M AQHF24-25 Manual
Contents
1. PE en AQHF24 25 MANUAL 27SEP05 charger as failed Replacing the Charger A 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 A 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 jewelry to avoid arcing and electric shock A WARNING Do not disassemble the charger Take it to a factory authorized service agent when service or repair is required High voltages inside the charger are an electric shock hazard and can result in serious injury or death Replace only with charger designed for use with the batteries and machine to ensure compatibility with all machine systems Make sure the charger is unplugged before replacing and be careful tools do not short battery connections which can cause electric sparks Ensure connections are the same as the original charger with wires connected by a qualified person see tag on AC cord AC Ground green with yellow stripe AC Neutral light blue AC Line Hot brown DC Battery Negative black DC Battery Positi2. Causes gt BATTERIES ARE EXTREMELY DISCHARGED UNPLUG AND THEN PLUG IN CHARGER TO RE START CHARGE CYCLE TO COMPLETE CHARGING gt BATTERIES ARE WEAK OLD OR HAVE ONE OR MORE BAD CELLS BATTERIES WILL STILL CHARGE BUT CAPACITY WILL BE REDUCED REPLACE BATTERIES gt BATTERY PACK TOO LARGE FOR THE CHARGER USE HIGHER OUTPUT CHARGER OR UN PLUG WAIT 20 SECONDS THEN PLUG IN CHARGER TO RE START CHARGE CYCLE TO COMPLETE CHARGING 4 BATTERIES DO NOT FULLY CHARGE If the batteries are charged overnight make sure the AC supply is not being switched off at night with other building circuits Check battery condition following the battery supplier s instructions Check for dead cells or reduced capacity Replace charger only if other problems are not found 5 THE AC LINE CIRCUIT BREAKER OR FUSE 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 charger to a different AC outlet on a different circuit in the building If the charger operates properly on other AC outlets a qualified person should correct the AC circuit problem If the AC supply checks good the charger should be replaced Note Over 1 2 of all battery chargers returned as failed are good Please follow the troubleshooting procedures carefully and check all other items before returning the
3. Safety General e Do not operate a charger that is not working correctly An electric shock hazard or battery explosion hazard from overcharging may exist e 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 e 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 AQHF24 25 MANUAL 27SEP05 opened Always follow installation instructions closely The high voltages inside the charger are a shock hazard and can cause serious injury or death 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 e 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 ba
4. terminals while batteries are charging Sparking can occur which could ignite flammable battery gases and cause an explosion Always turn the charger off first unplug from AC e Do not touch battery terminals or any exposed electrical parts Contact 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 A CAUTION Use of an incorrect charger for the type of battery or battery voltage can result in battery explosion and serious injury and property damage Determine if the batteries to be charged are flooded or Absorbed Glass Mat AGM lead acid type For AGM type batteries the yellow wire loop at the back of the charger should be cut and the wire ends taped This selects the charging profile for the AGM type batteries AQHF 24 25 MANUAL 27SEP05 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
5. AQHF 24 25 MANUAL 27SEP05 User s Manual Supplement to DYNO EUROPE BATTERY SUPPLIES N V Manual s Automatic Switch Mode Battery Charger Part Number HF24 25 IMPORTANT Read understand and follow these safety rules and operating instructions before using this battery charger Only authorized and trained service personnel shall be permitted to operate or perform any maintenance or service This manual should be considered a permanent part of your machine and should remain with the machine at all times This manual is a supplement to the manuals and information provided by DYNO EUROPE BATTERY SUPPLIES N V DYNO EUROPE If you have any questions call 00 32 56 617977 Dyno to provide phone number CONTENTS Page Safety 2 Operation 5 Maintenance 7 Troubleshooting 8 Replacing the Charger 10 Specifications 11 AQHF 24 25 MANUAL 27SEP05 Failure to obey the safety rules and instructions in this manual will result in death or serious injury Label and Safety Rules Legend A DANGER Indicates the presence of a hazard that will cause death or serious injury A WARNING Indicates the presence of a hazard that may cause death or serious injury A CAUTION Indicates the presence of a hazard that will or may cause serious injury or property damage
6. EL LED Charging State 0 to 50 charged Blinking Off Off X 50 to 75 charged On Blinking Off X 75 to 100 charged On On Blinking X 100 charged On On On X Charge for flooded type x x x Off batteries Charge for Sealed type x x x On batteries See Troubleshooting Off Off Blinking X Note X in the table means don t care LED may be off blinking or on Technical Operation Summary The charger is an advanced microprocessor controlled high frequency switching type charger From 0 to 75 a constant current is provided to the battery bulk charging until a pre set battery voltage is reached From 75 to 100 a constant 6 AQHF24 25 MANUAL 27SEP05 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 18 hour timer in case charging can not be completed due to battery problems see troubleshooting section The charger senses and flashes error codes for problems see troubleshooting section Maintenance A WARNING Disconnect from AC voltage before doing any service When plugged in the AC wiring is an electr
7. black wire to the NEGATIVE NEG N terminal Ensure that any terminals used are capable of carrying 20 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 A WARNING There could be a spark during charging Be careful when using fuels solvents or other flammables near the charger or batteries An explosion may result causing serious injury or death A WARNING To reduce the risk of an electric shock connect only to a properly grounded single phase 3wire outlet Electric shock hazard may cause serious injury or death A 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 a
8. djusts to the AC voltage and frequency The charger will flash the LEDs in a start up check then start charging the batteries The GEL LED on the front panel identifies the charge profile for the battery type If the lamp is off the charger 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 The three green LED s indicate the charging progress When the battery is 0 to 50 charged the 50 LED flashes When the battery is between 50 to 75 charged the 50 LED is on while the 75 LED flashes When the battery is between 75 to 100 charged the 75 LED is on and the 100 LED flashes When the battery is fully charged the 50 75 and 100 LEDs are on Charging time is dependent on depth of battery zi AQHF24 25 MANUAL 27SEP05 discharge battery condition and temperature 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 The charger continuously measures battery voltage and restarts the charging cycle if the battery voltage drops below about 25V 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 Charging State amp LED Display 50 75 100 G
9. e LEDs go into normal operational mode and the buzzer stops O0 3 LEDS BLINK ONCE SIMULTANEOUSLY OUTPUT CONNECTION ERROR gt 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 8 AQHF 24 25 MANUAL 27SEP05 corroded or loosened The output may be shorted due to improper connection to the batteries or pinched wires The output may be connected in reverse polarity to the batteries The charger is not damaged by any of these problems 3 LEDS BLINK TWICE SIMULTANEOUSLY AC VOLTAGE PROBLEM gt CHECK THE AC INPUT VOLTAGE THE CHARGER IS INDICATING THE AC VOLTAGE IS TOO LOW OR TOO HIGH CORRECT See the electrical specification table for the allowable AC voltage input ranges This is an unusual problem and would most likely occur with a very poorly regulated engine generator set providing the AC voltage to the charger 3 LEDS BLINK THREE TIMES SIMULTANEOUSLY CHARGER IS OVERHEATED gt NO ACTION REQUIRED WHEN THE CHARGER COOLS CHARGING WILL RE START AUTOMATICALLY CHECK AND CORRECT FOR DIRT OR OTHER DEBRIS ON CHARGER THAT MAY BE REDUCING COOLING 3 LEDS BLINK FOUR TIMES SIMULTANEOUSLY INPUT OR OUTPUT OVER CURRENT gt NO ACTION REQUIRED CHARGER WILL CORRECT AND RE START AUTOMATICALLY 3 100 LED BLINKS WHILE 50 AND 75 LED S ARE OFF The 18 hour timer has elapsed or a bad cell in the battery has been detected
10. ic 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 A 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 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 charger s 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 AQHF24 25 MANUAL 27SEP05 5 Follow battery supplier recommendations for battery care and maintenance Note most battery charging problems relate to batte
11. ry care and not charger problems Troubleshooting A 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 A WARNING Do not disassemble the charger High voltages inside the charger are an electric shock hazard and may result in serious injury or death Identify the problem from the following list and refer to the appropriate section for detailed instructions CHARGER DOES NOT TURN ON 3 LED s BLINK 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 a Pon gt 1 CHARGER DOES NOT TURN ON Double check the outlet to ensure it is working by trying out another known good piece of equipment on the outlet Check the AC plug and wire to ensure both are in good condition Replace charger if everything else is correct Bestia If the AC plug or receptacle is broken twisted bent or loose it cannot make a good electrical connection and an electric shock hazard may exist Have it repaired or replaced by a qualified person immediately DO NOT USE THE CHARGER UNDER THIS CONDITION Fire injury or death may result if not corrected 2 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 th
12. ttery explosion causing serious injury or death Safety Power e 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 voltages can result in an electric shock and fire hazard e lf 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 AQHF24 25 MANUAL 27SEP05 e Do not operate charger if wiring is damaged including cut insulation or pinched wires An electric shock could cause serious injury or death Safety Batteries 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 e When attaching charger leads to battery terminals be careful that tools do not short between battery terminals Shorting between battery terminals may cause extreme arcing resulting in explosion or extreme heat that can cause burns e Do not disconnect charger
13. ve 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 410 AQHF24 25 MANUAL 27SEP05 Specifications Electrical Specifications AC Input DC Output 115V 85 132V Max 31 7 VDC Voltage 230V 170 264V 29 6V 26 C for Flooded Automatically Selects 28 3V 26C for GEL 9 5A at 85V Applicable Battery Specifications For use with 24Volt 180 305 Amp Hour deep cycle lead acid Batteries flooded or sealed gel AGM type
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