Railroad Products RRP-431 User manual

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Instruction Manual
RRP-431 Single Port
RRP-432 Dual Port
Battery Chargers
for
Battery Packs
RediPak™ & SmartPack®
~9 sec
STATUS Modes:
Healthy Battery [Mode 0]:
This is the normal mode for most batteries. Once the CHARGE cycle is
complete, the battery can be returned to service.
Battery Capacity Warning [MODE 1]:
After the charger has entered the Pulsed-Current float cycle, it will periodically
check the battery capacity - approximately once an hour. It does this by
stopping the top-up pulses for a short duration and checking the battery
terminal voltage response. If the battery terminal voltage drops below the
threshold level then the charger will go into [MODE 1]. Even if the unit
detects a low battery capacity, it will continue to charge the battery.
[MODE 1] is a warning that the battery capacity is getting low and may be
nearing the end of its usable life. Before the battery is replaced, it should
be checked by a calibrated battery tester.
Defective or Disconnected Battery [MODE 2]:
If the battery is disconnected or is defective, the charger will go into [MODE 2]
and remain there until a healthy battery is connected. The charger will not
charge a battery in this mode. When a healthy battery is reconnected the
charger will return to [MODE 1] and begin the charging cycle, unless a problem
is detected.
Over Temperature [MODE 3]:
If a battery over temperature condition occurs, the charger will stop the charge
cycle and enter into [MODE 3]. The charger will periodically check the
temperature of the battery and if the temperature drops below the maximum
allowed temperature the charger will resume the charge cycle and return to
[MODE 1].
Over Current [MODE 4]:
If an over current / short circuit condition is detected, the charger will stop the
charge cycle and enter into [MODE 4]. This is considered a major fault condition.
To protect the battery and the charger itself, the charger will need to be powered
off and restarted to resume the charge cycle.

This manual contains safety and operating instructions for the RRP-431
Single Port and RRP-432 Dual Port chargers for Redi-Pak and SmartPack
battery packs. Before using this charger, please read all of the instructions
for both the charger and also for the battery pack to be charged.
®
™
To reduce the risk of injury, charge only 12V 5-20 Ahr RediPak /
SmartPack battery packs. Do not charge non-rechargable batteries.
®
Other types of batteries might burst the casing causing personal
injury or other damage!
Do not disassemble the charger. Opening the charger will void the
warranty and can result in risk of electrical shock or fire.
Never operate the charger with a damaged cord or plug. Use only the cord
supplied with the charger. Inspect both input and output cords for damage
before using charger.
Never unplug a cord by pulling on the cord itself. Always grasp the plug
when disconnecting the charger.
For indoor use only. Do not expose the charger to rain, snow, or excessive
moisture.
Three stage charge cycle
Battery manufacturers recommend using multi-stage charging to reduce the stress
on the battery while giving the shortest possible charge time. The RRP-431 /
RRP-432 series chargers implement the ideal charge cycle by applying a
Constant-Current charge for 70%-80% of the charge cycle and a Constant-Voltage
charge for the remaining 20%-30%. This is done to prevent the battery from
gassing as it approaches full charge, thus extending the usable life of the battery.
Once the battery has achieved it's optimal charge level, the charger will maintain
the charge using a Pulsed-Current float charge.
Thermal Compensation
In order to obtain maximum service life of the battery pack, a temperature sensor
built into the charge connector monitors the overall temperature of the battery
pack. The optimum terminal voltage for the charging process is dependant on
battery temperature. As the temperature of the battery pack rises, the charging
voltage is reduced to prevent over charge. As the temperature falls, the charge
voltage is increased to avoid under charge. If the battery pack temperature
exceeds 120 F,the charger will stop charging the battery pack and the STATUS
light will report an over temperature error. Once the battery pack temperature
falls back into the acceptable range, the charger will resume charging the battery.
Charging Process
1. Plug in and turn on the charger. The STATUS light will flash: [MODE 2]
indicating that the unit is powered and there is no battery attached.
2. Attach the battery to be charged.
3. The unit will analyze the battery and begin the charging process indicated
by the constant illumination of the STATUS light (indicting a healthy battery)
and the constant illumination of the CHARGE light (indicating the charge
cycle is in process).
4. The battery is fully charged when the CHARGE light is no longer lit and
the STATUS light is constantly illuminated.
The CHARGE light may repeatedly briefly illuminate at the conclusion of the charge
cycle. This is normal and indicates that the charger is in the Pulse-Current float charge.
The battery is fully charged and is ready for use.
Status Mode Descriptions on Back
™
CAUTION: For use with Sealed Lead Acid (SLA) Batteries only.
Warnings
Never use the charger as a DC power source for any electrical equipment.
Never charge a frozen battery.
Please save these instructions for future reference.
Charger Safety Features
Short Circuit Protection: Protects the charger from short-circuit damage.
Over Current Protection: Protects the charger from over-current demand.
Over Voltage Protection: Protects the battery pack from damage.
Battery Polarity Reversal: Protects the charger and battery pack against
incorrectly installed batteries.
Low Battery Voltage: When the battery pack falls below 7V, the charger will
not operate in Normal Charge Mode.
Charger Specifications
Input Voltage: 100-120VAC
Input Frequency: 47-63Hz
Output Voltage: @Fast Charge: 14.4VDC; Float: 13.6VDC
Output Current: DC 1,000mA (Fast Charge)
Battery Capacity: 5-20Ahr (recommended)
Operating Temp: +32F/0C to +104F/40C
Storage Temp: -4F/-20C to +140F/60C
The battery must be placed in a well ventilated area during charging.