Yale 524150797, Maintenance Manual

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Excessive Charge Time Error: Occurs when
charging took too long AND the battery voltage was
not allowed to increase above 2.17V/cell. Possible
causes include: use of a battery load that is draining
energy from the battery while the charger is trying to
charge that same battery, aged or unbalanced battery
cell conditions, etc.
Mode Selected Empty: The selected Charge
Algorithm, set via the User Selected Switch Setting, is
empty and not a valid setting for charging batteries –
reset the MODE Select switches to a valid value.
Lockout (Inhibit) Enable Defective: If an Equipment
Lockout (Inhibit) Cable is installed and supposed to be
active, but it is not, this error is produced – Check
Inhibit vehicle wiring. If correct, internal inhibit switch
may have been overload – contact factory. Also refer
to the Lockout Inhibit Option Section for External
Wiring diagram for this circuit schematic and how it
interfaces to an equipment’s Run-Contactor.
Lockout (Inhibit) Disable Defective: If an Equipment
Lockout (Inhibit) Cable is installed and supposed to be
deactivated, but was not, this error is produced –
Check Inhibit vehicle wiring. If correct, internal inhibit
switch may have been overload – contact factory. Also
refer to the Lockout Inhibit Option Section for External
Wiring diagram for this circuit schematic and how it
interfaces to an equipment’s Run-Contactor.
Internal Over Temperature: Charger shut down due
to an internal over temperature condition – check fan
operation and remove blockages, if any. Also, remove
any air flow obstructions in and around the immediate
vicinity of the product. Clean/clear away grease, grime
and any debris from product. If this does not remedy
situation, product may have been permanently
damaged. Contact the factory or your point of
distribution.
A.C. Convenience Port Accessory
If the optional A.C. Convenience Port Accessory is
include with your system, the LED display mirrors the
Charger LED Display – with one exception:
If an LED pattern flashes from the center LED out, in a
repeating pattern, the Port is indicating a Lost
Communications error. Check wiring for continuity.
GENERAL TROUBLESHOOTING
Wake-Up Circuit
For the battery to come up from the shut down or
sleep mode state, B- must be connected to pin 3 of the
battery connector. Refer to Figure 6 and Figure 8. The
B- input through pin 3 is what the battery use as a
signal to indicate that battery shall provide all available
voltage through the poles or "awake" the battery. To
awake the battery, key switch is being used to connect
B- to pin 3 of the battery. Upon closing key switch
(moving key switch to the ON position), the connection
between lithium ion battery pin 3 and B- terminal pole
is made. The B- connection at the key switch is also
used to provide ground to a relay circuit that is
connected in parallel to the pin 3. Thus, using the key
switch to connect B- to the wake-up pin of the battery,
will turn on the battery and through the relay circuit will
also turn ON the truck. When the relay coil is
connected to ground, the coil is energized and the
magnetic field generated in the coil close the relay
contacts. The 4A fuse is connected at one side of the
relay contacts, while the controller's power input is
connected at the other side of the relay's contact.
When the coil is energized, and the relay contacts
close, the truck is powered ON.
NOTE: The relay coil is polarity sensitive, since it has
an internal and external fly-back diode connected to it.
1. POSITIVE BATTERY TERMINAL
2. PIN 3, WAKE-UP CIRCUIT
3. BATTERY CONNECTOR CPS019
4. NEGATIVE BATTERY TERMINAL
5. LITHIUM-ION BATTERY
Figure 8. Battery Connector CPS019
2240 YRM 1890 Charging and Troubleshooting
13