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Dane Technologies, Inc.
QuicKART 2000 Series
Service Manual
7105 Northland Terrace, Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234
www.danetechnologies.com
970-011 Rev. 3/1/06
65
CLIPLIGHT BATTERY CHARGER OPERATION
Battery Charger, 810-037, supplied with the QK-2000E machine, and the 810-036
supplied with the QK-2000 uses a sophisticated charging algorithm that continually tests
the charging process from start to finish. Once the charger’s output leads are properly
connected to the batteries terminals and the charger is plugged into an AC receptacle,
the charger waits 3 seconds before starting its 5-stage charging process. These 5-
stages are described in the order in which they take place as follows:
PRE-QUALIFICATION TEST - STAGE ONE
The Yellow “ Light Emitting Diode” (L.E.D.) flashes on and off.
The duration of this stage is dependent on the condition of the batteries. If the batteries
have been left in a state of discharge for a long period of time (days to months). The
terminal voltage of the batteries has decayed to less than 1.75V per cell, then the
charger may require up to 3 hours of pre-qualification controlled charging. This is to
determine if the batteries will even accept a charge. The charger will not function if the
total voltage of the three batteries is less than 18 volts. Between 18 and 24 volts the
charger will slowly charge the batteries. During this extended testing stage, the Yellow
L.E.D. will flash at a slow rate.
CONSTANT CURRENT CHARGE - STAGE TWO
Once the Pre-Qualification Test completes successfully, the Yellow L.E.D. illuminates
continuously indicating that the charger is charging the batteries at the full rated output
of 16 amperes. This stage ends when the batteries state of charge is at approximately
50-70%. The voltage during this period will be about 41 volts.
CONSTANT VOLTAGE CHARGE - STAGE THREE
The Green L.E.D. flashes on and off and the Yellow L.E.D. flashes fast.
This stage is also referred to as the Absorption Charge or Equalization Charge, since
the individual cells inside the batteries are forced to become “equalized” in charge. This
stage is exited when the state of charge of the battery has approached near, or is at
100% charge. The voltage will peak at about 43.5 volts when the charger disconnects.
FLOAT CHARGE—STAGE FOUR
This final stage is signaled with the Green “Charged “ L.E.D. on. The Trickle Charge will
begin when the battery voltage slowly decays to about 40 to 40.5 volts. The charger will
now deliver about 300MA which will maintain the charge. If an excessive load is at any
time applied and the Terminal Voltage has been forced below a preset level, the
charger will reinitiate a charge cycle starting with the Constant Current Stage. In this
standby “Float” state the charger can be left connected indefinitely (limited only by the
practical service life of the battery), until disconnected.