Pro Charging Systems DUAL PRO Patriot Series Assembly instructions

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PRO CHARGING SYSTEMS, LLC
1551 Heil Quaker Boulevard
LaVergne, TN 37086-3539
*For addional informaon, please call our Technical Support Group at 615.471.5300
Or email us at [email protected] 70384 - 091222
Safety, Installaon, and Operang Instrucon
Instrucons importantes concernant la securite
Patriot Series 2420 High Frequency
SPECIFICATIONS:
PS2420 Output: 24 VDC @ 20 ADC, 120VAC @ 8 Amps, 50/60 HZ
PS2420230 Output: 24 VDC @ 20 ADC, 230VAC @ 4 Amps, 50/60 HZ

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Table of Contents
Descripon Secon Descripon Secon
Important Safety Instrucons 2Troubleshoot / Technical Guide 14
Personal Safety Precauons 3Output Connector Circuit 15
AC and Ulity Requirements 7Temperature Compensaon Opon 15
Safe Grounding Instrucons 8Vehicle Lockout Control Opon 16
Assembly and Preparing to Charge 9AC Convenience Port Opon 16
Charging a Rechargeable Baery 11 Limited Warranty 16
Mul-Stage Charge—LED 12
Mul-Stage Charge—LCD 12
Error Code Descripon 12
IMPORTANT SAFETY INSTRUCTIONS
INSTRUCTIONS IMPORTANTES CONCERNANT LA SÉCURITÉ :
SAVE THESE INSTRUCTIONS. This manual contains important safety and operang instrucons for future reference.
CONCERVER CES INSTRUCTIONS. CE MANUEL CONTIENT DES INSTRUCTIONS IMPORTANTES CONCERNANT LA SÉCU-
RITÉ ET LE FONCTIONNEMENT.
This symbol means: Hazards or unsafe pracces, which could result in severe personal
injury or death.
This symbol means: Immediate hazards, which will result in severe personal injury or
death.
This symbol means: Hazards or unsafe pracces, which may result in minor personal
injury, product, or property damage.
Always read all instrucons before using your PCS product!
This symbol means: BE ALERT! Your safety, or the safety of others, is involved.

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PERSONAL SAFETY PRECAUTIONS
• Wear complete eye protecon and clothing protecon. Avoid touching eyes while working near baery. Have
plenty of fresh water and soap nearby in case baery acid contacts skin, clothing, eyes, or other surfaces. If
baery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye, immediately
ood eye with running cold water for at least 10 minutes and seek medical aenon promptly.
• Dress properly. Wear protecve, electrically nonconducve clothes, and nonskid footwear. Remove personal
metal items such as rings, bracelets, necklaces, and watches when working with a lead-acid baery. A lead-
acid baery can produce a short-circuit current high enough to weld a ring or the like to metal, causing a se-
vere burn. Wear restricve hair covering to contain long hair.
• 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 baery.
• Stay Alert. Watch what you are doing and use common sense. Do Not operate any PCS product when you are
red.
• Keep Children Away. Children must never be allowed in the work area. Do not let them handle machines,
tools, baery chargers, or extension cords.
• Observe Work Area Condions. NEVER smoke or allow a spark or ame in the vicinity of a baery or engine.
Don’t expose to rain. Keep work area well lit.
• Do Not Overreach. Keep proper foong and balance at all mes. Do not reach over or across electrical cables
or frames.
• Avoid Electrical Shock. To reduce risk of electrical shock, unplug charger from outlet before aempng any
maintenance or cleaning.
• Do Not Operate PCS Product 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 disconnecng charger. If damaged, replace the elec-
trical cord or plug immediately.
• Store Idle Equipment. When not in use, store equipment in a dry locaon to inhibit rust. Always lock up tools
and equipment and keep out of reach of children.
• Maintain PCS Product Care. Inspect periodically and, if it has received a sharp blow, been dropped, or other-
wise 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 re.
• Check for Damaged Parts. Before using any PCS product, carefully check any part that appears damaged to
determine that it will operate properly and perform its intended funcon. Check for broken parts and any oth-
er condion that may aect proper operaon. Any part that is damaged should be properly repaired or re-
placed by a qualied technician. Do not use the charger if any part does not operate properly.
• Replacement Parts and Accessories. When maintaining, only use accessories intended for use with this PCS
product. Approved accessories are available from Pro Charging Systems (800.742.2740).

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To reduce risk of baery explosion, follow these instrucons, those published by the
baery manufacturer, and by the manufacturer of any equipment that you intend to use in
the vicinity of baery. Review all cauonary markings on these products and on the
engine.
Pour réduire le risque d’explosion, lire ces instrucons et celles qui gurent sur la baerie.
If it is necessary to relocate the baery for charging, rst remove the grounded terminal from the baery.
Then make sure all accessories are o, so as not to cause baery arcing.
RISK OF EXPLOSIVE GASES: WORKING IN THE VICINITY OF A LEAD-ACID BATTERY IS DANGER-
OUS. Baeries generate explosive gases during normal baery operaon. For this reason, it
is of utmost importance that prior to each use of your charger, you read this manual and follow the instruc-
ons exactly. Il est dangereux de travailler a proximité d’une baerie au plomb. Les baeries produisent des gaz
explosifs en service normal. Il est aussi important de toujours relire les instrucons avant d’uliser le chargeur et
de les suivre à la lere.
Do not operate charger in a closed-in area or restrict venlaon in any way.
Ne pas faire fonconner le chargeur dans un espace close et/ou ne pas gener la venlaon.
Clean baery terminals. Be careful to keep corrosion from coming into contact with eyes. Add dislled water to
each cell unl baery acid reaches level specied by baery manufacturer. This helps purge excessive gas from
cells. Do not overll. For a baery without cell caps, carefully follow manufacturer’s recharging instrucons.
Study all baery manufacturers’ specic precauons 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 rang of charger.
Always make your extension cord connecon on the charger side before connecng to a near-
by 120VAC GFCI protected (Ground Fault Circuit Interrupt) outlet. Failure to use a GFCI out-
let may result in electrical shock. Note: U(Universal) chargers should be connected to a 110, 115 or 230VAC
GFCI protected outlet. The DC connecon should always be made before connecng or disconnecng the AC
side.
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 the GFCI protected
(Ground Fault Circuit Interrupt) outlet.
Always remove the extension cord from the GFCI protected outlet rst when charging is completed, followed by
unplugging the charger.

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Use charger for charging a LEAD-ACID (lead acid, sealed lead acid, gel cell and AGM) baery
only. It is not intended to supply power to a low voltage electrical system other than in a
starter-motor applicaon. Do not use baery charger for charging dry-cell baeries that are
commonly used with home
appliances. These baeries may burst, causing personal injury and damage to property.
Uliser le chargeur pour charger une baerie 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’uliser le charger des piles sèch-
espourait entrainer l’éclatement des piles et causer des blessures ou des dommages.
DO NOT aempt to aach a charger to a baery pack if the output of the charger does not match the baery
pack voltage. Example: Model i-3625 is a 36 volt output charger and is only usable on 36 volt baery systems.
NEVER connect to just one baery (ie. 6V) in the pack. Damage can occur.
Be extra cauous to reduce risk of dropping a metal tool onto baery. It might cause a spark or short-circuit a
baery or other electrical part, possibly resulng in an explosion. If damaged, contact PCS
(615.471.5300).
NEVER charge a frozen baery.
Ne jamais charger une baerie gelée.
Assure that the area around your charger and baeries is properly venlated. Connect your extension cord, with
no AC Power present, to the baery 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 baery charger output
connector, baery connector, or baery terminals.
Once you plug in your PCS baery charging system, the charge cycle will begin automacally.
State of charge will be displayed by illuminaon of the Light Eming Diodes (LEDS) on the
baery status indicator located on the front of the unit.
DO NOT connect or disconnect the DC output electrical cord to or from the baery
receptacle when the charger is on. Arcing and / or burning of the plug and receptacle could result and could
cause the baeries to explode. If the charger must be stopped, rst
disconnect the AC power supply cord from its outlet, then disconnect the charger DC output
plug from the baery receptacle.
We recommend that you leave your system plugged in. This will reduce sulfaon on the lead
plates of the baeries and allow your PCS charging system to keep your baeries fully main-
tained and ready to perform at their best.
Study all baery manufacturers’ specic precauons such as removing or not removing cell caps while charg-
ing and recommended rates of charge.
Prendre connaissance des measures de précauon spéciés par le fabricant de la baerie, p. ex., vérier s’il faut
enlever les bouchons des cellules lors du chargement de la baerie, et les taux de chargement recommandés.

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Never place the charger directly above or below the baery being charged; gases or uids
from the baery will corrode and damage the charger. Locate the charger as far away from
the baery as DC cables permit.
Ne jamais placer le chargeur directment sous la baerie à charger ou audessus de cee dernière. Les gaz ou les
uids qui sèchappent de la baerie peuvent entrainer la corrosion du chargeur ou l’endommager. Placer le
chargeur aussi loin de la baerie qui les cables c.c. le permeent.
If it is necessary to remove baery from vehicle to charge it, always remove grounded
terminal from baery rst. Make sure all accessories in the vehicle are o in order to
prevent an arc.
S’il est nécessaire de rerer la baerie 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 an d’éviter la formaon d’un arc.
Never smoke or allow an open spark or ame in the vicinity of the BATTERY the baery or
engine.
Ne jamais fumer près de la baerie ou du moteur et éviter toute éncelle ou amme nue à proximité de ces der-
nie.
Working in the vicinity of a lead-acid baery is dangerous. Baeries generate explosive gases
during normal operaon. For this reason it is of the utmost importance that prior to each use
of your charger, you read and follow the instrucons provided exactly.
Il est dangereux de travailler a proximité d’une baerie au plomb. Les baeries produisent des gaz explosifs en
service normal. Il est aussi important de toujours relire les instrucons avant d’uliser le chargeur et de les suivre
à la lere.
• To reduce risk of baery explosion, follow all safety instrucons below and those published by baery manu-
facturer. Review cauonary markings on vehicle or equipment containing baery.
• Use of an aachment not recommended or sold by the baery charger manufacturer may result in a risk of
re, electric shock or injury to persons.
• Do not operate this charger if it has received a sharp blow, was dropped or otherwise damaged in any man-
ner. Refer to a qualied service agent.
• Charger contains no serviceable parts. If it fails during its warranty period, contact your dealer, OEM suppli-
er, or visit the PCS website at www. Pcsdv.com for informaon concerning how to obtain a warranty replace-
ment.
• To reduce risk of electric shock, unplug charger from AC outlet before aempng any maintenance or clean-
ing.
• For external cleaning, use a clean damp towel.
• Have your distributor, dealer or other qualied service agent repair or replace worn or damaged parts imme-
diately. Repairs should not be aempted by people who are not qualied.

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• Whenever removing AC plug from the receptacle, pull from the plug body, not from the cord.
• Do not operate the charger if it malfuncons. Personal injury or property damage could result.
• Do not charge non-rechargeable baeries.
• During charging, baery and charger must be placed in a well venlated area.
• When charging a baery mounted in an automobile, take the following precauons:
• The baery terminal not connected to the chassis must be connected rst. The other connecon must be
made to the chassis as far away from the baery and fuel line as possible. The baery charger is then to
be connected to the supply mains.
• Aer charging, rst disconnect the baery charger from the supply mains. Then remove the chassis con-
necon and, nally, the baery connecon.
PERSONAL PRECAUTIONS WHILE WORKING WITH BATTERIES
• Have someone within range of your voice ready to come to your aid if needed.
• Have plenty of fresh water and soap nearby in case baery acid contacts your skin, clothing, or eyes. Wear eye
and clothing protecon and avoid touching eyes.
• If baery acid contacts skin or clothing, wash immediately with soap and water.
• If acid enters eye, immediately ush eye with running cold water for at least 10 minutes. Get medical aenon
immediately.
• NEVER smoke or allow a spark or ame in vicinity of baery.
• Be extra cauous not to drop a metal tool onto baery. It might spark or short circuit a baery or other electri-
cal part that may cause an explosion.
• Remove personal metal items such as rings, necklaces, watches, etc. Baeries can produce a short-circuit strong
enough to weld such items causing a severe burn.
• NEVER charge a frozen baery. Thaw it out for safer and more ecient charging.
AC AND UTILITY REQUIREMENTS
The use of an improper extension cord could result in a risk of a re or electric shock. If an extension cord must be
used, it must be UL and CSA approved. Locate all cords so that they will not be stepped on, tripped over, or other-
wise subjected to damage or stress. Extension cord must be properly wired, must be in good electrical condion,
and must be properly rated (at least 1.25 mes the AC rang of the charger as specied in the following table:

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RECOMMENDED MINIMUM GAUGE (AWG) FOR EXTENSION CORDS FOR PATRIOT SERIES 2420
HIGH FREQUENCY BATTERY CHARGER
• Refer to the Product ID Label axed to the product and idenfy the input requirements such as ‘120VAC, 60Hz,
10Amps’. Make sure the product will be connected to a matching ulity power rang. For example, if product is
rated at 60Hz, do not connect to a 50Hz ulity.
• The rang of the input AC cord, if replaced by a cered technician, must not be less than 16AWG, 300V for
100VAC or 120VAC ulies and not less than 18AWG, 300V for 230VAC or 240VAC ulity power. Cord must be
hard usage SJT type or beer and must be UL?CSA approved. The cable end connecng to charger must be an
approved IEC 60320 power connector.
• Do not connect product to AC receptacles that share power with any other moderate to heavy loads such as air
condioners, motors and other common appliances. Most appliances turn on/o at random and cause power
surges and power droops that can severely aect the product connected to that same power circuit.
• Inspect AC Receptacles for general wear, including loose or hanging receptacles and be very aware of potenally
worn contacts. If any heat is felt in and around the receptacle while the charger is operang, this is an immedi-
ate indicaon of danger caused by a worn receptacle.
SAFE GROUNDING INSTRUCTIONS
• Do not remove Ground Pin from charger’s A.C. Plug, or connect to ulity power via an adaptor that bypasses the
product’s ground pin connecon. The product must be grounded at all mes when connected to ulity power.
• This baery charger must be grounded to reduce the risk of electric shock. This charger is equipped with an AC
cord set having an equipment-grounding conductor. This AC cord set must be connected to an appropriate re-
ceptacle that is properly installed and grounded in accordance with the Naonal Electrical Code (NEC) and all
local codes and ordinances.
WARNING: IMPROPER CONNECTION OF THE EQUIPMENT-GROUNDING CONDUCTOR MAY
RESULT IN THE RISK OF AN ELECTRIC SHOCK.
• The equipment grounding connector has green insulaon with or without yellow stripe(s). If repair or replace-
ment of the charger’s AC cord set is necessary, refer to a qualied service agent. Do not connect the equipment
grounding connector to a live terminal.
Length of cord (feet) 25 50 100 150
AWG 16 16 14 12

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ASSEMBLY AND PREPARING TO CHARGE
WARNING: The instrucons printed on the charger are for daily reference.. For your own protecon, when
using ANY type of charger, always ensure that the baeries in your Baery Pack ARE ALL at the same state of
charge, same condion, same size, and same rang. DO NOT MIX DIFFERING BATTERY SIZES, BATTERY TYPES OR
OLD BATTERIES WITH NEW. Never use charger for any purpose contrary to its intended purpose of charging re-
chargeable baeries in accordance with ALL instrucons printed in this manual.
• IMPORTANT: Aach Output DC Cable to Charger BEFORE Connecng to equipment or vehicle. Insert Ca-
ble Connector into Charger Output Connector and Rotate Lock unl the Lock CLICKS into posion and the
wings on the Rotate Lock line up with the Lock Mark posion on the front product
• Be sure area around baeries is well venlated while baeries are being charged. Gas can be forcefully blown
away using a non-metallic material like cardboard.
• Inspect the receptacle found on the equipment or vehicle into which the charger output cable connector is ex-
pected to mate into:
• The receptacle must not be worn in any way. Also, carefully inspect receptacle contacts for wearing,
burn or ping marks.
• The receptacle contacts must be clean and free of any dirt, grime, grease, liquids, or other contamina-
on.
• High power currents ow across the contacts between Charger Plug and Vehicle Receptacle and can be
a source of high heat when mang contact surfaces are worn or dirty. Replace receptacle or charger
plug, or both when worn. It is also highly suggested to periodically replace the plug and receptacle
every three years, but subjecve to use, as is the case with all plugs and receptacles on all appliances.
• Inspect the equipment or vehicle cabling once every 30 days for loose or worn wires, connectors, terminals and
ensure fuse safety devices (over current protecon) have been installed by the equipment or vehicle manufac-
turer. Start at the receptacle and inspect each wire and joint connecng the baery along with any series or
parallel wires.
• Follow the wire connecon from the equipment or vehicle’s receptacle down to the rst baery on both the
posive and negave conductors. On one of those conductors, an in-line fuse or a fuse-box ed with an over-
current device (fuse) must be installed within 6 inches of the baery post on the rst baery. If fusing is not
found, install fuse protecon prior to using charger with equipment or vehicle.
• The charger is factory preset to charge in MODE-1, unless supplied with an OEM’s equipment nor vehicle—in
which case, the MODE will be set to that mode dened by the OEM Equipment Specicaon. If changing
baery type, verify and re-establish the charger MODE sengs.
• If charger was purchase ‘used’ or with used equipment—IDENTIFY THE TYPE OF BATTERIES INSTALLED IN THE
EUIPMENT AND VERIFY THAT THE MODE IN WHICH THE CHARGER IS SET IS APPROPRIATELY SELECT FOR THE
BATTERIES. This will ensure that an ‘inventory-stocked charger’ at the dealer’s locaon was not mismatched
with the baeries installed on the equipment or vehicle.

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Charging Algorithms are selectable by referencing the table below. Each mode is set to charge a parcular baery
pack AND MUST BE SET CORRECTLY IN ACCORDANCE WITH THE FOLLOWING TABLE:
MODE—Switch Seng: 0 = Switch Up 1 = Switch Down
Mode Baery Name Type AH Range
(20hr)
Absorb
VPC* 12345
01 Crown CR-225 Flooded 200-250 2.380 00000
02 Exide GC-135 Flooded 200-250 2.400 00001
03 JCI 6V-GC2 Energizer Flooded 210-260 2.450 00010
04 Trojan T105 Flooded 200-250 2.400 00011
05 Trojan T1275 Flooded 130-170 2.400 00100
06 Trojan L16G-AC Flooded 355-425 2.400 00101
07 USBaery US1800 Flooded 190-235 2.450 00110
08 USBaery US2200 Flooded 205-260 2.450 00111
09 Full River DC220-6 AGM 195-245 2.450 01000
10 Full River DC335-6 AGM 305-365 2.450 01001
11 GNB / Crown AGM 200-250 2.330 01010
12 Trojan T105 Reliant AGM 210-230 2.450 01011
13 DEKA / USBaery AGM 200-250 2.400 01100
14 Trojan 6V-GEL GEL 165-215 2.333 01101
15 PsZ-Cell – Lead Acid Flooded 075-125 2.400 01110
16 PsZ-Cell – Lead Acid Flooded 125-175 2.400 01111
17 PsZ-Cell – Lead Acid Flooded 200-250 2.400 10000
18 PsZ-Cell – Lead Acid Flooded 300-350 2.400 10001
19 PsZ-Cell – Lead Acid AGM 075-125 2.450 10010
20 PsZ-Cell – Lead Acid AGM 125-175 2.450 10011
21 PsZ-Cell – Lead Acid AGM 200-250 2.450 10100
22 DEKA / GNB-Cell AGM 300-375 2.450 10101
23 General – GEL GEL 075-125 2.333 10110
24 Enersys 12XFC82 Pure Lead 075-125 2.450 10111
25 Enersys – AGM Pure Lead 200-250 2.433 11000
26 Enersys – AGM Pure Lead 300-375 2.433 11001
27 Opma OPT-D31M Spiral 050-100 2.450 11010
28 General – Spiral Lead Spiral 130-170 2.450 11011
29 Sony LiFePO4 Cell Li+ 055-065 4.172 11100
30 Sony LiFePO4 Cell Li+ 190-210 4.172 11101
31 BMZ LiFePO4 Cell Li+ 160-175 4.175 11110
32 Empty User ———- ———- 11111
Switch Seng (Le to Right)
Absorb VPC = Absorpon Volts Per Cell, the standard in the lead-acid baery industry for specifying voltage param-
eters for charging. 12 volt lead-acid baery pack has 6 cells, a 24 volt lead-acid baery pack has 12 cells, etc.
For Lithium applicaons or baery types not listed, please contact Pro Charging Systems at 615.471.5300 .

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CHARGING A RECHARGEABLE BATTERY
• An LED Display is assumed to be used. For products using an LCD (Liquid Crystal Display) Display, the infor-
maon below is displayed in readable format—refer to the secon tled ‘LCD Display Menu Formats’ for a com-
plete descripon of how the LED informaon is translated and displayed on the LCD.
• For 4 consecuve seconds, upon connecon to AC Power, the Front Panel LEDs will ash a paern to annunciate
the mode seng as Described in the following table where ‘0’ = O, and ‘1’ indicates LED Flashing:
LED CHARGE MODE INDICATOR TABLE
LED’s Le to Right LED’s Le to Right
Note: Once the charging algorithm (MODE) has been changed, there will be a longer than normal
startup me (up to 10 minutes) for the rst use aer the algorithm change. LEDs will not ash
and the charger will appear to be frozen. DO NOT UNPLUG THE CHARGER DURING THIS PERIOD,
THE INTERNAL DATABASE IS BEING REBUILT.
For addional charging algorithm informaon including a detailed descripon of the numerous
charging stages, please scan the following QR code:
1345MODE 123452MODE
000110 0101001
001011 0101102
001112 0110003
010013 0110104
010114 0111005
011015 0111106
011116 1000007
80100017 10001
90100118 10010

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MULTI-STAGE CHARGE (TYPICAL) WITH LED DISPLAY
For addional informaon including a detailed descripon of LED indicaons and funconality,
please scan the following QR code:
MULTI-STAGE CHARGE (TYPICAL) WITH LCD DISPLAY
• Use of an LCD display converts messages from what is otherwise a blinking LED into readable characters. There-
fore, refer to the previous secon for a descripon of a typical charge stage.
For addional informaon including a detailed descripon of LCD messages and funconality,
please scan the following QR code:
ERROR CODE DESCRIPTION
There are numerous Error Codes available to alert the user to possible baery issues or charger related issues. For
chargers ulizing an LED display, the error codes will be displayed by ashing LED’s. For chargers equipped with LCD
displays, the Error Code Number will be displayed.
During an Error Code Annunciaon, the charge cycle has terminated its normal operaon, prematurely. An abnormal
charging condion was detected and charging stopped due to a Charge Error Condion. Refer to the following
Charge Error Table for an extended descripon of the failure or condion and its possible remedy. Error Code Values
1-31, which use the rst ash paern, are not highlighted. Error Code Values 32-64, which use the second ash
paern are highlighted in yellow.
‘ALERTS’ are highlighted in magenta.
Power On (Red) Illuminates connuously when AC POWER IS PRESENT.
Shutdown (Red) Illuminates typically when used only during Error Decode Mode. Refer to
‘TROUBLESHOOTING IF FLASHING.
Detecon (Red) Illuminates when baery not connected while powered by AC. Refer to
‘TROUBLESHOOTING IF FLASHING.
Charging (Yellow) Charge Status Indicator—May illuminate steady or ash during the Mul-Stage
Charge Process.
Charged (Green) Illuminates during the Finishing and Float/Maintenance Stages. When ashing
in conjuncon with a connuously illuminated Power On Red LED, it is signifying
and alert. Refer to Error Code Descripon for alert denion.

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Condion LED 1 LED 2 LED 3 LED 4 LED 5 Error Number
Baery Over Voltage 000011
Baery Temperature Low 000113
Baery Temperature High 001004
Baery Pack Unbalanced –V 001117
Baery Pack Unbalanced –A 010008
Ba Is 100% Discharged 010019
Ba Beyond Over Discharged! 0101010
Ba Emergency Under-Voltage 0101111
Ba Temperature Sensor Open 0111115
Ba Temperature Sensor Shorted 1000016
Ba Over-Temperature 1000117
Baery Storage Error 1001119
Baery Tesng Error – Sulphated 1010020
Baery Tesng Error – Discharged 1010121
Bulk Charge Safety Time Error 1100125
Absorpon Safety Time Error 1101026
Excessive Safety Time Error 0000132
Mode Selected Not Valid – Empty 0001033
Product Not Operaonal! 0001134
Lockout (Inhibit) Enable Defecve 0010035
Lockout (Inhibit) Disable Defecve 0010036
Internal Over Temperature 1000148
Finish Stage Exit via High Voltage S0001—-
Equalizaon Stage Exit via High Voltage S0001—-
CHARGE ERROR TABLE
FLASHING LEDS: 0 = OFF, 1 = FLASHING, S = SOLID
For detailed informaon regarding each of these charge errors, please scan the following QR
code:

14
TROUBLESHOOTING AND TECHNICAL GUIDE
To be able to troubleshoot safely and eecvely, it is important to read this guide completely before beginning any
tests.
WARNING: DO NOT DESASSEMBLE 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 FOL-
LOWING PROCEDURES ARE INTENDED ONLY TO DETERMINE IF A MALFUNCTION MAY EXIST IN THE CHARGER.
DANGER: TO REDUCE THE RISK OF ELECTRIC SHOCK, ALWAYS DISCONNECT THE CHARGER’S AC CORD SET
FROM AC POWER AND ITS DC CORD SET FROM BATTERIES BEFORE ATTEMPTING ANY MAINTENANCE OR CLEAN-
ING.
• LEDs Frozen (no acvity) or Charger seems inoperable:
• Baery may have been subjected to an Over-Discharge condion. Using a DC voltmeter, check if baery
voltage is well under its 100% depth of discharge level dened as 1.75 volts per cell (VPC) for lead acid
baeries (21.0 volts for a 24V baery system). Disconnect AC, then disconnect the DC charge cables and
re-connect. Connect AC to resume charging.,
• Baeries Hot To the Touch—Charger connues to charge:
• A hot baery or baeries may signify cells that are:
• Shorted due to material collected at the boom of the cell and not able to break down and re-
combine back into the baery plates, and/or
• Stracaon of the acid into layers were a denser acid layer is carrying most of the amperage
• An overcharged cell due to other cells being unbalanced and at a much lower state of charge
Possible correcons include:
• Cease charging, operate vehicle to slightly discharge baery pack, then resume charging
• Breaking apart the baery pack and load test each baery—replace defecve baeries
• Check Charger MODE seng and conrm charger is congured for the proper charge algorithm
TECHNICAL NOTES
• Do not connect charger to a receptacle that shares its circuit with other loads such as motors and most all
common appliances. These shared circuits cause severe line voltage droops that, upon appliance abruptly
turning on or o, will cause instantaneous line voltage changes that may be beyond the ability of the charger
to compensate fast enough, causing permanent non-warranty damage to charger.
• Do not charge more than one baery pack at a me. Baery pack characteriscs dier and may cause the micro-
processor to misinterpret algorithmic values and possibly funcon improperly.
• Do not charge more than one baery pack at a me. Baery pack characteriscs dier and may cause the micro-
processor to misinterpret algorithmic values and possibly funcon improperly.
• If charging a series connected string of two or more baeries or cells, ensure that all baeries and cells in the
series connected string, are all at the same state of charge, age, type, and condion.
• The charger uses RF energy only for its internal funcons. Therefore its RF emissions are very low and are unlike-
ly to cause any interference in nearby electronic equipment.

15
• The charger has an operang temperature range of -35C to +55C, and a shipping/storage temperature range of
-40C to +125C. It needs to be stored in clean, dry condions.
• Medical Electrical Equipment needs special precauons regarding EMC and needs to be installed and put into
service according to the EMC informaon provided in this manual.
• Portable and mobile RF communicaons equipment can aect Medical Electrical Equipment.
• The use of Accessories, transducers, and cables other than those specied by the manufacturer, may result in
increased Emissions or decreased Immunity of the Baery Charger.
• The Baery Charger should not be used adjacent to or stacked with other equipment and that, if adjacent or
stacked use is necessary, the Baery Charger should be observed to verify normal operaon in the congura-
on in which it will be used.
• Important: If baeries are le in storage for a lengthy period (months), Charger should be connected to AC
Power connually or periodically (once per month) to replenish baeries self- discharged condion to prevent
possible permanent damage to baery.
OUTPUT CONNECTOR CIRCUIT
OUTPUT CONNECTOR FIGURE
• PIN 1: Temperature Compensaon Posive (+)
• PIN 2: Temperature Compensaon Negave (-)
• PIN 3: Baery Charge Output Posive (+)
• PIN 4: Vehicle Lockout (Inhibit) Posive (+)
• PIN 5: Baery Charge Output Negave (_)
• PIN 6: No Connecon
• PIN 7: Vehicle Lockout (Inhibit) Negave (-)
OPTIONAL TEMPERATURE COMPENSATION
The charger contains a temperature compensaon circuit to accommodate an oponal Temperature Compensaon
Cable.
• If your charger is equipped with a Temperature Compensaon Cable, charging set points will automacally be
adjusted based on baery temperature.
• If your charger does not have the Temperature Compensaon Cable, the charger will funcon based on baery
performance at 25 Degrees C. (77 degrees F).
• For addional informaon, please call Pro Charging Systems tech support at 615.471.5300.

16
LIMITED WARRANTY
Pro Charging Systems, LLC (PCS) makes this Limited Warranty only to the original retail purchaser.
PCS warrants this baery charger for three years (unless the charger is used outside of the USA or the charger has a part number with
the RM designaon) from the date of retail purchase against defecve materials and/or workmanship. *-RM sux refers to
“Restricted Markets” such as Rental applicaons and Heavy Industrial applicaons. These chargers, along with any chargers used
outside of the USA, will have a warranty period of 18 months from the date of retail purchase against defecve materials and/or
workmanship. CR refers to “Cered Recondioned” and designates a 1 year warranty.
If such defects should occur, this unit will either be repaired or replaced at the discreon of the manufacturer. It is the responsibility
of the original purchaser to return the charger along with proof of purchase, transportaon, and/or any mailing or handling charges
prepaid to the manufacturer or its authorized representave. Chargers that are purchased more than two years beyond the date of
producon will automacally have a warranty start date that will be the two year anniversary of the producon date.
This limited warranty is void if the product is misused, improperly maintained, handled carelessly or incorrectly operated.
Addionally, this warranty is void if the charger is disassembled, the charger’s charge cables are cut, the power cord is cut o, the
charger is altered without authorizaon from PCS, the serial number is removed, or repair is aempted by anyone other than an au-
thorized representave.
PCS makes no other warranty other than this limited warranty and expressly excludes any implied warranty, including warranty for
any incidental or consequenal damages. This is the only expressed limited three year warranty authorized by PCS and does not au-
thorize anyone to assume or make any other obligaon towards the product other than this three year Limited Warranty. Some
states do not allow limitaon of incidental or consequenal damages. This warranty gives you specic legal rights and you may also
have other rights which vary from state to state.
Please call Pro Charging Systems, LLC for full warranty informaon at (615.471.5300).
VEHICLE LOCKOUT CONTROL OPTION
INHIBIT (LOCKOUT) WIRING
SW1
WHITE
BLACK
When charging, SW1 is open.
When not charging SW1 is closed.
SW1 maximum current = 3Adc
AC CONVENIENCE PORT ACCESORY OPTION
• This opon is mounted on equipment or vehicle body and allows an A.C. extension Cord to
connect to it, where the charger is mounted deep inside the vehicle. It provides a 5-LED
Status display. This opon is not available for ‘R-Series’ charger products. For component
informaon, please scan the following QR code:
• The circuit depicted above, when applied as an applicaon with the equipment or vehicle, will prevent the
operang of that equipment or vehicle while the charger is connected to A.C. Ulity Power.
• The White connecon on the vehicle side is connected to baery posive (+). Max voltage 100VDC.
• The Black connecon on the vehicle side is connected to the lockout contactor.
• For products with ‘Pigtail’ Lockout Inhibit Cable already installed, a tethered output pigtail is in-
cluded on some models and exits the front of the charger. For component informaon, please
scan the following QR code: