Read, understand, and follow these safety rules and
AQHF24-19 MANUAL
VER 1.0 0612
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.(DYNQO EUROPE) If you
have any questions call 00-32-56-617977 Dyno to provide phone number.
Page
Safety--- - === 2
Operation 5
Maintenance---- 6
Troubleshooting 9
Replacing the Charger - 11
Specifications 12
AQHF24-19 MANUAL
VER 1.0 0612
Safety
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
ih DANGER Indicates the presence of a hazard that will cause death
| Or serious injury.
А WARNING Indicates the presence of a hazard that may cause death
or serious injury.
is CAUTION Indicates the presence of a hazard that will or may cause
serious injury or property damage.
Safety: General
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,
AQHF24-19 MANUAL
VER 1.0 0612
e 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.
e 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.
e 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.
Safety: Power
е To 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
voitages, can result in an electric shock and fire hazard.
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.
о Do not operate charger if wiring is damaged including cut insulation
or pinched wires. An electric shock could cause serious injury, or death.
AQHF24-19 MANUAL
VER 1.0 0612
Safety: E
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.
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.
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).
Do not touch battery terminals or any exposed electrical parts. Contact with
terminals or other exposed electrical parts may cause an electric shock.
Remove watches, rings, and jewelry to avoid arcing and electric shock.
initial Installation
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.
{i CAUTION: Use of an incorrect charger for the type of battery or battery voltage can
result i 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.
AQHF24-19 MANUAL
VER 1.0 0612
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 19 amperes,
that all crimp connections are good, and that the connections are clean and tight.
If the equipment requires use of an interlock connect the black and white wires
as necessary. The wires connect to relay contacts inside the charger that are
open when the charger is on and closed when the charger is off.
The wires are not polarity (+ or -) sensitive.
Operation
ÁS. 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 iniury or death.
#4. 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.
#44 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 all 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, 230V, -or 240V and a frequency rating of 50 or
60Hz. The charger automatically senses and adjusts to the AC voltage and
frequency.
2) The charger will flash the LEDs i 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.
- 5H —
AQHF24-19 MANUAL
VER 1.0 0612
If the lamp is off, the charger is operated in the charging profile for normal flooded
lead acid batteries. if the GEL LED is on, the charger operates a charging profile
for sealed gel (AGM) type lead acid batteries. |
3) The three green LED's indicate the charging progress. When the battery is O 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) If the charger is left plugged in after charging is complete (all LEDs on) the
charger goes into maintenance mode to keep batteries charged while in storage.
In this mode constant voltage is maintained while replenishing internal battery
losses for long term storage. 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).
Technical Operation Summary — The charger is an advanced, microprocessor
controlied, 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 charging curve is temperature compensated
using the starting temperature of the charger as the battery temperature.
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 24 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.
AQHF24-18 MANUAL
VER 1.0 0612
Charging State & LED Display
58% 75% 100% HP/BT GEL
oe |e © O
Charging State
0 to 50% charged Blinking Off Off X X
50% to 75% charged On Blinking Off X X
75% to 100% charged On On Blinking X X
100% charged On On On X X
Power reduction X X X On X |
|
Charge for flooded type X x X X Off |
batteries
Charge for Sealed type Y Y X Y On
batteries
See Troubleshooting X X X Blinking X
|
Note 1) X in the table means “don't care”, LED may be off, blinking, or on.
T_T"
Note 2) Power Reduction: If the charger's internal temperature exceeds a specific level,
the HP/BT lamp stays on and the output current is reduced. If the temperature exceeds
a limit despite the reduced output charging will stop. Charging restarts automatically
once the charger internal temperature reduces to a normal level.
AQHF24-19 MANUAL
VER 1.0 0612
E 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.
ED, WARNING: Risk of an electric shock causing serious injury or death. Do not touch
un-insulated paris of the charger wires, battery connector or battery terminais. Be careful
with fools as shock or arcing from shorting of electrical parts 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 blue
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.
AQHF24-19 MANUAL
VER 1.0 0812
Troubleshooting
d'à 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,
£4. 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.
1. CHARGER DOES NOT TURN ON.
3 LED’s BLINK SIMULTANEOUSLY
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
GR wh
1. CHARGER DOES NOT TURN GN.
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.
dd CAUTION: If the AC plug or receptacle is broken, twisted, bent or loose, it cannot make
à 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. iniurv. or death mav result if not corrected.
2. 3 LEDS BLINK SIMULTANEOUSLY
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.
- 0
AQHF24-19 MANUAL
VER 1.0 0612
The charger is not damaged by any of these problems.)
> 3 LEDS BLINK TWICE SIMULTANEOUSLY : AC VOLTAGE PROBLEM.
— CHECK THE AC INPUT VOLTAGE. THE CHARGER IS INDICATING THE AC VOLTAGE
IS TOO LOW OR TOO HIGH.
(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 SIMULTANEOUSLY : CHARGER IS OVERHEATED.
— NO ACTION REQUIRED. WHEN THE CHARGER COOLS, CHARGING WILL
RE-STARTAUTOMATICALLY. 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% L.ED 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 suppliers instructions. Check for dead cells or reduced capacity.
Replace charger only if other problems are not found.
- 10 -
AQHF24-19 MANUAL
VER 1.0 0612
5. THE AC LINE CIRCUIT BREAKER OR FUSE IS 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 chargerto 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.
Replacing the Charger
I 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.
4h WARNING: Do not disassembie 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.
£1. 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 parts can cause serious Injury or
death. Remove rings, watches, and iewelrv to avoid arcing and electric shock.
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
- 11 -
AQHF24-19 MANUAL
VER 1.0 0612
AG Line (Hot) — brown
DC Battery Negative (-) - black
DC Battery Positive (+) — red
Interlock — small white wire
Interlock — small black wire
Make sure all connections are clean and tight to provide a good electrical
connection. Check all machine operating systems after replacement to ensure
proper operation (see machine operating manual).
Specifications
Electrical Specifications
item AC Input DC Output
115V (85-132V) Max. 31.7 VDC
Voltage 230V (170-264V) ([email protected]°C for Flooded)
(Automatically Selects) ([email protected]"°C for GEL)
5.0A at 85V
Max. C t Max. 19.0 ADC
„Чел 2.5A at 170V ax. 13
Frequency 60 / 50 Hz -
Phase SINGLE | -
Output Power 600 Waits
Applicable Battery Specifications: For use with 24Volt, 150 - 305 Amp-Hour,
deep cycle lead-acid Batieries - flooded or sealed gel (AGM) type
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