TM Series
Operating & Safety Instructions
USA – 05/11
Issue 01
25
5) BATTERIES DON’T RECEIVE FULL CHARGE
If you have the charger plugged into a long extension cord that is too small, a voltage drop will cause a
decrease in charger output, extending charge times.
UNDER NO CIRCUMSTANCES SHOULD BATTERIES BE LEFT ON CHARGE FOR
PERIODS IN EXCESS OF 24 HOURS
DISCONNECT FROM POWER SUPPLY ONCE BATTERIES ARE FULLY CHARGED
.
The machine can
now be left unattended, however, in the event of the machine being left unused for extensive periods
then a
4 to 6 hour
‘top-up’ charge every
4 weeks
is recommended. A ‘top-up’ charge the day before
use ensures a full day of operation from the machine.
UNDER NO CIRCUMSTANCES SHOULD A MACHINE BE LEFT FULLY
DISCHARGED AS SEVERE BATTERY DAMAGE CAN OCCUR IN A RELATIVELY
SHORT TIME.
To avoid damage to charger disconnect from mains supply before using machine.
CHARGING LIMITATIONS
Attention should be given to the use of extension cables as power leads. Excessive cable lengths from
the supply point to the battery charger will result in significant voltage drop, leading to a reduction in
the chargers efficiency. In addition, inadequate sized cable cores will have a limiting effect on its
current carrying capacity, which will again lead to a reduction in the chargers efficiency. Both of these
can result in over-heating of the cable with the attendant risk of fire, short circuits or damage to the
components themselves.
The charger requires a minimum battery voltage of 4.5 volts per battery (overall for two batteries 9
volts, for 4 batteries 19 volts for 8 batteries 38 volts). If the voltage is below these values then the
charger will not function (Charger will not detect batteries to begin charge.) If the batteries have fallen
to such a poor state they will have to be removed from the machine and charged individually with an
independent charger until the optimum voltage has been reached. This is best performed at very low
currents to ‘recover’ the batteries if sulphation has already started i.e. a ‘trickle’ charger. This can take
several hours, possibly days. Careful monitoring of the rise of battery voltage will indicate when
recovery has been achieved.
TOPPING UP
During the course of normal operation, the batteries should be inspected at least once a fortnight to
check the level of electrolyte. During the end of charge, gassing takes place, which will cause a slight
reduction in the volume of acid in the battery. This can be topped up with de-ionised water as required.
During this inspection, it is useful to note any imbalance in the fluid levels. One indication of a faulty
cell would be an increase in the loss of battery acid, which would then require more frequent topping
up on that cell, or cells. Faulty cells can liberate excess hydrogen, even during normal operation, with
the resulting risk of explosion if ignited.
Any faulty batteries should be replaced as soon as
possible with an equivalent sized and rated unit.
Note: BATTERIES CONTAIN ACID, therefore: - protective safety glasses and gloves
(Appropriate PPE) MUST be worn whilst performing these checks.
