Read, understand, and follow these safety rules and
AQHF12-15 MANUAL 250CT05
Read, understand, and follow these safety rules and operating instructions before
using this battery charger. Only authorized and trained service personnel shall be
permitted to operate or perform any maintenance or service. This manual should
be considered a permanent part of your machine and should remain with the
machine at all times. This manual is a supplement to the manuals and
Information provided by DYNO EUROPE BATTERY SUPPLIES N.V.(DYNO
EUROPE) If you have any questions call 00-32-56-617977 Dyno to provide
phone number.
Operation-
Maintenance
Troubleshooting
Replacing the Charger
Specifications
Page
11
12
AQHE12-15 MANUAL 250CT05
ÉS Danger
Failure to obey the safety rules and instructions in this manual will result in death
or serious injury.
Label and Safety Rules Legend
ÉA DANGER Indicates the presence of a hazard that will cause death or
serious injury
4h WARNING Indicates the presence of a hazard that may cause death
or serious injury.
ED CAUTION Indicates the presence of a hazard that will or may cause
serious injury or property damage.
AQHF 12-15 MANUAL 250CT05
safety: General
o
Do not operate a charger that is not working correctly. An electric shock
hazard or battery explosion hazard from overcharging may exist.
Make sure the charger is the correct voltage and type for the battery or
battery pack to be charged. Use of an incorrect charger may result in
battery explosion and serious injury and/or property damage.
Do not attempt to service the charger yourself unless you are a trained
service technician. The warranty is void if the charger case has been
opened. Always follow installation instructions closely. The high voltages
inside the charger are a shock hazard and can cause serious Injury or
death.
Though the charger is resistant to water and spray washing do not fully
immerse or spray wash for an extended (more the 5 seconds in one
position) time. Liquid can get inside charger and may cause serious Injury
or death. |
The charger is designed for use in industrial areas. It is not designed to be
used in medical (hospital) environments where interference with life critical
equipment could cause death or serious Injury.
There could be a spark during charging. Be careful when using fuels.
solvents or other flammables near the charger or batteries. An explosion
could result causing death or serious injury.
This charger is intended only for use on DYNO EUROPE equipment and
batteries installed on that equipment. Use on other batteries may result in
overcharging and battery explosion causing serious injury or death.
AQHF 12-15 MANUAL 250CT05
Safety: Power
е [0 reduce the risk of an electric shock, connect only to a properly grounded
single phase (3wire) outlet.
e Ensure that the AC voltage supplied to the charger is within the ranges in
the specification table. Voltages outside this range, particularly high
voltages, can result in an electric shock and fire hazard.
o If you use an extension power cable with your charger, ensure the total
current draw of the items plugged into the extension power cable do no
exceed the current rating of the extension cable and meet all national and
local electrical code requirements. See Specifications page for current
draw of charger. Overloaded extension cords can catch fire and cause
property damage, serious injury or death.
е Do not operate charger if wiring is damaged Including cut insulation or
pinched wires. An electric shock could cause serious injury, or death.
Safety: Batteries -
е See battery suppliers guide for proper care of batteries and follow directions
carefully. Failure to follow battery care instructions can result in battery
explosion and property damage, severe injury, or death during charging.
ое When attaching charger leads to battery terminals be careful that tools do
not short between battery terminals. Shorting between battery terminals
may cause extreme arcing resulting in explosion or extreme heat that can
cause burns.
e Do not disconnect charger terminals while batteries are charging. Sparking
can occur which could ignite flammable battery gases and cause an
explosion. Always turn the charger off first (unplug from AC).
e Do not touch battery terminals or any exposed electrical parts. Contact
- 4 —
AQHF 12-15 MANUAL 250CT05
with battery terminals or other exposed electrical parts may cause an
electric shock. Remove all watches, rings, and jewelry to avoid arcing and
electric shock.
Initial Instaliation
Only trained technicians with knowledge of the equipment and batteries the charger will be
used with should install the charger.
Ensure that the charger is the correct type and voltage for the battery pack to be charged. This
charger is only to be used with lead acid type flooded or Absorbed Glass Mat (AGM) type
batteries only.
O CAUTION: Use of an incorrect charger for the type of battery or battery voltage
can result in battery explosion and serious injury and property damage.
Determine if the batteries to be charged are flooded or Absorbed Glass Mat (AGM) lead acid
type. For AGM type batteries the yellow wire loop at the back of the charger should be cut and
the wire ends taped. This selects the charging profile for the AGM type batteries.
Wire the output (separate red and black wires) of the charger to the battery. For on-board or
other installations the charger can remain permanently connected to the battery. Connect the
red wire to the POSITIVE (POS, P, +) terminal of the battery. Connect the black wire to the
NEGATIVE (NEG, N, -) terminal. Ensure that any terminals used are capable of carrying 15
amperes, that all crimp connections are good, and that the connections are clean and tight.
AQHF12-15 MANUAL 250CT05
£8 WARNING: There could be a spark during charging. Be careful when using fuels,
solvents or other flammables near the charger or batteries. An explosion may result
causing serious injury or death.
a WARNING: To reduce the risk of an electric shock, connect only to a properly
grounded single phase (3wire) outlet. Electric shock hazard may cause serious injury
or death.
“ЗА CAUTION: To reduce the risk of fire, use this charger only on AC circuits and
extension cords capable of handling the AC Input currents (Max. Amps) defined in the
electrical specifications. Use must be in accordance with al! National and Local
Electrical Codes for the location of use. Overloaded cords or circuits present a fire
and shock hazard and may result in property damage, serious injury, or death.
1) Plug the charger into a single phase AC socket with a nominal voltage rating of 100V,
110V, 115V, 120V, 220V, 230Y, or 240V anda frequency rating of 50 or 80Hz. The
charger automatically senses and adjusts to the AC voltage and frequency
2) The charger will flash the LEDs in a start-up check then start charging the batteries.
The "GEL" LED on the front panel identifies the charge profile for the battery type.
If the lamp is off, the charger runs the charging profile for normal flooded lead
‚acid batteries. If the lamp is on, the charger runs the charging profile for sealed
gel (AGM) type lead acid batteries,
3) The three green LED's indicate the charging progress. When the battery is 0 to 50%
charged the 50% LED flashes. When the battery is between 50 to 75% charged the 50%
LED is on while the 75% LED flashes. When the battery is between 75 to 100% charged
the 75% LED is on and the 100% LED flashes. When the battery is fully charged the
50%, 75% and 100% LEDs are on. Charging time is dependent on depth of battery
discharge, battery condition, and temperature.
4) lfthe charger is left plugged in after charging is complete (ali LEDs on) the charger goes
into maintenance mode to keep batteries charged while in storage. The charger
continuously measures battery voltage and restarts the charging cycle if the battery
voltage drops below about 12.5V. This keeps batteries charged while in storage but
does not boil-out the electrolyte over time.
5) Turn-off charger by unplugging (disconnect from AC voltage).
- A —
)
AQHF12-15 MANUAL 250CT05
Charging State & LED Display
| 50% 75% 100% GEL |
Charging State | ©
0 to 50% charged Blinking Off Off X
50% to 75% charged On Blinking Off XK.
75% to 100% charged ~~ On On Blinking X
100% charged On On On X
Charge for flooded type X X X Off
batteries
Charge for Sealed type X / X X On
batteries
See Troubleshooting Off Off Blinking X |
Note: X in the table means “don’t care”, LED may be off, blinking, or on.
Technical Operation. Summary — The charger is an advanced, microprocessor controlled, high
frequency switching type charger. From 0% to 75% a constant current is provided to the battery
(bulk charging) until a pre-set battery voltage is reached. From 75% to 100% a constant
voltage is maintained and the charging current decreases (absorption charging). When the
charging current falls below 2 to 3A charging is complete. The charger will work even with
batteries in a severe discharge state with terminal voltages as low as 2V and there is no need to
boost charge” weak batteries before charging. The charger has an 18 hour timer in case
charging can not be completed due to battery problems — see troubleshooting section. The
charger senses and flashes error codes for problems — see troubleshooting section.
AQHF12-15 MANUAL 250C705
a8. WARNING: Disconnect from AC voltage before doing any service. When
plugged-in the AC wiring is an electric shock hazard. Disconnecting the DC output
wires near the batteries when the charger is ON may cause the batteries to explode
resulting in serious injury or death.
AA WARNING: Risk of an electric shock causing serious injury or death. Do not
touch un-insulated parts of the charger wires, battery connector or battery terminals.
Be careful with tools as shock or arcing from shorting of electrical parís may cause
serious injury or death. Remove rings, watches, and jewelry to avoid arcing and
electric shock,
1) All electrical connections must be kept clean and tight. Sometimes connections can look
good outside but be corroded inside causing an output connection error (one flash failure,
see troubleshooting).
2} The charger cools through the case fins. If the fins become covered with debris the
chargers over-temperature protection system may reduce charging power. Clean-off
fins to improve cooling.
3) Replace the charger if case damage breaks the water-tight seal.
4) Inspect wiring weekly, including AC plug, AC cord, DC wires to battery, and interlock
wires for cut insulation, pinching, or other damage. Repair to avoid electric shock.
AC Ground — green with yellow stripe
AC Neutral — light biue
AC Line (Hot) — brown
DC Battery Negative (-) - black
DC Battery Positive (+) - red
5) Follow battery supplier recommendations for battery care and maintenance.
Note — most battery charging problems relate to battery care and not charger
problems.
AQHF12-15 MANUAL 250CT05
Troubleshooting
£ WARNING: Do not operate the charger if it is malfunctioning. Personal injury
or property damage could result. Electric shock hazard may cause serious injury or
death.
E. WARNING: Do not disassemble the charger. High voltages inside the charger
| are an electric shock hazard and may result in serious injury or death.
identify the problem from the following list and refer to the appropriate section for detailed
instructions. |
CHARGER DOES NOT TURN ON.
3 LED's BLINK SIMULTANEQUSL Y
100% LED BLINKS WHILE 50% AND 75% LED'S ARE "OFF"
BATTERIES DO NOT FULLY CHARGE
THE AC SUPPLY CIRCUIT BREAKER OR FUSE IS BLOWN
ason7
1, CHARGER DOES NOT TURN ON.
Double check the outlet to ensure it is working by trying out another known good piece of
equipment on the outlet. Check the AC plug and wire to ensure both are in good condition.
Replace charger if everything else is correct.
ВН CAUTION: if the AC plug or receptacle is broken, twisted, bent or loose, it cannot
make a good electrical connection and an electric shock hazard may exist. Have it
repaired or replaced by a qualified person immediately. DO NOT USE THE CHARGER. |
UNDER THIS CONDITION. Fire, injury, or death may result if not corrected.
2. $ LEDS BLINK SIMULTANEOQUSLY
The faults identified below cause the 3 LED's to blink simultaneously and a buzzer to sound. If
the cause of the fault is removed the charger restarts automatically, the LEDs go into normal
operational mode, and the buzzer stops. |
> 3 LEDS BLINK ONCE SIMULTANEOUSLY : OUTPUT CONNECTION ERROR.
-> CHECK THE BATTERY AND CHARGER CONNECTION AND CORRECT
(The output may not be connected to the batteries or the connections to the batteries may have
corroded or loosened. The output may be shorted due to improper connection to the batteries
or pinched wires. The output may be connected in reverse polarity to the batteries. The
charger is not damaged by any of these problems.) В О
» 3 LEDS BLINK TWICE SIMULTANEOUSLY : AC VOLTAGE PROBLEM.
-> CHECK THE AC INPUT VOLTAGE. THE CHARGER IS INDICATING
-0Q
AQHF12-15 MANUAL 250CT05
THE AC VOLTAGE IS TOO LOW OR TOO HIGH. CORRECT.
(See the electrical specification table for the allowable AC voltage input ranges. This is an
unusual problem and would most likely occur with a very poorly regulated engine-generator set
providing the AC voltage to the charger)
» 3 LEDS BLINK THREE TIMES SIMULTANEOUSL Y : CHARGER IS OVERHEATED.
> NO ACTIÓN REQUIRED. WHEN THE CHARGER COOLS, CHARGING WILL
RE-START AUTOMATICALLY. CHECK AND CORRECT FOR DIRT OR OTHER DEBRIS
ON CHARGER THAT MAY BE REDUCING COOLING.
> 3 LEDS BLINK FOUR TIMES SIMULTANEOUSLY : INPUT OR OUTPUT
OVER CURRENT. |
-> NO ACTION REQUIRED, CHARGER WILL CORRECT AND RE-START
AUTOMATICALLY.
3. 100% LED BLINKS WHILE 50% AND 75% LED'S ARE "OFF"
The 18 hour timer has elapsed or a bad cell in the battery has been detected. Causes:
-> BATTERIES ARE EXTREMELY DISCHARGED. UNPLUG, WAIT 20 SECONDS, AND
THEN PLUG-IN CHARGER TO RE-START CHARGE CYCLE TO COMPLETE
CHARGING.
> BATTERIES ARE WEAK, OLD, OR HAVE ONE OR MORE BAD CELLS. BATTERIES
WILL STILL CHARGE BUT CAPACITY WILL BE REDUCED. REPLACE BATTERIES.
-> BATTERY PACK TOO LARGE FOR THE CHARGER. USE HIGHER OUTPUT CHARGER OR
UN-PLUG, WAIT 20 SECONDS, THEN PLUG-IN CHARGER TO RE-START CHARGE CYCLE TO
COMPLETE CHARGING.
4. BATTERIES DO NOT FULLY CHARGE
If the batteries are charged overnight, make sure the AC supply is not being switched-off at
night with other building circuits. Check battery condition following the battery supplier's
instructions. Check for dead cells or reduced capacity. Replace charger only if other problems
are not found.
5. THE AC LINE CIRCUIT BREAKER OR FUSE 15 BLOWN
An overloaded AC circuit, defective circuit breaker, defective fuse, or a charger problem can
cause this condition. First check to see what the total load is on the AC circuit to avoid overload.
If total AC load is OK connect the charger to a different AC outlet (on a different circuit) in the
building. If the charger operates properly on other AC outlets, a qualified person should correct
the AC circuit problem. If the AC supply checks good, the charger should be replaced.
Note: Over 1/2 of all battery chargers returned as "failed" are good. Please follow the
troubleshooting procedures carefully and check all other items before returning the
charger as failed.
- 10 —
AQHF12-15 MANUAL 250CT05
Replacing the Charger
AD WARNING: Disconnect from AC voltage before doing any service. When
plugged-in the AC wiring is an electric shock hazard. Disconnecting the DC output
wires near the batteries when the charger is ON may cause arcing and the batteries to
explode resulting in serious Injury or death.
FA WARNING: Risk of an electric shock causing serious injury or death. Do not
touch un-insulated parts of the charger wires, battery connector or battery terminals.
Be careful with fools as shock or arcing from shorting of electrical parts can cause
serious injury or death. Remove rings, watches, and jewelry to avoid arcing and
electric shock.
E WARNING: Do not disassemble the charger. Take it to a factory-authorized
service agent when service or repair is required. High voltages inside the charger are
an electric shock hazard and can result in serious injury or death.
Replace only with charger designed for use with the batteries and machine to ensure
compatibility with all machine systems. Make sure the charger is unplugged before replacing
and be careful tools do not short battery connections which can cause electric sparks. Ensure
connections are the same as the original charger with wires connected by a qualified person
(see tag on AC cord):
AC Ground - green with yellow stripe
AC Neutral — light blue
AC Line (Hot) — brown
DC Battery Negative (-) - black
DC Battery Positive (+) - red
Make sure all connections are clean and tight to provide a good electrica! connection. Check all
machine operating systems after replacement to ensure proper operation (see manual).
- 11 —
AQHF 12-15 MANUAL 250CT05
Specifications
Electrical Specifications
Item AC Input DC Output
115V (85-132V) Max. 15.3V for Flooded
Voltage 230V (170-264V) (14.8V @ 26C for flooded)
(Automatically Selects) ([email protected]°C for GEL/AGM)
Max. Current Jo oy Max. 15 ADC
Frequency 60/50 Hz -
Phase SINGLE -
Output Power 230 Watts
Applicable Battery Specifications: For use with 24Voit, 105 ~ 195 Amp-Hour,
deep cycle lead-acid Batteries - flooded or sealed gel (AGM) type
- 12 -
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