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Hardware description
DPCT IOM InsTruCTIOn OPeraTIOn Manual
MN124018EN January 2023 www.eaton.com
3. Hardware description
3.1 General
The purpose of this section is to familiarize the reader with
the DPCT controller hardware, its nomenclature, and to list
the unit’s specifications.
3.1.1 Battery chargers
Battery chargers are independent of each other and produce
a maximum of 10 amps each at full rate. Each battery
charger is fully electronic and will protect itself by shutting
down during a short circuit condition.
The maximum current draw that the chargers will draw
when operating at 100% charging rate is:
12 Volt System
24 Volt System
1.6 amps - 120V
3.2 amps - 120V
0.8 amps - 240V 1.6 amps - 240V
3.1.2 Three-step charge
The battery chargers incorporate a three-step charge
to guarantee the fastest charge times while optimizing
battery life.
The three steps are referred to as Bulk mode, Overcharge
mode and Float mode.
3.1.2.1 Bulk
In Bulk mode, a current of 10 Amps is delivered into the
battery until the voltage reaches 2.4 Volts per cell for Lead
Acid Batteries. (14.4 Volts for a 12 Volt battery). At this
point, the battery has recovered approximately 90% of
its capacity.
When the charger senses this state, it switches to the
Overcharge mode.
The bulk mode charging may take up to 24 hours depending
on the battery capacity and the level to which it was
discharged. The charge mode is recorded in the Diesel Plus
message history.
3.2.1.2 Overcharge
In the Overcharge mode, the voltage on the battery is
held at 14.4 Volts and the current into the battery declines.
This mode is maintained until the current into the battery
declines to 1.5 Amps. At this moment, the battery is
approximately 99% charged and the charger will change to
Float Mode.
The overcharge mode charging may take up to 12 hours
depending on the battery capacity and the level to which it
was discharged. The charge mode is recorded in the Diesel
Plus message history.
3.2.1.3 Float
In Float Mode, the charger maintains the battery voltage
at 2.23 Volts per cell for a lead acid battery (13.4 Volts for
a 12 Volt battery). Once Bulk and Overcharge modes are
completed, the charger will maintain the battery charge in
Float mode by regulating to 13.3V. If the charger cannot
maintain the battery capacity while in Float mode, the
charger will begin a new charging sequence by entering
Bulk mode.
3.1.3 Charger shut down
The charger will automatically shut down if there is no load
connected to the output or if there is a short on the load
side of the charger. In addition, the charger will not operate
if a battery is connected incorrectly or if the wrong voltage
of battery is connected.
3.1.4 AC input fuse protection
The AC Supply is protected by a 6 Amp fuse which will
blow in case of a breakdown of the charger. This fuse will
not blow because of overloading of the charger since the
electronics will shut down the charger in this event before
the fuse blows. If this fuse is blown the charger must
be replaced.
3.1.5 Battery charger display
The DPCT charger’s history will display Charging Voltage and
Amperage as well as error messages. The following will be
recorded according to the conditions that exist.
“NO BATTERY” is displayed if no battery is attached to
the charger.
“BATTERY ERROR” is displayed if a battery is connected to
the charger, but the voltage is not within the minimum and
maximum thresholds for the selected battery type.
“ERROR, RECOVERING” is displayed if the maximum
battery charger output voltage (31.4V) has been exceeded.
3.1.6 Battery charger setup: lead acid / NiCad
DIP switches on the charger can be used to select
several setup options including battery type, battery
voltage and Forced Charging. Options currently supported
for the charger include: 12 or 24 Volt and Lead Acid or
NiCad Batteries.
3.1.6.1 Lead acid
To select 12 Volt battery charging with Lead Acid batteries
set all DIP switches to the OFF position.
