Installation
Location
Do not mount directly over or under a battery or onto a
carpeted, upholstered or varnished surface.
Install in an area where all charger electrical cords will avoid
hot surfaces such as exhaust pipes and moving parts such
as fan wheels.
Operating temperature is -10°C to 55°C (-14°F to 131°F).
Storage temperature is -30°C to 80°C (-22°F to 176°F).
Provide as much surrounding cooling clearance as possible
for maximum efficiency, safety, and shortest recharge times.
At a minimum, maintain a 3 inch clearance around the
perimeter and the top side of the charger.
Never mount in the vicinity of explosives, pressurized cans
or other flammable material.
Mounting
Wear safety goggles, gloves and a long sleeve shirt when
drilling mounting holes near a battery.
In most cases, #10 stainless steel mounting bolts with aircraft
nuts, nylocks, or #10 screws will provide for solid mounting.
For extreme vibration conditions common in ATV and PWC
applications, added security such as crossed shock cords
are recommended.
Electrical
AC wire connections
The CT500-6 is equipped with a factory installed 6 foot AC
cord with a ground connection. The ground connection is the
round pin on the AC plug.
It is extremely important that
only grounded electrical outlets or extension cords with
a ground connection should be used when operating this
charger.
Never connect the AC plug into an electrical outlet if you are
wet or barefoot.
Ensure that the AC cord cannot reach moving parts, lids,
hoods, etc. Secure with a cable tie to solid anchor point if
necessary.
The charger will operate properly with either 220 volts 50 Hz
or 220 volts 60 Hz AC input.
DC wire connections
DC wire connections to the battery should be made before
plugging in the AC cord.
The charger should only be used with lead-acid type batteries
such as AGM, SLA, flooded or maintenance free. If there is
any question, please contact the factory.
The charger will not operate until DC connections are made.
When installing in the bilge of boats or any battery compart-
ment, ensure that hatches are open and bilge blowers are
operating for ten minutes to remove any fumes and hydrogen
gas. Be certain the area is ventilated for personal health and
safety.
Keep wire routing from the charger to the battery neat and
secure by anchoring with cable tie to a solid surface every
few inches, not to exceed 18 inch intervals.
Ensure that cables have sufficient clearance from moving
parts and hot surfaces such as exhaust components.
The CT500-6 is short circuit protected. Batteries are a high
current source and additional protection is needed in the
event of physical damage to the DC cables or the charger,
or electrical damage that may be externally induced. An
in-line fuse (32 volts/5 amps rating) connected between the
positive battery charger lead and the battery positive terminal
is required for maximum safety. The fuse’s mechanical at
-
tributes are installation and environmentally specific. Consult
the factory if selection assistance is required.
For a single 24 volt battery, connect the charger DC cable to
the battery as follows: the red lead is connected to the posi
-
tive terminal of the battery and the black lead is connected
to the negative terminal of the battery. When charging two 6
volt batteries connected in a series, connect the red lead of
the charger to the positive terminal of battery #1. Connect
the negative terminal of battery #1 to the positive terminal
of battery #2. Connect the black lead of the charger to the
negative terminal of battery #2. All connections should be
clean and tight. See installation diagram below.
When connecting two batteries in series, it is imperative that
the amount of charge and discharge be equal for both bat-
teries. If there is an imbalance during charge or discharge,
excessive battery voltage will occur. This results in an over
-
voltaged battery and will cause dangerous battery out gassing
and destruction. For accurate charge balancing, use the dual
output chargers such as the CT500-1 or TPRO series.
Safety instructions
CAUTION: The following are important safety instructions.
Save these instructions.
Charge only lead acid, maintenance free, refillable, or “gel-
cell” rechargeable batteries. Other types of batteries may
burst causing personal injury or damage.
Never smoke or allow sparks or flame in the vicinity of a
battery.
Someone should be within the range of your voice and close
enough to come to your aid when you are working near a
battery.
Wear eye protection and clothing protection. Avoid touching
your eyes while working near a battery.
Have plenty of fresh water and soap nearby in case the battery
acid contacts your skin, clothing or eyes.
If the battery acid contacts skin or clothing, wash immediately
with soap and water. If acid enters your eyes, immediately
flood them with cold running water for at least ten minutes
and get immediate medical attention.
Never operate a charger with a damaged cord or plug.
Degradation of AC and DC cords, accidentally nicking or
cutting the cords could result in sparking and cause injury.
Never operate a charger that has been damaged in any way
or try to disassemble it. Return it to the factory when service
or replacement is required. Incorrect reassembly may result
in an electrical shock or fire.
Become familiar with all instructions and cautionary markings
on chargers, batteries and equipment used. Only adults
should install and operate the charger. The charger and
batteries should be kept out of the reach of children.
When using an extension cord, the CT500-6 requires a quality
grounded extension cord of at least 18 awg wire size for cords
up to 50 feet and a minimum of 16 awg for cords up to 150
feet.
Never unplug a cord by pulling on the cord itself. Always
grasp the plug when disconnecting the charger.
The CT500-6 is waterproof and designed for harsh
environments. It is not designed to be submerged. Please
consult the factory if there are any questions.
Never charge a frozen battery. If the battery has an odor or
is visibly damaged, disconnect the charger and consult the
factory.
Study the battery manufacturer’s precautions such as
removing or not removing cell caps while charging.
Keep batteries full. Add distilled water in each cell until it
reaches the levels specified by the battery. Check the battery
fluid levels regularly.
Good battery maintenance procedures dictate that the battery
fluid levels be checked on a regular basis, especially in high
ambient temperatures.
Keep the battery terminals clean. Always unplug the charger
before cleaning. Keep corrosion from coming into contact
with your eyes.
Remove personal metal items such as rings, bracelets,
necklaces, and watches when working with a lead-acid
battery. A lead-acid battery can produce a short circuit high
enough to weld objects to metal, causing a severe burn.
Stage 1: Constant current or bulk charge mode
Assuming that the battery is starting in a discharged state, the
charger is operating in constant current mode. The charger
current is maintained at a constant value and the battery voltage
is allowed to rise as it is being recharged. Approximately 80%
of battery capacity is returned in the constant current region.
Stage 2: Absorption mode
When the battery voltage reaches approximately 2.4 volts per
cell, or 14.4 volts for a 12V battery, the charger voltage is held
constant at this level and the battery current is allowed to reduce.
This voltage is maintained until the charging current reduces
substantially indicating a full charge. At this point, the battery
is fully charged.
Stage 3: Float mode
Float mode is the final stage of the charging routine. During float
mode, the voltage on the battery is maintained at approximately
2.25 volts per cell, or 13.5 volts for a 12V battery. This voltage
will maintain the full charge condition of the battery without boil
-
ing out electrolyte or overcharging the battery.
Three stage charging curve
Three stage charge cycle
The CT500-6 employs a three stage charge routine. This is the
charging procedure most lead-acid battery manufacturers rec-
ommend to return full capacity efficiently and extend battery life.
Single 24V battery connection
Two 12V battery connections
Battery
voltage
Stage 1: Bulk
(constant current)
Stage 2: Absorption
(constant voltage)
Voltage constant,
current decreasing
Battery
current
Absorption
Voltage constant,
full charge maintained
Stage 3: Float
(constant voltage)
Float
Bulk
