Tornado 24 Volt User manual

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34094A
TORNADO© CORP.
7401 W. LAWRENCE AVENUE
CHICAGO, IL 60656-3489
[phone] FAX [phone]
R
Tornado
24 Volt
Automatic
Battery Charger
15
U.S. PAT. NO. 3,794,905
GR. BR. PAT. NO. 1,414,359
FR. PAT. NO. 2,203,199
W. GR. PAT. NO. 2,351,559
JAPAN PAT. NO. 33133/1978
12 3
Mfd. Exclusively for
R
Tornado Corp., Chicago, IL, USA
TESTED TO CANADIAN AND
U.S. STANDARDS FOR
SAFETY BY UNDERWRITERS
LABORATORIES, INC.
UL
C
UL
L1618 FOR COMMERCIAL USE ONLY; CATALOG NO. 99522, 99622
B/T 10/94

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This illustrated parts book covers:
CATALOG NO. 99522, 99622
VOLTS 24V
U.L. *
*Tested to Canadian and U.S. standards for safety by Underwriters Laboratories, Inc.
All specifications are subject to change without notice.
Table of Contents:
Introduction and Installation 3
Operation Instructions and Maintenance 4
Troubleshooting Guide 6
Limited Warranty
Tornado Corp. warrants each new Battery Charger for defects in material and workmanship for a period of two
years from the date of original purchase of the complete unit. Repairs can be made at the factory. To do so,
send the defective unit with transportation charges prepaid to an authorized Tornado service centers.
For repairs made at other than the service centers, Tornado Corp. will provide only the replacement parts.
If the unit or parts are found in the reasonable judgment of Tornado Corp. to be defective in material or
workmanship, repair, or replacement will be made by Tornado Corp. without charge for parts or labor. Repair or
replacement will be at the discretion of the service center or factory with replacements being made using current
models or parts performing the equivalent function. Labor charges other than those incurred at the service center
or factory are not covered under this warranty. All expenses associated with delivering defective items to the
service center or factory and the expense of returning repaired or replaced items from the service center or
factory to the owner will be paid for by the owner. All warranty work accomplished at the service center or factory
will be completed within a reasonable time after receipt of defective items.
This warranty does not cover any semiconductor parts, such as diodes, which are vulnerable to electrical
overloads beyond the control of Tornado Corp.
This warranty does not cover any charger that has been subject to misuse, neglect, negligence, or accident, or
operated in any way contrary to instructions specified on the charger case and in the owner's manual. No claim of
breach of warranty shall be cause for cancellation of the contract of sale of any charger. Tornado Corp. assumes
no responsibility for loss of time, inconvenience, or other damage, consequential or otherwise, resulting from a
defective charger. All implied warranties (including merchantability) are limited in duration to the two years from
date of manufacture warranty period.
Some states do not allow the exclusion or limitation of incidental or consequential damages; or limitations on how
long an implied warranty lasts, so the above limitations may not apply to you. This warranty gives you specific
legal rights, and you may also have other rights, which vary from state to state.
Tornado Corp.'s obligation under this warranty is strictly and exclusively limited to the repair or replacement of
defective items. Tornado Corp. issues this warranty in good faith and with full confidence in the workmanship and
quality of Tornado Corp. products.

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R
Tornado
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.
IMPORTANT SAFETY INSTRUCTIONS
1. This manual contains important safety and
operating instructions for battery charger Model
99522, 99622.
2. Before using battery charger, read all
instructions and cautionary markings on battery
charger, battery, and product using battery;
DANGER: USE OF AN ATTACHMENT NOT
RECOMMENED OR SOLD BY BATTERY
CHARGER MANUFACTURER MAY RESULT
IN A RISK OF FIRE, ELECTRIC SHOCK, OR
INJURY TO PERSONS.
3. To reduce risk of damage to electric plug and
cord, pull by plug rather than cord when
disconnecting charger.
4. Do not disassemble charger; take it to a
qualified service center when service or repair is
required. Incorrect reassembly may result in a
risk of electric shock or fire.
5. To reduce risk of electric shock, always
disconnect both the power supply cord and the
output cord before attempting any maintenance
or cleaning. Turning off controls will not reduce
this risk.
INTRODUCTION
The Dual-Mode battery charger is designed to
recharge deep-cycle batteries of conventional
replaceable electrolyte or gel-cell and sealed
"maintenance-free" design. The different charge
characteristics required by these different types of
battery design are selected by sliding the "BATTERY
TYPE" selector switch to the correct setting. 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 12 CELL, 50-120 AMP-HR. (20 HR.
RATE), 2.38-2.50 VOLTS PER CELL MAXIMUM
VOLTAGE RECHARGEABLE, DEEP-CYCLE
BATTERY SYSTEMS. THIS CHARGER IS FOR
USE ON REPLACEABLE ELECTROLYTE OR GEL
CELL AND SEALED "MAINTENANCE-FREE"
DEEP-CYCLE BATTERIES. THE "BATTERY
TYPE" SWITCH MUST BE SET TO THE PROPER
TYPE OF BATTERY. BATTERIES IMPROPERLY
MATCHED WITH CHARGER MAY BURST,
CAUSING PERSONAL INJURY AND DAMAGE TO
BATTERIES OR CHARGER.
RECEIVING AND INSTALLING THE CHARGER
When the charger is received, check for possible
in-transit damage. If any damage is found, it should
be reported as a claim to the carrier.
Proper installation of the charger is important in
order to achieve good charger performance and to
prevent damage to the charger and batteries.
Circuit breaker or fuse protection in the 120 volt AC
outlet to which the charger is to be plugged should
allow 7 amps per charger. Do not overload electrical
outlet. Use of an extension cord with the charger
should be avoided unless necessary. 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

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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 the
battery charger has received a sharp blow, or 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.
The charger should be located in a clean, cool, dry,
and well ventilated area. To permit free air flow for
convection cooling, allow three inches (3") minimum
between the charger and any wall and six inches
(6") between the charger and other equipment.
Position the charger on a foundation of stone, brick,
concrete or grounded metal.
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,
SOLVENTS, THINNERS, OR OTHER
FLAMMABLES.
WARNING: KEEP THIS CHARGER DRY; DO
NOT EXPOSE TO RAIN OR SPRAY. FOR
STORAGE, KEEP IN A BUILDING. REPLACE
WORN, CUT, OR DAMAGED ELECTRICAL
CORDS AND PLUGS IMMEDIATELY.
AC INPUT
CAUTION: TO REDUCE RISK OF ELECTRIC
SHOCK OR FIRE, DISCONNECT POWER TO
RECEPTACLE BEFORE INSTALLING OR
REMOVING UNIT.
This battery charger must be connected to a 120
VAC, 60 Hertz, single-phase AC power source.
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 local codes and ordinances.
DANGER: IMPROPER CONNECTION OF
THE EQUIPMENT-GROUNDING CONDUCTOR
CAN RESULT IN RISK OF ELECTRIC SHOCK.
DO NOT REMOVE GROUNDING PRONG FROM
PLUG.
DANGER: NEVER ALTER AC CORD OR
PLUG IF IT WILL NOT FIT OUTLET. HAVE A
PROPER OUTLET INSTALLED BY A QUALIFIED
ELECTRICIAN. IMPROPER CONNECTION CAN
RESULT IN A RISK OF AN ELECTRIC SHOCK.
GROUNDING INSTRUCTIONS
This battery charger is for use on a nominal 120 volt
circuit and has a grounding plug, which looks like the
adapter illustrated in Figure A. A temporary adapter,
which looks like the adapter 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.
GROUNDING METHODS
NOTE: Use of an adapter shown in Figures B and C
is not permitted in Canada.
DANGER: BEFORE USING ADAPTER AS
ILLUSTRATED, BE CERTAIN THE CENTER
SCREW OF OUTLET PANEL PLATE IS
GROUNDED.
The green-colored rigid ear or lug extending from
adapter must be connected to a properly grounded
outlet. If necessary, replace original outlet cover
plate screw with a longer screw that will secure
adapter ear or lug to outlet cover plate and make
ground connection to grounded outlet.
BATTERY TYPE
Battery manufacturers frequently use the same
battery cases for different battery types.
Replaceable liquid electrolyte deep-cycle batteries
have removable cell caps. Water electrolyzed by
discharging and charging the battery is replaced
through these openings.
Non-removable cell caps generally distinguish gel
cell and sealed "maintenance-free" deep-cycle
batteries. The physical appearance of the battery
case is frequently the same as that of a replacement
liquid electrolyte battery, although the cell caps are
generally not removable.
Refer to the battery manufacturer information panel

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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. Refer to your dealer
if you do not understand what type battery you are
using and have them set the "BATTERY TYPE"
switch accordingly.
The "BATTERY TYPE" switch is a two-position slide
switch visible in the rectangular opening on the front
of the charger. Using a small screwdriver, slide the
switch from one setting to the other through the
opening. Take care not to damage the switch when
moving it to the desired setting.
NORMAL OPERATION
Instructions printed on cover of charger are for
daily reference.
1. Set "BATTERY TYPE" switch to the proper style
of battery to be charged.
CAUTION: MAKE SURE THE BATTERY
PACK IS A 24-VOLT, 12-CELL, SERIES
CONNECTED, 50-120 AMP-HOUR (20 HR. RATE),
RECHARGEABLE DEEP-CYCLE BATTERY
SYSTEM. THE "GEL CELL AND SEALED DEEP-
CYCLE BATTERY" SETTING CHARGES TO A
MAXIMUM ON-CHARGE VOLTAGE OF 2.38
VOLTS PER CELL. THE "REPLACEABLE
ELECTROLYTE DEEP-CYCLE BATTERY"
SETTING HAS AN ON-CHARGE VOLTAGE OF AT
LEAST 2.50 VOLTS PER CELL. VISUALLY
CHECK THAT THE BATTERY TYPE SWITCH IS
SET CORRECTLY FOR THE TYPE OF BATTERY
YOU ARE USING.
DANGER: TO PREVENT ELECTRIC SHOCK,
DO NOT TOUCH UNINSULATED PARTS OF THE
CHARGER DC OUTPUT CONNECTOR, BATTERY
CONNECTOR, OR BATTERY TERMINALS. MAKE
SURE ALL ELECTRICAL CONNECTORS ARE IN
GOOD WORKING CONDITION. DO NOT USE
CONNECTORS THAT ARE CRACKED,
CORRODED OR DO NOT MAKE ADEQUATE
ELECTRICAL CONTACT. USE OF A DAMAGED
OR DEFECTIVE CONNECTOR MAY RESULT IN A
RISK OF OVERHEATING OR ELECTRIC SHOCK.
2. Move the power switch to "OFF" position.
3. Connect the power supply cord to a properly
grounded, 120-volt, 60 Hertz single-phase
outlet.
4. Connect the charger’s DC output plug to the
equipment-charging receptacle. Do not connect
the DC plug unless the power switch is in the
"OFF" position. The BLACK wire must be
connected to battery negative (-), and the RED
or WHITE wire to battery positive (+). Make
sure all connections are clean and tight.
5. Move the power switch to "ON" and the RED
and GREEN lights will come on steady for a few
seconds to test the lights. If the lights do not
come on, either the AC cord is not plugged in or
the AC outlet is not live. Test for a live AC outlet
by connecting a suitable appliance into the
specific outlet.
WARNING: CHARGER IS NOT TO BE USED
WHILE THE EQUIPMENT IS OPERATING.
ATTENTION: Ne pas utiliser le charger
pendant que l’equipment est en marche.
WARNING: LEAD-ACID BATTERIES
GENERATE GASES THAT CAN BE EXPLOSIVE.
TO PREVENT ARCING OR BURNING NEAR
BATTERIES, DO NOT DISCONNECT DC
CHARGING CORD FROM BATTERIES WHEN
THE CHARGER IS OPERATING. IF THE CHARGE
CYCLE MUST BE INTERRUPTED, MOVE THE
POWER SWITCH TO "OFF" AND DISCONNECT
THE CHARGER POWER SUPPLY CORD BEFORE
DISCONNECTING THE DC OUTPUT CORD FROM
THE BATTERIES. KEEP SPARKS, FLAME, AND
SMOKING MATERIALS AWAY FROM
BATTERIES.
WARNING: ALWAYS SHIELD EYES WHEN
WORKING NEAR BATTERIES. DO NOT PUT
WRENCHES OR OTHER METAL OBJECTS
ACROSS BATTERY TERMINAL OR BATTERY
TOP. ARCING OR EXPLOSION OF THE
BATTERY CAN RESULT.
Charger will output power three to five (3-5)
seconds after turning switch "ON" as indicated
by the RED light turning off, the slow blinking
GREEN light (once per second), and a slight
transformer hum.
If both lights go off about five seconds after AC is
applied, check to see if the DC plug is correctly
connected to the battery. If the DC plug is
connected properly, either an open circuit exists
in the equipment’s internal circuitry, or the
battery voltage is below 7 volts (see
Troubleshooting).
The charger has an under-voltage protection
mode, which will terminate the charge if battery
voltage does not increase above 18 volts after
10 minutes of charging. This prevents
destroying 12-volt battery systems with this 24-
volt charger. When this occurs, the RED light
will come on steady.
6. Correct initial charge rate should be between 11
to 13 amps. As the batteries become more
charged the charge rate decreases. When the
batteries reach approximately 80% of full

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charge, the GREEN light will fast blink (eight
times per second), the charge rate will have
decreased as determined by the "BATTERY
TYPE" switch setting and the condition of the
batteries.
Replaceable Electrolyte Deep-Cycle Batteries
With healthy batteries, the charging current will
decrease to between 2 to 4 amps and remain there
until the charger turns off. As replaceable electrolyte
deep-cycle batteries lose capacity, the charge rate
may no longer decrease to this reading. The
charger will still determine when the batteries are as
charged as they are capable of being and will turn
off. When battery capacity has decreased to where
the charger is no longer able to taper down to less
than 4 amps, or the batteries will no longer perform
as desired, they should be replaced.
Gel Cell and Sealed Deep-cycle Batteries
The charging current will 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.
7. Charger is equipped with thermal breakers that
automatically turn the charger off if it overheats.
Should charger turn off before the batteries are
fully charged, check to be sure that all of the
ventilation openings are free from obstructions.
After charger cools down to a safe temperature,
it will automatically restart. If charger repeatedly
overheats, refer to a qualified service agent.
8. Charger turns off automatically when batteries
are fully charged as indicated by steady on
GREEN light. Charge time varies with battery
size and depth of discharge. Allow 8 hours for
normal charging. Larger batteries (greater than
120 ampere-hours) or severely discharged
batteries may require up to 16 hours to be
properly charged and equalized. If the charger
operates for 16 hours and is unable to fully
charge the batteries, an internal timer turns the
charger off and begins a fast blink of the RED
light. A maximum voltage shutoff for wet
batteries is an additional safety feature of the
charger. When the battery potential increases
above 2.83 volts per cell, the charger cycle is
terminated and the RED light begins to slow
blink.
9. After the charger has turned off, move the power
switch to the "OFF" position, disconnect AC cord
first, then disconnect the DC output cord from
the equipment charging receptacle.
CAUTION: TO AVOID DAMAGE TO THE
CHARGER CORD AND BATTERY CONNECTOR,
DISCONNECT BY GRASPING THE PLUG
HANDLE OR BODY AND PULLING IT STRAIGHT
OUT OF THE BATTERY CONNECTOR. DO NOT
PULL ON THE CHARGER CORD. DO NOT
TWIST, ROCK OR PULL THE PLUG SIDEWAYS.
WARNING: TO PREVENT ARCING OR
BURNING NEAR THE BATTERIES, DO NOT
DISCONNECT THE OUTPUT CORD FROM THE
BATTERIES WHILE THE CHARGER IS
OPERATING. IF THE CHARGE CYCLE MUST BE
INTERRUPTED, FIRST SLIDE THE POWER
SWITCH TO THE "OFF" POSITION, DISCONNECT
AC CORD, FOLLOWED BY DISCONNECTING
THE OUTPUT CORD FROM THE BATTERIES.
KEEP SPARKS, FLAME, AND SMOKING
MATERIALS AWAY FROM BATTERIES.
WARNING: DO NOT LEAVE THE DC
OUTPUT CONNECTOR PLUGGED IN WHILE
UNATTENDED FOR MORE THAN TWO (2) DAYS.
SEVERE OVERCHARGING AND DAMAGE TO
THE BATTERIES MAY RESULT IF THE
CHARGER DOES NOT TURN OFF.
PROPER CARE OF DEEP-CYCLE MOTIVE
POWER BATTERIES
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. Although these batteries are designed to
withstand such duty, the following precautions must
be observed to obtain good performance and
maximum cycle life.
CAUTION: ALWAYS WEAR PROTECTIVE
CLOTHING AND EYE SHIELDS WHEN WORKING
WITH BATTERIES. BATTERIES CONTAIN ACID
THAT CAN CAUSE BODILY HARM. DO NOT
PLACE WRENCHES OR OTHER METAL
OBJECTS ACROSS THE BATTERY TERMINALS
OR BATTERY TOP. ARCING OR AN EXPLOSION
OF THE BATTERY MAY RESULT. SOMEONE
SHOULD BE WITHIN THE RANGE OF YOUR
VOICE OR CLOSE ENOUGH TO COME TO YOUR
AID WHEN YOU WORK NEAR A LEAD-ACID
BATTERY. HAVE PLENTY OF FRESH WATER
AND SOAP NEARBY IN CASE BATTERY ACID
CONTACTS SKIN, CLOTHING OR EYES.
WARNING: RISK OF EXPLOSIVE GASES.
WORKING IN THE VICINITY OF A LEAD-ACID

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BATTERY IS DANGEROUS. BATTERIES
GENERATE EXPLOSIVE GASES DURING
NORMAL BATTERY OPERATION. IT IS VERY
IMPORTANT THAT YOU READ THIS MANUAL
AND FOLLOW THE INSTRUCTIONS EXACTLY,
EACH TIME BEFORE USING YOUR CHARGER.
1. New batteries should be given a full charge
before their first use because it is difficult to
know how long batteries have been stored.
2. Limit use of new batteries for first 5 cycles. New
batteries are not capable of their rated output
until they have been discharged a number of
times.
3. Do not excessively discharge batteries.
Excessive discharge can cause polarity reversal
of individual cells resulting in complete failure
shortly thereafter. Limited use of new batteries
will minimize the chance of cell reversal.
4. Check the level of the electrolyte in conventional
liquid electrolyte lead-acid batteries monthly.
Maintain the proper electrolyte level by adding
distilled or purified water when necessary.
Electrolyte levels lower during discharge and
rise during charge. Therefore, it is mandatory
that water be added to cells ONLY when they
are fully charged; do not overfill. Old batteries
require more frequent additions of water
compared to new batteries.
5. Keep the tops of batteries clean and dry to
prevent excessive self-discharge. Keep the
battery terminals reasonably tight.
MAINTENANCE INSTRUCTIONS
The battery charger requires minimal maintenance.
It should be kept clean and all connections are to be
tightly secured. In the event of intermittent
operation, examine and tighten, if necessary, all
connections. BE SURE THE CHASSIS IS
SECURELY GROUNDED. If any problems cannot
be resolved, consult a qualified service center.
Observe the following battery maintenance
procedures to obtain good performance and
maximum cycle life.
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 and
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 the risk of dropping a
metal tool onto the battery. It might spark or
short-circuit the battery or other electrical part
that may cause an 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 current high enough to
weld a ring or other metal material, causing a
severe burn.
8. Never charge a frozen battery.
TROUBLESHOOTING GUIDE
For safe and efficient troubleshooting, read this
guide completely before beginning any tests.
CAUTION: DO NOT DISASSEMBLE THE
CHARGER. TAKE THE CHARGER 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,
or in the equipment and batteries.
DANGER: TO REDUCE RISK OF ELECTRIC
SHOCK, ALWAYS DISCONNECT BOTH THE
POWER SUPPLY CORD AND THE OUTPUT
CORD BEFORE ATTEMPTING ANY
MAINTENANCE OR CLEANING.
CAUTION: DO NOT OPERATE THE
CHARGER IF IT IS DAMAGED OR APPEARS TO
BE MALFUNCTIONING. PERSONAL INJURY OR
DAMAGE TO THE CHARGER AND/OR
BATTERIES MAY RESULT.
Use the following chart to help you troubleshoot
problems with the battery and charger system.
There are four different modes that each light can
have: OFF (light is off), SLOW BLINK (light blinks
on and off once per second), FAST BLINK, (light
blinks on and off eight times per second), and
STEADY (light is full on).

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RED
LIGHT
GREEN
LIGHT FUNCTION
Off Off No AC power or No battery connected
Steady Steady Light test when AC connected
Low Glow Slow Blink Charging (less than 80% charged)
Low Glow Fast Blink Charging (over 80% charged)
Low Glow Steady Normal charge completed
Low Glow Off AC power connected, not charging
Steady Off Under voltage shutoff, < 18.0 volts
Slow Blink Off Over voltage shutoff, > 33.96 volts
Fast Blink Off Max. timer shutoff, > 16 hours
1. If the RED and GREEN lights do not illuminate
within three seconds after the AC power is
applied to the charger, it indicates one of the
following:
a. The power switch is not in the "ON" position.
b. The charger is not plugged into a live AC
outlet.
2. If both lights go off and stay off three to five (3-5)
seconds after the charger connections are
completed, it indicates one of the following and
the charger is prevented from turning on:
a. The DC plug is not connected to the
equipment receptacle.
b. A fault has occurred in the equipment wiring.
The connections in the wiring are not
making proper contact or are making poor
contact to the batteries. Have your dealer
check for and repair corroded terminals,
loose or worn plugs, receptacles, and
fuseholders.
c. The battery connections in the equipment
are wrong (reverse polarity).
d. One or both of the batteries are no longer
serviceable (voltage below 7 volts for a 24-
volt system).
3. If the charger turns off before the batteries are
fully charged, it indicates one of the following:
a. The chargers internal thermal breaker
turned the charger off due to overheating.
The charger ventilation openings are
blocked. After the charger has cooled down
to a safe temperature, it will automatically
restart. If the charger repeatedly overheats,
it may be malfunctioning.
b. The AC power was interrupted during the
charge.
c. The DC cord plug was accidentally
disconnected during the charge.
d. A fault has occurred in the equipment wiring.
The equipment charging circuit has high
resistance, or corroded, loose connections,
loose or worn charging receptacle, or loose,
worn fuseholders.
4. A decrease in equipment range where it loses
power faster and faster indicates one of the
following:
a. Using the equipment before the batteries
have been fully charged. This shortens
battery life and hastens the onset of this
reduced daily range. The battery capacity
lost in this manner is permanent and is not
recovered with additional charge cycles.
b. The conventional, replaceable liquid
electrolyte batteries are being under
charged on the gel cell "BATTERY TYPE"
switch setting. The battery capacity lost in
this manner is permanent and is not
recovered with additional charge cycles.
c. Severe overcharging occurs when gel cell
(maintenance free) batteries are charged on
the conventional wet lead acid "BATTERY
TYPE" switch setting. The battery capacity
lost in this manner is permanent and occurs
very rapidly. Check with your dealer about
battery replacement.
d. The batteries have been allowed to sulfate.
Charge the batteries more frequently than
once every three days when the wheelchair
is lightly utilized. Once sulfation is allowed
to take place, it may be partially reduced by
returning, temporarily, to daily charging.
e. The electrolyte level in conventional, liquid
electrolyte lead-acid batteries was allowed
to drop below the top of the battery plates.
Add distilled water to just cover the tops of
the plates immediately upon discovery and
fill to the proper level with distilled water at
the completion of the next charge cycle.
Battery capacity lost in this manner is
permanent and is not recovered with
additional charge cycles.
f. This is the normal wearout process for all
types of deep-cycle motive power batteries.
5. If battery voltage does not exceed 18 volts after
10 minutes of charging, the charger turns off and
the RED light will turn on steady, indicating one
of the following:
a. An improper battery is being used with the
charger. The batteries must be 12 cell,
series connected 2.38-2.50 volts per cell
battery system.

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9 34094A
b. There are failed cells in the batteries being
charged. This cell failure prevents the
battery voltage to rise above 18 volts.
6. If the charger operates through 16 hours before
turning off, the RED light will begin to blink very
rapidly, indicating one of the following:
a. Batteries of higher than 120 amp-hour
capacity (20 hr. rate) can require more than
16 hours to charge.
b. New batteries (5 cycles or less) can require
more than 16 hours to charge.
c. Very deeply discharged batteries (100%
discharged) can require more than 16 hours
to charge.
d. Several failed cells in the batteries that do
not allow the charge rate to taper below 4
amps.
7. If battery voltage exceeds 2.83 volts per cell, the
charger turns off and the RED light begins to
slow blink, indicating one of the following:
a. An improper battery is being used with the
battery charger. The batteries being
charged must be a 12 cell, 2.38-2.50 volts
per cell battery system.
b. The battery being charged has a design that
may be inappropriate for this use. Check
with your dealer for deep-cycle batteries
only.
c. Sulfation of batteries may have occurred.