PRO Charging System 3620 Safety, Installation And Operating Instructions

3620
Marque
PRO Charging System
Modèle
3620
Taper
Safety, Installation And Operating Instructions

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Safety, Installation and Operating Instructions
Instructions importantes concernant la sécurité
Manual for the Following Battery Charger Models
i2412, i3612, i4809, i2425, i3625, and i4818
________________________________________
081808
IMPORTANT NOTICE:
Please save and read these safety, operating and installation instructions before installing or applying AC power
to your Pro Charging Systems (PCS) charger. Contact technical support at PCS with any product, installation, or
service questions (800.742.2740).
Pro Charging Systems, LLC
LaVergne, TN 37086-3539
2
INSTRUCTIONS FOR THE FOLLOWING BATTERY CHARGER MODELS:
For lead-acid batteries with capacities of 70 to 260 ampere-hours (20 HR rating):
MODEL AC Supply DC Output Battery System
i-2412 120 volts, 60 Hertz 12 amps @ 24 volts 24 volt, 12 cell, series connected
i-3612 120 volts, 60 Hertz 12 amps @ 36 volts 36 volt, 18 cell, series connected
i-4809 120 volts, 60 Hertz 9 amps @ 48 volts 48 volt, 24 cell, series connected
For lead-acid batteries with capacities of 180 to 260 ampere-hours (20 HR rating):
MODEL AC Supply DC Output Battery System
i-2425 120 volts, 60 Hertz 25 amps @ 24 volts 24 volt, 12 cell, series connected
i-3625 120 volts, 60 Hertz 25 amps @ 36 volts 36 volt, 18 cell, series connected
i-4818 120 volts, 60 Hertz 18 amps @ 48 volts 48 volt, 24 cell, series connected
TABLE OF CONTENTS
Important Safety Instructions……………………………………………………. Pages 2-3
Installation and Preparation ………………………………………………………Page 4
General Operation …………………………………………………………………Pages 4-5
Charging Indications……………………………………………………………….Page 6
Troubleshooting ……………………………………………………………………Page 6
LED Fault Code Indications ……………………………………………………..Page 7
Limited Warranty Information……………………………………………………..Page 7
Additional Products……………………………………………………………….. Page 8
IMPORTANT SAFETY INSTRUCTIONS
INSTRUCTIONS IMPORTANTES CONCERNANT LA SÉCURITÉ
SAVE THESE INSTRUCTIONS. This manual contains important safety and operating instructions for future
reference.
CONCERVER CES INSTRUCTIONS. CE MANUEL CONTIENT DES INSTRUCTIONS IMPORTANTES CONCERNANT LA
SÉCURITÉ ET LE FONCTIONNEMENT.
Understand and relate the Hazard Levels and Signal Words utilized in this manual with the following definitions:
This symbol means: Immediate hazards, which will result in severe personal injury or death.
This symbol means: Hazards or unsafe practices, which could result in severe personal injury or death.
This symbol means: Hazards or unsafe practices, which may result in minor personal injury, product or
property damage.
This symbol means BE ALERT! Your safety, or the safety of others, is involved!
3
PERSONAL SAFETY PRECAUTIONS
Always read all instructions before using your charger!
1. Wear complete eye protection and clothing protection. Avoid touching eyes while working near battery. Have plenty of
fresh water and soap nearby in case battery acid contacts skin, clothing, eyes, or other surfaces. If battery acid contacts skin
or clothing, wash immediately with soap and water. If acid enters eye, immediately flood eye with running cold water for at
least 10 minutes and seek medical attention promptly.
2. Dress properly. Wear protective, electrically nonconductive clothes and nonskid footwear. Remove personal metal items
such as rings, bracelets, necklaces, and watches when working with a lead-acid battery. A lead-acid battery can produce a
short-circuit current high enough to weld a ring or the like to metal, causing a severe burn. Wear restrictive hair covering to
contain long hair.
3. Avoid working alone. Be sure someone is within range of your voice or close enough to come to your aid when you work
near a lead-acid battery.
4. Stay alert. Watch what you are doing, and use common sense. Do not operate any charger when you are tired.
5. Keep children away. Children must never be allowed in the work area. Do not let them handle machines, tools, battery
chargers, or extension cords.
6. Keep work area clean. Cluttered areas invite injuries.
7. Observe work area conditions. NEVER smoke or allow a spark or flame in the vicinity of battery or engine. Don’t expose
to rain. Keep work area well lit.
8. Do not overreach. Keep proper footing and balance at all times. Do not reach over or across electrical cables or frames.
9. Avoid electrical shock. To reduce risk of electrical shock, unplug charger from outlet before attempting any maintenance
or cleaning.
10. Do not operate charger with damaged electrical cord or plug. To reduce risk of damage to the electrical plug and
cord, pull by plug rather than by the cord when disconnecting charger. If damaged, replace the electrical cord or plug
immediately.
11. Store idle equipment. When not in use, store equipment in a dry location to inhibit rust. Always lock up tools and
equipment and keep out of reach of children.
12. Maintain charger with care. Inspect periodically and, if it has received a sharp blow, been dropped, or otherwise
damaged in any way, have it repaired by an authorized technician. Do not disassemble charger; contact PCS technical
support when service or repair is required (800.742.2740). Incorrect reassembly may result in risk of electrical shock or fire.
13. Check for damaged parts. Before using any battery charger, carefully check any part that appears damaged to
determine that it will operate properly and perform its intended function. Check for broken parts and any other condition that
may affect proper operation. Any part that is damaged should be properly repaired or replaced by a qualified technician. Do
not use the charger if any part does not operate properly.
14. Replacement parts and accessories. When maintaining, only use accessories intended for use with this charger.
Approved accessories are available from Pro Charging Systems (800.742.2740).
SAVE THESE INSTRUCTIONS!
4
INSTALLATION AND PREPARATION
To reduce risk of battery explosion, follow these instructions, those published by the battery
manufacturer, and by the manufacturer of any equipment that you intend to use in the vicinity of
battery. Review all cautionary markings on these products and on the engine.
Pour réduire le risque d’explosion, lire ces instructions et celles qui figurent sur la batterie.
If it is necessary to relocate the battery for charging, first remove the grounded terminal from the battery. Then make
sure all accessories are off, so as not to cause battery arcing.
RISK OF EXPLOSIVE GASES: WORKING IN THE VICINITY OF A LEAD-ACID BATTERY IS
DANGEROUS. Batteries generate explosive gases during normal battery operation. For this reason, it
is of utmost importance that prior to each use of your charger, you read this manual and follow the
instructions exactly.
Il est dangereux de travailler a proximité d’une batterie au plomb. Les batteries produisent des gaz explosifs en service
normal. Il est aussi important de toujours relire les instructions avant d’utiliser le chargeur et de les suivre à la lettre.
Be sure area around battery is well ventilated while batteries are being charged. Gas fumes can be forcefully blown away by
using a piece of cardboard or other nonmetallic material as a fan.
Clean battery terminals. Be careful to keep corrosion from coming into contact with eyes.
Add distilled water to each cell until battery acid reaches level specified by battery manufacturer. This helps purge excessive
gas from cells. Do not overfill. For a battery without cell caps, carefully follow manufacturer’s recharging instructions.
Study all battery manufacturers’ specific precautions such as removing or not removing cell caps while charging and
recommended rates of charge.
When using an extension cord, make sure:
• that pins on plug of extension cord are the same number, size, and shape as
those of the charger’s plug;
• that extension cord meets UL (Underwriters Laboratories, Inc.) acceptance;
• that wire size is large enough for AC ampere rating of charger.
Always make your extension cord connection on the charger side before connecting to a nearby
120VAC GFCI protected (Ground Fault Circuit Interrupt) outlet. Failure to use a GFCI outlet may
result in electrical shock.
Note: Extension cords should be industrial grade/heavy duty UL approved and grounded. Check extension cord before use
for damage, bent prongs and cuts. Replace if damaged.
Connect the extension cord to the charger; then proceed to plug the extension cord to a nearby 120VAC GFCI protected
(Ground Fault Circuit Interrupt) outlet.
Always remove the extension cord from the 120VAC outlet first when charging is completed, followed by unplugging the
charger.
GENERAL OPERATION
Use charger for charging a LEAD-ACID (lead acid, sealed lead acid, gel cell and AGM) battery only. It
is not intended to supply power to a low voltage electrical system other than in a starter-motor
application. Do not use battery charger for charging dry-cell batteries that are commonly used with
home appliances. These batteries may burst, causing personal injury and damage to property.
5
Utiliser le chargeur pour charger une batterie au plomb uniquement. Ce chargeur n’est pas concu pour alimenter un réseau
électrique très basse tension ni pour charger des piles sèches. Le fait d’utiliser le charger des piles sèchespourait entrainer
l’éclatement des piles et causer des blessures ou des dommages.
DO NOT attempt to attach a charger to a battery pack if the output of the charger does not match the
battery pack voltage. Example: Model i-3625 is a 36 volt output charger and is only usable on 36
volt battery systems. Charger and battery damage can occur.
Be extra cautious to reduce risk of dropping a metal tool onto battery. It might cause a spark or
short-circuit a battery or other electrical part, possibly resulting in an explosion. If damaged, contact
PCS (800.742.2740).
NEVER charge a frozen battery.
Ne jamais charger une batterie gelée.
Assure that the area around your charger and batteries is properly ventilated. Connect your extension cord, with no AC
Power present, to the battery charger and proceed to plug your extension cord into a 120VAC GFCI protected (Ground Fault
Circuit Interrupt) outlet.
Risk of electrical shock! Do not touch uninsulated parts of the battery charger output connector,
battery connector, or battery terminals.
Once you plug in your PCS battery charging system, the charge cycle will begin automatically. State of charge will be
displayed by illumination of the Light Emitting Diodes (LEDS) on the battery status indicator located on the front of the unit.
DO NOT disconnect the DC output electrical cord from the battery receptacle when the charger is
on. The resulting arcing and burning of the plug and receptacle could cause the batteries to
explode. If the charger must be stopped, first disconnect the AC power supply cord from its outlet,
then disconnect the charger DC output plug from the battery receptacle.
We recommend that you leave your system plugged in. This will reduce sulfation on the lead plates of the batteries and allow
your PCS charging system to keep your batteries fully maintained and ready to perform at their best.
To reduce the risk of fire, use only on circuits provided with 15Amperes Branch Circuit Protection
in accordance with the National Electrical Code, ANSI/NFPA 70.
Study all battery manufacturers’ specific precautions such as removing or not removing cell caps
while charging and recommended rates of charge.
Prendre connaissance des measures de précaution spécifiés par le fabricant de la batterie, p. ex., vérifier s’il faut enlever les
bouchons des cellules lors du chargement de la batterie, et les taux de chargement recommandés.
Never place the charger directly above or below the battery being charged; gases or fluids from the
battery will corrode and damage the charger. Locate the charger as far away from the battery as DC
cables permit.
Ne jamais placer le chargeur directment sous la batterie à charger ou audessus de cette dernière. Les gaz ou les fluids qui
sèchappent de la batterie peuvent entrainer la corrosion du chargeur ou l’endommager. Placer le chargeur aussi loin de la
batterie qui les cables c.c. le permettent.
If it is necessary to remove battery from vehicle to charge it, always remove grounded terminal from
battery first. Make sure all accesproes in the vehicle are off in order to prevent an arc.
S’il est nécessaire de retirer la batterie du véhicule pour la charger, toujours d'ébrancher la borne de mise à la masse en
premier. S'assurer que le courant aux accessories du véhicule est coupe afin d’éviter la formation d’un arc.
Never smoke or allow an open spark or flame in the vicinity of the BATTERY the battery or engine.
6
Ne jamais fumer près de la batterie ou du moteur et éviter toute étincelle ou flamme nue à proximité de ces dernie.
Working in the vicinity of a lead-acid battery is dangerous. Batteries generate explosive gases
during normal operation. For this reason it is of the utmost importance that prior to each use of your charger, you
read and follow the instructions provided exactly.
Il est dangereux de travailler a proximité d’une batterie au plomb. Les batteries produisent des gaz explosifs en service
normal. Il est aussi important de toujours relire les instructions avant d’utiliser le chargeur et de les suivre à la lettre.
CHARGING INDICATIONS
When your battery charging system is activated, the battery status indicator provides charging information utilizing five red
LED indicators and one green LED indicator.
Battery Type Indicators
Two red LED indicators are provided in order to display what type of battery the
charger has been programmed to charge.
Battery System Percent Charged Indicators
Four LED indicators are provided in order to display the progress of the charge cycle
in percentage of charge.
Indications are as follows:
1
ST
RED LED . . . . . . . . . . . . . . Illuminated configured for Wet Cell and AGM batteries
2
ND
RED LED . . . . . . . . . . . . . Illuminated configured for Gel Cell batteries
3
RD
RED LED . . . . . . . . . . . . . Charging - Initial Charging Up To 30%
3
RD
& 4
TH
RED LEDS . . . . . . . Charging - 60% Complete
3
RD
, 4
TH
& 5
TH
RED LEDS . . . . Charging - 90% Complete
BLINKING GREEN LED . . . . Finishing Stage
STEADY GREEN LED . . . . . . Charge Complete - Monitoring Batteries
The green LED is illuminated whenever the charge cycle has terminated and the internal circuitry has determined the
batteries to be fully charged. The green LED will blink during the finishing stage of the charge cycle. After the completion of
the charge cycle, the green LED will remain on steady during the float-maintenance stage.
TROUBLESHOOTING
PROBLEM: No LED indicators illuminated on battery status indicator.
Solution Sequence:
1. Confirm that current is being delivered to the charger. Use a meter or test light to check the AC power supply from its
source through all connecting points up to the charger.
2. Check that the AC circuit breaker (on front of the unit) is depressed.
3. Call technical support for further assistance (800.742-2740).
PROBLEM: The charge status indicator changes rapidly back and forth from red to green or the green LED will not
illuminate after excessive charging time (24 hours or more).
Solution Sequence:
1. Disconnect AC power from the charging system. This indication may signify a possible battery problem.
2. Call technical support for further assistance (800.742.2740).
PROBLEM: A green LED was illuminated before disconnecting the power from the charger, but upon reconnection,
red LEDs appear and remain on.
7
This is the normal operating procedure for the system. It indicates that a reanalysis of the battery status was initiated and
after a series of steps the green LED will illuminate.
LIGHT EMITTING DIODES (LED) FAULT CODE INDICATIONS
The microprocessor is constantly monitoring the charger circuitry and will both detect and display blinking LED indications if a
fault is detected. The battery type LED will be OFF
during a fault code condition.
30% RED LED BLINKING .....................................................NO BATTERY DETECTED
This indication occurs whenever the charger circuitry cannot detect a battery. The charger circuitry will not allow charge
current to flow under this condition. With the AC power supply cord unplugged, check the connection to the batteries for
proper polarity (black wire to negative or -). Also check for corrosion free secure connections to the battery. Please call
technical support for further assistance (800.742.2740).
30 & 60% RED BLINKING LEDS …………FORMING STAGE TIMEOUT SHUTDOWN
This indication occurs if the battery voltage has not risen above 1.75 volts per cell within the first 3 hours of charging. This
indicates that a possible battery problem exists and that the charge cycle has been terminated at this point. Please call
technical support for further assistance (800.742.2740).
30, 60 & 90% RED BLINKING LEDS ............................OVERALL TIMER SHUTDOWN
This indication occurs if the charger has not completed the charge cycle within the allowable factory set time period. This
indicates that a possible battery problem exists and that the charge cycle has been terminated at this point. Please call
technical support for further assistance (800.742-2740).
30, 60, 90% RED and 100% GREEN BLINKING LEDS…....................INTERNAL OVERTEMP SHUTDOWN
This indication occurs if the charger circuitry has detected operating temperatures inside the charger enclosure that are
above factory specified levels. This could indicate that a possible charger problem exists and that the charge cycle has been
terminated. Please call technical support for further assistance (800.742.2740).
Note: Disconnecting and reconnecting the AC power supply cord will reset the charger.
LIMITED WARRANTY
Pro Charging Systems, LLC (PCS) makes this Limited Warranty only to the original retail purchaser.
PCS warrants this battery charger for three years from the date of retail purchase against defective materials and/or
workmanship. If such defects should occur, this unit will either be repaired or replaced at the discretion of the manufacturer.
It is the responsibility of the original purchaser to return the charger along with proof of purchase, transportation, and/or any
mailing or handling charges prepaid to the manufacturer or its authorized representative.
This limited warranty is void if the product is misused, improperly maintained, handled carelessly or incorrectly operated.
Additionally, this warranty is void if the charger is disassembled, the charger’s charge cables are cut, the power cord is cut
off, the charger is altered without authorization from PCS, the serial number is removed, or repair is attempted by anyone
other than an authorized representative.
PCS makes no other warranty other than this limited warranty and expressly excludes any implied warranty, including
warranty for any incidental or consequential damages.
This is the only expressed limited three year warranty authorized by PCS and does not authorize anyone to assume or make
any other obligation towards the product other than this three year Limited Warranty. Some states do not allow limitation of
incidental or consequential damages.
8
This warranty gives you specific legal rights and you may also have other rights which vary from state to state.
Please call Pro Charging Systems, LLC for full warranty information and/or service please call (800.742.2740).
Below are some of our other options in chargers and battery accessories. Call our technical support group for more detailed
information or visit our web site www.dualpro.com.
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PRO Charging System 3620 Safety, Installation And Operating Instructions

3620
Marque
PRO Charging System
Modèle
3620
Taper
Safety, Installation And Operating Instructions
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