Battery and Charger
MERGE 11-24
Chapter 11
On-board charger
Operating Instructions
1.
Always use a grounded outlet. When using an extension cord, avoid excessive voltage drops by
using a grounded 3-wire 12 AWG cord.
2.
The charger will automatically turn on and go through a short LED indicator self-test(Models
912-xx0x will flash all LED’s in an up-down sequence and Models 912-xx1x will alternatively flash
its LED RED-GREEN) for two seconds. If the charger is connected to battery pack, a trickle current
will be applied until a minimum voltage is reached. If the charger is used in an off-board application
and the charger is waiting to be plugged into a batter pack, the charging algorithm number will be
displayed for 11 seconds(see “Check/Change Charging Algorithm”) before ultimately displaying an
under-voltage fault(fault disappears when plugged into battery pack).
3.
Once a minimum battery voltage is detected, the charger will enter the bulk charging
constant-current stage. Models 912-xx0x will display the current to the battery on the bar graph
and Model 912-xx1x will flash its LED GREEN off more than on to indicate<80% charge status.
The length of charge time will vary by how large and how depleted the battery pack is, the input
voltage (the higher, the better), and ambient temperatures (the lower, the better). If the input AC
voltage is low (below 104VAC), then the charging power will be reduced to avoid high input
currents (Models 912-xx0x ‘AC’ LED and Models 912-xx1x single LED both flash YELLOW). If the
ambient temperature is too high, then the power will also be reduced to maintain a maximum
internal temperature (Models 912-xx0x bar graph flashes and Models 912-xx1x single LED flashes
YELLOW).
4.
When the battery is at approximately 80% state of charge, the bulk stage has completed and an >
80% charge indication is given (Models 912-xx0x turn on the ‘80%’ LED and Models 912-xx1x will
flash its LED GREEN on more than off). In the next phase known as the absorption or
constant-voltage phase, the last 20% of charge is then returned to the battery. The charging could
be terminated at this point if the vehicle requires immediate usage, however, it is highly
recommended to wait until 100% charge indication is given to ensure maximum battery capacity
and life.
5.
A low current “finish-charge” phase is next applied to return and maintain maximum battery
capacity (Models 912-xx0x will flash the ‘100%’ LED).
6.
When Models 912-xx0x “100%” LED or Models 912-xx1x single LED is continuously GREEN, the
batteries are completely charged. The charger may now be unplugged from AC power (always pull on
plug and not cord to reduce risk of damage to the cord). If left plugged in, the charger will automatically
restart a complete chare cycle if the battery pack voltage drops below a minimum voltage or 30 days
has elapsed.
7.
If a fault occurred anytime during charging, a fault indication is given by flashing RED with a code
corresponding to the error. There are several possible conditions that generate errors. Some
errors are serious and require human intervention to first resolve the problem and then to reset the
charger by interrupting AC power for at least 15 seconds. Others may be simply transient and will
automatically recover when the fault condition is eliminated. To indicate which error occurred, a
fault indication will flash RED a number of times, pause, and then repeat.
[1 FLASH] Battery Voltage High: auto-recover
[2 FLASH] Battery Voltage Low: auto-recover
[3 FLASH] Charge Timeout : the charge did not complete in the allowed time. This may indicate
Summary of Contents for 2010 E-Merge
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Page 79: ...Electric Component MERGE 9 7 Chapter 9 Control circuit ...
