NSS CHARGER DB User manual

OPERATION MANUAL
CHARGER DB (Wheel Drive)
Char
g
er DB Wheel Drive with On Board Char
g
er 9096427 Ori
g
.10-04
SAVE THESE INSTRUCTIONS
IMPORTANT SAFETY INSTRUCTIONS
WARNING: Failure to observe these instructions can cause
personal injury to machine operator or bystanders.
WARNING: Fire or explosion hazard.
NEVER operate this machine in an
explosive atmosphere (grain dust,
flammable liquids or fumes, etc.).
WARNING: Fire or explosion hazard.
NEVER use flammable liquids
(gas, kerosene, solvents, or thinners)
to clean or burnish floor.
INTENDED USE
NSS Burnishers are intended for commercial use,
buffing and burnishing floors in an indoor environment.
It is not intended for spray burnishing.
NSS does not recommend using these machines for
any other purpose.
FOR SAFETY
• ALWAYS read and understand all instructions before
operating or servicing machine.
• ALWAYS use this machine ONLY as described in
this manual.
• NEVER attempt to operate this machine unless you
have been trained in its operation.
• NEVER allow an untrained person to operate this
machine.
• ALWAYS operate this machine from the rear control
panel, not from the side.
• ALWAYS turn off master switch when attaching or
changing pads.
• NEVER attempt to operate this machine if it is not
working properly or has been damaged in any
manner.
• NEVER disconnect or modify any switches or safety
devices (circuit breaker).
• NEVER drop or insert any object into any machine
opening.
• NEVER operate this machine with any air opening
blocked. Keep all air openings free of dust, lint, hair,
etc.
• NEVER pick up anything that is burning or smoking,
such as cigarettes, matches or hot ashes.
• NEVER allow this machine to be used as a toy. Close
attention is necessary when used by or near children.
• ALWAYS wear clean tennis shoes or “non-slip” shoes.
Leather soled shoes will be extremely slippery.
• ALWAYS keep face, fingers, hair or any other body
part or loose clothing away from any machine opening
or moving part (revolving pad driver).
• ALWAYS be sure that the ramp is secured to the
vehicle before attempting to load / unload.
• ALWAYS use extreme caution when operating the
machine on a ramp or loading / unloading this machine
into or out of a truck / trailer. Use extreme caution if
the ramp is wet, oily, or covered with cleaning
chemicals.
• NEVER stop or turn the machine on a ramp or incline.
• NEVER attempt to climb a grade or operate this
machine on a ramp or incline of more than 20 degrees.
• ALWAYS store this machine indoors in a dry, cool
area.
• NEVER park or store the machine near a dock, on
ramps, near a furnace, boiler, open flame, or other
high heat source.
• NEVER spray this machine with water or any liquids.
• NEVER allow the vacuum motor or battery charging
plug to get wet or a short may occur.
• NEVER operate this machine when the battery
charger is plugged in.
• NEVER operate the machine outdoors or allow
machine to freeze.
• NEVER expose the machine to rain, snow, or extreme
temperatures.
• NEVER store any items on the machine.
ALL REPAIR SERVICE MUST BE PERFORMED BY AN NSS AUTHORIZED DISTRIBUTOR /
SERVICE STATION USING ONLY NSS ORIGINAL EQUIPMENT PARTS.

IMPORTANT SAFETY INSTRUCTIONS
BATTERY POWERED EQUIPMENT WITH ON BOARD CHARGERS
WARNING: Failure to observe these instructions can cause personal
injury to machine operator or bystanders.
GENERAL
• ALWAYS read and understand all instructions before
installing or charging batteries.
• NEVER attempt to install or charge batteries unless
you have been trained to do so.
• NEVER allow an untrained person to install or charge
batteries.
• ALWAYS remove all jewelry when working on or
near the batteries.
• ALWAYS turn off all switches during installation and
service.
• ALWAYS disconnect the battery leads before
performing any service or repair.
• ALWAYS wear eye protection and protective clothing
to avoid contact with battery acid.
• NEVER lay anything on top of batteries as arcing
may occur.
• IF CONTACT WITH BATTERY ACID OCCURS,
follow these instructions:
• SKIN – rinse area with water.
• EYES – Flush with water for 15 minutes.
• INTERNAL – Drink water or milk. Follow with Milk
of Magnesia, beaten egg or vegetable oil. Call a
physician immediately.
BATTERY INSTALLATION
• ALWAYS use two people to install, as batteries are
heavy.
• ALWAYS turn off all machine switches.
• ALWAYS position batteries as shown on the
machine installation decal to maintain machine
balance.
• ALWAYS connect batteries as shown on the
machine installation decal to avoid shorting out the
batteries and the electrical system.
BATTERY CHARGING
• ALWAYS read instructions on charger carefully.
• ALWAYS use the NSS supplied charger with proper
voltage rating.
For lead acid batteries only, (does not apply to gel
cell or maintenance free batteries).
• ALWAYS check to ensure the battery water level
covers the battery plates before charging.
• ALWAYS check water level after charging and add
water if necessary to bring level to the bottom of the
fill hole.
• NEVER
overfill batteries as
battery
and machine damage may
result.
• ALWAYS wipe any acid from the top of batteries
using a soap solution.
• ALWAYS study battery manufacturers’ specific
precautions such as recommended rates of charge.
• ALWAYS reattach caps to batteries. Do not charge
with caps loose or removed.
• ADD only distilled or treated city water. Not well
water.
• NEVER charge a frozen battery.
• ALWAYS plug the charger into an earthed socket-
outlet.
• NEVER touch uninsulated portion of output connector
or uninsulated battery terminal.
• ALWAYS disconnect the AC supply before making or
breaking the connections to the battery while
charging.
• NEVER open or disassemble charger.
• NEVER operate charger if the AC supply cord is
damaged or if the charger has received a sharp blow,
been dropped, or otherwise damaged in any way.
Read and understand all
instructions before installing
or charging batteries.
No smoking, open
flames, or sparks while
working with batteries. Contains acid.
Avoid contact Poison. Causes
severe burns. Avoid
contact.
WARNING: Batteries emit hydrogen, which can cause fire or explosion.
NEVER smoke, light a match, or cause a spark during operation or charging.
ALWAYS char
g
e in a well-ventilated area awa
y
from o
p
en flame.
ALL REPAIR SERVICE MUST BE PERFORMED BY AN NSS AUTHORIZED DISTRIBUTOR/
SERVICE STATION USING ONLY NSS ORIGINAL EQUIPMENT PARTS

NOISE AND VIBRATION
MACHINE INSPECTION
• Now that the machine is unpacked remember to
recycle all packing materials.
• Inspect the machine for damage or missing
components. If damage is found, contact the local
freight company to file a freight claim.
MACHINE COMPONENTS
Housing
The housing protects both the batteries and the
internal components. It is made of durable
Polyethylene.
Pad Pressure Knob
This knob is centered slightly above the two control
panels. Turning this knob controls the pressure the
pad exerts on the floor.
Operator Control Panel
The operator control panels are located at the upper
rear area of the machine. These panels have
components that control various machine functions.
• In the middle of the two control panels are two (2)
rubber twist grips. These grips rotate forward and
backward to control the direction and speed of the
machine. The farther the grips are rotated, the
faster the machine will move. These twist grips
have a “dead man” feature that returns the machine
to the neutral position when the handles are
released.
• The toggle switch on the right control panel turns
the unit on and off, (Key Switch is Optional).
• To the right of the toggle switch is the light, when lit
up; it indicates the unit is turned on.
• There are two circuit breakers located on the left
control panel, the button to the far left is for the
wheel drive motor, to it’s right is the breaker for the
brush motor.
• Too much pad pressure may cause the circuit
breakers to disconnect the circuit to the motor.
• If this happens, reduce the pad pressure, reset
the breaker, and continue running the machine.
Battery Meter
The battery meter is located on the left control panel
and shows the state of charge of batteries during
operation and recharge.
• Work Range - This is the green area in the middle
of the meter. It shows the approximate amount of
“power” available in the batteries. Observe this
reading when operating this machine.
• Recharge Range - This is the red area on the left of
the meter. It shows when the batteries need to be
recharged. Continued machine operation in this
area will cause battery damage and potential
machine damage.
AMP Meter
• The AMP meter is located on the right control panel
and is a visual indication of the amount of pad
pressure.
• The pad is adjusted properly when the needle on the
AMP meter, on average stays in the green area
indicating proper machine use.
Battery Charging
For Machines with independent chargers:
• The charging plug is located on the left side of the
rear panel.
• To recharge the batteries, insert the battery charger
plug into the charging plug.
• This plug is gray on 36-volt machines.
• See charging instructions for more details.
For Machines with On Board Chargers:
• To recharge the batteries plug the charger cord,
located at the rear of the machine, into an electrical
outlet.
• When the cord is plugged into an outlet the machine
is currently disabled.
• See charging instructions for more details.
Release Knob
• Located in the center of the back panel, this knob is
used to adjust the positions of the machine. Lifting
the knob releases the machine allowing it to tip back
raising the pad off of the floor.
• The machine is in the operating position when the
Operation handle is at its highest level.
• The machine is in the transport position when the
Operation handle is in the center position.
• The machine is in the pad changing position when
the Operation handle is at its lowest level.
Battery Compartment Drain Plugs
These plugs are located on the left and right side of the
machine under the rear panel. Spilled liquids from the
battery compartment area are collected here. Remove
the plug to drain, dispose of all liquids according to
your local EPA regulations.
Flexiwall Shield
The Flexiwall shield creates a seal with the floor to
contain and collect any dust created by the burnishing
operation. A steel skirt protects the Flexiwall shield.
Brush Motor
This machine has a 36-volt brush motor located at the
front of the machine.
• This machine utilizes a 3 HP (2.2 KW.) permanent
magnet motor to drive the 27” (69cm) pad.
• These motors have carbon brushes that must be
serviced on a regular basis.
• Refer to the maintenance section later in this book.
NOISE
Sound pressure level at Operator
position
71 dB(A)
VIBRATION
Weighted RMS acceleration value
(ISO 5349)
.269 m/s2

Wheel Drive Motor
• A 36-volt drive motor powers this machine.
• The speed is electronically controlled for smooth
increase and decrease of speed.
• The motor moves the drive wheels through a chain
and sprocket system.
• This motor has carbon brushes that must be
serviced on a regular basis.
• Refer to the maintenance section later in this book.
Battery Packages
• These machines utilize a 36-volt system, and are
available with either three (3) 12-volt, 210-Amp
Hour Batteries or six (6) 6-volt, 325-Amp Hour
Batteries.
• Consult your local NSS authorized distributor for
application recommendations.
• Do not substitute smaller or larger batteries, as the
balance of the machine will be affected.
MACHINE OPERATION
General Information
This machine works best with dry polishing or
burnishing. Use mop on restorers rather than spray
buff systems to restore the shine.
Spray buffing is time consuming, uses more pads
because they become loaded with floor finish, and
can cause overloading of the machine’s circuit
breaker.
Preparing the Machine for use
Install the batteries:
• Always wear protective glasses and clothing when
handling batteries.
See Battery Warnings on page 2.
• Turn off all switches, unlatch the clasps and slide
the housing forward to expose the battery
compartment.
• Batteries are heavy - use two people to install.
• Refer to wiring diagram inside the battery
compartment. Align batteries in compartment as
shown on diagram.
• Install battery cables as shown on wiring diagram.
• Tighten bolts and hex nuts with a wrench.
Caution: Do not short across two terminals with a
wrench.
Caution: Loose or improper battery connections will
cause battery or machine damage and possible
personal injury.
• Install terminal boots over terminals to complete
installation.
Check the Battery Charge
Turn the switch to the “I” position. Check to see that
the indicator light is on. With master switch on, check
battery meter for charge indication.
• When the needle is in the red area on the left side,
marked “recharge”, the batteries are too low to
operate and should be recharged.
• When the needle is in the green area, the batteries
are within the high to low working range.
• When the needle is in the red area on the right side
of the gauge it indicates the level of battery charge
while connected to the charger.
• When needle is in the far right, red area, shown as
high, and the automatic charger has shut off,
charging of the batteries is complete.
Pad Installation / Changing
Lower the back of the machine to Position 3, by lifting
up on the release knob with one hand, and with your
other hand on one of the twist grips, gently lower the
back of the machine until it rest on the floor.
• Make sure that the correct pad (7/8" to 1") X 27" is
being installed.
• Place the pad flat on the floor, and remove the
center hole of the pad, step on the center of the pad
to compress the edges around the center hole.
This allows easier installation of the pad holding cup.
• With the machine in the pad changing position,
carefully center the pad on the driver.
Caution: Pads must be installed concentric (evenly
aligned) with the outside edge of the pad driver. Failure
to follow these precautions will cause excessive
machine vibration, a reduction in pad life and produce
unsatisfactory burnishing results.
• Place the pad grabber in the center hole of the pad.
• Holding the pad driver and pad, push upward on the
pad grabber until the spring clip has clicked twice.
Caution: Failure to install the pad grabber tightly may
allow the pad to be thrown from the driver.
There is a wide range of pads and brushes available
for the many burnishing applications of this machine.
Consult your local NSS authorized distributor for
application recommendations.

Transporting the Machine to the work site
From the pad changing position raise the back of the
machine up by lifting up on the twist grips with both
hands, until you hear the adjustment knob “click” into
position. The machine is now ready for transport.
Operating the Machine
From the transport position raise the back of the
machine up by lifting up on the twist grips with both
hands.
The machine will automatically stop in position 1.
• Turn the master switch to “I”; check the level of
battery work range (put machine on “charge” if not
in the high range).
• Twist the handle grips forward (away from you) to
activate the pad driving motor. To move backward
twist the handle grips backward (toward you).
• The machine will tilt forward slightly as the pad
sucks to the floor.
CAUTION: This Machine must be moving at all times
when the pad is rotating or the floor may be damaged.
Never operate this machine with the needle in the red
area of the amp meter, or damage to the machine
from overload may result.
See Setting / Adjusting Pad pressure.
Setting / Adjusting Pad Pressure
• Adjust the black knob in the center of the Control
Panel counter clockwise to increase the pad
pressure. It will move the AMP indicator needle
more toward the right or the red area.
• Adjust the knob clockwise to decrease the pad
pressure, decreasing the amps, which moves the
needle to the left.
• Adjust until the AMP meter needle averages in the
area of the green arrow, indicating proper amps.
• With the machine moving forward, watch the AMP
meter for the average needle position on the meter.
Pad pressure relates to buffing performance.
• Too much pad pressure, (operating the machine
continuously in the red area), may damage the floor,
give uneven results, and / or cause the circuit
breaker to blow. Push the button to reset, then,
adjust the pad pressure.
• Operating the machine with higher than
recommended pad pressure in the red area will also
shorten the operating time per battery charge.
• Maximum operating time can be achieved by
adjusting pad pressure throughout the buffing cycle.
• Too light pad pressure will also give poor results
and no contact with the floor.
• The thickness of a new pad varies during the
manufacturing process; however, ALL pads will thin
down during use and require periodic adjustment of
the pad.
• Floors that have high or low spots will cause the
amp meter to enter into the red area occasionally.
This is to be expected and will cause no harm to the
machine.
Maintenance
Daily Maintenance
• Recharge the batteries when indicated by the
Battery Meter.
• Check water level after charging batteries.
• Inspect the machine components for wear, loose
fasteners, or damage.
• Call authorized service center for repairs.
• Wipe machine down with a damp cloth.
• NEVER spray this machine with water or any
liquids.
Weekly Maintenance (Every 25 Hours)
• Verify all daily maintenance has been performed.
• Check the vac hose for connection to the Flexiwall
Shield and filter bag. Empty the filter bag when it is
more than one-half (1/2) full.
• Inspect Flexiwall Shield for dents, cracks and wear.
A damaged Flexiwall Shield will greatly reduce the
burnishing and dust control capabilities.
• Dirt build up on the brush should be removed.
• Never spray this machine with water or any liquids.
• Check the Battery Compartment for liquid level on a
weekly basis.
• Dispose of liquids according to your local EPA
regulations.
Monthly Maintenance (Every 100 Hours)
• Verify all weekly maintenance has been performed.
• Lubricate the caster and drive bearings with an
industrial grade bearing grease. Failure to lubricate
caster and drive bearings will cause the machine to
maneuver with difficulty and premature failure of the
caster and bearings.
• Tighten and Lube the drive motor chain.
Every 60 days (every 300 Hours)
• Verify all monthly maintenance has been
performed.
• The motors require very little service. Using
compressed air, blow the entire motor. Pay close
attention to the carbon brush area. Accumulated
dirt will cause excessive carbon brush arcing,
reduced brush life, poor machine performance, and
possible damage.
• Inspect ALL pad pressure / pivot linkage
connections in the pad pressure adjustment and
pivot linkage assembly. All linkage must move
freely and smoothly to ensure proper machine
operation. Lubricate each part as required with
small amount of grease such as Lubriplate®.
• Failure to lubricate these components may make it
impossible to adjust the pad pressure or place
machine into all three positions.
Every 6 Months (every 650 – 700 Hours)
• Call your Authorized NSS distributor / Service
Station to have the Drive Motor and Brush Motor
carbon brushes inspected for wear.
• Failure to replace carbon brushes will cause poor
machine performance and possible motor damage.

Battery charger
Operating instructions
1. Connect charger power cord to a properly grounded
outlet. When using an extension cord, avoid excessive
voltage drop and extended charge times by using a
grounded 3-wire 12 AWG cord for 50’ lengths or
shorter and 10AWG for greater than 50’ lengths.
2. If a minimum battery voltage is not detected, a trickle
current will be applied until a minimum voltage is
reached.
3. Once a minimum battery voltage is detected, the
charger will enter the bulk charging constant-current
stage. The current bar graph will indicate the current to
the battery as the charger moves through its charge
profile. The length of charge time will vary by how
large and how depleted the battery pack is.
4. When the yellow 80% LED is lit, the charger has
completed the bulk stage of the charge and the battery
is at approximately 80% of charge. The charging could
be terminated at this point if the machine requires
immediate usage, however, it is highly recommended
to wait until the green 100% charge LED illuminates to
ensure maximum battery capacity and battery life.
5. When the green 100% LED is continuously on, the
batteries are completely charged. The charger may
now be unplugged from AC power (always pull on
plug and not cord to reduce risk of damage to the
cord). If left plugged in, the charger will automatically
restart a complete charge cycle if the battery pack
voltage drops on average below 2.1 volts-per-cell or
30 days has elapsed.
6. If a fault occurred anytime during charging, the red
FAULT LED will flash with a code corresponding to
the error. To indicate which error, the FAULT LED
will flash a number of times at a rate of two times per
second, pause 0.5 seconds, then repeat.
[1 FLASH] Battery Voltage High: auto-recover
[2 FLASH] Battery Voltage Low: auto-recover
[3 FLASH] Charge Timeout: the charge did not
complete in the allowed time. This may indicate a
problem with the battery pack (voltage not attaining
the required level), or that the charger output was
reduced due to high ambient temperatures.
[4 FLASH] Check Battery: the battery pack could
not be trickle charged up to the minimum level
required for the charge to be started. This may
indicate that one or more cells in the battery pack
are shorted or damaged.
[5 FLASH] Over-Temperature: auto-recover.
Charger has shutdown due to high internal
temperature. Charger will restart and charge to
completion if temperature comes within accepted
limits, but the fault LED indication will remain until
the charger has been reset (AC removed).
[6 FLASH] QuiQ Fault: an internal fault has been
detected. If Fault 6 is again displayed after
interrupting AC power for at least 10 seconds, the
charger must be brought to a qualified service depot.
Maintenance Instructions
1. For flooded lead-acid batteries, regularly check
water levels of each battery cell after charging and
add water as required to level specified by battery
manufacturer. Follow the safety instructions
recommended by the battery manufacturer.
2. Make sure charger connections to battery
terminals are tight and clean.
3. Do not expose charger to oil or to direct heavy
water spraying when cleaning machine.
DC Battery Connection Procedure:
1. The green wire outputs a battery voltage when
the charger is not plugged in to AC to provide an
Interlock function.
2. Securely fasten the black ring terminal from the
charger to the negative terminal ("-", "NEG",
NEGATIVE") of the battery pack.
3. Select Charge Algorithm if battery type is other
than factory default.
Check / Change Charging Algorithm:
The charger comes pre-loaded with nine algorithms
for Lead Acid batteries as detailed in Table 1. Each
time AC power is applied with the battery pack NOT
connected, the charger enters an algorithm
select/display mode for approximately 11 seconds -
this is the only time the algorithm can be changed. In
this mode, the present algorithm is displayed on the
LED bar graph or 80% LED as shown in Table 1.
If the algorithm # is from one to six, it will be
displayed on the bar graph with the lowest LED
indicating that Algorithm 1 is selected; the second
lowest LED indicates that Algorithm 2 is selected, etc.
For all algorithm #’s, the algorithm number is also
indicated on the 80% LED by the number of blinks
separated by a pause. ** Note- algorithms 7-9 are
indicated only with the 80% LED indication - no bar
graph indication is given.
Check or change the charging algorithm:
a. Disconnect the positive connector from battery
pack. Apply AC power and after an up/down flash
of the LEDs, the algorithm # will display for 11
seconds.
b. To change algorithm, touch connector during the
11-second display period to the battery pack’s
positive terminal for 3 seconds and then remove-
the algorithm # will advance after 3 seconds.
Repeat until desired algorithm # is displayed. A 30
second timeout is extended for every increment.
Incrementing beyond algorithm 9 moves back to
algorithm 1.
After desired algorithm is displayed, touch the
charger connector to the battery positive until the
output relay is heard to click (~10 seconds)-
algorithm is now in permanent memory.
c. Remove AC power from the charger and
reconnect the charger positive connector to the
battery pack. It is highly recommended to check a
newly changed algorithm by repeating the above
steps a) and c).

Delta-Q Battery Charger - Battery Types
NSS Part
Number
Crown
Part
Number
Battery Volts
System Volts
Amp Hour
Recommended
Algorithm
4491061 1-1470 12 36 210 # 1
3390361 1-1435 6 24 & 36 225 # 1
2392111 1-1427 12 24 115 # 5
6393651 1-1428 12 24 145 # 5
2392731** 1-12145 12 24 100 # 6
6491931** 1-1437 6 24 & 36 180 # 6
2691501 1-1450 6 36 325 # 7
7691401 1-1460 6 36 395 # 7
Table 1.
** Note: Gell Battery

TROUBLE SHOOTING
PROBLEM CAUSE SOLUTION
Pad Does Not Turn. Low battery charge. Recharge batteries.
Loose battery cable. Tighten and clamp battery cables.
Circuit breaker has tripped. Reduce pad pressure / change pad reset
breaker.
Worn motor carbon brushes. Change carbon brushes.
Pad load adjustment knob out of
adjustment. Adjust knob until motor will turn on.
Micro switch not engaged. Adjust mounting bracket.
Uneven Floor Buffing. Worn pad. Change pad.
Motor out of alignment. Call NSS Service Center for repair.
Machine Vibrates. Pad is torn or not centered. Center pad.
Change pad.
Check pad driver for damage and replace
if necessary.
Circuit Breaker Trips. Pad pressure too heavy. Reduce pad pressure. Run machine in
green area of amp meter.
Spray buffing. Do not spray buff.
Pad rubbing on flexiwall shield. Realign pad on driver or replace with new
pad.
Check pad size.
Short Running Time on Battery
Charge. Dead cell in battery. Test batteries and replace.
Excessive pad pressure. Reduce pad pressure.
Incorrect pad. Use NSS pads or recommended
equivalent.
Battery Charger Does Not Turn
On. Connection not made between battery charger and machine. Check Anderson connecters for proper contact on both charger and machine.
Improper charger sequence. Read instructions on battery charger or in
instruction manual.
Overly discharged batteries. Contact NSS Service Center for repair.
Repairs performed by an unauthorized company will void the machine warranty.
If
y
ou re
q
uire assistance findin
g
an authorized service center
,
contact NSS Enter
p
rises.
NSS®Enterprises, Inc.
3115 Frenchmens Road, Toledo, Ohio 43607
PHONE [phone] FAX [phone]
NSS ® Enterprises, Inc. European Distribution Centre
Unit II, Pinfold Trading Estate * 55 Nottingham Road
STAPLEFORD, NOTTINGHAM NG9 8AD ENGLAND U.K.
PHONE: [phone] * FAX: [phone]