Christie SA10012 User manual

IMPORTANT SAFETY INFORMATION
INSTALLATION and OPERATING INSTRUCTIONS
SA Series Chargers (SA10012, SA17512, SA25012)
INSTALLATION
INSPECTION:
Inspect the charger immediately upon receipt. If
there is any damage, call the carrier for an
inspection and file a claim.
APPLICATION:
These chargers are designed to charge groups
of 12 volt batteries connected in parallel. Six
volt batteries may also be charged by
connecting two of them in series (making the
equivalent of a single 12 volt battery).
VENTILATION:
The chargers are designed for continuous duty
use and to provide reliability, the free air
circulation method of cooling is used, (no cooling
fan). Under the circumstances, chargers must
be installed in a well ventilated area and in a
manner so that air flow through the charger is
not restricted. Severe damage may result if air
flow around the cabinet is obstructed.
CAUTION: BE SURE TO DISCONNECT
CHARGER FROM AC SOURCE BEFORE
ENTERING CABINET
CONNECTION TO AC INPUT:
Model SA10012
Measure the voltage of AC power source
available. The charger model SA10012 can be
operated from a nominal 115 volt line (actual
operating range 105 to 125 volts) or a nominal
230 volt line (actual operating range 195 to 255
volts). Factory settings are at 230 volts AC. To
change the AC voltage setting, remove the front
panel and reconnect terminal board as shown
on the wiring diagram furnished with the charger.
Model SA 10012 is furnished with an AC power
cord. Attach a 115 V or 230 V A-C plug to fit
your requirements.
Models SA17512 and SA25012
Measure the voltage of AC power source
available. The charger can be operated from a
nominal 230 volt line (actual operating range 195
to 255 volts) or a nominal 460 volt line (actual
operating range 420 to 510 volts). Factory
settings are at 460 volts AC. To change the AC
voltage setting, remove the front panel and
reconnect terminal board as shown on the wiring
diagram furnished with the charger.
Models SA17512 and SA25012 are designed to
be conduit wired to the AC supply. Connect the
charger to the AC disconnect switch or circuit
breaker with the proper size wire (10 AWG for
230 volt supply, 12 AWG for 460 volt supply).
Remove the back panel and connect wires to
terminals L1, L2, and L3 (if applicable) and
ground on the terminal block mounted near the
AC input conduit fitting.
ADJUSTING DC OUTPUT
Chargers should be adjusted for proper DC
output at time of installation.
CAUTION: BE SURE TO DISCONNECT
CHARGER FROM AC SOURCE BEFORE
MAKING ADJUSTMENTS
SET VOLTAGE BETWEEN 14.8 - 15.2. The
end charge voltage (the voltage which the
batteries approach when fully charged) will then
be 14.4 to 14.8 volts. Batteries will be
recharged in the minimum length of time, require
a minimum of attention and with good batteries
there will be no excessive gassing or
overheating.
Models SA17512 and SA25012
Adjustment taps are provided internally, on the
same terminal board as AC input voltage setting.
With an accurate voltmeter, measure the DC
open circuit voltage (output voltage with the
charger turned on but without batteries
connected) at the ends of the DC cables.
If the voltage is too low, move the adjustment
leads to the right. If the voltage is too high move
the adjustment leads to the left. The coarse
adjustment lead should be moved first to set the
output voltage at or just below the desired
voltage (14.8 - 15.2V). Then move the fine
adjustment lead.

Model SA10012
Adjustment controls are located on front of unit.
With an accurate voltmeter, measure the DC
open circuit voltage (output voltage with the
charger turned on but without batteries
connected) at the ends of the DC cables.
IF AC INPUT IS CONNECTED TO 230 VOLTS,
set open circuit voltage (output voltage with the
charger turned on but without batteries
connected to 14.6 -14.8. Once set, no further
adjustment should be required.
IF AC INPUT IS CONNECTED TO 115 VOLTS,
adjustment of controls may be required at
intervals during charging since most 115 volt AC
lines are not as stable as 230 volt AC lines.
Also, more current is drawn from a 115 volt line,
which may cause an AC voltage drop,
particularly when charging at full output of the
charger. For this reason, connection to a 230
volt AC input is strongly recommended.
When necessary to adjust controls, it is
important to have them set so that DC voltage
will be between 14.6-14.8 when batteries are
substantially charged. Experience in using the
charger will dictate settings, depending on
characteristics of your particular 115 volt AC line
and number of batteries connected.
CHARGING BENCH CONSTRUCTION:
Clore Automotive has available the Christie
Model BR-1 charging rack for 10 batteries.
Multiples of these racks may be connected in
parallel to charge more batteries. You may wish
to construct a charging rack of your own design.
The rack can be constructed to any height,
width, length and configuration desired. Heavy
lumber must be used throughout and with
substantial bracing to prevent swaying. You
must consider the total weight of all batteries to
be charged. Bus bars can be mounted on wood
uprights at the back of the rack or through center
of the rack, which permits batteries to be
charged on both sides. Recommended copper
bus bar minimum size for charging rack is 1/8" x
3/4". Holes must be drilled for mounting of bars
and connecting charging leads.
CONNECTING TO BUS BARS:
WARNING
***CARE MUST BE TAKEN NOT TO
REVERSE CONNECTIONS, WHICH WILL
CAUSE EXTREME SPARKING AT
BATTERY TERMINALS. BATTERY GASES
ARE HIGHLY EXPLOSIVE AND EASILY
IGNITED FROM SPARKING.
***DO NOT STAND OVER BATTERIES
WHILE CONNECTING/DISCONNECTING.
***DO NOT SMOKE OR STRIKE MATCH
AROUND BATTERIES.
***KEEP CHARGING ROOM AND BATTERY
AREA WELL VENTILATED.
***AS BATTERIES ARE ADDED, DO NOT
EXCEED RATED OUTPUT OF CHARGER,
WHICH MAY RESULT IN SEVERE DAMAGE.
Chargers are provided with 10 foot charging
cables terminated with lugs suitable for
connecting to bus bars. The positive cable is
marked with a (+) and the negative cable (-).
When connecting, make sure all surfaces are
clean and connections tight.
BUS BAR TO BATTERY CONNECTION:
Positive and negative leads must be attached to
the bus bars for parallel connection to the
batteries. Christie CL-24 and CL-48 Charging
Leads are recommended for this purpose. They
are supplied in pairs, one positive and one
negative. Leads are #10 wire, 24 or 48 inches
long, with a lug on one end for bolting to the bus
bar and a battery clamp on the other end,
including a color coded insulator (red for
positive, +, pos and black for negative, -, neg).
When connecting leads to bus bars, make sure
all surfaces are clean and connections tight.
Christie type SC18 Series Connectors are
recommended for connecting two 6 volt batteries
in series. Leads are #10 AWG wire, 18 inches
long, with charging clamps and insulators on
both ends.
OPERATION
STARTING TO CHARGE:
Models SA17512 and SA25012
On chargers with 230/460 volts AC input, once
set up, as under "ADJUSTING CHARGER DC
OUTPUT", should not have to be readjusted.
Model SA10012
If connected based on 230 volts AC input, once
set up, as under "ADJUSTING CHARGER DC
OUTPUT", should not have to be readjusted.
If connected based on 115 volts AC input, this
model has coarse and fine adjustment controls
on the instrument panel and may need
adjustments during charging
Charging rate will taper after batteries have been
on charge for a period of time, then more
batteries may be connected, again only until
rated output of charger is reached. For best
performance, minimum number of cells (either 6
or 12 volt batteries) to be connected is:
Model SA10012: 24 cells (4 12V batteries)
Model SA17512: 36 cells (6 12V batteries)
Model SA25012: 60 cells (10 12V batteries)
As battery voltage reaches 14.4-14.8 volts,
charging rate will taper to a very small amount
and batteries should be near full charge. If this

voltage is not exceeded, batteries may be left on
for several hours after full charge without
damage.
DISTRIBUTION OF CHARGING CURRENT:
Total amount of current being delivered is shown
on the ammeter. This current is divided among
the batteries connected, but does not mean that
all batteries will receive the same amount of
current initially. Examples are as follows:
1. Discharged batteries will receive more
current than those that are half charged.
2. Warm batteries will receive more current
than those that are cold.
3. Sulphated batteries will accept very little if
any current.
4. Batteries with shorted cells will take high
current and should not be put on the
charging line.
5. All other conditions being equal, a large
battery will receive more current than a
small battery.
When batteries have been on the charging line
for several hours, current will then be distributed
equally and all come up to full charge at about
the same time.
AMOUNT OF CHARGING TIME:
Charging time will vary, depending on the
number of batteries connected, and the
conditions stated in "DISTRIBUTION OF
CHARGING CURRENT" above. Normally, with
a full rack of batteries connected to the charger,
recharge time would be approximately 10-15
hours. With half the maximum number of
batteries connected, charging time would be
approximately 6-8 hours. But, the best final
determination of full charge is battery voltage of
the batteries being charged. When the voltage of
the batteries being charged reaches 14.6-14.8
volts, full charge has been reached.
GENERAL CHARGING INFORMATION:
If all batteries on the charging line tend to
overheat and gas violently, charger voltage must
be adjusted downward. If one battery in the line
is overheating and gassing excessively, it is
defective (likely due to a shorted cell) and must
be removed. If all batteries are not coming up to
full charge or are taking abnormal time to
charge, charger voltage must be adjusted
upward. If one battery in the line is not coming
up to full charge, it may be defective. Also
check charging leads to make sure all
connections are clean and tight.
TROUBLESHOOTING
IF CIRCUIT BREAKER IN AC PANEL TRIPS:
1. Exceeding charger DC output rating may
have been the cause.
2. Check ampere rating of circuit breaker
against nameplate AC input amp on charger
to be sure that breaker is of proper size.
Breaker may be defective.
3. With AC disconnected and on-off switch
turned ON, check for continuity between AC
input lines and ground. If there is continuity,
a short circuit exists and must be corrected.
If there is no continuity, proceed as follows:
3.1) Disconnect transformer leads from
all power diodes and check each
diode by measuring for continuity
between the diode input and heat
sink. If either diode shows
continuity in both directions, it is
shorted and must be replaced.
Reconnect diodes after completion
of tests.
3.2) Remove adjustment leads from
both coarse and fine adjustment
taps of terminal board and operate
unit. If fuse blows, check contactor
and auxiliary transformer T-2.
(NOTE: Models SA 5012 and SA
10012 do not have contactor or
auxiliary transformer: check on-off
switch for short circuit.)
3.3 Reconnect adjustment leads and
operate unit. If fuse blows, replace
transformer.
IF CHARGER OUTPUT FUSE BLOWS:
1. Check power diodes as in Step 3.1 above,
or choke coil may be burned out.
IF ON-OFF SWITCH DOES NOT TURN OFF:
1. With AC disconnected and on-off switch
turned OFF, check continuity across switch
terminals and contacts of contactor. If there
is continuity, replace switch or contactor.
IF LOW OR NO CHARGING CURRENT:
1. Verify that electrical supply is operating
properly.
2. Turn charger ON and verify that transformer
hums. If so, proceed to Step 3 below.
2.1) If transformer does not hum, there
is an open circuit in the AC line. To
isolate the problem, perform a
systematic continuity check of AC
input circuits following the wiring
diagram furnished for the unit.
Disconnect charger from the AC
power source before conducting
these tests.
2.2) If there is continuity throughout the
AC circuits, the contactor is
probably defective.

3. If transformer hums, disconnect transformer
leads from power diodes and perform
continuity checks as listed in the OUTPUT
CIRCUIT TEST sequence outlined below:
a) Test from -DC lead end to output side of
fuse. Source of trouble if no continuity:
DC lead open.
b) Test from -DC lead end to transformer
side of fuse. Source of trouble if no
continuity: fuse open.
c) Test from -DC lead end to each side of
disc. trans. leads. Source of trouble if no
continuity: transformer open.
d) Test from +DC end to output side of
ammeter. Source of trouble if no
continuity: +DC lead open.
e) Test from +DC lead end to choke side of
meter shunt. Source of trouble if no
continuity: meter and shunt open (replace
both).
f) Test from +DC lead end to head sink.
Source of trouble if no continuity: choke
L1 open.
4. Check each diode by measuring for
continuity between the diode input and the
heat sink. A good diode will indicate
continuity with the tester connected one way
and will indicate an open when the tester
leads are reversed.
5. Reconnect the diodes after completion of all
of the above tests.
HOW TO OBTAIN SERVICE WHEN NEEDED:
Parts and warranty/repair services for Christie
equipment are available through a nationwide
system of Authorized Service Centers, which are
carefully selected by Christie/Clore Automotive.
A list of these service centers is available on our
web site at www.cloreautomotive.com.
Check this list to find the closest location. It is
always best to contact the Center by telephone
to verify that its address is still correct. If the
Service Center is within reasonable driving
distance, you should deliver the charger. If it is
necessary to ship it, put suitable packing
material around the charger to help prevent
handling damage. Identify with proper shipping
information and return address.
Attach a note to the Service Center, giving them
your name, address and telephone number.
Explain trouble experienced with the charger
and if still under warranty, ask for warranty
service. If not under warranty, ask for an
estimate on cost of repair, which will help to
eliminate misunderstanding. When charger is
ready for shipment, either phone one of your
local truck lines, or if preferred, deliver to
Authorized Service Center.
WARRANTY:
This battery charger is warranted to the original
purchaser to be free from defects in
workmanship and materials for a period of one
year from date of purchase. If the product fails
within this period, it will be repaired or replaced
at the option of the manufacturer.
If the product fails within the first 90 days from
date of purchase by original purchaser, Christie
will pay transportation charges one way to from
the Service Center. If the product fails on or after
90 days from date of purchase by original
purchaser, the owner will pay all transportation
charges to and from the Service Center.
Liability under this warranty is expressly limited
to repairing or replacing the defective product or
parts thereof. This warranty does not apply to a
product or part which fails as a result of
accident, alteration, misuse, abuse, or improper
packing of returned equipment.
A Clore Automotive Brand
8600 NE Underground Dr., Pillar 248
Kansas City, MO 64161
Phone [phone] •Fax. [phone]
www.christieautomotive.com
842-443-000