Owner Manual

Battery Charger
15Amp(12Volt), 12Amp(24Volt)

0300−5878−01, 0300−5878−02, 0300−5878−03,

0300−5878−04, 0300−5878−05, 0300−5878−06,
0300−5878−07, 0300−5878−08, 0300−5878−09,
0300−5878−10, 0300−5878−11, 0300−5878−12,
0300−5878−13, 0300−5878−14, 0300−5878−15,
0300−5878−16, 0300−5878−17, 0300−5878−18,
A029Y213, A029Y217, A029Y218, A029Y219,
A029Y220, A029Y221, A030K698

English − Original Instructions 11−2012 901−0107 (Issue 7)

Table of Contents
TITLE PAGE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII
Battery Charger Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Weight and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
UL Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
Electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Battery Charger Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . 4
Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Reset Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LED Status Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Circuit Breakers and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DC Output Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AC Input Circuit Breakers / Fuses . . . . . . . . . . . . . . . . . . . 5
Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Internal Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . 6
Battery Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . 6
Alarm Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BATTERY CHARGING AND MAINTENANCE . . . . . . . . . . . . . . . 7
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Stage 1 — Low / Dead Battery Charging . . . . . . . . . . . . . 7
Stage 2 — High (Bulk) Charging . . . . . . . . . . . . . . . . . . . . 7
Stage 3 — Medium (Absorption) Charging . . . . . . . . . . . 7
Stage 4 — Low (Float) Charging . . . . . . . . . . . . . . . . . . . . 7
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

i
Table of Contents (continued)
Connecting / Disconnecting Batteries . . . . . . . . . . . . . . . . . . 9
Always First Disconnect AC Power and DC Loads . . . . . 9
Always Observe Proper Battery Terminal Connection / Dis-
connection Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Always Observe Proper Battery Polarity . . . . . . . . . . . . . 10
Battery Type Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Equalize Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Reasons for Equalize Charging . . . . . . . . . . . . . . . . . . . . 10
Safety Precautions for Equalize Charging . . . . . . . . . . . 10
Equalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Replacing Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Generator Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Wall Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Bench Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Charger Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Generator Installations With Chargers Used in Parallel 17
Battery Charger Configuration . . . . . . . . . . . . . . . . . . . . . . . . 17
Alarm Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Battery Temperature Sensor Installation . . . . . . . . . . . . . . . 18
TROUBLESHOOTING AND SERVICE . . . . . . . . . . . . . . . . . . . . 19
Fault Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Troubleshooting at the Battery Charger Digital Display 19
Clearing Displayed Faults . . . . . . . . . . . . . . . . . . . . . . . . . 19
Loss of AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Replacing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Battery Temperature Sensor Test . . . . . . . . . . . . . . . . . . . . . 22
PARTS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

ii
List of Figures
FIGURE TITLE PAGE
Figure 1. Certification Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 2. Typical Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 3. Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 4. High Battery Voltage Fault . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 5. Circuit Breaker Information . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 6. Optional Battery Temperature Sensor . . . . . . . . . . . . . 6
Figure 7. Battery Charger Dimensions . . . . . . . . . . . . . . . . . . . . . 14
Figure 8. Wiring Connections (Access Cover Removed) . . . . . . 15
Figure 9. Removing Battery Charger Panels . . . . . . . . . . . . . . . . 16
Figure 10. Control Panel Identification Screen . . . . . . . . . . . . . . 17
Figure 11. Battery Voltage Setup Menu . . . . . . . . . . . . . . . . . . . . . 18
Figure 12. Battery Type Setup Menu . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 13. Float voltage Setup Menu . . . . . . . . . . . . . . . . . . . . . . 18
Figure 14. Equalize Battery Screen . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 15. Battery Charger Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 23

iii
List of Tables
TABLE TITLE PAGE
Table 1. Required Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 2. Default Battery Charging Parameters at 25_C6 . . . . . . 8
Table 3. Recommended DC Battery Cable Size for Installations with
NFPA110 Battery Charge Requirement . . . . . . . . . . . . . . . . . 17
Table 4. Recommended DC Battery Cable Size for Installations without
NFPA110 Battery Charge Requirement . . . . . . . . . . . . . . . . . 17
Table 5. Recommended Torque Values . . . . . . . . . . . . . . . . . . . . . 17
Table 6. Float Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Table 7. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

iv
Specifications

BATTERY CHARGER FEATURES

Compatible Battery Types 12 or 24-Volt Lead-Acid, Gel, AGM, Ni−Cad
Maximum Charge Rate 15 Amps @ 12 VDC or 12 Amps @ 24 VDC
Operating Input Voltage 120, 208, 240, 277, 380, 416, 480, 600 VAC
Operating Input Frequency 50 or 60 Hz
Charge Control 4-Stage Automatic Charger with Equalize
Charging Capabilities
Available Battery Type Settings Lead-Acid / Gel / AGM / Ni-Cad
Configurations Stand-Alone and Transfer Switch Assembly
Temperature Sensing:
Charger Temperature Internal Charger Temperature Sensor
Temperature Compensation Charging Optional Battery Temperature Sensor
Network Interface (Not currently available) RS-485 Connector
Alarm Contacts 2 Amps, 30 VDC

ENVIRONMENT
Temperature Range When Operating Within UL BBHH −22 to +122 Degrees F
Specifications (−30 to +50 Degrees C)
Operating Temperature Range −22 to +140 Degrees F
(−30 to +60 Degrees C)
Non-Operating Temperature Range −22 to +158 Degrees F
(−30 to +70 Degrees C)
Relative Humidity 95% (Drip-Proof)

WEIGHT AND DIMENSIONS

Weight 11.6 lbs (5.22 kg)
Dimensions: Length x Depth x Height 9.75 x 5.56 x 6.14 Inches
(247.6 x 141.2 x 156 MM)
ELECTRICAL RATINGS
INPUT 12V BATTERY CHARGER 24V BATTERY CHARGER
OUTPUT OUTPUT
VOLTAGE CURRENT OUTPUT FLOAT OUTPUT FLOAT
CURRENT CURRENT
(NOMINAL) (AMPS) VOLTAGE VOLTAGE VOLTAGE VOLTAGE
(AMPS) (AMPS)
120, 208, 240 4.7, 2.75, 2.4 15.0 13.5 15.0 30.0 27.0 12.0
277 2.1 15.0 13.5 15.0 30.0 27.0 12.0
380 1.5 15.0 13.5 15.0 30.0 27.0 12.0
416 1.4 15.0 13.5 15.0 30.0 27.0 12.0
480 1.2 15.0 13.5 15.0 30.0 27.0 12.0
600 1.0 15.0 13.5 15.0 30.0 27.0 12.0

v
 UL LISTING  The battery charger is rated at 50_C ambient.
 The maximum amp-hour capacity rating for this
The battery charger is UL listed for BBHH and charger is 200 amp-hours for BBHH and BBGQ
BBGQ type applications (battery chargers for emer- applications. This is based on the maximum
gency standby generators). In BBHH and BBGQ ap- size battery bank the charger can completely
plications,
charge from a 0% state of charge in a 24 hour
 The battery charger can only be used with lead- time frame. For Non−BBHH or BBGQ applica-
acid batteries. Other battery types can be used tions the amp−hour capacity rating should be
in non-BBHH/BBGQ applications. kept under 400 amp−hours.

120, 208, AND 240 VAC

BATTERY CHARGERS

277, 380, 416, 480,

AND 600 VAC
BATTERY CHARGERS

FIGURE A. BATTERY CHARGERS WITH UL MARKINGS

vi
Safety Precautions
Electricity and batteries present hazards which can BATTERY CHARGER
result in severe personal injury or death.
Do not use the battery charger unless the battery
Thoroughly read this manual before operating the voltage matches the output voltage rating of the
battery charger. Safe operation and top performance charger.
can only be attained when equipment is operated
and maintained properly. Do not operate the battery charger in a closed-in
area or restrict ventilation in any way.
The following symbols in this manual alert you to
hazards to operators, service personnel, and equip- Never place the battery charger directly above or be-
ment. low the battery. Gases or fluids from the battery can
corrode and damage the charger.
DANGER This symbol alerts you to an imme-
diate hazard which will result in severe personal Do not expose the battery charger to rain, snow, or
injury or death. other precipitation.
WARNING This symbol alerts you to a hazard or Do not operate the battery charger if it has received
unsafe practice that can result in severe person- a sharp blow, been dropped, or otherwise been
al injury or death. damaged in any way. If damaged, take it to a quali-
fied service technician.
CAUTION This symbol alerts you to a hazard or
unsafe practice that can result in personal injury Grounding Instructions: This battery charger should
or equipment damage. be connected to a grounded, metal, permanent wir-
ing system; or an equipment-grounding conductor
ELECTRICITY should be run with circuit conductors and connected
All electrical connections must be made by trained to an equipment-grounding terminal or lead on the
and experienced electricians in accordance with ap- battery charger. Connections to the battery charger
plicable codes. must comply with all local codes and ordinances.

Use caution when working on live electrical equip- Use of an attachment not recommended or sold by
ment. Remove jewelry, use tools with insulated han- the battery charger manufacturer can result in a risk
dles, make sure clothing and shoes are dry, and of fire, electric shock, or personal injury.
stand on a dry wooden platform or insulating pad.
Disconnect all sources of AC and DC power from the
battery charger before servicing.

SAVE THIS MANUAL — IMPORTANT SAFETY INSTRUCTIONS

vii
 BATTERIES charger and turn off all DC loads before disconnect-
ing the battery cables.
To reduce the risk of injury, only use this battery
charger to charge rechargeable batteries of the The high capacitance of the battery charger can
types listed in this manual. Other types of batteries cause sparking whenever battery cables are discon-
can burst, causing personal injury and property nected or reconnected. This is normal, do not be
damage. alarmed. Take the following precautions:
Carefully read and follow all of the battery manufac- 1. Do not disconnect or reconnect the battery
turer’s instructions and safety precautions, such as charger when fuel fumes are present.
removing or not removing cell caps while charging. 2. To keep sparking away from the batteries
Recommended rates of charge and allowable oper- when disconnecting battery cables:
atoring/charging ambient temperature range. Bat-
teries should be provided appropriate ventilation a. Disconnect the negative (−) cable from the
when being charged. battery charger and then the Batteries.
b. Disconnect the positive (+) cable from the
Never charge a frozen battery. battery charger and then the Batteries.
Do not smoke when servicing batteries. Wear safety 3. To keep sparking away from the batteries
glasses. If acid gets in your eyes or on your skin, when reconnecting battery cables:
flush with water for 15 minutes and get medical a. Reconnect the positive (+) cable at the Bat-
attention. teries and then at the battery charger.
To keep sparks from igniting explosive battery b. Reconnect the negative (−) cable at the
gases, always disconnect AC power to the battery Batteries and then at the battery charger.

viii
Introduction
This manual provides information on the installation work must be Belden 9729 Two Pair,
and operation of the 4-stage, 15 and 12 amp, bat- Stranded, Shielded Twisted Pair Cable
tery chargers with equalize charging capabilities. (24 AWG).
These battery chargers can charge 12 volt or 24 volt
lead-acid, Ni-Cad, AGM, or Gel batteries. WARNING Improper service can result in se-
vere personal injury or death and damage to
NOTE: Starting with version 1.22, this battery char- equipment. Service must be performed by
ger supports adjustable float voltages and trained and experienced personnel.
Ni-Cad batteries. For versions prior to
1.22, do not use your battery charger to
charge Ni-Cad batteries! To determine
version, see BATTERY CHARGER CON-
FIGURATION section.

This battery charger is intended for use in perma-

nently wired, industrial applications. This battery
charger is designed for use as a stand-alone char-
ger.

MODEL IDENTIFICATION
To identify your model, refer to the certification label
located on the top of the battery charger (see Fig-
ure 1). Electrical characteristics are shown on the
nameplate.
If there is a problem with the operation of the battery
charger, contact your local distributor and give the
complete description. This information is necessary
to properly identify your unit among the various
types manufactured.

HOW TO OBTAIN SERVICE

If your battery charger requires servicing, contact
your nearest Cummins Power Generation dealer or
distributor. Factory-trained Parts and Service repre-
sentatives are ready to handle all of your service
needs.

Information to have available when calling:

 Part Number including Spec Letter, Serial
Number, and Date Manufactured (gray boxes
in Figure 1)
 Nature of problem (see Troubleshooting, on
page 19).

NOTE: When using any PCCNet device on a

genset control application, the wiring
used to connect ALL devices in the net- FIGURE 1. CERTIFICATION LABEL

1
THIS PAGE INTENTIONALLY LEFT BLANK

2
Description and Operation
DESCRIPTION tery charger (see Figure 2). 120, 208, and 240 VAC
battery chargers include two 10 amp AC circuit
The control panel is located on the top of the battery breaker switches. All other models include two AC
charger. fuse holders on the front of the battery charger.

A 20 amp DC circuit breaker switch, AC wiring, and The battery charger contains an internal tempera-
three connectors are included on the front of the bat- ture sensor and cooling fan.

CONTROL
PANEL

KNOCKOUT
FOR AC WIRING

KNOCKOUT
FOR DC WIRING

20 AMP DC OUTPUT
CIRCUIT BREAKER
SWITCH (SHOWN IN
“ON” POSITION)

FUSE HOLDERS
(NOT INCLUDED
IN ALL MODELS)

OPTIONAL BATTERY
TEMPERATURE
SENSOR
CONNECTOR

FAULT ALARM COOLING FAN

OUTPUT (LOCATED INSIDE
CONNECTOR THE CHARGER)
RS-485 CONNECTOR FOR CIRCUIT
FUNCTIONAL TESTING BREAKER
(FUTURE EXPANSION) INFORMATION

FIGURE 2. TYPICAL BATTERY CHARGER

3
 BATTERY CHARGER CONTROL PANEL Setup Menus
The battery charger control panel includes a digital The Configuration Mode includes setup menus that
display, a RESET button, and an LED status indica- can be used to set the battery voltage and type. Re-
tor (see Figure 3). fer to page 17 for more information. All battery
charging is disabled when Configuration Mode is
Digital Display entered.
The battery charger includes a 2-line x 16-character
digital display that displays menus and faults. Faults

Reset Button The following is a list of the eight possible faults that
can be displayed on the control panel digital display.
The RESET button is used to select menu options
and to clear fault messages.  Overcurrent (fault code 379)
 High battery voltage (fault code 442)
LED Status Indicator  Low battery voltage (fault code 441)
 Input undervoltage (fault code 2331)
The control panel includes a status LED that dis-
 Input overvoltage (fault code 2358)
plays the appropriate color for the following condi-
 Charger overtemp (fault code 2544)
tions.
 Unrecoverable battery (fault code 9115)
 Green − On solid indicates unit is charging  Battery overtemp (fault code 2263) − only avail-
 Amber − On solid indicates Equalizing able on installations that include the optional
battery temperature sensor
 Red − On solid indicates a fault condition. See
the digital display for the fault number. Each fault displayed includes a description and a
fault code number (an example is shown in Figure
4). Battery charging will cease when any of these
DIGITAL LED STATUS faults occur. More information on battery charger
DISPLAY INDICATOR
faults is included in the Troubleshooting section,
starting on page 19.

FAULT 442
High Batt Volts
FIGURE 4. HIGH BATTERY VOLTAGE FAULT

RESET
BUTTON

FIGURE 3. CONTROL PANEL

4
 CIRCUIT BREAKERS AND FUSES

All units include a 20 amp DC output circuit breaker.

Battery chargers also include either two 10 amp AC
input circuit breakers or two fuses. As indicated on
the label on the lower front panel, circuit breakers
are enabled when in the up position (see Figure 5).
This label also includes circuit breaker wiring infor-
mation.

DC Output Circuit Breaker

The 20 amp DC circuit breaker provides output cir-

cuit overcurrent protection. If the circuit breaker trips
(is in the OFF (down) position), there will be no DC
output. Correct the possible overload and reset the
circuit breaker.

AC Input Circuit Breakers / Fuses

The 10 amp AC circuit breakers (120, 208, and 240

VAC battery chargers) or fuses (277, 380, 416, 480
and 600 VAC battery chargers) provides input cir-
cuit overcurrent protection. They protect the AC
power input leads connected to the battery charger.
If an AC circuit breaker is tripped (is in the OFF
(down) position) or a fuse is blown, there will be no
DC output. The required fuses for models that use
them are listed in Table 1. FIGURE 5. CIRCUIT BREAKER INFORMATION

To power down the unit and then power it back up, TABLE 1. REQUIRED FUSES
trip one of the AC input breakers.
Charger Input Voltage Fuse
277 VAC 5 Amp
If either circuit breaker trips, the circuit has shorted.
380 or 416 VAC 3.5 Amp
If a circuit breaker trips, reset the circuit breaker. If a
fuse is blown, it must be replaced. 480 or 600 VAC 2.5 Amp

5
 TEMPERATURE SENSORS the battery. A fault message (fault code 2263) is dis-
played if the battery temperature is too high (reach-
Internal Temperature Sensor es 131 degrees F (55 degrees C)).

An internal temperature sensor monitors the tem- If the temp sender becomes open/disconnected,
perature of the charger and displays a warning mes- the charger temperature defaults to 100 _F.
sage (fault code 2544) if the temperature is too high.
ALARM OUTPUT
Battery Temperature Sensor
The battery charger includes a fault output relay that
Most battery manufacturers recommend that bat- is activated (contacts close) when faults occur. The
teries not be used in conditions higher than 120 de- contacts are rated at 2 amps/30 VDC. This feature
grees F (48.6 degrees C) for Nicad, and 104 can be used by wiring a fault indicator to the fault
degrees F (40 degrees C) for Lead−Acid (wet LA, alarm output connector located on the front of the
Gel, AGM). Batteries exposed to high temperatures battery charger (see Figure 2).
can result in shorted battery cells or an improperly
vented battery chamber. Valve Regulated Lead COOLING FAN
Acid batteries are particulary prone to gassing due
to high temperatures. The cooling fan is located inside the battery char-
ger (see Figure 2). The fan turns on when the inter-
The connector for the battery temperature sensor is nal battery charger temperatures reaches 158
located on the front of the battery charger (see Fig- degrees F (70 degrees C). The fan turns off once
ure 6). The battery temperature sensor is connected the internal battery charger temperatures drops to
from the battery charger to the positive terminal of 140 degrees F (60 degrees C).

FIGURE 6. OPTIONAL BATTERY TEMPERATURE SENSOR

6
Battery Charging and Maintenance
BATTERY CHARGING charging, current is limited by the maximum charg-
ing current, maximum charger current draw, and/or
The battery charger normally goes through the fol- AC circuit breaker rating.
lowing four stages when charging a battery.
The battery charger maintains Stage 2 charging un-
1 − Low / Dead Battery Charging − Only required til the bulk voltage is reached.
if the battery is deeply discharged
2 − High (Bulk) Charging Stage 3 — Medium (Absorption) Charging
3 − Medium (Absorption) Charging
The battery charger switches to Stage 3 charging
4 − Low (Float) Charging when the high charge (bulk) voltage is reached.
When in the absorption stage, the unit outputs
Stage 1 — Low / Dead Battery Charging constant voltage. The current is only limited by the
charger’s output capability or the maximum charger
If the battery is deeply discharged, this stage is re- output set point. If the optional battery temperature
quired to determine if the battery can be charged or sensor is used, the regulated voltage is compen-
needs to be replaced. sated, based on the battery temperature.
A battery is considered to be deeply discharged
The absorption current level depends upon battery
when its voltage is less than 10.2 VDC (12V batter-
type and bank size (see Table 2).
ies) or 20.4 VDC (24V batteries). If the charger de-
termines that the battery is not deeply discharged,
The battery charger maintains the high charge volt-
the charger immediately transitions to bulk charging
age until one of the following conditions are met.
mode.
 The maximum absorption time has elapsed (3
When a battery is deeply discharged, the battery hours).
charger transitions to a trickle current mode and lim-
its the DC output current to 0.5 amps until a DC volt-  The charging current is over 14.2 amps. It then
age of 10.2 (or 20.4) VDC is reached. At that time, reverts back to bulk charging mode.
the battery charger transitions from Stage 1 charg-  Charging current is at or less than the absorp-
ing to bulk charging mode (Stage 2) and continues tion current threshold (4 amps).
charging at full output.
After the absorption state is complete or the maxi-
If the battery voltage does not rise to 10.2 (or 20.4) mum absorption time has elapsed, the charger
VDC within ten hours, the battery is considered to switches to float charging mode.
be dead and the warning message “BATT FAIL”
(fault code 9115) is displayed. Replace the battery.
Stage 4 — Low (Float) Charging
Stage 2 — High (Bulk) Charging
The battery charger switches to Stage 4 charging
The charger enters bulk charging mode when exter- after the absorption stage is completed or the ab-
nal AC power is applied and the battery voltage is sorption time expires. The battery charger remains
greater than 10.2 volts for 12 volt batteries or 20.4 in Stage 4 charging until charging is disabled, exter-
volts for 24 volt batteries. Otherwise, the charger nal AC power is removed, or output exceeds 90% of
enters a low battery charging mode (see “Stage 4 − the bulk mode. If output exceeds 90% of the bulk
Low (Float) Charging”). mode, the charger reverts back to bulk charging
mode. If the optional battery temperature sensor is
The battery charger maintains constant charging used, the float voltage is compensated, based on
current during high (bulk) charging. During Stage 2 the battery temperature.

7
 TABLE 2. DEFAULT BATTERY CHARGING PARAMETERS AT 25_C6
Gel
Parameter Wet Cell (Standard) AGM Ni-Cad5

Bulk Volts − 12V Battery (VDC)1 14.2 14.0 14.4 15.5

Bulk Volts − 24V Battery (VDC)1 28.4 28.0 28.8 29.0
Float Volts − 12V Battery (VDC)1 13.54 13.54 13.54 13.54
Float Volts − 24V Battery (VDC)1 27.04 27.04 27.04 27.04
Equalize Volts − 12V Battery 15.5 N/A N/A N/A
Equalize Volts − 24V Battery 31.0 N/A N/A N/A
Maximum Absorption Time (Hours) 3 3 3 3
Absorption Amps2 4 4 4 4
Temperature Compensation Offset (VDC)3 0.03 0.03 0.03 0.03
1. The default Bulk and Float voltages shown are at the default battery temperature of 80_ F (27_ C). Battery char-
gers that have a battery temperature sensor connected will automatically recalculate charge voltage based on
battery temperature. See the diagram below.
2. Absorption Amps is the current level at which the charging algorithm transitions to Float (Low) Charging. See the
diagram.
3. The Temperature Compensation Offset is the voltage offset per cell per 10_ F (5.6_ C) increment in battery tem-
perature greater or less than 77_ F. The voltage offset is added to charging voltage for temperatures below 77_ F
and subtracted for temperatures above. Using the default value in the table, the voltage offset for 12 VDC is plus
or minus 0.18 volts per 10_ F (0.03 x 6 cells = 0.18). (A 12-volt battery consists of 6, 2-volt cells in series.)
4. Float voltage is configurable. The value indicated is the default.
5. Ni-Cad batteries are only supported in software version 1.22 or greater.
6. If the temp sender is open or disconnected, the default temperature is 100_F, and all voltage levels are reduced
by the appropriate compensation of .03 volts per cell per 10_F.

Charging Begins HIGH (BULK) CHARGING MED (ABSORPTION) CHARGING LOW (FLOAT) CHARGING

VOLTAGE (DC) Float Voltage

Bulk Voltage (Note 1)
(Note 1) Max Absorption Time (3 Hours)

Absorption Amps Level

(Note 2)

CURRENT (DC)
CONSTANT CURRENT CONSTANT VOLTAGE REDUCED VOLTAGE / CURRENT

8
 BATTERY MAINTENANCE sociation (CSA) certified fuses of the specified
amp rating (see page 23).
Carefully read and follow all of the battery manufac-
turer’s recommendations for maintenance and stor- CONNECTING / DISCONNECTING
age and observe all safety precautions. BATTERIES
In addition, the following guidelines for wet-cell bat- Always First Disconnect AC Power and DC
teries will help to ensure long battery life. Loads
 Shallow battery discharges lead to longer bat-
tery life. Discharges of 50 percent or less are To keep sparks from igniting explosive battery
preferable. It is recommended that batteries be gases, always disconnect AC power to the battery
recharged after each period of use. charger and turn off all DC loads before disconnect-
ing the battery cables.
 Discharging more than 80 percent of a battery’s
total capacity can reduce its life. Leaving a bat- WARNING Battery acid can cause severe
tery discharged more than 50 percent for ex- burns. Always wear safety glasses and protec-
tended periods of time can damage the battery tive clothing when working with batteries. If acid
plates and reduce its life. For maximum battery gets in your eyes or on your skin, flush with wa-
life, do not discharge more than 40 percent of ter for 15 minutes and get medical attention.
a battery’s capacity.
WARNING Remove hanging jewelry, rings and
 Batteries that can be charged but cannot sup- bracelets before working on batteries. They can
port a load are probably failing and should be short and weld to battery terminals causing se-
replaced. vere burns.
 Periodic equalize charging is recommended to
WARNING Lead-Acid Batteries produce explo-
remove sulfate crystals that can build up on the
lead plates. The failure to eliminate sulfation sive hydrogen gas that can lead to severe per-
can result in reduced battery capacity and life. sonal injury—Do not smoke near batteries—To
Many battery experts recommend that batter- reduce sparking, always disconnect AC power
ies be equalized periodically, ranging any- to the battery charger, turn off all DC loads be-
where from once a month to once or twice per fore disconnecting the battery cables and ob-
year, depending on usage. Consult the litera- server the Proper Battery Terminal Connection /
ture provided by the battery manufacturer for Disconnection Sequence below.
recommendations.
Always Observe Proper Battery Terminal
 The electrolyte level in Wet Cell batteries Connection / Disconnection Sequence
should the checked at least once a month. Al-
ways keep the level just above the top of the The high capacitance of the battery charger can
plates in each battery cell by adding as much cause sparking whenever the battery cables are
distilled water as necessary. Allowing the elec- disconnected or reconnected. This is normal, do not
trolyte level to fall below the top of the plates will be alarmed. Take the following precautions:
lead to shorter battery life. Using tap water will
1. Do not disconnect or reconnect the battery
lead to shorter battery life due to its high con-
charger when fuel fumes are present.
ductivity (500 to 5000 times that of distilled wa-
ter). 2. To keep sparking away from the batteries
when disconnecting battery cables:
CAUTION Allowing the electrolyte level to
a. Disconnect the negative (−) cable from the
fall below the top of the plates in a Wet Cell
battery charger and then the batteries,
battery will lead to shorter battery life.
 Equalize charging is an important maintenance b Disconnect the positive (+) cable from the
procedure for Wet Cell batteries, though not all battery charger and then the batteries.
Wet Cell batteries require equalization (see 3. To keep sparking away from the batteries
EQUALIZE CHARGING on page 10). when reconnecting battery cables:
 For models with fuse holders, always replace a. Reconnect the positive (+) cable at the
the fuses with UL and Canadian Standards As- Batteries and then at the battery charger,

9
 b. Reconnect the negative (−) cable at the ic gravity throughout the battery cell necessary
batteries and then at the battery charger. for optimum battery performance.
 Equalize charging is also useful for determining
Always Observe Proper Battery Polarity
whether a battery should be replaced. The
Always observe battery polarity when making bat- higher the specific gravity, the higher the State
tery connections to the battery charger. Positive (+) of Charge (SOC). If specific gravity after equal-
must always be connected to Positive (+) and Nega- ization is still less than that specified by the bat-
tive (−) to Negative (−). tery manufacturer:
− The battery might be old, approaching the
CAUTION Damage as a result of reverse polar- end of its life
ity is not covered under Warranty.
− The battery might have been left dis-
BATTERY TYPE CONFIGURATION charged for too long

The installer must configure the battery charger for − Electrolyte might have been lost or spilled
the type of batteries installed, unless Lead-Acid, − A bad cell might be developing
which is the default. This can be done at the digital − Too much water might have been added to
display of the battery charger control panel (see the electrolyte.
page 17).
Safety Precautions for Equalize Charging
EQUALIZE CHARGING
 Equalizing will evaporate water from the bat-
Equalize charging is an important maintenance pro- tery cells. Add just enough distilled water be-
cedure for wet cell batteries, though not all wet cell fore and after equalizing to cover the tops of the
batteries require equalization. plates.
 Open up the battery compartment as much as
Reasons for Equalize Charging
possible for better cooling and ventilation.
 Batteries produce electricity as the electrolyte
 Disconnect all DC appliances before equaliz-
(sulfuric acid and water) chemically reacts with
ing to prevent damage from the high equalize
the lead plates to form lead sulfate. Charging
charging voltage.
with electricity reverses the process: the lead
plates are restored and the sulfate ion is re- CAUTION Disconnect all DC appliances
turned to the electrolyte. Normal charging does before equalizing to prevent damage from
not, however, completely restore the lead the high equalize charging voltage. Liability
plates. After many cycles lead sulfate can accu- for damage to appliances left connected is
mulate on the plates reducing the effective the sole responsibility of the person per-
plate area, thus robbing battery capacity. Over forming equalize charging.
time the lead sulfate will crystallize, further in-
creasing battery resistance. Equalize charging  Batteries must be attended while equalize
removes most of the accumulation of lead sul- charging. Be prepared to stop charging if a bat-
fate by controlled over-charging at a higher tery cell overflows, splits, or cracks.
charging voltage for a specific length of time. CAUTION Equalize charging can destroy
 Because sulfuric acid is denser than water batteries for which it is not a suitable main-
(higher specific gravity), stratification of water tenance procedure. Read the battery
and acid takes place over time. The bubbling manufacturer’s instructions to make sure
action involved in equalize charging remixes equalize charging is a suitable maintenance
the water and acid to restore the uniform specif- procedure.

10
Equalization REPLACING BATTERIES
WARNING Do not use batteries of other types
Battery experts recommend that Wet Cell batteries than specified for use with this battery charger.
be equalized periodically. This should be done any- Other types of batteries can explode, causing
where from once a month to twice a year, depending severe personal injury.
on usage. Follow the recommendations of your bat-
 The battery charger is designed for use only
tery’s manufacturer.
with batteries of the Wet Cell (lead-acid), Gel
Cell (GEL), Absorbed Glass Mat (AGM), or
NOTE: Equalize charging is to used only when the Nickel-Cadmium (Ni-Cad) types. Other types
battery charger is configured for Wet Cell of batteries can explode when subjected to the
(Lead-Acid) batteries. To skip over the charging duty cycle of this application. (Engine
Equalize Battery menu, press and hold the starting batteries are not suitable for deep-
RESET button until normal operation com- cycle service. They have thin plates designed
mences. for brief, high-current service. They tend to
warp and become unserviceable as a result of
the heat generated in deep-cycle service.)
It can take up to 6 hours to equalize charge. Batter-
ies must be attended while equalizing. Someone fa- WARNING Do not use batteries of other
miliar with the process and safety procedures types than specified for use with this bat-
should be present to stop charging if a battery over- tery charger. They can explode causing se-
heats or a cell overflows, splits, or cracks. vere personal injury.
 Do not mix different types of batteries (Wet Cell,
GEL, AGM, Ni-Cad). Each type of battery has
WARNING Lead-Acid Batteries produce explo-
a different set of optimum charging parame-
sive hydrogen gas that can lead to severe per-
ters. Performance will not be optimum if there
sonal injury. Do not smoke near batteries. Wear
is a mix of battery types. Some will be over-
safety glasses. Keep sparks and other sources
charged, others undercharged. Overcharging
of ignition away. Make sure you understand all
a battery reduces its life.
of the safety precautions described above be-
fore equalize charging your batteries.  For units that include the DC output circuit
breaker and the two AC input circuit breakers,
trip all three circuit breakers to remove power
CAUTION Disconnect all DC appliances be- before replacing a battery.
fore equalizing to prevent damage from the high
 For units that include the DC output circuit
equalize charging voltage. Liability for damage
breaker and the two fuses, remove the AC pow-
to appliances left connected is the sole respon-
er source before replacing a battery.
sibility of the person performing equalize charg-
ing.  Before connecting the charger, check the bat-
tery voltage and make sure that the battery
charger is configured for the correct battery
Equalize charge cannot be started until the battery voltage (see page 18).
is fully charged. The battery should be in float mode
before you enter the configuration mode and try to  Before connecting the charger, make sure that
start equalize charging. the battery charger is configured for the type of
batteries installed (see page 18). When replac-
ing batteries with a different type, it will be nec-
Use the RESET button to initiate Equalize Charging essary to reconfigure the battery charge for the
after the battery charger is configured for wet cell new type of batteries.
batteries. For more information on using the config-
uration mode of the battery charger to equalize  Make sure to reconnect the batteries properly.
charge, see “Battery Charger Configuration” on  Used batteries must be disposed of in accor-
page 17. dance with local environmental regulations.

11
THIS PAGE INTENTIONALLY LEFT BLANK

12
Installation
WARNING Improper installation can result in  Be isolated from batteries and fuel tanks and
severe personal injury, death, or damage to other sources of flammable or explosive gases.
equipment. The installer must be trained and ex- The charger (which can cause sparks) should
perienced in the installation of electrical and be located as far away from the battery as prac-
mechanical equipment. tical.
This battery charger can be installed for use with a  Allow for free air flow through the space or
generator. compartment. The battery charger has an inter-
nal cooling fan. Make sure there is no blockage
This battery charger should be connected to a of the air vents. Air flow is from right to left
grounded, metal, permanent wiring system; or an through the battery charger. Provide at least
equipment-grounding conductor should be run with 2 inches (50.8 mm) of clearance to the right
circuit conductors and connected to an equipment- and left sides for good cooling air flow.
grounding terminal or lead on the battery charger.
 Allow for adequate space for all electrical con-
Connections to the battery charger must comply nections.
with all local codes and ordinances. Guidelines for  Allow for easy access to remove the charger for
connecting and disconnecting batteries are listed service or replacement.
on page 9.
 Allow for easy access to the digital display and
All DC connections must be performed by or super- the circuit breaker(s).
vised by a trained and experienced electrician in ac-
cordance with the NEC (National Electric Code, The battery charger should be mounted on a wall or
NFPA No. 70). on a horizontal surface, such as a bench.

GENERATOR INSTALLATIONS Wall Mounting

The top of the charger is drip-proof when it is wall
Location
mounted. For wall mounting, do not place the char-
Select a mounting location that is large enough to ger above the battery; gases from the battery can
install the battery charger (see Figure 7). corrode and damage the charger.
1. Make sure that the AC power source is discon-
WARNING The charger can cause sparks that nected.
can result in severe personal injury and equip-
ment damage. Do not mount the charger near 2. Check the location to be sure that no wires,
batteries, fuel tanks, or other sources of flam- plumbing, gas lines, or exhaust lines running
behind the wall.
mable or explosive gases.
3. Position the charger on the wall.
CAUTION Gases or fluids from the battery can 4. Mark the location for the top two mounting
corrode and damage the charger. Never place holes.
the battery charger directly above or below the
battery. 5. Remove the charger and drill the mounting
holes.
The mounting location for the battery charger must: 6. Use two 1/4” bolts to mount the charger on the
 Be water proof. wall.
 Be on a vibration-free mounting surface that will 7. Mark the location for the bottom two mounting
support the weight of the charger holes.
8. Drill the mounting holes.
 Not be hot, moist, or dusty. The battery charger
is suitable for operation in a temperature range 9. Use two 1/4” bolts to secure the charger to the
of −22 to +122 Degrees F (−30 to +50 Degrees wall.
C). 10. Tighten the bolts.

13
1/4 X 5/8” (6.4 X 15.9 MM)
(4 SLOTTED HOLES) 3.25” (82.6 MM) 1.17” (29.8 MM)

8.96” 9.75”
(228 MM) (247.6 MM)

3.125” (80 MM) 1.06”( 26.9 MM)

6.14“
( 156 MM)

ACCESS
COVER

5.56“ ( 141.2 MM)

FIGURE 7. BATTERY CHARGER DIMENSIONS

14
Bench Mounting a. Remove the nut(s) securing the circuit
breaker switch(es) to the panel.
For bench mounting, do not place the charger b. Remove the screw securing the top panel
above or below the battery; gases or fluids from the to the battery charger. Then remove the
battery can corrode and damage the charger. top panel.
1. Make sure that the AC power source is discon- c. Install the grommet(s).
nected.
d. Use the screw to reinstall the top panel.
2. Position the charger on the mounting surface.
e. Reinstall the nut(s) on the circuit breaker
3. Mark the location for the four mounting holes. switch(es).
4. Remove the charger and drill the mounting 6. Use 16 AWG or larger wire for AC connections
holes. of up to 100 feet. Feed the wires through an
5. Reposition the charger on the mounting sur- opening. Connect AC input wires to AC1 and
face. AC2 of TB1 (see Figure 8).
6. Install four 1/4” diameter mounting bolts.
7. Tighten the bolts. KNOCKOUTS REMOVED AND
GROMMETS INSTALLED
Charger Wiring
WARNING AC voltages present an electrical
TB2 TB1
shock hazard that can cause severe personal
injury or death. Make sure that the AC power
source is disconnected before proceeding.
1. Make sure that the AC power source is discon-
nected.
2. Remove the ground (−) cable of any battery that
will be connected to the charger.

WARNING Ignition of explosive battery

gases can cause severe personal injury and
equipment damage. Do not smoke or cause
any spark, arc, or flame while servicing bat-
teries.
3. Remove the three screws, and the access cov-
er (bottom panel) from the front of the battery
charger.
4. Remove one or both of the knockouts from the
front of the battery charger (see Figure 8).
5. Install grommet(s) in the opening(s).
If necessary, remove the top panel to install the GROUND
LUG
grommet(s), as described below (see Figure
9). Removing the top panel may also be benefi- FIGURE 8. WIRING CONNECTIONS
cial for installing the wiring (see steps 6 and 7). (ACCESS COVER REMOVED)

15
 TOP
PANEL

GROMMET CIRCUIT
BREAKER
NUT

TOP
PANEL
FUSE
HOLDERS

ACCESS COVER
(BOTTOM PANEL)

FIGURE 9. REMOVING BATTERY CHARGER PANELS

7. Install DC wiring to the battery charger. tances greater than 10 feet require
that 10 feet of 12 AWG wiring first
CAUTION Undersized cables can result in be installed on the terminal block
additional charger stress, lower efficiency, and then the appropriate larger
and diminished charger performance. Al- cable be attached for the remain-
ways use the recommended cable sizes. All ing distance.
cables must be UL and CSA certified.
a. Select the appropriate DC battery cable(s) b. Feed the wires selected through an open-
for the distance between the battery char- ing.
ger and the batteries. If your installation c. Connect the positive wire to B+ and the
must meet the NFPA110 requirement to negative battery lead to B− of TB2.
return a fully discharged battery to 100% 8. If the battery charger is more than 10 feet from
of its ampere-hour rating within 24 hours, the battery, connect additional wiring to the
see Table 3. If your installation does not cable installed in step 7.
need to meet the NFPA110 requirement,
see Table 4. 9. Remove the hex nut and one of the EIT lock
washer from the ground lug inside the battery
NOTE: Only 12 AWG or smaller cable can charger. Feed a ground lead (16 AWG or larger)
be installed on the battery charger through an opening and use the hardware to se-
terminal block. Therefore, any dis- cure the lead to the ground lug (see Figure 8).

16
 TABLE 3. RECOMMENDED DC BATTERY TABLE 5. RECOMMENDED TORQUE VALUES
CABLE SIZE FOR INSTALLATIONS WITH Terminal Type Max Torque Value
NFPA110 BATTERY CHARGE REQUIREMENT
SAE, Tapered Terminal Posts 50−70 in-lbs
Distance Gauge
Slide Terminals 70−90 in-lbs
1 to 3 Feet (.3048 to .9144 Meters) 14
Threaded Stud Terminals 120−180 in-lbs
3 to 5 Feet (.9144 to 1.524 Meters) 14
5 to 10 Feet (1.524 to 3.048 Meters) 12 Generator Installations With Chargers
10 to 15 Feet (3.048 to 4.532 Meters) 12 and 10 Used in Parallel
15 to 25 Feet (4.532 to 7.62 Meters) 12 and 8
For parallel use, battery chargers should be hooked
25 to 40 Feet (7.62 to 12.192 Meters) 12 and 6 up as if each one is the only charger. A minimum of
40 to 60 Feet (12.192 to 18.288 Meters) 12 and 4 six inches of space between chargers is necessary
60 to 100 Feet (18.288 to 30.48 Meters) 12 and 2 for adequate air flow. Attach the cables for each
charger at the battery terminals only. Do not hook
them in series or at each others terminal blocks.
TABLE 4. RECOMMENDED DC BATTERY Each charger needs its own set of wires running to
CABLE SIZE FOR INSTALLATIONS WITHOUT the battery and attached at the battery. The wire
NFPA110 BATTERY CHARGE REQUIREMENT lengths from each charger should be the same
Distance Gauge length. Power up all chargers at the same time.
1 to 20 Feet (.3048 to 6.096 Meters) 14 BATTERY CHARGER CONFIGURATION
20 to 30 Feet (6.096 to 9.14 Meters) 12
30 to 50 Feet (9.14 to 15.24 Meters) 12 and 10 The charger identification screen is displayed on the
control panel for less than one second upon power-
50 to 80 Feet (15.24 to 24.38 Meters) 12 and 8 up (see Figure 10).
80 to 125 Feet (24.38 to 38.1 Meters) 12 and 6
NOTE: The charger identification screen shown in
10. Reinstall the access cover (bottom panel). Figure 10 is for version 1.22. For older char-
gers, the version is not displayed. If the ver-
WARNING Ignition of explosive gases can sion is not displayed, do not use your
cause severe personal injury and equip- charger to charge Ni-Cad batteries!
ment damage. Do not smoke or cause any
spark, arc, or flame while servicing batter-
ies.

WARNING AC voltages present an electri-

cal shock hazard that can cause severe per- 15AMP V1.22
sonal injury or death. Take special care to
BATTERY CHARGER
avoid contact with a hot AC line.
11. Connect AC power to the battery charger.
12. Configure the battery charger as described on
page 17.

WARNING Batteries can cause severe per- RESET LED STATUS

sonal injury due to sparks, explosion and BUTTON INDICATOR
acid. Always connect or disconnect a bat-
tery in accordance with CONNECTING / DIS- FIGURE 10. CONTROL PANEL IDENTIFICATION
SCREEN
CONNECTING BATTERIES (see page 9).
13. Connect the DC output wires to the battery The battery charger must be configured for the cor-
(negative [−] lead last). Use the torque speci- rect battery voltage and type before it is connected
fied in Table 5 for the terminal type used for to the battery. To configure the battery charger,
cable connections. press and hold the RESET button for two seconds to

17
enter the Configuration Mode. Adjust the Setup me- TABLE 6. FLOAT VOLTAGES
nus, as necessary. 12 VDC 24 VDC
1. The first charger Setup menu displayed is for 12.8 25.7
setting the battery voltage. Press the RESET
13.0 26.1
button to change the battery voltage (12 or 24
VDC, default = 12 VDC) − see Figure 11. 13.3 26.6
13.5 27.0

SET BATTERY 13.6 27.2

14.3 28.6
VOLTAGE: 12VDC 6. Press and hold the RESET button for two sec-
FIGURE 11. BATTERY VOLTAGE SETUP MENU onds to save the setting.
2. Press and hold the RESET button for two sec- 7. If the battery type selected is lead-acid and it is
onds to save the setting and display the second completely charged, the Equalize Battery
Setup menu (Battery Type). screen is displayed (see Figure 14).
3. When the Battery Type Setup menu is dis-
played (see Figure 12), press the RESET but-
ton to select the battery type (Lead-Acid, Gel,
EQUALIZE
Ni-Cad [version 1.22 or greater], or AGM, de-
fault = Lead-Acid).
BATTERY!
FIGURE 14. EQUALIZE BATTERY SCREEN

SET BATT TYPE: 8. Press the RESET button and release it immedi-
ately to begin equalize. The LED status indica-
Lead-Acid tor turns amber.
FIGURE 12. BATTERY TYPE SETUP MENU NOTE: To skip over the Equalize Battery!
menu, press and hold the RESET but-
4. Press and hold the RESET button for two sec- ton until normal operation commences.
onds to save the setting and display the third Equalize can be stopped by pressing
Setup menu (Float Voltage). the RESET button for two seconds (re-
NOTE: The Float Voltage menu is only avail- entering Setup) or by powering down
able in software versions 1.22 or great- the battery charger.
er.
ALARM OUTPUT WIRING

SELECT FLOAT A two-position terminal block is included for wiring

the alarm output relay to a customer-provided exter-
VOLTAGE: 13.5 VDC nal fault indicator (LED, alarm, etc.).

FIGURE 13. FLOAT VOLTAGE SETUP MENU BATTERY TEMPERATURE SENSOR

INSTALLATION
5. When the Float Voltage setup menu is dis-
played, press the RESET button to select avail- If the optional battery temperature sensor is to be in-
able float voltages (see Table 6). Consult your cluded in your installation, refer to the Instruction
battery datasheet for the best possible choice. Sheet included with the temperature sensor kit.

18
Troubleshooting and Service
FAULT INDICATIONS Troubleshooting at the Battery Charger
Digital Display
Most troubleshooting issues result in fault codes When a fault occurs, the red fault LED lights and a
that are displayed on the battery charger’s digital brief description of the fault and the numeric fault
display. Overload conditions or equipment failures code is displayed on the digital display (see Fig-
may require additional troubleshooting. Trouble- ure 4). To correct the fault, find the fault code num-
shooting procedures are listed in Table 7. ber in Table 7 and take the suggested corrective
actions. Call an authorized distributor for help if the
problem persists.
NOTE: Any fault code stops the charger from
charging the battery. Clearing Displayed Faults
Most displayed faults are cleared by the fault code
NOTE: There are no serviceable parts inside the
being removed. However, faults 379 − OVER
charger assembly.
CURR, 442 − HIGH BATT VOLT, and 9115 − BATT
FAIL can only be cleared by cycling completely
NOTE: Fill out a failure incident report for any trou- through the Setup menus or by powering down the
bleshooting. charger.

TABLE 7. TROUBLESHOOTING
WARNING Some battery charger service procedures present hazards that can result in se-
vere personal injury or death. Only trained and experienced personnel may perform service.
WARNING Ignition of explosive battery gasses can cause severe personal injury. Do not
smoke or cause any spark, arc, or flame while servicing batteries.
Fault Description Possible Cause Solution
379 − OVER Output Overload Output current is excessive. Cycle through the Setup menus to
CURR The charger control may be try and clear the fault. If the fault
failing. returns, the charger control may
have failed. Replace the charger.
441 − LOW Low Batteryy 1. No battery connected. Verify that the battery is connected.
BATT VOLT V l
Voltage 2. Output breaker is in the Verify that the output breaker is in
“Off” (down) position. “On” (up) position.
3. The charger is set for 24V Attach a 24V battery or set the
charging with a 12V bat- charger for 12V charging.
tery connected.
4. The battery can no longer Replace the battery.
maintain a charge.
5. The wire between the Check the wire. Verify connections.
charger and the battery is Verify wire resistance is less than 1
loose or broken. Ohm.
6. The battery is undersized. Replace the battery with a properly
sized battery.
7. The battery cables are un- Verify the cable gauge using Tables
dersized. 3 and 4.

19
 TABLE 7. TROUBLESHOOTING (CONT.)
WARNING Some battery charger service procedures present hazards that can result in se-
vere personal injury or death. Only trained and experienced personnel may perform service.
WARNING Ignition of explosive battery gasses can cause severe personal injury. Do not
smoke or cause any spark, arc, or flame while servicing batteries.
Fault Description Possible Cause Solution
442 − HIGH High Battery 1. The charger is set for 12V Attach a 12V battery or set the
BATT VOLT Voltage charging with a 24V bat- charger for 24V charging.
tery connected.
2. A large load dump may Verify that large loads are switching
have caused momentary in and out and are causing voltage
voltage rise. changes.
2331 − LOW AC Low Input AC input voltage is more Check the level of the input voltage.
VOLT Voltage than 10% below nominal The charger will not operate with
rated voltage. voltage 10% or more below
nominal.
2358 − HIGH AC High Input AC input voltage is more Check the level of the input voltage.
VOLT Voltage than 10% above nominal The charger will not operate with
rated voltage. voltage 10% or more above
nominal.
2263 − HIGH Battery 1. The battery’s ambient tem- Move the battery into a cooler
BATT TEMP Temperature is perature is too high. location. The charger will
above 55 automatically begin charging again
(For installations degrees C after the battery temperature
that include the lowers.
optional battery
temperature 2. The battery sensor has Replace the battery sensor.
sensor) failed.
3. Possible shorted cells Replace the battery.
within the battery is caus-
ing an excessive battery
temperature increase.
4. The battery is undersized. Replace the battery with a properly
sized battery.
2544 − OVER Charger is 1. The charger’s ambient Move the charger to a cooler
TEMP overheating temperature is too high. location. The charger will
automatically start charging again
after the internal temperature
lowers.
2. The charger’s internal Verify that the charger’s air inlets
cooling fan is blocked or on the side of the charger are not
air inlets are covered. blocked and nothing is interfering
with fan rotation.
3. The charger’s internal Replace the charger.
cooling fan has failed.
9114 − OUTPUT No Battery 1. Their is no current draw Check battery wire and terminals
LOST Connected from the charger for 8 sec- for continuity.
onds.

20
 TABLE 7. TROUBLESHOOTING (CONT.)
WARNING Some battery charger service procedures present hazards that can result in se-
vere personal injury or death. Only trained and experienced personnel may perform service.
WARNING Ignition of explosive battery gasses can cause severe personal injury. Do not
smoke or cause any spark, arc, or flame while servicing batteries.
Fault Description Possible Cause Solution
9115 − BATT Unrecoverable The battery can no longer Replace the battery and cycle
FAIL battery hold a charge or it has been through the Setup menus to clear
damaged excessively due to the fault.
extremely deep discharge.
No DC Output Charger not 1. Tripped DC circuit break- Correct the possible overload and
charging er reset the circuit breaker.
2. No battery attached Make sure the battery is attached
before attemting to read DC volts.
3. No active AC source Verify that the AC source is
supplying the charger with power.
4. Blown AC fuse(s) (277, Correct the possible overload and
380, 416, 480, and 600 replace the fuse(s).
VAC battery chargers)
5. Tripped AC circuit break- Correct the possible overload and
er(s) (120, 208, and 240 reset the circuit breaker.
VAC battery chargers)
6. Active fault code on char- Clear the fault and verify operation.
ger
7. Failed charger Replace the charger.
No Display
p y Display
p y not 1. The charger is damaged. Replace the charger.
working
ki 2. AC protection is acti- Verify that the AC circuit breakers
vated. are “On” (up) (120, 208, and 240
VAC chargers) or that the AC input
fuses are not blown (277, 380, 416,
480, and 600 VAC chargers).
3. AC input is miswired. Verify that there is AC input voltage
at the charger’s input terminals.
4. There is no active AC Verify that the AC source is
source. supplying the charger with power.
NOTE: The following faults can only be cleared by cycling completely through the Setup menu or by power-
ing down the charger.
379 − OVER CURR
442 − HIGH BATT VOLT
9115 − BATT FAIL

21
Loss of AC Power 1. Disconnect the battery charger from AC power
and the battery.
When there is a loss of power, the relay contacts an-
2. Unscrew the fuse holders from the front of the
nounce this fault as an AC power loss. Since the
battery charger.
charger is no longer powered, nothing is displayed
on the digital display. 3. Check the fuses and replace the blown
fuses(s).
REPLACING FUSES
4. Reinstall the fuse holders.
When replacing a blown fuse on models that use 5. Reconnect the battery charger to AC power
them, be sure to use a fuse of the same rating and and reconnect the charger to the battery.
type. Do not use fuses of a higher rating. Fuses
must be UL and CSA certified. Replacement fuses BATTERY TEMPERATURE SENSOR TEST
are listed on page 23.
To determine that the optional battery temperature
WARNING Voltages within the charging sys- sensor functions properly, disconnect the sensor at
tem present an electrical shock hazard that can the battery charger (see page 3) and measure
cause severe personal injury or death. Discon- electrical resistance across the two leads of the sen-
nect all sources of AC and DC power from the sor. Replace the sensor if resistance is not 8000 to
battery charger before servicing. 15,000 Ohms at room temperature.

22
Parts Information

5
4

FIGURE 15. BATTERY CHARGER PARTS

REF PART QTY PART REF PART QTY PART

NO. NO. USED DESCRIPTION NO. NO. USED DESCRIPTION

1 Kit, Battery Charger 300−5878−11 1 480 VAC (ATS production

300−5878−01 1 120, 208, 240 VAC only)
(Accessories) 300−5878−12 1 600 VAC (ATS production
300−5878−02 1 277 VAC (Accessories) only)
300−5878−03 1 380 VAC (Accessories) 300−5878−13 1 120, 208, 240 VAC (Field
300−5878−04 1 416 VAC (Accessories) installed ATS accessories)
300−5878−05 1 480 VAC (Accessories) 300−5878−14 1 277 VAC (Field
300−5878−06 1 600 VAC (Accessories) installed ATS accessories)
300−5878−07 1 120, 208, 240 VAC (ATS 300−5878−15 1 380 VAC (Field
production only) installed ATS accessories)
300−5878−08 1 277 VAC (ATS production 300−5878−16 1 416 VAC (Field
only) installed ATS accessories)
300−5878−09 1 380 VAC (ATS production 300−5878−17 1 480 VAC (Field
only) installed ATS accessories)
300−5878−10 1 416 VAC (ATS production 300−5878−18 1 600 VAC (Field
only) installed ATS accessories)

23
REF PART QTY PART REF PART QTY PART
NO. NO. USED DESCRIPTION NO. NO. USED DESCRIPTION

A029Y213 1 120, 208, 240 VAC (THOR 3 Fuse

production) 0321−0405−01 2 5 Amp − 277 VAC
A029Y217 1 277 VAC (THOR 0321−0405−02 2 3.5 Amp − 380 and 416 VAC
production) 0321−0405−03 2 2.5 Amp − 480 and 600 VAC
A029Y218 1 380 VAC (THOR 4 541−0918 1 Sensor Kit, Battery
production) Temperature
A029Y219 1 416 VAC (THOR 5 323−1678−02 1 Connector, Fault Alarm Output
production)
A029Y220 1 480 VAC (THOR
production)
A029Y221 1 600 VAC (THOR
production)
A030K698 1 120, 208, 240 VAC (Low
range production)
2 508−0071 2 Grommet

24
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1
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Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Email [email protected]
www.cumminspower.com
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