Fairplay 25930 Maintenance and service guide

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FULLY AUTOMATIC
SCR BATTERY CHARGER
FEATURES
•Microprocessor controlled charge circuit monitors battery state of charge and automatically turns charger off
when the batteries reach full charge.
•Line voltage compensation produces consistent charger output for input voltage variations from nominal.
•Automatic taper of charge rate for superior battery life through optimum equalization of cells and low water
use rate.
•Convection cooled design for maximum reliability and minimum maintenance.
•Factory set for either flooded or sealed batteries, but is field changeable.
•Battery maintenance feature keeps batteries charged while they are in storage.
•UL and CSA listed.
SPECIFICATIONS
Model 25930
AC volts 105 - 128
Frequency / Phase 60 / 1
AC Amps (Maximum) 11.5
Battery Pack Voltage 48 V
DC Output Current 17 Amps tapering to 6 Amps
Battery Capacity (20 hr. rate) 105 - 210
Size (H x W x L) / Weight 9” x 8.75” x 11” / 39 Lbs.
PLEASE SAVE THESE IMPORTANT SAFETY AND OPERATING INSTRUCTIONS
For correct operation of the equipment, it is important to read and be familiar
with this entire manual before installing and operating the charger.
DO NOT DISCARD THIS MANUAL AFTER READING.
LOOK FOR THIS SYMBOL TO POINT OUT SAFETY PRECAUTIONS. IT MEANS:
BECOME ALERT—YOUR SAFETY IS INVOLVED. IF YOU DO NOT FOLLOW THESE
SAFETY INSTRUCTIONS, INJURY OR PROPERTY DAMAGE CAN OCCUR.
*35589*

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IMPORTANT SAFETY INSTRUCTIONS
Before using battery charger, read all instructions
and cautionary markings on battery charger, battery
and equipment. Use of an attachment not
recommended or sold by battery charger
manufacturer may result in a risk of fire, electric
shock, or injury to persons.
INTRODUCTION
This battery charger is designed to recharge deep-
cycle batteries of flooded or valve regulated design.
A patented electronic circuit turns the charger on
and off automatically.
Batteries used on industrial equipment are subjected
to severe deep-cycle duty on a daily basis. For this
reason, it is important that only deep-cycle batteries
be used.
CAUTION: THIS CHARGER IS FOR USE
ONLY ON RECHARGEABLE DEEP-CYCLE
BATTERY SYSTEMS. THE FLOODED REPLACE-
ABLE ELECTROLYTE DEEP-CYCLE BATTERY
SETTING HAS AN ON-CHARGE VOLTAGE OF AT
LEAST 2.50 VOLTS PER CELL. THE VALVE
REGULATED GEL CELL OR SEALED DEEP-
CYCLE BATTERY SETTING CHARGES TO A
MAXIMUM ON-CHARGE VOLTAGE OF 2.38
VOLTS PER CELL. BATTERIES IMPROPERLY
MATCHED WITH CHARGER MAY BURST
CAUSING PERSONAL INJURY AND DAMAGE TO
BATTERIES OR CHARGER.
Battery manufacturers frequently use the same
battery cases for different battery types. Replace-
able liquid electrolyte deep-cycle batteries have
removable cell caps. Water electrolyzed by dis-
charging and charging the battery is replaced
through these openings.
Valve regulated gel cell or sealed “maintenance-
free” deep-cycle batteries are generally
distinguished by non-removable cell caps. The
physical appearance of the battery case is frequently
the same as a replacement liquid electrolyte battery,
though the cell caps are generally not removable.
Refer to the battery manufacturer's information panel
on the battery case to determine the type battery
you have. If the information panel is missing or not
legible, do not use the battery.
The charger is shipped to charge either flooded
(replaceable liquid electrolyte) or valve regulated
(gel or sealed maintenance free) lead-acid batteries
as marked on the front of the charger. An internal
jumper on the electronic controller may be adjusted
to select which type of battery to charger. Remove
the cover and position the jumper as shown in the
following figure. If changed from the factory setting,
place a decal on the front of the charger over the
existing marking “SET FOR XXX BATTERIES” to
indicate the type of batteries to charger.
INITIAL INSTALLATION
Circuit breaker or fuse protection in the 120 volt AC
outlet to which the charger is to be plugged should
allow 15 amps per charger. Do not overload
electrical outlet. Use of an extension cord with the
charger should be avoided. Use of an improper
extension cord could result in a risk of a fire and
electric shock. If an extension cord is needed, use a
three-conductor, No. 14 AWG (or larger) cord with
ground, properly wired, in good electrical condition
and keep as short as possible. Make sure that the
pins on the plug of the extension cord are the same
number, size, and shape as that of the plug on the
battery charger. Locate all cords so that they will not
be stepped on, tripped over, or otherwise subjected
to damage or stress. Do not operate the battery
charger with a damaged cord or plug. Do not
operate the battery charger if it has received a sharp
blow, was dropped or otherwise damaged in any
manner. Refer to a qualified service agent.
Provide adequate ventilation for both batteries and
charger. The convection cooled design requires an
unobstructed flow of cooling air for proper operation.
Keep all charger ventilation openings at least two
inches (2") (5.08cm) away from walls and other
objects. Do not allow clothing, blankets, or other
material to cover charger.
WARNING: CHARGERS CAN IGNITE
FLAMMABLE MATERIALS AND VAPORS. DO
NOT USE NEAR FUELS, GRAIN DUST, SOL-
VENTS, THINNERS, OR OTHER FLAMMABLES.
WARNING: REPLACE WORN, DAMAGED,
OR CUT ELECTRICAL CORDS AND PLUGS
IMMEDIATELY.
WARNING: KEEP DRY; DO NOT EXPOSE TO
RAIN OR SPRAY. FOR STORAGE, KEEP
CHARGER IN A BUILDING. NE PAS EXPOSER
A LA PLUIE.

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AC INPUT
This battery charger must be grounded to reduce the
risk of electric shock. It is equipped with an electric
cord having an equipment-grounding conductor and
a grounding-type plug. The plug must be plugged
into an appropriate outlet that is properly installed
and grounded in accordance with the National
Electrical Code and all local codes and ordinances.
DANGER: IMPROPER CONNECTION OF THE
GROUNDING CONDUCTOR CAN RESULT IN A
RISK OF ELECTRIC SHOCK. DO NOT REMOVE
GROUNDING PRONG FROM PLUG.
The conductor with insulation having an outer
surface that is green, with or without yellow stripe(s),
is the equipment-grounding conductor. If repair or
replacement of the electric cord or plug is necessary,
do not connect the equipment-grounding connector
to a live terminal. Refer to a qualified service agent.
This battery charger is equipped with a grounding
plug as illustrated in Figure A, for use on a nominal
120 volt, 60 Hertz circuit. A temporary adapter, as
illustrated in Figures B and C, may be used to
connect this plug to a two-pole receptacle as shown
in Figure B if a properly grounded outlet is not
available. The temporary adapter should be used
only until a properly grounded outlet can be installed
by a qualified electrician. The green-colored rigid
ear extending from the adapter must be connected
to a permanent ground such as a properly grounded
outlet box.
DANGER: BEFORE USING THE ADAPTER
AS ILLUSTRATED, BE CERTAIN THAT THE
CENTER SCREW OF THE OUTLET PLATE IS
GROUNDED.
GROUNDING METHODS
NOTE: Use of adapter shown in Figures B and C is
NOT permitted in Canada.
NORMAL OPERATION
The instructions printed on the charger are for
daily reference.
1. With the charger DC output cord disconnected
from the batteries, connect the power supply
cord to a 120 Volt, 60 Hertz outlet.
WARNING: TO REDUCE THE RISK OF AN
ELECTRIC SHOCK, CONNECT ONLY TO A
PROPERLY GROUNDED, SINGLE-PHASE
(3-WIRE) OUTLET. REFER TO GROUNDING
INSTRUCTIONS.
CAUTION: MAKE SURE THE BATTERY
PACK IS A SERIES CONNECTED LEAD-ACID
SYSTEM WITH A VOLTAGE AND CAPACITY
RATING AS SHOWN IN SPECIFICATION TABLE
ON PAGE ONE. THE FLOODED REPLACEABLE
ELECTROLYTE DEEP-CYCLE BATTERY
SETTING HAS AN ON-CHARGE VOLTAGE OF AT
LEAST 2.50 VOLTS PER CELL. THE VALVE
REGULATED GEL CELL OR SEALED DEEP-
CYCLE BATTERY SETTING CHARGES TO A
MAXIMUM ON-CHARGE VOLTAGE OF 2.38
VOLTS PER CELL. DAMAGE TO THE CHARGER
AND BATTERIES MAY RESULT IF THIS
CHARGER IS USED ON THE WRONG
BATTERIES.
DANGER: RISK OF ELECTRIC SHOCK! DO
NOT TOUCH UNINSULATED PARTS OF THE
CHARGER OUTPUT CONNECTOR, BATTERY
CONNECTOR, OR BATTERY TERMINALS.
DANGER: VISUALLY AND MANUALLY
INSPECT TO VERIFY THAT THE DC OUTPUT
CORDSET, PLUG AND BATTERY CHARGING
RECEPTACLE ARE IN GOOD WORKING
CONDITION BEFORE EACH AND EVERY USE
AND DO NOT USE THE CHARGER IF:
•The DC charging receptacle does not grip the
DC output plug tightly, is loose or does not make
a good electrical connection.
•The DC output plug and/or charging receptacle
feel hotter than normal.
•The DC output plug contacts or receptacle
contacts are bent, corroded or are dark or bluish
in appearance.
•The DC output plug, cords, receptacle or
equipment charging wiring are cut, worn,
broken, or have any exposed conductors.
•The DC output plug, cords, charger or
receptacles are damaged or distressed in any
way.

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Using the charger with any of the above symptoms
could result in a fire, property damage, or personal
injury.
Have your distributor, dealer or other qualified
service agent repair or replace worn or damaged
parts immediately. Repairs should not be attempted
by people who are not qualified.
2. Connect the DC output plug to the battery
receptacle by grasping the plug body or handle
and pushing the plug straight into the receptacle.
The charger will start automatically in three to
five (3-5) seconds.
WARNING: DO NOT DISCONNECT THE DC
OUTPUT 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.
3. Monitor the ammeter for the correct charge rate.
The initial charge rate could vary several amps
from the start current listed in the specifications,
depending upon the condition of the batteries
and how much the batteries have been
discharged.
FLOODED ELECTROLYTE BATTERIES
During charge, the battery voltage increases
gradually which causes the charge rate to
decrease. Good battery cells should each rise
to approximately 2.5 volts per cell DC which will
allow the charge rate to taper to less than 10
amps. Since each cell accepts charge at a
slightly different rate, normal charging with the
ammeter reading in the 5 to 10 amps area for
the last few hours of charge is important to
achieve equalization of all battery cells every
time the batteries are charged.
As batteries age, individual cells weaken
resulting in lower than normal finish charge
voltage. As the finish charge voltage decreases,
the charge rate will no longer decrease and
taper into the 5 to 10 amps range on the
ammeter. The charger will, however, still
determine when the batteries have reached full
charge and turn off. Even though they are
properly charged, older batteries will gradually
lose capacity, and should be replaced when they
will no longer perform as required.
VALVE REGULATED BATTERIES
During charge, the battery voltage increases
gradually which causes the charge to decrease
to near zero and remain there until the charger
turns off. Gel cell deep-cycle batteries will still
taper to near zero charge current even as they
wear out and lose capacity and range. As
sealed deep-cycle batteries lose capacity and
range, the charge current may no longer
decrease to this low a reading. The charger will
still determine when the batteries are as charged
as they are capable of being and turn off. When
the batteries will no longer perform as desired,
they should be replaced.
4. The charger turns off automatically when the
batteries reach full charge. The necessary
charge time is affected by numerous factors.
The major factors affecting the required charge
time are battery amp-hour capacity, depth of
discharge, battery temperature and if the battery
is new or broken in.
5. After the charger has turned off, disconnect the
charger DC output plug from the battery
receptacle by grasping the plug body or handle
and pulling the plug straight out of the
receptacle.
WARNING: TO AVOID DAMAGE TO THE
CHARGER CORD, PLUG, AND BATTERY
RECEPTACLE, DO NOT PULL ON THE
CHARGER CORD. DO NOT TWIST, ROCK, OR
PULL THE PLUG SIDEWAYS.
OFF-SEASON BATTERY STORAGE
MAINTENANCE
When the equipment is not in use, the charger is
designed to be left connected to the batteries with
the AC power on. The charger will periodically
provide a special refresh and conditioning charge to
the batteries during long-term storage to help
overcome battery self-discharge losses and to
reduce sulfation.
Several charge cycles may be required to return the
batteries to their full output after equipment has
been in long term storage.
PROPER CARE OF DEEP CYCLE
MOTIVE POWER BATTERIES
Motive power batteries are subjected to severe
deep-cycle duty on a daily basis. Although these
batteries are designed to withstand such duty, the
following precautions must be observed to obtain
good performance and maximum cycle life:

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CAUTION: ALWAYS WEAR PROTECTIVE
EYE SHIELDS AND CLOTHING WHEN WORKING
WITH BATTERIES. BATTERIES CONTAIN ACIDS
WHICH CAN CAUSE BODILY HARM. DO NOT
PUT WRENCHES OR OTHER METAL OBJECTS
ACROSS THE BATTERY TERMINAL OR
BATTERY TOP. ARCING OR EXPLOSION OF
THE BATTERY CAN RESULT.
1. When installing new batteries, be sure the
polarity of each battery and overall battery pack
is correct. Battery and/or charger damage can
result.
2. New batteries should be given a full charge
before their first use because it is difficult to
know how long the batteries have been stored.
3. Limit the use of new batteries for the first 20
cycles. New batteries and older batteries that
have been in storage are not capable of their
rated output until they have been discharged
and charged a number of times.
4. DO NOT EXCESSIVELY DISCHARGE THE
BATTERIES. Excessive discharge can cause
polarity reversal of individual cells resulting in
complete failure shortly thereafter. Heavily
discharging (over 60%) new batteries before
they have been broken in (approximately 20
cycles) can cause permanent cell damage,
resulting in reduced energy capacity and
shortened life.
5. Maintain the proper electrolyte level of flooded
electrolyte batteries by adding water when
necessary. Distilled or deionized water is free of
contaminants and preferred for this use. Never
allow the electrolyte level to fall below the top of
the battery plates. Electrolyte levels lower
during discharge and rise during charge.
Therefore, to prevent the overflow of electrolyte
when charging, it is mandatory that water be
added to cells AFTER they have been fully
charged; do not overfill. Old batteries require
more frequent additions of water than do new
batteries.
6. Hard crystalline sulfates form when batteries in
storage are not maintained in a charged active
state. Internal self-discharge can bring about
the start of this condition in as little as three days
in warm temperatures. Batteries allowed to sit
unmaintained in storage will self-discharge,
sulfate to various degrees and lose capacity.
Repeated charging without using the batteries
between charges can recover some of the lost
power, range, and life, but some permanent loss
should be expected.
7. When the temperature falls below 65°F, the
batteries should be placed on charge as soon
after use as possible. Cold batteries require
more time to fully recharge.
8. The tops of the batteries and battery hold-downs
must be kept clean and dry at all times to
prevent excessive self-discharge and flow of
current between the battery posts and frame.
Electrolyte spilled on the batteries never dries or
evaporates.
9. All connections to batteries that are bolted must
be maintained clean and bright. Due to heating
and discharge rates, bolted connections loosen
over time. Re-tighten the connections twice
yearly to the manufacturer's specified torque.
10. Follow all operating instructions, cautions, and
warnings as specified in this manual, on the
charger, and in your vehicle owner’s manual.
PERSONAL PRECAUTIONS
1. Someone should be within range of your voice
or close enough to come to your aid when you
work near a lead-acid battery.
2. Have plenty of fresh water and soap nearby in
case battery acid contacts skin, clothing, or
eyes.
3. Wear complete eye and clothing protection.
Avoid touching eyes while working near battery.
4. 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 get medical
attention immediately.
5. NEVER smoke or allow a spark or flame in
vicinity of battery.
6. Be extra cautious to reduce risk of dropping a
metal tool onto battery. It might spark or short-
circuit battery or other electrical part that may
cause explosion.
7. 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.
8. NEVER charge a frozen battery.

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TROUBLESHOOTING GUIDE
To be able to troubleshoot safely and effectively,
it is important to read this guide completely
before beginning any tests.
CAUTION: DO NOT DISASSEMBLE THE
CHARGER. TAKE IT TO A QUALIFIED SERVICE
AGENT WHEN SERVICE OR REPAIR IS
REQUIRED. INCORRECT REASSEMBLY MAY
RESULT IN A RISK OF ELECTRIC SHOCK OR
FIRE. THE FOLLOWING PROCEDURES ARE
INTENDED ONLY TO DETERMINE IF A
MALFUNCTION MAY EXIST IN THE CHARGER.
DANGER: TO REDUCE THE RISK OF
ELECTRIC SHOCK, ALWAYS DISCONNECT
BOTH THE POWER SUPPLY CORD AND THE
OUTPUT CORD BEFORE ATTEMPTING ANY
MAINTENANCE OR CLEANING.
WARNING: DO NOT OPERATE THE
CHARGER IF IT IS MALFUNCTIONING.
PERSONAL INJURY OR PROPERTY DAMAGE
COULD RESULT.
To determine if a charger malfunction exists, identify
the problem from the following list and refer to the
appropriate section for detailed instructions.
1. CHARGER DOES NOT TURN ON
2. CHARGER FUSE BLOWS
3. CHARGER DOES NOT TURN OFF
4. THE BUILDING AC LINE CIRCUIT BREAKER
OR FUSE BLOWS
If the problem is other than listed above, refer to a
qualified service agent for additional troubleshooting
procedures.
1. CHARGER DOES NOT TURN ON
The DC plug must be disconnected and reconnected
to start or restart the charger after turn off.
Connect the power supply cord securely to a live AC
outlet. Visually inspect the DC output plug and
battery receptacle to be sure they are in good
working condition.
WARNING: IF THE PLUG OR RECEPTACLE
IS BROKEN, TWISTED, BENT OR LOOSE AND
DOES NOT MAKE GOOD ELECTRICAL
CONTACT, HAVE IT REPLACED BY A
QUALIFIED SERVICE AGENT IMMEDIATELY. DO
NOT USE THIS CHARGER IN THIS CONDITION
AS FIRE OR PERSONAL INJURY CAN RESULT.
If the plug and receptacle are good, connect the DC
plug into the receptacle and listen for the power
relay inside the charger to "click" on within five
seconds. If the "click" is not heard remove the DC
plug from the receptacle and connect the DC plug of
another charger, which you know is operating
properly, to the receptacle.
If still no "click" is heard, a malfunction in the
batteries or receptacle wiring exists. If the "click" is
heard, the batteries and receptacle are good, and a
malfunction exists in the original charger.
If the relay "click" is heard, a hum from the
transformer should be heard and the ammeter
should indicate the charge rate. If no transformer
hum is heard, check to be sure the AC power supply
cord is securely connected to a live AC outlet.
When three-prong to two-prong adapters are used,
they tend to work loose, resulting in a poor
connection. Check the AC line fuse or circuit
breaker and, if possible, connect a functioning
charger, utility light, or other electrical appliance to
the outlet to verify the presence of AC power. If AC
power is present, and still no transformer hum is
heard, the charger is malfunctioning.
If the relay "clicks" and the transformer hums, but no
charge rate is indicated on the ammeter, the charger
is malfunctioning.
2. CHARGER FUSE BLOWS
The charger fuse assembly consists of a fuse wire
with a transparent cover visible on the front of the
charger. The fuse link protects the charger in the
event the SCR or transformer fails.
Check the fuse assembly visually for an open or
blown fuse link. If the fuse assembly blows as soon
as the DC output plug is connected to the battery
receptacle, the charger is malfunctioning.
3. THE CHARGER DOES NOT TURN OFF
New batteries or batteries charged in cold
temperatures may require an extended charge time
to achieve full charge. The charger implements a 20
hour maximum timer to protect the system. If the
charger runs for more than 20 hours without shutting
off, the charger is malfunctioning.
4. THE BUILDING AC LINE CIRCUIT BREAKER
OR FUSE BLOWS
This condition can be caused by a charger problem,
a "weak" fuse or circuit breaker protecting the circuit,
or an overloaded circuit. If the building AC power
fuse or circuit breaker blows, connect the charger to
other outlets (on different circuits) in the building. If
the charger operates properly on other circuits, have
a qualified electrician inspect and test the original
circuit. If the charger causes other fuses or circuit
breakers (in the building) to blow, the charger should
be tested for a problem.

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EXPLODED VIEW
SERVICE PARTS LIST
# Service Part Description 25930
48V 17A
1 Case assembly 35606S
2 Transformer assembly 25935S
3 Fuse assembly 08776S
4 Relay 21238S
5 SCR assembly, blue & brown wires 35332S
6 SCR assembly, violet & white wires 35318S
7 Electronic controller assembly 25855S
8 AC circuit breaker 34882S
9 Ammeter 16895S
10 AC surge suppressor 35554S
11 AC cordset, 5-15P plug & bushing 21307-08S
12 DC cordset, Lester two blade plug 35586-08
DO NOT DISASSEMBLE THE CHARGER.
TAKE IT TO A QUALIFIED SERVICE AGENT WHEN SERVICE OR REPAIR IS REQUIRED.

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WIRING DIAGRAM