14
TROUBLESHOOTING AND TECHNICAL GUIDE
To be able to troubleshoot safely and effectively, it is important to read this guide completely before beginning any
tests.
WARNING: DO NOT DESASSEMBLE THE CHARGER. TAKE IT TO A QUALIFIED SERVICE AGENT WHEN SERVICE OR
REPAIR IS REQUIRED. INCORRECT REASSEMBLY MAY RESULT IN A RISK OF ELECTRIC SHOCK OR FIRE. THE FOL-
LOWING PROCEDURES ARE INTENDED ONLY TO DETERMINE IF A MALFUNCTION MAY EXIST IN THE CHARGER.
DANGER: TO REDUCE THE RISK OF ELECTRIC SHOCK, ALWAYS DISCONNECT THE CHARGER
’
S AC CORD SET
FROM AC POWER AND ITS DC CORD SET FROM BATTERIES BEFORE ATTEMPTING ANY MAINTENANCE OR CLEAN-
ING.
•
LEDs Frozen (no activity) or Charger seems inoperable:
•
Battery may have been subjected to an Over
-
Discharge condition. Using a DC voltmeter, check if battery
voltage is well under its 100% depth of discharge level defined as 1.75 volts per cell (VPC) for lead acid
batteries (21.0 volts for a 24V battery system). Disconnect AC, then disconnect the DC charge cables and
re
-
connect. Connect AC to resume charging.,
•
Batteries Hot To the Touch—Charger continues to charge:
•
A hot battery or batteries may signify cells that are:
•
Shorted due to material collected at the bottom of the cell and not able to break down and re-
combine back into the battery plates, and/or
•
Stratification of the acid into layers were a denser acid layer is carrying most of the amperage
•
An overcharged cell due to other cells being unbalanced and at a much lower state of charge
Possible corrections include:
•
Cease charging, operate vehicle to slightly discharge battery pack, then resume charging
•
Breaking apart the battery pack and load test each battery—replace defective batteries
•
Check Charger MODE setting and confirm charger is configured for the proper charge algorithm
TECHNICAL NOTES
•
Do not connect
charger to a receptacle that shares its circuit with other loads such as motors and most all
common appliances. These shared circuits cause severe line voltage droops that, upon appliance abruptly
turning on or off, will cause instantaneous line voltage changes that may be beyond the ability of the charger
to compensate fast enough, causing permanent non
-
warranty damage to charger.
•
Do not charge more than one battery pack at a time. Battery pack characteristics differ and may cause the micro-
processor to misinterpret algorithmic values and possibly function improperly.
•
Do not charge more than one battery pack at a time. Battery pack characteristics differ and may cause the micro-
processor to misinterpret algorithmic values and possibly function improperly.
•
If charging a series connected string of two or more batteries or cells, ensure that all batteries and cells in the
series connected string, are all at the same state of charge, age, type, and condition.
•
The charger uses RF energy only for its internal functions. Therefore its RF emissions are very low and are unlike-
ly to cause any interference in nearby electronic equipment.
