Club Car SVPP325511 User manual

HighFrequencyBattery
ChargerOwner’sManualfor
CustomSolutions

NOTICE
ClubCarisnotliableforerrorsinthismanualorforincidentalorconsequentialdamagesthatresultfromtheuseof
thematerialinthismanual.
TheClubCarLimitedWarrantyappearsattheendofthismanual.Nootherwarranties,expressorimplied,arecontained
herein.
Thismanualcontainsproprietaryinformationthatisprotectedbycopyright.Allrightsarereserved.Nopartofthismanual
maybephotocopied,reproduced,ortranslatedintoanotherlanguagewithoutthewrittenconsentofClubCar,LLC.
Theinformationcontainedinthisdocumentissubjecttochangewithoutnotice.
ClubCar,LLCreservestherighttochangespecicationsanddesignsatanytimewithoutnoticeandwithouttheobligation
ofmakingchangestounitspreviouslysold.
IfinEnglish,thismanualistheOriginalInstructionsprovidedbythemanufacturer.IfinanylanguageotherthanEnglish,
thismanualisatranslationoftheOriginalInstructions.
ThisisaClassAproductcomplyingwithUnitedStatesFederalCommunicationsCommission,CodeofFederal
Regulations;47CFRpart15.Inadomesticenvironmentthisproductmaycauseradiointerference,inwhichcasetheuser
mayberequiredtotakeadequatemeasures.
P .O.Box204658
Augusta,Georgia30917–4658USA
Telephone[phone]
ServicePartsFax706–855–7413
www.clubcar.com
Copyright©2010ClubCar,LLC
ClubCar,Tranquility,andArmorFlex
areregisteredtrademarksofClubCar,LLC
ThismanualeffectiveAugust2,2010
HighFrequencyBatteryChargerOwner’sManualforCustomSolutionsPage1

TABLEOFCONTENTS
BatteryandChargerCompatibility.........................................................................................................................3
SafetyDetails.......................................................................................................................................................4
GeneralWarnings.................................................................................................................................................5
GeneralInformation..............................................................................................................................................8
OperatingInstructions.........................................................................................................................................10
Maintenance......................................................................................................................................................12
TroubleshootingInstructions................................................................................................................................12
BatteryChargerSpecications............................................................................................................................13
Warranty............................................................................................................................................................14
Page2HighFrequencyBatteryChargerOwner’sManualforCustomSolutions

BatteryandChargerCompatibility
BATTERYANDCHARGERCOMPATIBILITY
BATTERYBATTERY
MODEL(PARTNUMBER)
HIGHFREQUENCYCHARGER
MODEL(PARTNUMBER)
6VGelCellEastPenn(SVPP08250)912-4852(SVPP325511)algorithm#26
6VAGM(AbsorbedGlassMats)FullriverDC224-6912-4852(SVPP325512)algorithm#125
8VAGM(AbsorbedGlassMats)FullriverDC180-8912-4852(SVPP325512)algorithm#125
6VFLA(FloodedLead-Acid)TrojanT105(101661601)
CrownCR225(103720301)
912-4852(SVPP325510)algorithm#11
6VHeavyDutyFLA(FloodedLead-Acid)TrojanT145(102764401)912-4852(SVPP325510)algorithm#11
8VFLA(FloodedLead-Acid)TrojanT875(101797701)
USBattery8VGCXC(103695801)
CrownCR165(103719701)
912-4852(SVPP325510)algorithm#11
8VHeavyDutyFLA(FloodedLead-Acid)TrojanT890(101964201)912-4852(SVPP325510)algorithm#11
HighFrequencyBatteryChargerOwner’sManualforCustomSolutionsPage3

SafetyDetails
SAFETYDETAILS
WARNING
•Thismanualshouldbereadcompletelybeforeattemptingtouseorservicethecharger.Failureto
followtheinstructionsinthismanualcouldresultinpropertydamage,severepersonalinjury,ordeath.
ItisimportanttonotethatthroughoutthismanualtherearestatementslabeledDANGER,WARNING,orCAUTION.
Thesespecialstatementsrelatetospecicsafetyissues,andmustberead,understood,andheededbefore
proceedingwithprocedures.TherearealsostatementslabeledNOTE,whichprovideotheressentialserviceor
maintenanceinformation.
Ifanyoftheinformationprintedonthecoverofthechargerbecomesdamaged,hasbeenremoved,orcannotbe
easilyread,replacethecoverimmediatelytoavoidpossiblepropertydamage,personalinjury,ordeath.Contactyour
ClubCardistributor/dealerforreplacementinformation.
DANGER
•ADANGERindicatesanimmediatehazardthatwillresultinseverepersonalinjuryordeath.
WARNING
•AWARNINGindicatesanimmediatehazardthatcouldresultinseverepersonalinjuryordeath.
CAUTION
•ACAUTIONwiththesafetyalertsymbolindicatesahazardorunsafepracticethatcouldresultin
minorpersonalinjury.
CAUTION
•ACAUTIONwithoutthesafetyalertsymbolindicatesapotentiallyhazardoussituationthatcould
resultinpropertydamage.
Thesafetyprecautionslistedmustbefollowedwheneverthechargerisbeingoperated,repaired,orserviced.Specic
warningsappearthroughoutthismanualandonthecharger.
Page4HighFrequencyBatteryChargerOwner’sManualforCustomSolutions

GeneralWarnings
GENERALWARNINGS
Thismanualcontainsimportantsafetyandoperatinginstructions–readbeforeusingcharger.
DANGER
•Battery–Explosivegases!Donotsmoke.Keepsparksandamesawayfromthevehicleandservice
area.Ventilatewhenchargingoroperatingvehicleinanenclosedarea.Wearafullfaceshieldand
rubbergloveswhenworkingonornearbatteries.
•Thechargingareamustbeventilated.Hydrogenlevelintheairmustneverexceed2%.Thetotal
volumeofairinthechargingareamustbechangedvetimesperhour.Exhaustfansshouldbe
locatedatthehighestpointoftheroof.ContactalocalHVACengineer.
•Donotchargethevehiclebatterieswiththevehiclecoveredorenclosed.Anyenclosureorcover
shouldberemovedorunzippedandpulledbackwhenbatteriesarebeingcharged.Anaccumulation
ofhydrogengascouldresultinanexplosion.
•Riskofelectricshock.Connectchargerpowercordtoanoutletthathasbeenproperlyinstalledand
groundedinaccordancewithalllocalcodesandordinances.Agroundedoutletisrequiredtoreduce
riskofelectricshock;donotusegroundadaptersormodifyplug.
•Donottouchuninsulatedportionofoutputconnectororuninsulatedbatteryterminals.
•DisconnecttheACsupplybeforemakingorbreakingtheconnectionstothebattery.
•Donotopenordisassemblecharger.
•DonotoperatethischargeriftheACsupplycordisdamagedorifthechargerhasreceivedasharp
blow,beendropped,orotherwisedamagedinanyway.Referallrepairworktothemanufacturer
orqualiedpersonnel.
•Thisapplianceisnotintendedforusebypersons(includingchildren)withreducedphysical,sensory
ormentalcapabilities,orlackofexperienceandknowledge,unlesstheyhavebeengivensupervision
orinstructionconcerninguseoftheappliancebyapersonresponsiblefortheirsafety.Children
shouldbesupervisedtoensurethattheydonotplaywiththeappliance.
WARNING
•Thehighfrequencybatterychargerisprogrammedwithanalgorithmthatmatchesthetypeand
designspecicationsofthebatteriesoriginallyinstalledinthevehicle.Neverusethischargerto
chargebatteriesofadifferenttypeanddesignspecication.Doingsowilldamagethenon-matching
batteriesandgreatlyreducetheirlifespan.Ifthebatteriescannotbereplacedwiththesameas
original,thechargermustbereplacedwithonethatmatchesthereplacementbatteries.SeeBattery
andChargerCompatibilityonpage3.
•Donotattempttochargefrozenbatteriesorbatterieswithbulgedcases.Discardthebatteryin
accordancewithallenvironmentallawsorreturntoanauthorizedClubCardealer.Frozenbatteries
canexplode.
•Onlytrainedtechniciansshouldrepairorservicethecharger.ContactyournearestClubCar
distributor/dealer.
•Eachchargershouldhaveitsowndedicated15or20ampereseparatelyprotected(circuitbreakeror
fuse)singlephasebranchcircuit,inaccordancewithallapplicableelectricalcodesforthelocation.
•ConnectthechargerACsupplycordtoaproperlygrounded,three-wireoutletofthepropervoltage
andfrequencyasshownonthecharger.
•Donotuseanadaptertoplugthechargerwithathree-prongplugintoatwo-prongoutlet.Improper
connectionoftheequipment-groundingconductorcanresultinareoranelectricalshock.
•UseonlyanappropriatelysizedACpowercord.SeeACPowerConnectiononpage11.
•Donotusenearfuels,graindust,solvents,thinners,orotherammables.Chargerscanignite
ammablematerialsandvapors.
WARNINGCONTINUEDONNEXTPAGE
HighFrequencyBatteryChargerOwner’sManualforCustomSolutionsPage5

GeneralWarnings
WARNING
•Donotexposetorainoranyliquid.Keepthechargerdry.
•Priortoservicingthecharger,disconnecttheACpowersupplycordfromthewalloutletandremove
thebatterychargerfromthevehicle.Seeremovalprocedureintheappropriatemaintenanceand
servicemanual.
•Donotuseabatterychargerifthecordorplugisdamagedinanyway.Replacewornordamaged
partsimmediately.Failuretoheedthiswarningcouldresultinare,propertydamage,severe
personalinjury,ordeath.
•Donotoperatethechargerifithasreceivedasharpblow,wasdropped,orotherwisedamaged
inanyway.
•Haveworn,cut,ordamagedpowercordsorwiresreplacedimmediately.
•InstallsurgearrestorsonincomingACpowerlines.Surgearrestorswillhelpprotectelectrical
componentsinthechargerandonthevehiclefromallbutdirectorcloselighteningstrikes.
•Ensurebatteryconnectionsarecleanandproperlytightened.
•Wearsafetyglassesorapprovedeyeprotectionwhenservicingthevehicleorbatterycharger.Weara
fullfaceshieldandrubbergloveswhenworkingonornearbatteries.
•Donotwearlooseclothingorjewelrysuchasrings,watches,chains,etc.,whenservicingthe
vehicleorbatterycharger.
•Useinsulatedtoolswhenworkingnearbatteriesorelectricalconnections.Useextremecautionto
avoidshortingofcomponentsorwiring.
Page6HighFrequencyBatteryChargerOwner’sManualforCustomSolutions

GeneralWarnings
RECYCLINGLEAD-ACIDBATTERIES
WARNING
•Lead-acidbatteriescontainlead(Pb),othermetals,acidsandothercompounds.Ifimproperlyhandled,
theycancontaminatebothwaterandsoil,causingenvironmentaldamageandpersonalinjury.
Lead-acidbatteriesareidentiedbythesymbolshownbelowandshouldbeproperlyrecycled(Figure1).Theycannot
bedisposedasmunicipalwasteandmustbecollectedseparately.Responsibilityforenvironmentalprotectionmustbe
shared,notonlybythemanufacturersofthebatteries,butbypeoplewhousethebatteriesaswell.Pleasecontact
yournearestClubCardealerordistributorforinformationonhowtoproperlyrecycleyourbatteries.
1403
Figure1DisposeofLead-acidBatteriesProperly
INTERNATIONALSAFETYSYMBOLSONBATTERIES
Anyoneusing,repairing,orservicingthevehiclemustunderstandandheedthesafetysymbolsonthevehiclebattery
orbatteries.
123456
1.Shieldeyes.3.Nosmoking,noopenames,nosparks.5.Batteryacidhazard.
2.Readandfollowoperatinginstructions.4.Keepawayfromchildren.6.Explosivegashazard.
RefertoGeneralWarningsformoreinformation.
1642
Figure2InternationalSafetySymbolsonBatteries
HighFrequencyBatteryChargerOwner’sManualforCustomSolutionsPage7

GeneralInformation
GENERALINFORMATION
TheHighFrequencyBatteryChargerfunctionsasanintegralpartofthevehicles’electricalsystemandwillnotwork
withotherelectricvehicles.Thechargerispre-programmedwithaspecicchargealgorithmthatisappropriate
tothespecicbatterytypeusedinthevehicle.SeeBatteryandChargerCompatibilityonpage3.Whenthe
chargerisconnected,LEDlightsonthechargeranddashperformstart-upself-test(LEDslightupinsequence).See
ChargerDisplaysonpage10.
Thechargerutilizessophisticatedchargeterminationcriteriontoshutoffautomatically,preventingthepossibilityof
eitherunderchargingorovercharging.Thechargeraccomplishesthisbymonitoringbatteryvoltage,chargecurrent,
chargetimeandusingstrictdV/dtterminationcriterion.
FEATURES
•ChargeInterlock
WhentheACpowercordisinsertedintoawallreceptacle,thechargerlocksoutthevehicledrivesystem.This
preventsthepossibilityofdrivingthevehiclewhilethechargerispluggedinandpotentiallydamagingthevehicle
andcharger.
•Long-T ermStorageCharge
ThischargerisdesignedtobeleftconnectedtoACpowerduringoff-seasonorlong-termstorage.Besuretocheck
thechargermonthlytoensurethechargerisoperatingcorrectlyduringstorage.Thechargerwillentermaintenance
modeifsupportedbythechargealgorithmorautomaticallyactivateifbatteryvoltagedrops<2.1Voltspercell
(24cellsis50.4Volts)or30dayshaveelapsed.Toreturnthevehicletoservice,disconnecttheACcordfrom
thewalloutlet,wait15secondsandthenplugtheACcordbackin.Thechargerwillactivate.Allowthevehicleto
completeonefullchargecyclebeforeputtingitintoservice.
ULANDCSALISTING
Whenoperatedona120-volt/60Hzelectricalsystem,thisbatterychargerhasbeenlistedbyUnderwriters
LaboratoriesandbytheCanadianUnderwriters(therebymeetingthecriteriaoftheCanadianStandardsAssociation).
CECOMPLIANCE
ThisbatterychargeriscompliantwiththeEUEMCDirective2004/108/EC.
IP(INGRESSPROTECTION)RATING
TheenclosureofthechargerhasbeentestedsuccessfullytoEN60529,meetingIP66.TheACsupplyinletisratedto
IP20,whichissuitableforindooruseonly.KeepallACconnectionscleananddry.
Page8HighFrequencyBatteryChargerOwner’sManualforCustomSolutions