Dynapulse™ 1224
Contents
1. Dynapulse 1224 and 3648 Systems Users Manual Maintenance and Servicing Locate the 12 position Terminal Board FIGURE 3 on the bottom pan between the EMI filter and the fan array The terminals are Number 1 12 starting at one 1 on the outside edge of the unit The wiring is symmetrical so it really does not matter which end of the Terminal Board is called Number 1 Remove Remove Remove 7 screws each side Remove FIGURE 17 2 1 1 Top and Side Views of the Dynapulse System with detail for location and removal of Philip screws Page 31 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Maintenance and Servicing 17 2 2 115 VAC Operation Single Phase If the instructions below are not clear and understandable to you DO NOT perform this work Either contact your local distributor or obtain assistance from an experienced electrician For 115 VAC operation connect a jumper link on the Terminal Board between terminal 3 and 4 and another between 9 and 10 Remove the jumper link between terminal 6 and 7 See FIGURE 17 2 2 1 For 115 VAC operation it is important that the power line neutral is NOT switched through the circuit breaker Connect the blue power wire the neutral wire leading from the power entrance connector to the front panel circuit breaker to the EMI filter blade nearest the top edge of the EMI filter See FIGURE 17 2 2 2 Place the blue jumper wire between the two o2. and stored in large storage capacitors Under microprocessor control these two sources are tied in parallel on the Dynapulse 1224 for use on a 12 Volt battery or in series for use on a 24 Volt battery For the Dynapulse 3648 the two sources are tied in parallel for use on a 36 Volt battery or in series for use on a 48 Volt battery The high internal voltage helps to force a high current pulse into the battery even if it is severely sulfated Current Pulsing Technique High power transistors connect the storage capacitors to the battery for short pulses under microprocessor control A series ballast resistor limits the current into the battery to avoid damage to the battery plates These transistor pulse at 100 120 pulses per second It has been observed that desulfation proceeds most rapidly with this range of pulse rate Patented Other researchers have published findings that there are significant benefits with pulsed current techniques A summary of the benefits are detailed below An order of magnitude reduction in charging time An increase in cycle life by a factor of 3 4 Recovery of capacity of heavily cycled cell Effective means for delaying the progressive increase in the crystallization process in the active material which causes capacity loss as well as the minimization of the growth of the resistive PbO layer immediately adjacent to the grid Average Current Control The peak current pulses are responsible
3. 3 DECLARATION OF CONFORMITY Based on the test results using appropriate standards the Dynapulse 1224 and 3648 Systems are in conformity with the following e EN 61000 6 3 2007 e EN 61000 6 1 2007 Conformity is indicated by the CE symbol Conformit Europ enne Page 2 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Copyright Notice 4 COPYRIGHT NOTICE Information in this document is subject to change without notice Global Energy Innovations All rights reserved Reproduction in any manner whatsoever without the written permission of Global Energy Innovations is strictly forbidden No Warranty This user manual is being delivered to you as is and Global Energy Innovations makes no warranty as to its accuracy or use Any use of this documentation or the information contained therein is at the risk of the user This documentation may include technical or other inaccuracies or typographical errors Global Energy Innovations reserves the right to make changes without prior notice Although every effort has been made to assure the accuracy of the representations of the Dynapulse 1224 and 3648 screen displays within this manual last minute changes and alterations may lead to slight differences in the information held within this manual and the actual display Trademarks Global Energy Innovations The GEI logo Dynapulse IBMS CELScan are trademarks of Global Energy Innovations Page
4. 3 set to 24 Volts for the Dynapulse 1224 The connected battery voltage must be above 6 Volts at the 36 Volt Battery Selector 3 set to 36 Volts and above 12 Volts Battery Selector 3 set to 48 Volts for the Dynapulse 3648 This voltage detection feature is part of the battery reverse protection circuitry In the case of a severely discharge battery it may be necessary to connect the discharged battery to a conventional charger for several minutes to get an adequate OCV Press the Start Push Button 6 and hold it until the Green Charge Indicator 11 illuminates about 2 seconds Observe that the Average Output Current 9 meter displays increasing current and both the Sulfated Battery Indicator 1 and the Charge Indictor 11 illuminate NOTE The Sulfated Battery Indicator 1 should extinguish almost immediately for a healthy battery Page 21 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Operating Instructions 16 6 16 7 16 8 16 9 Normal Operation On a good healthy charged battery the operator should observer that the average current climbs to the limited value up to 15 Amps very rapidly and after several minutes or hours for a discharged battery will taper down proportional to its capacity Amp Hour Rating The initial current may surge higher 20 Amps or more but will quickly come down to the 15 Amp level If the battery is not accepting full pulse cu
5. 3648 Systems Users Manual Principles of Operation Technology Background 15 4 15 5 15 6 15 7 The microprocessor adjusts the transistor on time pulse widths to regulate the average current as set by the front panel knob The range is approximately 11 15 Amps of current into the battery At 24 VDC Dynapulse 1224 and 48 VDC Dynapulse 3648 output with 115 VAC line input approximately 11 15 Amps of line current will flow At the lower VDC setting 12 VDC and 36 VDC for the various Dynapulse Systems the AC line current is roughly half the indicated average battery current CAUTION Never use the Dynapulse System on an AC power line that is not properly rated Voltage Control If the Dynapulse System is connected to a good charged battery or if it is left connected overnight to a lightly sulfated battery it will top charge the battery after mild conditioning and restoration The microprocessor constantly monitors the battery voltage and regulates the transistor on time pulse width to limit the open circuit battery voltage to a safe value This prevents battery overcharge and the resulting damage to the battery CAUTION Always ensure you have selected the correct Battery Voltage using the Battery Voltage Selector Failure to do so may result in damage to your battery excessive battery heating thermal runaway and possibly battery fire or explosion End of Charge The battery current is immediately m
6. Manual Operating Instructions 16 OPERATING INSTRUCTIONS 16 1 Front Panel Controls and Indicators 1 8 Sulfated Battery AC Power On Indicator Indicator 9 2 Average Output Output Voltage V Current A 3 B ae Battery Voltage pee Selector 11 4 Charging Done Indicator Indicator 12 Average 5 Current Control Reversed Battery Polarity Indicator 13 Stop Push Button Star a Push Button ale Power Switch 7 DC Battery Cable Connector FIGURE 16 1 1 Front Panel control and indicators Page 18 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Operating Instructions Amber Light When illuminated Indicates battery is NOT accepting peak charge current 1 Sulfated Battery Indicator All LEDs Flashing 1 4 5 and 11 Indicates that the batter has exceeded its overtemperature limit of 50 C 122 F See Section 15 for details on this fault condition Meter Displays average output voltage Volts When Dynapulse is not running displays battery Open Circuit Voltage OCV Knob Dynapulse 1224 Selects between 12 and 24 VDC battery output 3 Battery Voltage Selector Dynapulse 3648 A Selects between 36 and 48 VDC battery output 2 Output Voltage WARNING Always ensure you have set this selector to the proper battery voltage prior to starting Green Light Indicates battery charge has completed normally and sy
7. The balance of the original warranty or for ninety 90 Days from the date returned to the consumer whichever is longer Products or Accessories that are Repaired or Replaced Software as defined above Applies only to physical defects in the media that embodies Ninety 90 days from the date of purchase the copy of the software e g CD ROM What is not covered Exclusions Normal Wear and Tear Periodic maintenance repair and replacement of parts due to normal wear and tear are excluded from coverage Ornamental Decorations Ornamental decorations such as emblems and graphics and other decorative elements are excluded from coverage Batteries Only batteries whose fully charged capacity falls below 60 of their rated capacity and batteries that leak are covered by this limited warranty Abuse amp Misuse Defects or damage that result from a improper operation storage misuse or abuse accident or neglect such as physical damage cracks scratches etc to the surface of the product resulting from misuse b contact with liquid water rain extreme humidity or heavy perspiration sand dirt or the like extreme heat or food c Subjecting the Product or Accessory to abnormal usage or conditions or d other acts which are not the fault of Global Energy Innovations are excluded from coverage Use of Non Global Energy Innovations Products and Accessories Defects or damage that result from the use of Non Global E
8. and 3648 Systems Users Manual Quick Start Instructions 13 DYNAPULSE 1224 amp 3648 SYSTEMS QUICK START INSTRUCTIONS Please read the safety instructions in this Users Guide before operating the Dynapulse 1224 or 3648 Systems 1 The Dynapulse Systems 1224 and 3648 use high voltages internally Once connected to a normal battery the battery limits the voltage to a safe value Disconnecting the Dynapulse System however while it is running may cause high voltages to be present in the battery cables and clips NEVER disconnect the Dynapulse System without first turning it off or pushing the STOP button DO NOT touch the battery terminals for Dynapulse clips while the System is running Connect the Dynapulse System to a power line rated for 15 Amps at 115 VAC For operation at 220 VAC please refer to this Users Manual to change the factory settings from 1150 VAC to 220 VAC before proceeding Connect the DC clamps alligator clamps to the battery The RED clamp goes to battery positive and the BLACK clamp goes to battery negative If there is a beep and a red flashing light from the Dynapulse System you have connected the battery clamps backwards revered polarity This must be corrected for the Dynapulse System to run Turn on the Dynapulse System using the large white rocker switch in the lower right of the front panel Observe that battery open circuit voltage on the Voltage Display IMPO
9. circ A Set eta ns ere DA AAA ERA ARI Set AI Aa 8 10 LIST OF WARNINGS 8 SAFETY PRECAUTIONS GENERAL SAFETY INFORMATION c cceeceeececececeeeceeeceaeeceaecaaecaaesaeceaeeuaeeeeeeseeeeeseesaeesaeesaeetiaeeaes 9 11 UNPACKING THE DYNAPULSE 1224 amp 3648 SYSTEM KITS ccccecceecceeseeeseeceeeceeecaeecaaecaaeceaeceaeceaeceaeeceeeeeeeeeneecaeeseeeseeeseceesaeecaeecaeesaesaaesceeseesensesessaeeeas 11 12 INTRODUCTION a i 12 13 DYNAPULSE 1224 amp 3648 SYSTEMS QUICK START INSTRUCTIONS cecccecceeeeceeceseceeeeesaeceaeeceeeeseeeeeeeseeecaeecaeecacecaaesaaesaaesaeceaeeceeseeeseeeeeseeerees 13 14 PREPARATION FOR USE cunetas aria dbiistas 14 15 PRINCIPLES OF OPERATION TECHNOLOGY BACKGROUND cceeceeeceeeeeececeaeceaecaeceaeensaeceaeceaeeceeseaeeeeeeeceeecaeecaeesaaesaaesaaesaaesaeeeaeecaeeeeeeseeeeseeeseneees 15 16 OPERATING INSTRUCTIONS 02 o a ido 18 17 MAINTENANCE AND SERVICING PREVENTATIVE 8 CORRECTIVE ceccceceeeeeeeeceeeeeeaecaaeceaecaeceaeecaeeeaeeeeeesseeecaeecaeecaaesaaesaaecaaecaeseaeseaeeereseeeeeeetsneees 30 18 PREPARATION FOR SHIPPING si ctmceir iit aie eH Ad Ree nate ed arial cela eo ed ne Re es 35 19 STORAGE ii A A A dai al athe teed ad deli alte dentin AA 36 20 DYNAPULSE 1 224 amp 3648 SPECIFICATION vives castes ncond a a eed aie a a eee ie 37 Page 1 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Declaration of Conformity
10. for most of the work associated with desulfation of the battery The average charging current both charges the battery as well as causes gassing bubbles at the plate electrolyte interface allowing good electrolyte mixing The average current provided by the Dynapulse Systems and accepted by the battery is directly proportional to the power taken from the AC power line Consequently too great an average current will cause the AC power line circuit breaker to trip An average current control knob on the front panel is used to reduce the average current if circuit breaker tripping is a problem 1 L T Lam H Ozgun O V Lim J A Hamilton L H Vu D G Vella and D A J Rand Pulsed current charging of lead acid batteries a possible means for overcoming premature capacity loss Journal of Power Sources 53 1995 215 228 26 Yonglang R Groiss H Doring and J Garche Rate Determining Step Investigations of Oxidation Processes at the Positive Plate during Pulse Charge of Valve Regulated Lead Acid Batteries Journal of Electrochemical Society 146 11 1999 3949 3957 3 J J A Wilkinson and G A Covic A new pulse charging methodology for lead acid batteries IPENZ Transactions Vol 25 No 1 EMCh 1998 NOTE These and similar Technology Background publications can be found on the Global Energy Innovations Customer Support Site http support globalei com Page 15 Global Energy Innovations Dynapulse 1224 and
11. power The matter should be referred to a qualified technician Safety is likely to be impaired if for example the Dynapulse System fails to perform the intended procedure or shows visible damage Page 8 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual List of Warnings and Safety Precautions General Safety Information 10 LIST OF WARNINGS 8 SAFETY PRECAUTIONS GENERAL SAFETY INFORMATION Please read all of the following Warnings before operating your Dynapulse 1224 or 3648 Systems GENERAL SAFETY INFORMATION A CAUTION Removing the Dynapulse System covers or removing parts is likely to expose live parts and accessible terminals which can be dangerous to life WARNING AND SAFETY PRECAUTIONS 1 gt A EA 10 11 12 NEVER leave the Dynapulse System unattended while in operation A live person must be present during operation to shut the unit off or disconnect the battery if there are any unexpected battery faults There are battery fault modes that can lead to thermal runaway Do not use or operate the Dynapulse Systems 1224 and 3648 unless you have been formally trained at servicing electrical power systems including battery and other energy storage devices Before using the Dynapulse System be sure to read all instructions and CAUTIONS in this manual printed on the unit and on the battery Before using the Dynapulse System read all instructio
12. 3 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Safety Instructions Introduction 5 SAFETY INSTRUCTIONS INTRODUCTION Read these pages carefully before beginning to install unpack or use the Dynapulse 1224 and or 3648 Systems The following paragraphs contain information cautions and warning which must be followed to ensure safe operation and keep the Dynapulse System in safe condition WARNING Servicing described in this manual is to be done ONLY by qualified service personnel To avoid electrical shock DO NOT service the Dynapulse System unless you are qualified to do so WARNING DO NOT use the Dynapulse System unless you have been formally trained at servicing electrical power systems including battery and other energy storage devices Page 4 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Safety Precautions 6 SAFETY PRECAUTIONS For the correct and safe use of the Dynapulse 1224 and 3648 Systems it is essential that both operating and service personnel follow generally accepted safety procedures in addition to the safety precautions specified in this manual Specific warning and caution statements where they apply will be found throughout the manual Where necessary the warning and caution statements and or symbols are marked on the Dynapulse 1224 and 3648 Systems Page 5 Global Energy Innovations Dynapulse 1224 an
13. GLOBAL ENERGY INNOVATIONS Global Energy Innovations Dynapulse 1224 and 3648 Restoration Conditioner Charger Systems Users Manual December 2011 Revision 2 0 1 2009 2012 Global Energy Innovations All rights reserved Printed in the USA All product names are trademarks of the respective companies Document EN 5005 2001 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Limited Warranty amp Limitation of Liability 1 LIMITED WARRANTY amp LIMITATION OF LIABILITY Subject to the exclusions contained below Global Energy Innovations warrants its Dynapulse 1224 and 3648 Systems Products Global Energy Innovations branded or certified accessories sold for use with these Products Accessories and Global Energy Innovations software contained on CD ROMS or other tangible media and sold for use with these Products Software to be free from defects in materials and workmanship under normal consumer usage for the period s outlined below This limited warranty is a consumer s exclusive remedy and applies as follows to new Products Accessories and Software purchased by consumers which are accompanied by this written warranty One 1 year from the date of purchase by the Products as defined above first consumer purchaser of the product One 1 year from the date of purchase by the Accessories as defined above first consumer purchaser of the product
14. NOT adequate for packing Place this box in another sturdy cardboard box again with a minimum of 1 inch similar resilient packing material on the top bottom and all sides Contact your local distributor to obtain a Return Material Authorization RMA number and appropriate shipping details Place this number prominently on the outer container and include this number in your shipping materials Page 35 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Storage 19 STORAGE The Systems should only be operated in the following environmental conditions Failure to do so may result in System damage or faulty operation Temperature 0 C to 50 C 32 F to 122 F fi D Elevation See level to 10 000 Feet Note At 10 000 feet elevation the cooling fans are only approximately as effective as at see level Humidity 0 to 95 non condensing Storage may be from 20 C to 70 C 4 F to 158 F and between sea level and 15 000 feet Care must be taken to keep the System dry to prevent corrosion Humidity may range from 0 to 80 non condensing For extended storage at higher humidity pack the System with desiccant and seal it to prevent moister from entering Page 36 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Dynapulse 1224 amp 3648 Specification 20 DYNAPULSE 1224 amp 3648 SPECIFICATION For a complete listing of the Dynapulse 1224 and 3648 perform
15. RTANT Select the proper battery voltage setting on the Dynapulse System front panel Dynapulse 1224 Use 12 Volt for 6 Cell Batteries and 24 Volt for 12 Cell Batteries Dynapulse 3648 Use 36 Volt for 18 Cell Batteries and 48 for 24 Cell Batteries i Select the Battery Size using the selector switch This will change the peak conditioning current pulse amplitude Press the START button until the green CHARGING light comes on This may take a couple of seconds Release the START button The Dynapulse System will condition and charge the battery until the battery current falls below 4 0 Amps for two hours or for eight hours after the START button is pressed NEVER leave the Dynapulse System unattended while in operation A live person must be present during operation to shut the unit off or disconnect the battery if there are any unexpected battery faults Battery temperature must be monitored on a regular basis to ensure there are not any hot spots developing in the battery due to faulty cells There are battery fault modes that can lead to thermal runaway For extra added safety while in operation a Dynapulse 24 Input Temperature Monitoring Block accessory may be used This accessory allows the user to monitor temperature at 24 different locations on a battery while testing is occurring If the accessory is used in the appropriate fashion excessive battery temperature will automatically trigger the Dynapulse to shut dow
16. STOP and then START button must be pressed again at least every 8 hours Overtemperature Page 16 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Principles of Operation Technology Background 15 8 The Dynapulse Systems have temperature sensors built into the battery clamps for accurately measuring post and internal battery temperature If either battery terminal exceeds 50 C 122 F the Dynapulse System output current will shut off Both the ammeter and voltmeter will display all dashes and all front panel indicators LEDs will flash The Dynapulse System must be power cycled Turned OFF then back ON to reset this overtemperature fault condition If the power on the Dynapulse System is turned back before the battery clamps has cooled to below 50 C 122 F the System will not output current NEVER leave the Dynapulse System unattended while in operation A live person must be present during operation to shut the unit off or disconnect the battery if there are any unexpected battery faults Battery temperature must be monitored on a regular basis to ensure there are not any hot spots developing in the battery due to faulty cells There are battery fault modes that can lead to thermal runaway For extra added safety while in operation a Dynapulse 24 Input Temperature Monitoring Block accessory may be used This accessory allows the user to monitor temperature at 24 different locations o
17. Temperature Monitoring Block accessory may be used This accessory allows the user to monitor temperature at 24 different locations on a battery while testing is occurring If the accessory is used in the appropriate fashion excessive battery temperature will automatically trigger the Dynapulse to shut down Page 29 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Maintenance and Servicing 17 MAINTENANCE AND SERVICING PREVENTATIVE 8 CORRECTIVE 17 1 Preventative Maintenance At least monthly during normal operation view the fans through the rear grill to ensure all 4 are rotating A flashlight may be required to observe the fans and cycling the power on and off may help you see the fan blades start and stop Vacuum off any excess dust that obstructs the air inlet slots bottom or outlet grill No other preventative maintenance is required on the Dynapulse Systems 17 1 1 Corrective Maintenance Fan Operation The 4 internal fans are essential to providing proper cooling of the Dynapulse Systems They are also moving parts and subject to normal wear and tear normal wear out Ifa fan stops operating it MUST be replaced before continuing use of the equipment Refer to the Parts List in this manual for details on a replacement fan If the unit is not new and the fan has worn out it is recommended to replace all 4 fans in the same operation Fans are relatively inexpensive are commercially ava
18. Y WORKING IN THE VICINITY OF A LEAD ACID BATTERY IS DANGEROUS BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION FOR THIS REASON IT IS OF THE UTMOST IMPORTANCE THAT EACH TIME BEFORE USING YOUR DYNAPULSE SYSTEM YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY Page 10 Global Energy Innovations Dynapulse 1224 and 3648 Systems D Users Manual Unpacking the Dynapulse 1224 amp 3648 System Kits 11 UNPACKING THE DYNAPULSE 1224 amp 3648 SYSTEM KITS The following items are included in the Dynapulse 1224 and 3648 System kits TABLE 1 is a complete list of the Various Dynapulse System Kits including all standard and optional accessories as well as replacement parts product upgrade and warranty extension options Dynapulse 248 1224 3648 Model Battery Restoration Conditioner Charger Systems Ea eee EQUIPMENT Dynapulse 1224 8656 5002 Dynapulse 1224 System 8656 5002 EQUIPMENT Dynapulse 3648 8656 5003 Dynapulse 3648 System 8656 5003 EQUIPMENT OPTIONAL ACCESSORIES Hard Carrying Transportation Protective Case 8600 5001 REPLACEMENT PARTS Ship Standard with 1224 8656 5002 and 3648 8656 5003 5 Foot 1 53 Meters 6 Gauge Output Cable with Clamps 8600 5005 High Current AC Wall Plug 15 Amp 125 VAC 1010 5001 PRODUCT WARRANTY amp OTHER Calibration Certification Yearly with Certificate 8740 5001 Extended Warran
19. ance and operating specifications please refer to the Technical Data Sheet Dynapulse_1224 3648 Technical_Data_Sheet_EN 5000 2001 PDF This document can be found on the Global Energy Innovations website Performance Specifications and Operating Conditions Test Method Dynapulse Low Frequency Pulse Range 1 30 Ah to 60 Ah Amp Hour Capacity Range Range 2 Above 60 Ah for Batteries Under Test Amp hour measurement capabilities depend upon whether or not the battery impedance is within the measurement range of the device Typically the larger a battery s Ah capacity the lower its impedance Condition Batteries on Float Yes A Current Amplitude Up to 250 Amps Large Batteries 125 Amps Small Batteries Average Output Current 11 25 Amps Adjustable DC Output 1224 Model 12 or 24 VDC 3648 Model 36 or 48 VDC DC Voltage Limit 30 VDC for 12 Volt Setting 60 VDC for 24 Volt Setting Safety Features Voltage Control Regulation of transistor on time pulse widith limits voltage End of Charge Control 9 Amp Qualifying Current 8 4 Amp Minimum Current Ends Charge Timout 8 Hour Timer Shut Off Reverse Polarity Detection Reverse battery indicator light AC Power Input Input Voltage 115 VAC or 230 VAC 10 Page 37 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Dynapulse 1224 amp 3648 Specification Environment Conditions Operating Te
20. antly d your address and telephone number What Other Limitations Are There ANY IMPLIED WARRANTIES INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FORA PARTICULAR PURPOSE SHALL BE LIMITED TO THE DURATION OF THIS LIMITED WARRANTY OTHERWISE THE REPAIR REPLACEMENT OR REFUND AS PROVIDED UNDER THIS EXPRESS LIMITED WARRANTY IS THE EXCLUSIVE REMEDY OF THE CONSUMER AND IS PROVIDED IN LIEU OF ALL OTHER WARRANTIES EXPRESS OF IMPLIED INNO EVENT SHALL GLOBAL ENERGY INNOVATIONS BE LIABLE WHETHER IN CONTRACT OR NOT INCLUDING NEGLIGENCE FOR DAMAGES IN EXCESS OF THE PURCHASE PRICE OF THE PRODUCT ACCESSORY OR SOFTWARE OR FOR ANY INDIRECT INCIDENTAL SPECIAL OR CONSEQUENTIAL DAMAGES OF ANY KIND OR LOSS OF REVENUE OR PROFITS LOSS OF BUSINESS LOSS OF INFORMATION OR DATA SOFTWARE OR APPLICATIONS OR OTHER FINANCIAL LOSS ARISING OUT OF OR IN CONNECTION WITH THE ABILITY OR INABILITY TO USE THE PRODUCTS ACCESSORIES OR SOFTWARE TO THE FULL EXTENT THESE DAMAGES MAY BE DISCLAIMED BY LAW Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Limited Warranty amp Limitation of Liability Some states and jurisdictions do not allow the limitation or exclusion of incidental or consequential damages or limitation on the length of an implied warranty so the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights that var
21. current overloading 16 10 Dynapulse 24 Input Temperature Monitoring Block Accessory A The Dynapulse 24 Input Temperature Monitoring Block Temperature Switch accessory is used in conjunction with the Dynapulse 1224 and 3648 Systems for adding 24 channels of temperature monitoring protection When the Dynapulse System is running any of the 24 temperature switches may activate and turn off the Dynapulse Similar to the temperature switches present in the battery clamps See Section 15 7 when the sensed temperature exceeds 45 degrees Celsius This section details the various components of this accessory The user may select where to place the temperature monitoring switches on the battery or cell for maximum safety protection SSSORHSCECHEC CCT eoRe thes oe i gt eer gt sis gt La 5 D o 11 a Le 5 a 5 a G y S n TERMINAL A TERMINAL B FIGURE 16 10 1 Dynapulse 24 Input Temperature Monitoring Block Terminal A and B are used for inserting the temperature monitoring switched thermistors Page 23 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Operating Instructions FIGURE 16 10 2 Dynapulse 24 Input Temperature Monitoring Block showing connection for Dynapulse Page 24 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Operating Instructions a EXTENSION CONNECTOR FIGURE 16 10 3 Dynapulse 24 Input Temperat
22. d 3648 Systems Users Manual Caution and Warning Statement 7 CAUTION 8 WARNING STATEMENT WARNING Used to alert the user to the possibility of performing an incorrect maneuver which could lead to damage or destruction of the equipment or other property CAUTION Used to call attention to a potential danger that requires correct procedures or practices to prevent property damage personal injury or death Page 6 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Warning and Other Symbols 8 WARNING amp OTHER SYMBOLS Nomenclature and Formatting in this Manual The following safety symbols are used in the Users Manual or on labels on the Dynapulse 1224 and 3648 Systems Notes Warnings and Caution Symbols NOTE A note indicates important information that helps you make better use of your equipment WARNING A WARNING used to alert the user to the possibility of performing an incorrect maneuver which could lead to damage or destruction of the equipment or other property CAUTION A CAUTION calls attention to a potential danger that requires correct procedures or practices to prevent property damage personal injury or death Page 7 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Impaired Safety 9 IMPAIRED SAFETY Whenever it is likely that safety has been impairs the Dynapulse System must be turned off and disconnected from the line
23. ess is suspected remove the cover as instructed above and inspect for water or water damage If water is found the unit may be dried with a heat gun or hair dryer taking care not to overheat the wiring or electronic components Test for proper operation before returning to server If corrosion is found return the System to your local distributor or to the factor for inspection and maintenance Broken Panel Meters or Switches If front panel maters or switches are broken or damaged DO NOT operate the System Return the System to your local distributor or to the factor for inspection and maintenance Page 34 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Preparation for Shipping 18 PREPARATION FOR SHIPPING O The Dynapulse Systems are heavy equipment When properly packed the entire System weighs near 65 pounds 29 4 kg The Systems must be properly packed and cushioned to avoid shipping damage Due to the large mass weight of the Dynapulse Systems shipping damage is very common when not properly prepared and not shipped with a qualified shipping company Wrap the System in plastic to avoid water damage and to prevent packing material ingress during shipping and storage Cushion the front panel with at least 1 inch of form or Styrofoam Place in a sturdy cardboard box with at least 1 inch packing material such as Styrofoam on the top bottom and all sides Crumpled paper or other similar material is
24. he Systems should only be operated in the following environmental conditions Failure to do so may result in System damage or faulty operation Temperature 0 C to 50 C 32 F to 122 F i Elevation See level to 10 000 Feet Note At 10 000 feet elevation the cooling fans are only approximately as effective as at see level Humidity 0 to 95 non condensing WARNING It is very dangerous to attempt to charge a frozen battery Be sure to check for this condition if operating in freezing temperatures Initial Setup 1 Determine the Voltage and Size of the battery to be conditioned The voltage may be 12 24 Dynapulse 1224 36 or 48 Dynapulse 3648 Volts nominally Page 20 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Operating Instructions 2 Set the Battery Voltage Selector Knob 3 to the appropriate setting WARNING Never connect the Dynapulse System to a battery that is not of the appropriate voltage rating Only 12 24 36 and 48 Volt batteries are supported by the Dynapulse 1224 and 3648 For additional battery voltages please refer to the Dynapulse 248 that supports 2 to 48 Volt batteries 3 Set the Battery Size Selector Know 10 to the appropriate setting DM 4 Check the battery for proper electrolyte levels 16 4 Connection to Battery dl Be sure that battery is disconnected from the vehicle or device it is used in WARNING U
25. ilable and also may be ordered from your local distributor or Global Energy Innovations online store Remove the cover to the Dynapulse as instructed below in the Changing Line Voltage Section Remove the fan wiring and from the terminal board making note of the locations of the wires Turn the unit onto its left side Remove eight 8 10 32 Philips screws from the bottom retaining the fan bracket Remove the fan assembly Remove the 10 32 Philips screws retaining the defective fan s Replace the fan s being sure the airflow is directed towards the rear of the Dynapulse System and the fan wires are all gathered together at the common corner Crimp AWF 18 22 6 ring or spade terminals onto each fan wire or gather the wires from all 4 fans and crimp into a single terminal for easier attachment to the terminal board Reinstall the fan bracket Turn the unit upright Reconnect the fan wiring Replace the cover 17 2 Changing Line Voltage The Dynapulse Systems can operate from either 115 VAC or 230 VAC by changing an internal transformer tap A Philips screwdriver is the only tool required to perform the change 17 2 1 Removing the Cover To change operating voltage first be sure the Dynapulse System is unplugged Remove the cover by removing the two wheels at the rear seven 7 Philips screws from each side and four 4 Philips screws from the top as indicated in FIGURE 17 2 1 1 below Page 30 Global Energy Innovations
26. important to break both lines of the incoming power Connect the blue power wire from the AC entrance to the circuit breaker pole nearest the inside and bottom of the unit Connect a jumper between the remaining inside circuit breaker pole and the EMI filter pole 17 2 4 Label and Power Entrance Page 33 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Maintenance and Servicing 17 3 17 4 There is a voltage label at the power entrance on some Dynapulse Systems originally stating that the System operates at 115 VAC Ifthe System is rewired for 230 VAC it is imperative that a label be installed at the power entrance stating that the System is wired for 230 VAC If the unit is wired for 230 VAC and operating at 115 VAC operation will ne be satisfactory If the unit is wired for 115 VAC and operated at 230 VAC internal damage to the System will occur O 17 2 5 Replace Cover While the cover is off inspect for excessive dust or dirt Vacuum as needed Inspect to be sure all loose hardware has been removed Replace the cover in the opposite it was removed The holes in the cover only line up with the closer pair of top mounting hole towards the front of the unit The long handle connects to the front of the unit using the long screws Replace all other screws as well as the two 2 wheels Water Ingress Prevent water from getting into the Dynapulse System both in operation and in storage If water ingr
27. mp Range 0 to 50 C Storage 20 to 70 C Weight 50 Ibs 22 6 kg Dimensions 12 x 12 x 19 5 in 30 5 x 30 5 x 49 5 mm Warranty 1 Year Limited Warranty Replacement Parts Output Cable 5 Ft 1 53 M 6 Gauge DC Output Cable with Clamps AC Wall Plug High Current AC Wall Plug 15 AMp 125 VAC Optional Accessories Preminum Hard Carrying Protective Case Heavy duty carrying tranportation protective case Service Support Instrument Training Customer Support Website Technical Support Hotline Warranty Extension Available 1 and 2 Year Instrument Calibration Program Page 38
28. n Page 13 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Preparation for Use 14 PREPARATION FOR USE The Dynapulse Systems are packed in multiple cardboard boxes with cushioning foam or shipped in a Hard Carrying Transportation Protective Case Optional Accessory P N 8600 5001 Inspect the shipping box for damage before accepting the unit from the shipper Unpack the unit and inspect for obvious mechanical damage Not any rattling or loose parts when the unit is tilted on its wheels If there is any rattling DO NOT operate the equipment until it has been examined by a qualified repair facility If possible retain the packing material in the event the Dynapulse System must be returned to the factory for maintenance repair calibration or other Due to the large mass weight of the Dynapulse Systems shipping damage is very common when not properly prepared and not shipped with a qualified shipping company Page 14 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Principles of Operation Technology Background 15 PRINCIPLES OF OPERATION TECHNOLOGY BACKGROUND 15 1 15 2 15 3 Conversion from Line Voltage The input line voltage is turned on using the front panel circuit breaker power switch The AC line voltage is converted through a transformer and rectifiers to two 35 VDC sources Dynapulse 1224 or 60 VDC sources Dynapulse 3648
29. n a battery while testing is occurring If the accessory is used in the appropriate fashion excessive battery temperature will automatically trigger the Dynapulse to shut down Reverse Battery Polarity Correction amp Low Voltage Alarms CAUTION Connecting a charging source to any battery backwards this is with the positive of the charger feeding into the negative pole of the battery can destroy the battery Depending of the charger design and the battery capacity size the delivered energy can cause the battery to explode or bubble violently and vent electrolyte For this reason the Dynapulse systems monitor the battery connection as a safety measure for detection of reverse polarity A battery connected properly polarity with at lease 2 Volts 12 Volt Setting Dynapulse 1224 or 4 Volts 24 Volt Setting Dynapulse 1224 or 6 Volts 36 Volt Setting Dynapulse 3648 or 12 Volts 48 Volt Setting Dynapulse 3648 terminal voltage must be detected or the Dynapulse Systems will not apply power to the DC battery cable If one of the above conditions is not met the REVERSED ERROR LED indicator will illuminate and an alarm Beeper will sound even with no other power applied to the Dynapulse System Additionally when the Dynapulse System is turned on the red light will flash rapidly any time the output is below 6 Volts Page 17 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users
30. nder certain extreme battery conditions such as a severely sulfated battery or a very bad connection to the battery high voltage pulses can be present that may damage electronics in the device if the battery is not disconnected For vehicle applications it is safest to disconnect the negative chassis ground terminal 2 Connect the DC Battery Cables Red Clamp to positive and Black Clamp to negative battery terminals a 16 5 Startup 1 Plug the Dynapulse System into an AC line with sufficient capacity A dedicated 115 VAC 20 Amp or 230 VAC 10 Amp circuit is preferred but may not always be available in all locations If the circuit is known to be shared with other loads adjust the front panel Average Current Control Knob 12 all the way counterOclockwise to limit the current draw from the Dynapulse System This will limit the AC line current to about 10 Amps line current at the 24 and 48 Volt settings and 5 Amps at the 24 and 36 Volt settings Push the top half of the System Power Switch 14 circuit breaker which will turn on the Dynapulse System Observe the Output Voltage display 2 on the front panel The open circuit battery voltage OCV should be showing It will normally be close to the nominal battery voltage however may be much lower for a severely discharged battery NOTE The connected battery voltage must be above 2 Volts at the 12 Volt Battery Selector 3 set to 12 Volts and above 4 Volts Battery Selector
31. ndicates the System is connected to AC Power and is on This indicator does not indicate 8 AE POE Om indicator that a battery connection has been made 9 Average Output Current A Meter Displays average output current Amps when the Dynapulse is running 10 Battery Size Selector Knob Selects between a small less than 60 Amp Hour and large greater than 60 Amp Hour battery Green Light Indicates that bulk charging is in progress 11 Charge Indicator All LEDs Flashing 1 4 5 and 11 Indicates that the batter has exceeded its overtemperature limit of 50 C 122 F See Section 15 for details on this fault condition Knob Controls the average output current and consequently the average AC input line current This 1a Average Curren Control control is used to prevent reduce AC current load tripping the AC line circuit breaker 13 Stop Push Button rasa Push to stop the System before disconnecting the battery This also resets the internal 8 Hour i i i i TM 14 System Power Switch Switch This Circuit Breaker 2 Pole 20 Amp controls all power to the Dynapulse System and protects against internal faults TABLE 16 1 1 Listing of all Dynapulse System Controls and Indicators on the Front Panel 16 2 16 3 Environmental The Dynapulse Systems require free air circulation for internal cooling The Systems MUST be operated and stored in a dry sheltered environment T
32. nergy Innovations branded or certified Products Accessories Software or other peripheral equipment are excluded from coverage Unauthorized Service or Modification Defects or damages resulting from service testing adjustment installation maintenance alteration including without limitation software changes or modification in any way by someone other than Global Energy Innovations or its authorized service centers are excluded from coverage Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Limited Warranty amp Limitation of Liability Altered Products Products or Accessories with a serial numbers or date tags that have been removed altered or obliterated b broken seals or that show evidence of tampering c mismatched board serial numbers or d nonconforming or non Global Energy Innovations housings cases or parts are excluded from coverage Software Embodied in Physical Media No warranty is made that the software will meet your requirements or will work in combination with any hardware or software applications provided by third parties that the operation of the software products will be uninterrupted or error free or that all defects in the software products will be corrected Software NOT Embodied in Physical Media Software that is not embodied in physical media e g software that is downloaded from the internet is provided as is and without warranty Who is covered This warra
33. ns and cautionary markings on 1 the Dynapulse System 2 the battery and 3 the product that uses the battery The Dynapulse System must be disconnected from all voltage sources before it is opened Capacitors inside the System can hold their charge even if the System has been separated from all voltage sources When servicing the Dynapulse System use only specified replacement parts The Dynapulse Systems 1224 and 3648 use high voltages internally Once connected to a normal battery the battery limits the voltage to a safe value Disconnecting the Dynapulse System however while it is running may cause high voltages to be present in the battery cables and clips NEVER disconnect the Dynapulse System from a battery without first turning it off or pushing the STOP button DO NOT touch the battery terminals or Dynapulse clips while the System is running Hydrogen gas can be present near batteries that are charging and operating on the Dynapulse System Always operate your System in a well ventilated area NEVER smoke or allow a spark or flame in the vicinity of the battery It is recommended that you have baking soda NaHCO3 and water available to absorb neutralize any battery electrolyte that may leak or bubble from the battery Have plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes Wear complete eye protection and clothing protection and always avoid touching your eyes while w
34. nty extends only to the first consumer purchaser and is not transferable What will Global Energy Innovations Do Global Energy Innovations at its option will at no charge repair replace or refund the purchase price of any Products Accessories or Software that does not conform to this warranty We may use functionally equivalent reconditioned refurbished pre owned or new Products Accessories or parts No data software or applications added to your Product Accessory or Software including but not limited to personal contacts site data configurations will be reinstalled To avoid losing such data software and applications please create a back up prior to requesting service How to Obtain Warranty Service or Other Information To obtain service or information please contact Your Local Representative or Distributor e http www globalei com distributorsAndReps html Global Energy Innovations Customer Services Main Phone Number 1 415 354 5688 Facsimile 1 415 354 5738 Email support globalei com Or visit us online at http www globalei com You will receive instructions on how to ship the Products Accessories or Software at your expense to a Global Energy Innovations Authorized Repair Center To obtain service you must include a a copy of your receipt bill of sale or other comparable proof of purchase b a written description of the problem c the name of your distributor or representative if applicable and most import
35. ome very large capacity batteries although perfectly healthy may accept more than 4 Amps of charge for very long periods of time Regardless after 8 hours 15 minutes from the start cycle the Dynapulse System will shut down if the Done Indicator 4 has not illuminated Shutdown For most batteries the Dynapulse System will shut down automatically If the charge terminates normally due to reduced charging current the Done Indicator 4 will illuminate If charge terminates via the timer after 8 hours all lights will be extinguished At any time the Stop Push Button 13 can use used to terminate the Dynapulse System Emergency Shutdown In an emergency toggle the System Power Switch 14 on the front panel This removes all power from the Dynapulse System Circuit Breaker Tripping A Often it is unknown what other loads are on the AC circuit that is connected to the Dynapulse System Consequently the AC line circuit breaker may trip during normal operation If this happens reduce the Average Current Control 12 Knob setting on the front panel by rotating counter clockwise Reset the AC circuit breaker and try again If tripping continues try another circuit or remove other loads from the circuit you are using Page 22 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Operating Instructions CAUTION DO NOT operate the Dynapulse System on a circuit that continue to trip due to
36. onitored after the START button is pressed A heavily sulfated battery or a fully charged battery may refuse to accept charge or may accept a very low average charge current Even a fully charge battery will accept a high charge current for a short period of time several seconds or minutes when first connected where a heavily sulfated battery will not The battery charge current which is continually monitored by the microprocessor must exceed 9 0 Amps to Qualify the battery as being healthy and suitable for accepting a normal charge When the following three conditions are met the Dynapulse System turns off all charging current and displays a DONE light The battery reaches it maximum allowed voltage The battery s charge rate has exceeded the 9 0 Amps Qualifying current The charge current has decreased below a 4 0 Amps set minimum The fans continue to run and the front panel voltmeter continues to show battery voltage If the Dynapulse System times our or if the current drops below 4 0 Amps without ever exceeding the 9 0 Amps Qualifying current the System will turn off charging current but the DONE light will not illuminate Timeout The Dynapulse Systems have an 8 hour built in timer After the START button is pressed the Dynapulse Systems will charge a battery for up to 8 hours 15 minutes If a longer charging period is needed forklift industrial backup utility and other large capacity batteries the
37. orking near lead acid batteries Page 9 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual List of Warnings and Safety Precautions General Safety Information 13 14 15 16 17 18 19 20 21 22 23 24 25 If battery acid contacts your skin or clothing wash immediately with soap and water If acid enters your eyes immediately flood eyes with running cold water for at least 10 minutes and get medical attention immediately When using the Dynapulse on a battery that is still mounted in equipment i e a vehicle generator other disconnect the battery from the equipment and electrical electronic system Failure to do so may result in damage to the electrical system of your equipment DO NOT service or repair battery connections on a charged battery when the circuit is energized If you are using an extension cord power line with your Dynapulse System ensure that the cord meets safety requirements Also ensure the wire gauge is sufficient for the AC current rating The Dynapulse requires up to 15 Amps NEVER operate the Dynapulse System with a damaged AC cord or DC cables Replace any damaged cords or cables DO NOT disassemble the Dynapulse System except as specified in this Users Manual Contact your local distributor or the manufacturer for any repairs inspections or calibrations Improper reassembly may result in electrical shock fire or damage to the uni
38. ow state of charge the lead sulfate can be easily returned to the electrolyte and recovered Batteries that have not been charged for long periods of time will often not accept charge and consequently suffer from premature capacity fade loss The Dynapulse Systems allow for the rapid recovery and conditioning of batteries that have excessive reversible sulfation and prevent irreversible capacity loss due to this sulfation It should be noted that some batteries that have excessive irreversible sulfation will not be recoverable with the Dynapulse System These batteries have passed their usable service life and must be replaced The Dynapulse weighs approximately 50 lbs 18 6 kg It is provided with wheels and a handle for easy movement The unit is supplied with an AC power cord for North America 115 VAC line voltage The unit can be configured for 230 VAC operation When configured for 230 VAC an IEC320 C13 cord is required Instructions for changing from 115 VAC to 230 VAC are provided in this Users Manual The unit is supplied with a DC battery cable that has battery post clamps alligator clamps on one end and a mating connector that attaches to the Dynapulse System on the other end No tools or other equipment are required to operate the Dynapulse System The Dynapulse System is a ventilated electronic system and must be used and stored in a dry indoor environment Page 12 Global Energy Innovations Dynapulse 1224
39. rrent the Sulfated Battery Indicator 1 will stay illuminated Even on heavily sulfated batteries the pulsing of the Dynapulse System can usually dissolve the sulfation and return the battery to a state where it can readily accept charge On a heavily sulfated battery the average current will not climb up to its maximum very rapidly It may take up to 8 hours in an extreme case for the current to reach its maximum Some heavily sulfated batteries can never be recovered due to the excessive energy required for reversing the sulfation If this energy was allowed to enter the battery from the Dynapulse System the positive battery plates would likely suffer irreversible damage before adequate desulfation would take place The electrolyte levels should be regularly checked monitored because the desulfation method is often a vigorous process during which water in the electrolyte is decomposed to hydrogen and oxygen causing NOTE To add water at any time push the Stop Push Button 13 check and add water is accordance with the battery manufacturer s recommendations and then push and hold the Start Push Button 6 to resume desulfation and conditioning When the average current has tapered to less than 4 Amps the Dynapulse System believes the battery is fully charged and will commence a two hour topping charge Two hours after the Done Indicator 4 comes on the System will shut down and the Green Done Indicator 4 will illuminate S
40. stem has disconnected been disconnected from the battery This is only for completion of charge Indicator will not illuminate if shutdown if from The 8 Hour timeout after starting Manual shutdown If the battery never accepted a Qualifying charge of 9 0 Amps See Section 10 for details 4 Done Indicator All LEDs Flashing 1 4 5 and 11 Indicates that the batter has exceeded its overtemperature limit of 50 C 122 F See Section 15 for details on this fault condition Red Light Continuous When System is unpowered a continuous Red indicator accompanied with an audible alarm Beep indicates a Reversed battery connection polarity error Reversed Battery Polarity Red Light Blinking When powered a Red blinking light indicates no good battery connection is found or Indicator that a serious internal error has occurred All LEDs Flashing 1 4 5 and 11 Indicates that the batter has exceeded its overtemperature limit of 50 C 122 F See Section 15 for details on this fault condition 6 Start Push Button Button After connecting to the battery push to start the System This connector is used to connect the Dynapulse System to battery to be conditioned via the DC Battery f DC Battery Cable Connector Cable with Alligator Clamps Page 19 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Operating Instructions Amber Light I
41. t When using the Dynapulse System locate the unit as far away as possible from the battery as the DC cables allow DO NOT expose the Dynapulse System to rain snow or other harsh environmental conditions NEVER operate the Dynapulse System on a frozen very cold battery If the battery electrolyte is frozen or very cold bring the battery into a warm area and allow complete thawing before operating DO NOT allow the Dynapulse DC battery clips alligator clamps to touch each other when the System is on Remove all personal metal items i e necklaces rings watches bracelets etc when working with lead acid batteries and the Dynapulse System Batteries can produce a short circuit current high enough to vaporize or melt a ring or similar Take precautions to NOT drop any metal tools onto the battery or battery terminals Metal can cause sparking or short circuit battery or other electrical devices All tools used in or around a battery should be properly insulated Before using the Dynapulse System ensure that someone is within range of your voice or close enough to come to your aid when you work near a lead acid battery NEVER UNDER ANY CIRCUMSTANCES ATTEMPT TO CHARGE A 2 4 6 OR OTHER VOLTAGE BATTERY THAT IS NOT SUPPORTED BY THE DYNAPULSE 1224 OR 3648 DYNAPULSE SYSTEM THIS WILL RESULT IN SERIOUS DAMAGE TO THE BATTERY AND CREATE A RISK OF EXPLOSION IMPROPER CONNECTION CAN RESULT IN EXPLOSION AND SERIOUS INJUR
42. ty 1 Year Extension 8740 4001 Extended Warranty 2 Year Extension 8740 4002 TABLE 1 Listing of all Dynapulse System Kits including all standard and optional accessories as well as replacement parts product upgrade and warranty extension options Page 11 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Introduction 12 INTRODUCTION Please read all of the following Warnings before operating your Dynapulse 1224 or 3648 Systems The Dynapulse 1224 and 3648 Systems are designed for restoring conditioning and charging 12 and 24 Volt 1224 and 36 and 48 Volt 3648 lead acid batteries of any capacity size Although it works on large capacity batteries it is especially suited for golf cart utility electric vehicle starting lighting ignition SLI and other moderate to small lead acid batteries in the rage of 50 200 Amp Hours Lead acid batteries are happiest when they are fully charged As the battery discharges lead sulfate PbSO is deposited as an oxide onto the plates This is normal When the battery is recharged the lead sulfate is transformed back to lead and sulfuric acid H2SO on the negative plates When the battery is left in a low state of charge and the lead sulfate is left undisturbed ripening growth of the lead sulfate crystal occurs which ultimately impedes the future recharging of the battery If the time between charges is not long and the battery is not left a very l
43. ure Monitoring Block showing extension connector Page 25 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Operating Instructions FIGURE 16 10 4 Dynapulse 24 Input Temperature Monitoring Block connected to Dynapulse System Page 26 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Operating Instructions TERMINAL B lt lt x L FIGURE 16 10 5 Temperature monitor thermistor switch with installation instructions Page 27 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Operating Instructions FIGURE 16 10 6 Temperature switches connected to battery in two locations Page 28 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Operating Instructions ATTACHED TO TOP ATTACHED TO SIDE FIGURE 16 10 7 Temperature switches showing connections to TOP and SIDE Up to 24 locations may be used NEVER leave the Dynapulse System unattended while in operation A live person must be present during operation to shut the unit off or disconnect the battery if there are any unexpected battery faults Battery temperature must be monitored on a regular basis to ensure there are not any hot spots developing in the battery due to faulty cells There are battery fault modes that can lead to thermal runaway For extra added safety while in operation a Dynapulse 24 Input
44. utside blades of the circuit breaker for storage FIGURE 17 2 2 2 oe 115 VAC Oi Jumper 3 m A 3 230 VAC Jumper Z 5 gt Missing ae lt w pes O 0 115 VAC ES Jumper FIGURE 17 2 2 1 Terminal Board jumper settings for 115 230 VAC operation Page 32 Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Maintenance and Servicing System Power Switch 14 115 VAC Line to Switch 115 VAC Switch to EMI Filter Stored Jumper FIGURE 17 2 2 2 AC wiring for 115 VAC operation 17 2 3 230 VAC Operation Single Phase For 230 VAC operation connect the jumper link on the Terminal Board between terminal 6 and 7 Remove the jumper links between terminal 3 and 4 and between 9 and 10 Save the extra jumper link for later use if the unit is converted back to 115 VAC It can be placed between terminals 1 and 2 safely For European use it is important that the power line neutral blue is NOT switched through the System Power Switch 14 in FIGURE 1 Connect the blue wire the neutral wire to the EMI filter blade nearest to the top front of the unit Place the blue jumper wire between the two inside blades of the System Power Switch 14 in FIGURE 1 for storage FIGURE 4 This is the same as North America 115 VAC For North America use including United States Canada and Mexico 230 VAC is HOT on both legs and the neutral is not used by the Dynapulse Systems It is
45. y from state to state or from one jurisdiction to another Laws in the United States and other countries preserve for Global Energy Innovations certain exclusive rights for copyrighted Global Energy Innovations software such as the exclusive rights to reproduce and distribute copies of the Global Energy Innovations software Global Energy Innovations software may only be copied into used in and redistributed with the Products associated with such Global Energy Innovations software No other use including without limitation disassembly of such Global Energy Innovations software or exercise of the exclusive rights reserved for Global Energy Innovations is permitted iii Global Energy Innovations Dynapulse 1224 and 3648 Systems Users Manual Table of Contents 2 TABLE OF CONTENTS 1 LIMITED WARRANTY amp LIMITATION OF EIABIEMVY o 3 scseccet eleane A ides lactated E a a aa e a aA a laut diel a daga lidad eed i 2 TABLE OF CONTENTS iaa R A DA E aed dn lei A lee ene eed ae a eal 1 3 DECLARATION OF CONFORMITY cists 2itazaecsetten coed aiaee 2A eetet a A tdi 2 4 COPYRIGHT NOTICE sii A RR ii eve eel ia E saat A a tetas a AAA alee aetna desea de Te pee aden rer deere alae ede a 3 5 SAFETY INSTRUCTIONS INTRODUCTION cuicos aliadas 4 6 SAFETY PRECAUTION Scsi A A ia tries 5 7 CAUTION S WARNING STATEMENT lt td a dc ii 6 8 WARNING amp OTHER SYMBOLS cnica ideas ini dd eushadecdancdeslesdad deed solana dildo san 7 9 IMPAIRED SARET N
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