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1. The charger surface can get hot while operating and contact with the skin or surrounding materials should be avoided Safety Power ko To reduce the risk of an electric shock connect only to a properly grounded single phase 3wire outlet 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 If you use an extension power cable with your charger ensure the total current draw of the items plugged into the extension power cable do no exceed the current rating of the extension cable and meet all national and local electrical code requirements See Specifications page for current draw of charger 3 AQHF48 17 MANUAL VER 1 1 0712 Overloaded extension cords can catch fire and cause property damage serious injury or death e Do not operate charger if wiring is damaged including cut insulation or pinched wires An electric shock could cause serious injury or death e The charger includes an interlock relay to prevent the machine from operating while charging Please see the machine manufacturer s documentation for correct wiring and test to ensure correct operation 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 propert
2. GEL type lead acid batteries cut the yellow wire loop and ensure the ends do not short to any part 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 white wire to the POSITIVE POS P terminal of the battery Connect the black wire to the NEGATIVE NEG N terminal Ensure that any terminals used are capable of carrying 17 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 an
3. voltage to the charger Charging current is cut back to 8 to 8 5A because battery voltage is On off Six less then 39V No operator action required When battery voltage flash increases above 39V full charging current of 16 to 17A will be restored and the six flash will stop z When a fault occurs a buzzer sounds in the charger if the fault is removed the charger restarts automatically 10 AQHF48 17 MANUAL VER 1 1 0712 Note Over 1 2 of all battery chargers returned as failed are good Please follow the troubleshooting procedures carefully and check all other items before returning the charger as failed Replacing the Charger 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
4. voltages inside the charger are an electric shock hazard and can result in serious injury or death Replace only with parts department charger 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 AC Ground green with yellow stripe AC Neutral light blue AC Line Hot brown DC Battery Negative black DC Battery Positive white Interlock wires Small White and black wires from center back of charger 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 manual ii AQHF48 17 MANUAL VER 1 1 0712 Specifications 7 Electrical Specifications item AC input DC Output 115V 85 137V Voltage 230V 170 264V Automatically Selects 13A at 85V Max 1 ax Current 6 5A at 170V Max 17 ADC 48V nominal 63 4V max Frequency 60 50 Hz Phase SINGLE Output Power Max 1000 Watts teeter tunenrnatt A coremegeauenypamicrtyimseant SIGNET SYSTEMS INC id Mike Sang Choi 4061 Pacific Avenue S Lacey Washington 98503 Tel 1 360 556 6333 Fax 1 360 456 8645 E MAIL s
5. AQHF48 17 MANUAL VER 1 1 0712 User s Manual Supplement to BATTERY SUPPLIES N V Manual s Automatic Switching Mode Battery Charger Part Number AQHF48 17 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 BATTERY SUPPLIES N V If you have any questions call 00 32 56 617977 BATTERY SUPPLIES N V to provide phone number CONTENTS Page Safety nn nnn 2 Operation nnn nnn nnn nnn 5 Maintenance nnn y Troubleshooting m1 8 Replacing the Charger 11 Specifications 12 AQHF48 17 MANUAL VER 1 1 0712 Safety A Danger 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 in
6. Unplug and than plug in charger On Off On to re start charge cycle to complete charging Batteries are weak old or have one or more bad cells Batteries will still charge but capacity will be reduced Replace batteries Output open circuit or short circuit or reverse polarity connection of charger to battery This indicates the charger is in standby mode and ready to start charging at any time the DC is again plugged in On of To flash The output may not be connected to the batteries or the connections to the batteries may have corroded or loosened The output may be shorted due to improper connection to the batteries or pinched wires The output may be connected in reverse polarity to the batteries The charger is not damaged by any of these problems Three Battery voltage is too high may be connected to wrong voltage On Off flash battery Charger is OK but output has been reduced due to Off A h On r Four overheating No operator action required except to make sure BLINK flash charger fins are clean A Four flash may occur anywhere in charge cycle with overheat i AC Voltage too high or too low Check AC voltage and connect charger to correct voltage l On of Five See the electrical specification table for the allowable AC voltage flash input ranges This is an unusual problem and would most likely occur with a very poorly regulated engine generator set providing the AC
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8. ay only show flashing after overnight charging The batteries and charger are fine the machine should be used and charged overnight Within a few weeks green LED will go steady on at the end of charge If batteries are old check the battery condition following the Batteries do not fully battery supplier s instructions Check for dead cells or reduced charge capacity Replace charger only if other problems are not found if the charger LEDs are showing charging progress and charger case gets warm after several hours the charger is probably good and the batteries bad If the green LED is off and the red LED is steady on after a long charge time the batteries have not fully charged after 20 hours of charging time If this occurs with new batteries the machine shouid be used normally and the problem should go away after several weeks of use If the batteries are old they may be bad and should be checked AQHF48 17 MANUAL VER 1 1 0712 Operating and Fault Codes POWER CHRGE Fault Yellow Green Red CONDITION CHECK GUIDE LED LED LED Off Off Off No AC power to charger or inside auxiliary power supply failure On Off Off AC power on but charger is not operating On eet Off Normal battery is under 80 charged On ede Off Normal battery is over 80 charged On On Off Normal battery is 100 charged Charger has timed out at 20 hrs Batteries are extremely discharged
9. cycle will be restarted If the charger is left plugged into AC and the DC is unplugged after charging is completed the FAULT LED will two flash once every 4 seconds with no buzzer sounding This indicates the charger is in standby mode and ready to start charging at any time the DC is again plugged in if the charger is left plugged into AC and the DC is unplugged before charging is completed for 10 seconds the FAULT LED will flash together and the buzzer will sound After 10 seconds the charger reverts to the standby mode described in 7 where the LEDs flash once every 4 seconds but there is no buzzer and the charger is ready to charge again 7 ko 8 a Technical Operation Summary The charger is an advanced microprocessor controlled high frequency switching type charger From 0 to 75 a constant current is provided to the battery bulk charging until a pre set battery voltage is reached From 75 to 100 a constant voltage is maintained and the charging current decreases absorption charging When the charging current falls below 2 to 3A charging is complete The charge curve is temperature compensated to ensure correct charging in cold or hot 6 AQHF48 17 MANUAL VER 1 1 0712 conditions If the charger temperature is above the ambient temperature before charging starts the charger will adjust the charge cycle and somewhat undercharge the batteries Normally the charger will be at ambient te
10. d 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 A CAUTION The charger surface may get hot while charging Avoid skin contact with the charger surface Keep surrounding materials away from charger surface to avoid heat damage and to allow cooling 5 AQHF48 17 MANUAL VER 1 1 0712 1 Connect the DC output wires to the battery 2 Connect the power supply cord to a properly grounded 100VAC 50 or 60 Hz 115VAC 60 Hz or 230 or 240VAC 50 or 60 Hz socket This charger automatically senses and adjusts to the AC input voltage 3 The charger will start automatically within a few seconds Once the charging starts the LED s indicate the charging progress as described in the following Operating and Fault Codes table The charger will start even with severely discharged batteries down to 4V or lower terminal voltage 4 The charger goes into maintenance mode after the batteries are fully charged and the CHARGE LED is steady on In this mode the charger no longer supplies power to the batteries but it continues to monitor battery voltage If the voltage drops below 50V due to self discharge during storage the charger will re start and complete a charge cycle 5 Turn off the charger by disconnecting AC cord 6 If the DC connection to the battery is unplugged and plugged back in the charging
11. ion 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 Identify the problem from the following list and refer to the appropriate section for detailed instructions AQHF48 17 MANUAL VER 1 1 0712 CHECK GUIDE PROBLEM CHECK GUIDE Double check the outlet to ensure it is working by trying out Charger does not turn another known good piece of equipment on the outlet on Check the AC plug and wire to ensure both are in good condition Replace charger if everything else is correct An overloaded AC circuit defective circuit breaker defective fuse or a charger problem can cause this condition First check the total load on the AC circuit to avoid overload If total AC load The AC supply circuit is OK connect the charger to a different AC outlet on a different breaker or fuse is blown 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 If the batteries are charged overnight make sure the AC supply is not being switched off at night with other building items If batteries are new they sometimes need 20 to 30 charge discharge cycles before they charge normally With new batteries the charger green LED m
12. jury 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 AQHF48 17 MANUAL VER 1 1 0712 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 Do not attempt to service the charger yourself unless you are a trained service technician The warranty is void if the charger case has been opened Always follow installation instructions closely l The high voltages inside the charger are a shock hazard and can cause serious injury or death Though the charger is resistant to water and spray washing do not fully immerse or spray wash for an extended more the 5 seconds in one position time Liquid can get inside charger and may cause serious injury or death The charger is designed for use in industrial areas Itis not designed to be used in medical hospital environments where interference with life critical equipment could cause death or serious injury There could be a spark during charging Be careful when using fuels solvents or other flammables near the charger or batteries An explosion could result causing death or serious injury The charger contains chemicals known to the State of California to cause birth defects or other reproductive harm Wash hands thoroughly after handling
13. mperature at the start of charge and the charger will adjust and correctly charge the batteries for that temperature The Charger starts to reduce the output current gradually when the internal temperature gets too high The charger stops at excessive temperature and restarts automatically when the internal temperature decreases to a normal range As long as the battery voltage is at least 4V the charger will start Deeply discharged batteries take a longer time to charge then normal batteries and may require two charge cycles The charger has an 20 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 electric shock hazard Disconnecting the DC output wires near the batteries when the charger is ON may cause the batteries to explode resulting in serious injury or death 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 Some
14. times 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 7 AQHF48 17 MANUAL VER 1 1 0712 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 white Interlock wires smal black and white 5 Follow battery supplier recommendations for battery care and maintenance Note most battery charging problems relate to battery 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 WARNING Do not disassemble the charger High voitages inside the charger are an electric shock hazard and may result in serious injury or death A CAUTION If the AC plug or receptacle is broken twisted bent or loose it cannot make a good electrical connect
15. y 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 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 battery terminals or other exposed electrical parts may cause an electric shock Remove all watches rings and jewelry to avoid arcing and electric shock Initial 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 GEL 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 4 AQHF48 17 MANUAL VER 1 1 0712 The charger profile is selectable by means of a yellow wire loop inside the charger Before power on keep the yellow wire loop intact for wet gassing or flooded lead acid batteries For sealed

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