24 volt fully automatic battery charger

24 VOLT FULLY AUTOMATIC BATTERY CHARGER MODEL 18360L TYPE 24EL12-3ET AC Supply: DC Output: Battery Capacity: Battery Size: Normal Recharge Time: Specifications 120 volts AC, 60 Hertz, single-phase, 5 amps maximum 24 volts DC, 12 amps tapering to 3 amps Two series connected 6 cell, 12-volt, deep-cycle motive power batteries. Gel cell and sealed "maintenance-free" or conventional replaceable electrolyte deep-cycle batteries 50 to 150 amp hours 8 hours PLEASE SAVE THESE IMPORTANT SAFETY AND OPERATING INSTRUCTIONS For correct operation of the equipment, it is important to read and be familiar with this entire manual before installing and operating the charger. DO NOT DISCARD THIS MANUAL AFTER READING. LOOK FOR THIS SYMBOL TO POINT OUT SAFETY PRECAUTIONS. IT MEANS: BECOME ALERT—YOUR SAFETY IS INVOLVED. IF YOU DO NOT FOLLOW THESE SAFETY INSTRUCTIONS, INJURY OR PROPERTY DAMAGE CAN OCCUR. characteristics required by these different types of battery design are selected by sliding the BATTERY TYPE selector switch to the correct setting. A patented electronic circuit turns the charger on and off automatically. IMPORTANT SAFETY INSTRUCTIONS Before using battery charger, read all instructions and cautionary markings on battery charger, battery, equipment. Use of an attachment not recommended or sold by battery charger manufacturer may result in a risk of fire, electric shock, or injury to persons. Batteries used on industrial equipment are subjected to severe deep-cycle duty on a daily basis. For this reason, it is important that only deep-cycle batteries be used. INTRODUCTION CAUTION: THIS CHARGER IS FOR USE ONLY ON 12 CELL 50-150 AMP-HR (20 HR. RATE), 2.38-2.50 VOLTS PER CELL MAXIMUM VOLTAGE RECHARGEABLE, DEEP-CYCLE The Dual-Mode battery charger is designed to recharge deep-cycle batteries of conventional replaceable electrolyte or gel cell and sealed "maintenance-free" design. The different charge Operating Instructions 1 01746G BATTERY SYSTEMS. THIS CHARGER IS FOR USE ON REPLACEABLE ELECTROLYTE OR GEL CELL AND SEALED "MAINTENANCEFREE" DEEP-CYCLE BATTERIES. "BATTERY TYPE" SWITCH MUST BE SET TO THE PROPER TYPE OF BATTERY. BATTERIES IMPROPERLY MATCHED WITH CHARGER MAY BURST CAUSING PERSONAL INJURY AND DAMAGE TO BATTERIES OR CHARGER. AC INPUT The charger must be grounded to reduce the risk of electric shock. It is equipped with an electric cord having an equipment-grounding conductor and a grounding-type plug. The plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance with the National Electrical Code and all local codes and ordinances. DANGER: IMPROPER CONNECTION OF THE EQUIPMENT-GROUNDING CONDUCTOR CAN RESULT IN A RISK OF ELECTRIC SHOCK. DO NOT REMOVE GROUNDING PRONG FROM PLUG. INITIAL INSTALLATION Circuit breaker or fuse protection in the 120 volt AC outlet to which the charger is to be plugged should allow 7 amps per charger. Do not overload electrical outlet. Use of an extension cord with the charger should be avoided unless absolutely necessary. Use of an improper extension cord could result in a risk of a fire and electric shock. If an extension cord is needed, use a threeconductor, No. 14 AWG (or larger) cord with ground, properly wired, in good electrical condition and keep as short as possible. Make sure that the pins on the plug of the extension cord are the same number, size, and shape as that of the plug on the battery charger. Locate all cords so that they will not be stepped on, tripped over, or otherwise subjected to damage or stress. Do not operate the battery charger with a damaged cord or plug. Do not operate the battery charger if it received a sharp blow, was dropped or otherwise damaged in any manner. Refer to a qualified service agent. GROUNDING INSTRUCTIONS This battery charger is equipped with a grounding plug as illustrated in Figure A, for use on a nominal 120 volt, 60 Hertz circuit. A temporary adapter, as illustrated in Figure B and C, may be used to connect this plug to a two-pole receptacle as shown in Figure B if a properly grounded outlet is not available. The temporary adapter should be used only until a properly grounded outlet can be installed by a qualified electrician. The greencolored rigid ear extending from the adapter must be connected to a permanent ground such as a properly grounded outlet box. DANGER: BEFORE USING THE ADAPTER AS ILLUSTRATED, BE CERTAIN THAT THE CENTER SCREW OF THE OUTLET PLATE IS GROUNDED. Provide adequate ventilation for both batteries and charger. The convection cooled design requires an unobstructed flow of cooling air for proper operation. Keep all charger ventilation openings at least two inches (2") (5.08cm) away from walls and other objects. Do not allow clothing, blankets, or other material to cover charger. GROUNDING METHODS WARNING: CHARGERS CAN IGNITE FLAMMABLE MATERIALS AND VAPORS. DO NOT USE NEAR FUELS, GRAIN DUST, SOLVENTS, THINNERS, OR OTHER FLAMMABLES. NOTE: Use of adapter shown in Figures B and C is NOT permitted in Canada. WARNING: KEEP DRY; DO NOT EXPOSE TO RAIN OR SPRAY. FOR STORAGE, KEEP CHARGER IN A BUILDING. REPLACE WORN, CUT, OR DAMAGED ELECTRICAL CORDS AND PLUGS IMMEDIATELY. Operating Instructions BATTERY TYPE Battery manufacturers frequently use the same battery cases for different battery types. Replaceable liquid electrolyte deep-cycle batteries have removable cell caps. Water electrolyzed by discharging and charging the battery is replaced through these openings. 2 01746G Gel cell and sealed "maintenance-free" deepcycle batteries are generally distinguished by nonremovable cell caps. The physical appearance of the battery case is frequently the same as that of a replacement liquid electrolyte battery though the cell caps are generally not removable. 2. Move the POWER switch to "OFF" position. 3. Connect the power supply cord to a properly grounded, 120 volt, 60 Hertz, single-phase outlet. 4. Connect charger’s DC output plug to the equipment charging receptacle. Do not connect the DC plug unless the "POWER" switch is in the "OFF" position. Refer to the battery manufacturer's information panel on the battery case to determine the type battery you have. If the information panel is missing or not legible, do not use the battery. Refer to your dealer if you do not understand what type battery you are using and have them set the BATTERY TYPE switch accordingly. 5. Move the POWER switch to "ON" and the RED and GREEN lights will come on steady for a few seconds to test the lights. If the lights do not come on, either the AC cord is not plugged in or the AC outlet is not live. Test for a live AC outlet by connecting a suitable appliance into the specific outlet. The BATTERY TYPE switch is a two-position slide switch visible in the rectangular opening on the front of the charger. Using a small screwdriver, slide the switch from one setting to the other through the opening. Take care not to damage the switch when moving it to the desired setting. WARNING: CHARGER IS NOT TO BE USED WHILE THE EQUIPMENT IS OPERATING. ATTENTION: Ne pas utiliser le charger pendant que l’equipment est en marche. NORMAL OPERATION Instructions printed on cover of charger are for daily reference. WARNING: LEAD-ACID BATTERIES GENERATE GASES WHICH CAN BE EXPLOSIVE. TO PREVENT ARCING OR BURNING NEAR BATTERIES, DO NOT DISCONNECT DC CHARGING CORD FROM BATTERIES WHEN THE CHARGER IS OPERATING. IF THE CHARGE CYCLE MUST BE INTERRUPTED, MOVE THE "POWER" SWITCH TO "OFF" AND DISCONNECT THE CHARGER POWER SUPPLY CORD BEFORE DISCON-NECTING THE DC OUTPUT CORD FROM THE BATTERIES. KEEP SPARKS, FLAME, AND SMOKING MATERIALS AWAY FROM BATTERIES. 1. Set "BATTERY TYPE" switch to the proper style of battery to be charged. CAUTION: MAKE SURE THE BATTERY PACK IS A 24 VOLT, 12 CELL, SERIES CONNECTED, 50-150 AMP-HOUR (20 HR. RATE), RECHARGEABLE DEEP-CYCLE BATTERY SYSTEM. THE "GEL CELL AND SEALED DEEP-CYCLE BATTERY" SETTING CHARGES TO A MAXIMUM ON-CHARGE VOLTAGE OF 2.38 VOLTS PER CELL. THE "REPLACEABLE ELECTROLYTE DEEP-CYCLE BATTERY" SETTING HAS AN ON-CHARGE VOLTAGE OF AT LEAST 2.50 VOLTS PER CELL. VISUALLY CHECK THAT THE BATTERY TYPE SWITCH IS SET CORRECTLY FOR THE TYPE OF BATTERY YOU ARE USING. WARNING: ALWAYS SHIELD EYES WHEN WORKING NEAR BATTERIES. DO NOT PUT WRENCHES OR OTHER METAL OBJECTS ACROSS BATTERY TERMINAL OR BATTERY TOP. ARCING OR EXPLOSION OF THE BATTERY CAN RESULT! DANGER: TO PREVENT ELECTRIC SHOCK, DO NOT TOUCH UNINSULATED PARTS OF THE CHARGER DC OUTPUT CONNECTOR, BATTERY CONNECTOR, OR BATTERY TERMINALS. MAKE SURE ALL ELECTRICAL CONNECTORS ARE IN GOOD WORKING CONDITION. DO NOT USE CONNECTORS THAT ARE CRACKED, CORRODED OR DO NOT MAKE ADEQUATE ELECTRICAL CONTACT. USE OF A DAMAGED OR DEFECTIVE CONNECTOR MAY RESULT IN A RISK OF OVERHEATING OR ELECTRIC SHOCK. Operating Instructions Charger will output power three to five (3 to 5) seconds after turning switch "ON" as indicated by the RED light turning off, the slow blinking GREEN light (once per second), and a slight transformer hum. If both lights go off about five seconds after AC is applied, check to see if the DC plug is correctly connected to the battery. If the DC plug is connected properly, either an open circuit exits in the equipment's internal circuitry, or the battery voltage is below 7 volts (see Troubleshooting). 3 01746G normal charging. Larger batteries (greater than 150 ampere-hours) or severely discharged batteries may require up to 16 hours to be properly charged and equalized. If the charger operates for 16 hours and is unable to fully charge the batteries, an internal timer turns the charger off and begins to fast blink the RED light. The charger has an under-voltage protection mode which will terminate the charge if battery voltage does not increase above 18 volts after 10 minutes of charging. This prevents destroying 12 volt battery systems with this 24 volt charger. When this occurs, the RED light will come on steady. 6. Correct initial charge rate should be between 11 to 13 amps. As the batteries become more charged the charge rate decreases. When the batteries reach approximately 80% of full charge, the GREEN light will fast blink (8 times per second), the charge rate will have decreased as determined by the "BATTERY TYPE" switch setting and the condition of the batteries. A maximum voltage shutoff for wet batteries is an additional safety feature of the charger. When the battery potential increases above 2.83 volts per cell, the charger cycle is terminated and the RED light begins to slow blink. 9. After the charger has turned off, move the Power switch to "OFF", disconnect AC cord first, then the DC output cord from the equipment charging receptacle. Replaceable Electrolyte Deep Cycle Battery With healthy batteries, the charging current will decrease to between 2 to 4 amps and remain there until the charger turns off. As replaceable electrolyte deep cycle batteries lose capacity, the charge rate may no longer decrease to this reading. The charger will still determine when the batteries are as charged as they are capable of being and will turn off. When battery capacity has decreased to where the charger is no longer able to taper down to less than 4 amps, or the batteries will no longer perform as desired they should be replaced. CAUTION: TO AVOID DAMAGE TO THE CHARGER CORD AND BATTERY CONNECTOR, DISCONNECT BY GRASPING THE PLUG HANDLE OR BODY AND PULLING IT STRAIGHT OUT OF THE BATTERY CONNECTOR. DO NOT PULL ON THE CHARGER CORD. DO NOT TWIST, ROCK OR PULL THE PLUG SIDEWAYS. WARNING: TO PREVENT ARCING OR BURNING NEAR THE BATTERIES, DO NOT DISCONNECT THE OUTPUT CORD FROM THE BATTERIES WHILE THE CHARGER IS OPERATING. IF THE CHARGE CYCLE MUST BE INTERRUPTED, FIRST SLIDE THE POWER SWITCH TO "OFF", THEN DISCONNECT AC CORD, AND FINALLY THE OUTPUT CORD FROM THE BATTERIES. KEEP SPARKS, FLAME, AND SMOKING MATERIALS AWAY FROM BATTERIES. NO SMOKING. Gel Cell and Sealed Deep Cycle Battery The charging current will decrease to near zero and remain there until the charger turns off. Gel cell deep cycle batteries will still taper to near zero charge current even as they wear out and lose capacity and range. As sealed deep cycle batteries lose capacity and range, the charge current may no longer decrease to this low a reading. The charger will still determine when the batteries are as charged as they are capable of being and turn off. When the batteries will no longer perform as desired they should be replaced. WARNING: DO NOT LEAVE THE DC OUTPUT CONNECTOR PLUGGED IN WHILE UNATTENDED FOR MORE THAN TWO (2) DAYS. SEVERE OVERCHARGING AND DAMAGE TO THE BATTERIES MAY RESULT IF THE CHARGER DOES NOT TURN OFF. 7. Charger is equipped with a thermal breaker which automatically turns the charger off if it overheats. Should charger turn off before the batteries are fully charged, check to be sure all ventilation openings are free from obstructions. After charger cools down to a safe temperature it will automatically restart. If charger repeatedly overheats, refer to a qualified service agent. PROPER CARE OF DEEP-CYCLE MOTIVE POWER BATTERIES Batteries used on industrial equipment are subjected to severe deep-cycle duty on a daily basis. For this reason, it is important that only deep-cycle batteries be used. Although these batteries are designed to withstand such duty, the following precautions must be observed to obtain good performance and maximum cycle life. 8. Charger turns off automatically when batteries are fully charged as indicated by steady on GREEN light. Charge time varies with battery size and depth of discharge. Allow 8 hours for Operating Instructions 4 01746G PERSONAL PRECAUTIONS CAUTION: ALWAYS WEAR PROTECTIVE CLOTHING AND EYE SHIELDS WHEN WORKING WITH BATTERIES. BATTERIES CONTAIN ACID WHICH CAN CAUSE BODILY HARM. DO NOT PLACE WRENCHES OR OTHER METAL OBJECTS ACROSS THE BATTERY TERMINALS OR BATTERY TOP. ARCING OR EXPLOSION OF THE BATTERY MAY RESULT. SOMEONE SHOULD BE WITHIN THE RANGE OF YOUR VOICE OR CLOSE ENOUGH TO COME TO YOUR AID WHEN YOU WORK NEAR A LEAD-ACID BATTERY. HAVE PLENTY OF FRESH WATER AND SOAP NEARBY IN CASE BATTERY ACID CONTACTS SKIN, CLOTHING OR EYES. 1. Someone should be within range of your voice or close enough to come to your aid when you work near a lead-acid battery. 2. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes. 3. Wear complete eye and clothing protection. Avoid touching eyes while working near battery. 4. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye, immediately flood eye with running cold water for at least 10 minutes and get medical attention immediately. 5. NEVER smoke or allow a spark or flame in vicinity of battery. WARNING: RISK OF EXPLOSIVE GASES. WORKING IN VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE USING YOUR CHARGER, YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY. 6. Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or short-circuit battery or other electrical part that may cause explosion. 7. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a lead-acid battery. A lead-acid battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing a severe burn. 1. New batteries should be given a full charge before their first use because it is difficult to know how long batteries have been stored. 8. NEVER charge a frozen battery. 2. Limit use of new batteries for first 5 cycles. New batteries are not capable of their rated output until they have been discharged a number of times. TROUBLESHOOTING 3. Do not excessively discharge batteries. Excessive discharge can cause polarity reversal of individual cells resulting in complete failure shortly thereafter. Limited use of new batteries will minimize the chance of cell reversal. CAUTION: DO NOT DISASSEMBLE THE CHARGER. TAKE IT TO A QUALIFIED SERVICE AGENT WHEN SERVICE OR REPAIR IS REQUIRED. INCORRECT REASSEMBLY MAY RESULT IN RISK OF ELECTRIC SHOCK OR FIRE. 4. CHECK THE LEVEL OF THE ELECTROLYTE IN CONVENTIONAL LIQUID ELECTROLYTE LEAD ACID BATTERIES MONTHLY. MAINTAIN THE PROPER ELECTROLYTE LEVEL BY ADDING WATER WHEN NECESSARY. Electrolyte levels lower during discharge and rise during charge. Therefore, it is mandatory that water be added to cells ONLY when they are fully charged; do not overfill. Old batteries require more frequent additions of water compared to new batteries. The following procedures are intended only to determine if a malfunction may exist in the charger, or in the equipment and batteries. DANGER: TO REDUCE RISK OF ELECTRIC SHOCK, ALWAYS DISCONNECT BOTH THE POWER SUPPLY CORD AND THE OUTPUT CORD BEFORE ATTEMPTING ANY MAINTENANCE OR CLEANING. CAUTION: DO NOT OPERATE THE CHARGER IF IT IS DAMAGED OR APPEARS TO BE MALFUNCTIONING. PERSONAL INJURY OR DAMAGE TO THE CHARGER AND/OR BATTERIES MAY RESULT. 5. Keep tops of batteries clean and dry to prevent excessive self-discharge. Keep battery terminals reasonably tight. Operating Instructions 5 01746G automatically restart. repeatedly overheats malfunctioning. Use the following chart to help you troubleshoot problems with the battery and charger system. There are four different modes that each light can have: OFF (light is off), SLOW BLINK (light blinks on and off once per second), FAST BLINK, (light blinks on and off eight times per second), and STEADY (light is full on). RED LIGHT GREEN LIGHT Off Off b. The AC power was interrupted during charge. c. Steady Off Slow Blink Charging (less than 80% charged) Off Fast Blink Charging (over 80% charged) Light test when AC connected Off Steady Steady Off Undervoltage shutoff, < 18.0 volts Slow Blink Off Overvoltage shutoff, > 33.96 volts Fast Blink Off Max. timer shutoff, >18 hours 4. A decrease in equipment range where it loses power earlier and earlier in the day indicates one of the following: Normal charge completed a. Use of the equipment before the batteries have been fully charged and the charger turns off, shortens battery life and hastens the onset of this reduced daily range. Battery capacity lost in this manner is permanent and is not recovered with additional charge cycles. 1. If the RED and GREEN lights do not illuminate within three seconds after the AC power is applied to the charger, it indicates one of the following: b. Conventional replaceable liquid electrolyte batteries are being under charged on the gel cell "BATTERY TYPE" switch setting. Battery capacity lost in this manner is permanent and is not recovered with additional charge cycles. a. Charger "POWER" switch is not in "ON" position. b. Charger is not plugged into a live AC outlet. c. 2. If both lights go off and stay off three to five (3-5) seconds after the charger connections are completed, it indicates one of the following and the charger is prevented from turning on; a. DC plug not connected to the equipment receptacle. e. The electrolyte level in conventional liquid electrolyte lead-acid batteries was allowed to drop below the top of the battery plates. Add distilled water to just cover the tops of the plates immediately upon discovery and fill to the proper level with distilled water at the completion of the very next charge cycle. Battery capacity lost in this manner is permanent and is not recovered with additional charge cycles. Battery connections in equipment wrong (reverse polarity). d. One or both batteries no longer serviceable (voltage below 7 volts for a 24 volt system). 3. If the charger turns off before the batteries are fully charged, it indicates one of the following: a. Charger internal thermal breaker turned the charger off due to overheating because charger ventilation openings are blocked. After the charger has cooled down to a safe temperature, it will Operating Instructions Severe overcharging occurs when gel cell (maintenance free) batteries are charged on the conventional wet lead acid "BATTERY TYPE" switch setting. Battery capacity lost in this manner is permanent and occurs very rapidly. Check with your dealer about battery replacement. d. The battery has been allowed to sulfate. Charge the battery no less frequently than once every three days when the wheelchair is lightly utilized. Once sulfation is allowed to take place it may be partially reduced by returning, temporarily, to daily charging. b. Fault in equipment wiring. Poor or open connections in the wiring that connects to the batteries. Corroded terminals, loose or worn plugs and receptacles, loose or worn fuseholders (have your dealer repair the equipment). c. The DC cord charging plug accidentally disconnected during charge. d. Fault in equipment wiring. The equipment charging circuit has high resistance, corroded or loose connections, loose or worn charging receptacle, loose or worn fuseholders. FUNCTION No AC power or no battery connected Steady If the charger it may be f. 6 This is the normal wearout process for all types of deep-cycle motive power batteries. 01746G c. 5. If battery voltage does not exceed 18 volts after 10 minutes of charging, the charger turns off and the RED light will turn on steady, indicating one of the following: Very deeply discharged batteries (100% discharged) can require more than 16 hours to charge. d. Several failed cells in the batteries that do not allow the charge rate to taper below 4 amps. a. Improper batteries used with charger. Must be a 12 cell, series connected 2.382.50 volts per cell battery system. b. Failed cells in the battery do not allow the battery voltage to rise above 18 volts. 7. If battery voltage exceeds 2.83 volts per cell, the charger turns off and the RED light begins to slow blink, indicating one of the following: 6. The charger operates through 20 hours before turning off. The RED light will begin to blink very rapidly indicating one of the following: a. Improper batteries used with charger. Must be a 12 cell, 2.38-2.50 volts per cell battery system. a. Batteries of higher than 150 amp-hour capacity (20 hr. rate) can require more than 16 hours to charge. b. Battery design may be inappropriate for this use. Check with your dealer for deepcycle batteries only. b. New batteries (5 cycles or Less) can require more than 16 hours to charge. c. Operating Instructions 7 Sulfation of batteries may have occurred. 01746G WIRING DIAGRAM PARTS LIST FOR MODEL 18360L TYPE 24EL12-3ET 120 VAC / 60 HZ PART NO. QTY. 27628S 18365S 22458S 04275S 23083S 24286S 26054S 27717S 22667S 25523S 18965-02S 1 1 1 2 1 1 1 1 1 1 1 DESCRIPTION CASE ASSEMBLY TRANSFORMER POWER SWITCH BUSHING, STRAIN RELIEF, FOR CORDS CORDSET, AC, 18/3, 102", W/ MOLDED PLUG CORDSET, DC, 14/2, 108", W/ SB50 GRAY PLUG CORDSET, DC, 14/2, 108", W/ SB50 RED PLUG CORDSET, 14/2, 108" W/ SB175 GRAY PLUG CORDSET, DC, 14/2, 108", W/ CANNON PLUG CORDSET, DC, 14/2, 108", W/ CANNON PLUG CONTROL BOARD ASSEMBLY CAUTION: DO NOT DISASSEMBLE THE CHARGER. TAKE IT TO A QUALIFIED SERVICE AGENT WHEN SERVICE OR REPAIR IS REQUIRED. Operating Instructions 8 01746G
* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project
Related manuals
Download PDF
advertisement