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5A.
Charger turns off too soon
Check to be sure the AC input cord is securely connected to a live outlet. To determine if the
charger did shut off too soon, disconnect and reconnect the charger DC output plug. This will
restart the charger. Observe charger output on the ammeter.
1. The ammeter needle jumps smartly to between 18 and 22 amps and then tapers below 14
amps within 15 minutes. This indicates that the batteries were truly charged. The apparent
short charging time is in response to the batteries' ability to accept charge and the
electronic charge controller is performing properly.
2. The ammeter needle jumps smartly to between 18 and 22 amps, but does not taper below
14 amps within 15 minutes. If the batteries have been properly maintained and charged
regularly, this generally indicates that the batteries were not fully charged. If possible, use
a hydrometer to check the specific gravity of several battery cells. If the specific gravity
readings are more than 30 points (.030) lower than normal full charge readings, the
electronic timer has malfunctioned and the complete electronic charge controller must be
replaced. Refer to Replacement Procedures section of this manual
If the batteries have not been used or charged regularly, they may be sulfated and will not
produce their full capacity. Repeated cycles (at least 5) of a light discharge, followed by a full
charge, will generally result in the recovery of most of the battery's capacity. Do not interpret
this reduced battery capacity as being caused by the charger's turning off too soon. The
charger is working properly if, after several charge cycles, the battery capacity increases to
near normal. Sulfation occurs most often when the batteries have been stored without weekly
charging. New batteries may also be sulfated due to extended shipment or storage time prior
to sale.
As batteries age, individual cells may weaken, causing a reduction in battery capacity. This
condition normally results in a finish charge rate higher than 10 amps and less time is required
to fully charge the batteries. Do not interpret this shorter charging time and reduced battery
capacity as being caused by the charger's turning off too soon. The battery is aging naturally
and the charger is working properly. When the batteries will no longer perform as required,
they should be replaced.
5B.
Charger does not turn off
New batteries with all good cells should rise to at least 2.5 volts per cell. This will allow the
finish charge rate to taper below 6 amperes. As batteries age, individual cells may weaken
and these cells may not reach 2.5 volts. This will result in finish charge rates greater than 6
amperes, and less time will be required for the batteries to reach full charge. Regardless of
the finish charge rate, the electronic charge controller should turn the charger off at a
maximum of 16 hours.
If the charger remains on longer than the specified maximum time, check to see if the charger
turns on immediately when the DC output cord is connected without the normal three to five (3-
5) second delay. If the charger turns on instantly without the 3-5 second delay, the electronic
charge controller has probably failed. This type of malfunction generally results in the charger
not turning off. Refer to Component Test Procedures section to check the electronic charge
controller for proper operation.
