CONDITIONS DE GARANTIE

The Gysflash 8.48 PL-E is an on-board charger for recharging the traction batteries found on scrubber-driers or forklift-trucks, service batteries found in marine, heavy goods vehicles or buses, and for batteries used in electromobility-related transport equipment (bicycles, scooters, golf carts, etc.). It is suitable for charging most lead-acid batteries (liquid/gel, AGM) and lithium batteries (LiFePO4, lithium-ion, etc.).

This charger is ideal for charging and maintenance of:

• 48 V (24 cells in series) lead batteries (Liquid/Gel, AGM) ranging from 15 Ah to 160 Ah.
  • 48 V LFP batteries (15 cells in series) ranging from 8 Ah to 160 Ah.
• 48 V LFP batteries (16 cells in series) ranging from 8 Ah to 160 Ah.
  • 48 V «standard» lithium-ion batteries (13 cells in series)
  • 48 V «standard» Lithium-ion batteries (14 cells in series)

CONNECTIONS AND WIRING

GYS Press Liquid ADR LiFePb Pb Lithium 220-240 V - 300 W (50/60 Hz) 12 V ≈ 18 A Pb : 36 ▲ 270 Ah Lithium : 18 ▲ 270 Ah OPEN A B 1 1 3 2 3

Connectivity			Wire
			Type Section
A		POWER SUPPLY 230~1. PHASE2. NEUTRAL3. N.C.4. EARTHWürth Electronik connector reference number691344510004	H05RN-For equivalent	min:3G0.75 mm2max:3G2.5 mm2
B		48 V BATTERY CONNECTION1. SIGNAL power present (+48/2mA ) SIGNAL présence secteur(+48/2mA )————2. NEGATIVE CONNECTION - 48 V————3. POSITIVE CONNECTION + 48 V————Würth Electronik connector reference number691344510003	H01V-Kor equivalent	Battery (2/3)2.5 mm2orAWG14
				Signal (1)max 2.5 mm2

• Fit the appropriate cable crimps 1 for the cross-section of each cable.

• Screw the crimps into the connector as shown in the above connection diagrams for connectors A and B.

• Clip the connectors into their sockets on the board.

• Pass the cables through the rubber grommets 2 and secure them in the metal plate.
• Fix the clamps 3 in such a way that the wired sections inside the casing are not under tension (M3x20 - TORX 10 screws).

CALIBRATION CABLE FUNCTION

This procedure is used to calibrate the charging cables on the unit, so that the charger can compensate for the voltage drop caused by the cables as effectively as possible. It is strongly recommended that this procedure is carried out when the charger is first installed and whenever the cables are modified or changed.

1. Enter one of the lead charging modes.
2. Short-circuit the 2 clamps of the cable (do not short-circuit a battery).
3. Unplug the product from the mains and wait until the charger switches off.
4. Press and hold the Ⓞ button while plugging in the mains plug until the 📊 indicator light comes on.
5. OK on: the calibration was carried out successfully.
6. ⚠ on: If the calibration fails, remove the mains plug and repeat the process.
7. Unplug from the mains until the charger switches off.

CHARGE MODES

To modify the charging mode settings, you must:

1. Unlock the charger by pressing the ⬤ button for 3 seconds.

2. Select the mode by pressing the ● button again.

3. Lock the mode by pressing the 📄 button again for 3 seconds (or wait 10 seconds without pressing the button).

Pb

Lead-acid/gel charging mode (57.2 V/8 A):

Mode for charging 48 V lead/liquid batteries from 15 Ah to 160 Ah. 7-step automatic charging cycle.

Pb

Lead Liquid/Gel-Traction charging mode (57.6 V/8 A):

Mode for charging 48 V lead/liquid batteries from 15 Ah to 160 Ah. 7-step automatic charging cycle.

Pb

Lead-acid AGM charging mode (58.8 V/8 A):

Mode for charging 48 V lead/AGM batteries from 15 Ah to 160 Ah. 7-step automatic charging cycle.

Pb

Lead AGM-traction charging mode (58.8 V/8 A):

Mode for charging 48 V lead/AGM batteries from 15 Ah to 160 Ah. 7-step automatic charging cycle.

LiFePO4

Lithium Iron Phosphate charging mode 54.0V/15 cells (54.0 V/8 A):

Mode for charging 48 V LiFePO4 lithium batteries from 8 Ah to 160 Ah. 6-step automatic charging cycle.

LiFePO4

Lithium Iron Phosphate charge mode 58.0V/16 cells (57.6 V/8 A):

Mode for charging 48 V LiFePO4 lithium batteries from 8 Ah to 160 Ah. 6-step automatic charging cycle.

Li-ion

Lithium-ion charging mode 54.0V/13 cells (54.0 V/8 A):

Mode for charging 48 V lithium-ion batteries from 8 Ah to 160 Ah. 6-step automatic charging cycle.

Li-ion

Lithium-ion charge mode 58.0V/14 cells (58.1 V/8 A):

Mode for charging 48 V lithium-ion batteries from 8 Ah to 160 Ah. 6-step automatic charging cycle.

UVP wake-up function

Some Lithium batteries incorporate a UVP protection (Under Voltage Protection) which disconnects the battery in case of deep discharge. This protection prevents the charger from detecting the battery. To enable the Gysflash 8.48 PL-E to charge the battery, the UVP protection must be deactivated. To do this, activate the UVP Wake-up function on the charger. Once activated, this function will run a battery wake-up procedure every 5 minutes.

Procedure for activating or deactivating the UVP wake-up function:

1. Enter one of the Lithium charging modes.
2. Unplug the product from the mains and wait until the charger switches off.
3. Keep the ⬤ button pressed while connecting the mains plug.

- If the Li-ion, LiFePO4 and OK LEDs are lit, the UVP wake-up function is active.

- If the Li-ion, LiFePO4 and LEDs are lit, the UVP wake-up function is deactivated.

1. Unplug the mains plug until the charger switches off. The settings will be saved.

Tip for checking whether the UVP wake-up function is active:

• Restart the product.
• If all the LEDs light up at the same time for one second, the UVP wake-up function has been activated.
• If the LEDs illuminate one after the other, the UVP wake-up function is deactivated.

In the case of UVP protection on a lithium battery, it is recommended that all the consumers on the battery are removed so that the UVP wake-up function works correctly.

- Lead-acid charge curve:

The Gysflash 8.48 PL-E features an advanced 6 (or 7) stage charging curve that optimizes battery performance. This automatic charge curve is adapted to all types of lead-acid batteries (liquid/GEL and AGM) to ensure the optimal charge level for the battery. This curve is fully compatible even when there are consumers present on the battery.

graph LR
    A["1: Analyse Récupération Désulfatation Charge Absorption"] --> B["2: Max 12h<1s Max 8h"]
    B --> C["3: Solute Plateau"]
    C --> D["4: Traction Si option activée"]
    D --> E["5: 2h - 4h 1h - 4h No limit"]
    E --> F["6: Maintien de charge"]
    F --> G["7: Final state"]

Step 1: Analysis

Analysis of the battery status (level of charge, reverse polarity, incorrect battery connected...)

Step 2: Recovery (3 A)

Recovering damaged elements following a prolonged deep discharge.

Step 3 : Desulphation (62 V)

Battery desulphation process.

Step 4 : Charge (8 A)

Fast charge at maximum current to reach 80% charge level.

Liquid/Gel AGM	Liquid/Gel-Traction	AGM-Traction
57.2 V	58.8 V 57.6 V	58.8 V

Step 5 : Absorption

Constant voltage charging to bring the charge level up to 100%.

Liquid/Gel AGM	Liquid/Gel-Traction	AGM-Traction
57.2 V	58.8 V 57.6 V	58.8 V

Step 6 : Traction (62 V)

If the traction option has been selected, the charger will apply an additional current to create gas, which will mix the electrolyte and recondition the battery cells. During this phase, the battery may lose some water.

Step 7: Maintenance charge (54 V)

Battery charge level maintained at maximum.

• Lithium charging curve:

The Gysflash 8.48 PL-E uses an advanced 6-stage lithium charging curve to ensure optimum performance from the battery. This automatic charge curve is adapted to all types of Lithium batteries to provide the optimal level of charge for your battery. This curve is fully compatible even when there are consumers present on the battery.

Step 1: Analysis

Battery status analysis (level of charge, inversion of polarity, incorrect battery connected, etc).

Step 2 : Charge (8 A)

Fast charging at maximum current up to U1

LiFePO4 54.0 V Li	FePO4 58.0 V Li-ion	54.0 V Li-ion 58.0 V
51.8 V	55.2 V	53.3 V	57.4 V

Step 3 : Absorption

Charging at a constant voltage U1 to bring the charge level to 98%.

Step 4 : Completion

Gradual increase in voltage at U2 at reduced current to reach 100% charge level.

LiFePO4 54.0 V LiFePO4 58.0 V Li-ion 54.0 V Li-ion 58.0 V
54.0 V	57.6 V	54.0 V	58.1 V

Balancing the battery cells.

Step 6 : Floating

Maintains the battery charge level at maximum with a maintenance charge every 2 months.

- Protections:

The GYSFLASH 8.48 PL-E has a set of devices protecting it against short-circuits and polarity reversals. It has an anti-spark feature which prevents sparks whilst connecting the device to the battery. This charger has double insulation and is safe to use while the battery is connected to in-vehicle electronics.

The GYSFLASH 8.48 PL-E has a built-in temperature sensor that automatically adapts the charging current to suit the ambient temperature, so as to prevent the internal electronics from overheating.

DEFECTS, CAUSES, AND SOLUTIONS

	Troubleshooting	Causes	Solutions
1	The⚠ indicator flashes.	Polarity reversalBattery voltage too highBattery in short-circuit	Check that the charging cables are properly connectedCheck that it is a 48V battery.
2	The⚠ indicator is on.	Charging failure, battery not recoverable	Change the battery and press the select buttonto restart charging
3	The⚠ LED remains lit even after the selection button 🔑 is pressed.	Thermal protection	Ambient temperature is too high (>50°C), cool the room and let the charger cool down.

WARRANTY CONDITIONS

The warranty covers any defects or manufacturing faults for two years from the date of purchase (parts and labour).

The warranty does not cover:

• Any other damage caused during transport.
• The general wear and tear of parts (i.e. : cables, clamps, etc.).
• Incidents caused by misuse (incorrect power supply, dropping or dismantling).
• Environment-related faults (such as pollution, rust and dust).

In the event of a breakdown, please return the item to your distributor, along with:

- a dated proof of purchase (receipt or invoice etc.).

- a note explaining the malfunction.

Lademodus Lithium-Ion-Batterie 54,0 V/13 Zellen (54,0 V/8 A):

LiFePO4 54,0 V Li	LiFePO4 58,0 V Li-Ion	54,0 V Li-Ion 58,0 V
54,0 V 57,6 V	54,0 V 58,1 V

Etapa 1: Análisis

LiFePO4 54,0 V Li	FePO4 58,0 V Li-ion	54,0 V Li-ion 58,0 V
51,8 V 55,2 V	53,3 V 57,4 V

Paso ③: Absorción

LiFePO4 54,0 V Li	LiFePO4 58,0 V Li-ion	54,0 V Li-ion 58,0 V
54,0 V 57,6 V	54,0 V 58.1 V1 V

LiFePO4 54.0 V	LiFePO4 58.0 V	Li-ion 54.0 V	Li-ion 58.0 V
51.8 V	55.2 V	53.3 V	57.4 V

Этап 3 : Поглощение

Stap 1 : Analyse

Technical line drawing of a rectangular enclosure with a 80 mm height dimension label (no other text or symbols)

25 mm 65 mm 162,7 mm 110 mm Ø 5 mm

MOUNTING / WANDBEFESTIGUNG / MONTAJE / СБОРКА / MONTAGE / MONTAGGIO

1 vis non fournies / screws not supplied

Diagram showing two mechanical components with a downward arrow indicating motion, no text or symbols present

3 M5 x TORX 25

4 vis non fournies / screws not supplied

5 Consulter et réaliser la partie sur la connectique et câblage avant de passer à l'étape 6. --- Consult and complete the section on connectors and wiring before proceeding to step 6. --- Vor dem Übergang zu Stufe 6 ist der Abschnitt zu Anschlüssen und Verkabelung umzusetzen. --- Consulte y complete la sección de conectores y cableado antes de proceder al paso 6. --- Обратитесь к разделу «Разъемы и проводка», прежде чем перейти к шагу 6. --- Raadpleeg en vul het hoofdstuk over connectoren en bedrading in voordat u verder gaat met stap 6. --- Consultare e realizzare la parte sulla connettività e cablaggio prima di passare alla tappa 6.

Pure diagram of a mechanical or electrical component with no text, numbers, or symbols

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FR EN DE ES RU NL IT

1	Bouton de sélection	Selection button Auswahltaste		Botón de selección	Кнопка выбора Keuzeknop Tasto di selezione
2	Type Pb-Liquide/ GEL	Pb/GEL type	Typ μ Blei-Säure/nass	Tipo Pb/GEL	Tin Pb/GEL Type Lood/GEL	Tipo Pb/Liquido
3	Type Pb/AGM Pb/AGM type		Typ Blei-Säure/AGM	Tipo Pb/AGM	Tin Pb/AGM Type Lood/AGM	Tipo Pb/AGM
4	Option Traction Type Pb	Pb Traction Type	Typ Pb Traktion	Tipo Pb Tracción	Tin Pb Traction	Type Lood Tractie	Tipo Pb Trazione
5	Option 54.0 V ou 58.0 V - Type Lithium	Option 54.0 V or 58.0 V - Lithium type	Option 54,0 V oder 58,0 V - Typ Lithium	Opción 54,0 V o 58.0 V - Tipo Litio	54,0 Выбор или 58,0 B - Tin Lithium	Optie 54,0 V of 58,0 V - Type Lithium	Opzione 54,0 V o 58,0 V - Tipo Litio
6	Type Lithium Li-Ion	Lead Traction type	Typ Lithium Li-Ionen	Tipo Litio-Ion	Tin Lithium Li-Ion	Type Lithium Li-Ion	Tipo Litio Li-Ion
7	Type Lithium LiFePO4	Lithium LiFeO4 type	Typ Lithium LiFePO4	Tipo Litio LiFeO4	Tin Lithium LiFeO4	Type Lithium LiFeO4	Tipo Litio LiFePO4
8	Voyant veille	Standby light	Kontrollleuchte Stand-by-Modus	Indicador de Standby	Индикатор режима ожидания	Standby lampje	Spia stand-by
9	Voyant charge en cours	Charge in progress indicator	Kontrollleuchte Ladevorgang	Indicador carga en curso	Индикатор заряда в процессе	Lampje	Spia carica in corso
10	Voyant Charge OK	LED Indicator Charge OK	Kontrollleuchte Ladung OK	Testigo Carga OK	Индикатор Зарядка OK	Laden OK	Spia Carica OK
11	Voyant défaut	Fault indicator	Kontrollleuchte Fehler	Testigo de fallo	Индикатор неисправности	Lampje storing Spia difetto

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