Xtreme Power HIGH FREQUENCY Series User manual

High Frequency
Battery Charger
Installation and Operation Manual

FERRO MAGNETICS CORPORATION INDUSTRIAL CHARGER WARRANTY
High Frequency Industrial Battery Chargers
This Warranty Agreement entered between Ferro Magnetics Corporation, "Ferro", and the Original End User is with respect to Ferro Magnetics
Corporation motive power battery charger product lines as stated above, for industrial electrical truck battery charging usage.
1.0 GENERAL: Ferro Magnetics Corporation (hereinafter called "Ferro") warrants that each new industrial battery charger supplied by it, is of good
workmanship and is free from any inherent mechanical defects, provided:
1.1 The product is installed and operated in accordance with generally accepted industrial standards and in accordance with the printed instructions
supplied with the charger.
1.2 The charger is used under conditions for which it was designed and is not subject to misuse, negligence or accident.
1.3 The charger receives proper care, protection, and maintenance under supervision of competent personnel.
1.4 The charger is used within the published performance rating for the unit involved.
1.5 The charger is used exclusively by the original end-user and by no other persons.
2.0 PERSONS COVERED: The charger is fully warranted for 3 years from the date of shipment by Ferro to the original end user, with the following
exceptions:
2.1 Power transformer is warranted for an additional 5 years parts only F.O.B. St. Louis, MO.
2.2 Primary switch contacts, fuses, bulbs, and filters are not warranted unless found to be defective prior to use.
3.0 LIMITATION OF REMEDY Any claimed defect is subject to Ferro's inspection and judgment, after the original user at its expense has returned
the defective product to Ferro Magnetics Corporation, St. Louis, MO.
3.1 Ferro's liability is limited to the repair of the defect or, at Ferro's option, the replacement of the defective parts. During the 3-year warranty
period, Ferro will bear all freight, (within the contiguous 48 states) parts, and labor costs per published warranty rate schedule of such repair or
replacement. During the last 5 years of the warranty on power transformers, Ferro will bear the cost of replacement parts only; no labor or other
services will be provided by Ferro. Ferro shall not be obligated to reimburse the original end user or any other person for any work performed.
3.2 Replacement parts will be warranted for the remainder of the original warranty period as defined above, or for 30 days; whichever is greater.
3.3 Ferro shall not be liable for direct or indirect, special or consequential damages in excess of such repair or replacement. In no event shall the
original end user be entitled to recover for contingent expenses resulting from, but not limited to, telephone calls, telegrams, travel expenses, lodging,
duties and taxes, labor, rental of replacement equipment, loss of business or profits or other commercial losses.
4.0 USE OF DEFECTIVE PRODUCT: Continued use of a defective charger after discovery of a defect will void all warranties.
5.0 REPAIRED EQUIPMENT: Except as authorized in writing, this warranty does not cover any equipment that has been repaired by any party
other than an authorized Ferro service agent.
6.0 MODIFIED EQUIPMENT: This warranty is void if this equipment has been modified without written permission from Ferro Magnetics.
7.0 NOT COVERED: Failure due to imbalance of incoming A/C line, line harmonics (distortion) or disconnecting the charger while under load will
not be covered.
EXCEPT AS STATED ABOVE, ALL OTHER WARRANTIES AND CONDITIONS, EITHER EXPRESS OR IMPLIED, INCLUDING IMPLIED
WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE EXCLUDED AND ORIGINAL END USER
ASSUMES ALL RISK AND LIABILITY RESULTING FROM USE OF THE PRODUCT. FERRO NEITHER ASSUMES NOR AUTHORIZES
ANY PERSON TO ASSUME FOR FERRO ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OR USE OF THE PRODUCT AND
THERE ARE NO ORAL AGREEMENTS OR WARRANTIES COLLATERAL TO OR AFFECTING THIS WRITTEN WARRANTY.
FM_WAR_0717_HF

INDEX
Pa
g
e Section Description
4 - Safety Instructions
5 1.0 Installation
5 1.1 Receiving
5 1.2 Location
5 1.3 Line Voltage
6 1.4
A
C Service Requirements
6 1.5 Connecting AC Service to Charger
6 1.6 Grounding the Charge
r
6 1.7 Battery Connector and Charger Cable
7-13 2.0 Operation
7 2.1 046-0304 Control
11-12 Charge Indications
13 Module LED Codes
14 3.0 Troubleshooting & Maintenance
15 4.0 Replaceable Parts
15 4.1 Ordering Information
15 4.2 Recommended Spares
15 4.3 Spare Parts List
16-17 Schematics

4
SAFETY INSTRUCTIONS
WARNING
THIS EQUIPMENT CONTAINS LETHAL VOLTAGE LEVELS. INSTALLATION AND SERVICING
MUST BE PERFORMED BY QUALIFIED PERSONNEL
IMPORTANT: SAVE THESE INSTRUCTIONS!
READ AND FOLLOW ALL INSTRUCTIONS BEFORE INSTALLING, OPERATING, OR
SERVICING CHARGER. ANY DEVIATION CAN CAUSE SERIOUS AND PERMANENT
DAMAGE. FAILURE TO FOLLOW THE INSTRUCTIONS VOIDS THE WARRANTY.
1. Install and ground the charger in accordance with the National Electric Code and your local electric
code. Failure to properly ground the charger could result in a fatal electric shock.
2. “CAUTION” – Risk of fire. Use only on circuits provided with 30 amperes branch circuit protection in
accordance with the National Electrical Code, NFPA70.
3. To reduce the risk of fire, install chargers on a surface of non-combustible material, such as
concrete, stone, brick or grounded metal.
4. This charger has been designed to charge many chemistries of battery, the appropriate charge
algorithm for the chemistry of battery to be charged must be set in the controller. (Lead-acid flooded
or sealed, Ni-Cad and Lithium Ion)
5. Connect only batteries of the same number of cells as listed on the charger nameplate. Damage to
the battery could occur, particularly if the battery has fewer cells than the rating of the charger.
6. Do not touch uninsulated parts of the output connector or battery terminals. A possibility of serious
electrical shock exists.
7. During charge, batteries produce hydrogen gas, which can explode if ignited. Never smoke, use an
open flame, or create sparks in the vicinity of the battery. Ventilate well when the battery is in an
enclosed space.
8. Do not connect or disconnect the battery plug while the charger is on. Doing so will cause arching
and burning of the connector possibly resulting in charger damage or battery explosion and will void
the charger warranty.
9. Lead-acid batteries contain sulfuric acid, which is caustic and can cause chemical burns to the skin.
Refer to the battery manufacturer’s instructions for safe handling of batteries. Use proper personnel
protective equipment. Do not get in eyes, on skin, or on clothing. In cases of contact with eyes,
flush immediately with clean water for 15 minutes. Seek medical attention immediately.
10. Do not operate the charger with any panels removed. De-energize all AC and DC power
connections before servicing the charger.
11. The charger is not for outdoor use. Do not expose the charger to water spray, rain or snow.
12. Do not operate the charger with damaged cables, including cables with exposed conductors or
damaged connectors. Replace damaged cables before operation.
13. Do not operate the charger if it has been dropped, received a sharp blow, or otherwise damaged in
any way. Call your service representative.

5
SECTION 1 - INSTALLATION
1.1. Receiving
Immediately upon receipt of the charger, check it against the shipping invoice to ensure the shipment is
complete and undama
g
ed.
Examine the outside of the packing for signs of rough handling before accepting the charger from the
carrier.
If there is evidence of damage, the receipt should be signed, and both copies (carrier's and receiving
copies) marked "Shipment Received Damaged". The carrier's representative should be called
immediatel
y
and asked to make a "Carrier's Dama
g
e Report".
If concealed damage is later detected, the carrier should be called and requested to make a "Carrier's
Inspection for Concealed Dama
g
e Report".
After inspection by the carrier, arrangements should be made with the charger representative to have
the char
g
er repaired before placin
g
it in service.
When contacting your charger representative for assistance on a damage claim or shipment error,
provide the Model, and Serial Number of the char
g
er, and a full description of the dama
g
e or error.
It is good practice to move the charger to the installation site before uncrating. When using bars,
hammers, etc. for uncrating, use care to avoid damage to the charger.
WARNING: To reduce the risk of fire, install the battery charger on a non-combustible surface
such as concrete, stone, brick, or steel. DO NOT operate the charger on its shipping skid
materials.
1.2. Location
For the best operating conditions and longest life, take care in selecting an installation site. Avoid
locations exposed to high humidity, temperature extremes or dust. Moisture condensing on machine
parts and electrical components can cause corrosion, which seriously affects operation, efficiency and
life. The charger is designed to be used in an ambient temperature of 0-40°C and a relative humidity of
0-90% non-condensin
g
.
A
ll units are desi
g
ned for wall/stand or floor mountin
g
.
Dust and dirt will also decrease heat radiation from heat-generating components, such as transformers and
diodes. This will result in higher operating temperatures and shorter life. Adequate air circulation is needed
at all times in order to ensure proper operation. Provide a minimum of 6 inches of free air space at the sides
of the charger. The front of the charger must remain unobstructed for clean air intake and serviceability. The
top must remain unobstructed for serviceability.
1.3. Line Voltage
The HF chargers are designed and shipped set for a specific AC line voltage range and phase. The
nominal AC line voltage and appropriate phase is noted on the charger nameplate. Before connecting
the charger to the AC service, it should be verified that the charger AC voltage and phase matches the
available AC service voltage.

6
TABLE 1-1
Line Amperes Disconnect Switch Fuse Size Amps
000.0 - 02.5 30A 05
003.0 - 04.5 30A 07
005.0 - 07.5 30A 10
008.0 - 11.0 30A 15
011.5 - 15.5 30A 20
016.0 - 18.0 30A 25
018.5 - 22.0 30A 30
022.5 - 27.0 60A 35
027.5 - 32.0 60A 40
032.5 - 40.0 60A 50
040.5 - 48.0 60A 60
048.5 - 64.0 80A 80
065.0 - 80.0 100A 100
081.0 - 95.0 125A 125
096.0 - 125.0 150A 150
1.4. AC Service Requirements
Follow local code requirements if they are different than the instructions in this manual. Refer to Table 1-1, to
determine the correct ratings for the AC cable, AC fuses, and AC service disconnect switch for the line
amperes as listed on the nameplate of the charger for the available AC voltage.
“CAUTION” – Risk of fire. Use only on circuits provided with 30 amperes branch circuit protection in
accordance with the National Electrical Code, NFPA70.
For voltages up to 240, use a 240 volt disconnect switch.
For voltages greater than 240 to 600, use a 600 volt disconnect switch.
 Three conductors and ground wire required for three-phase
1.5. Connecting AC Service to the Charger
Three-Phase Models
Connect the AC service to the L1, L2 and L3 terminals located on the AC connection block.
1.6 Grounding the Charger
The charger must be grounded to the AC system ground for personnel safety.
The green ground wire in the AC input wiring must be connected to the charger ground stud identified by a
green dot and ground symbol.
1.7 Battery Connector and Charging Cable
Verify that the connectors on both the battery and the charger are attached so that the positive
output terminal of the charger is connected to the positive battery terminal.
CAUTION: If the polarity is reversed, the DC fuse will blow.
If in doubt, check the polarity with a DC voltmeter.

7
SECTION 2 - OPERATION
2.1 DESCRIPTION
The 046-0304 charger control provides fully automatic battery charging. The presence of a battery is
detected by the control and causes a charge cycle to begin automatically. The control has charging profiles
that handle standard flooded, gel-cell, and sealed lead-acid batteries, as well as other battery types such as
nickel-cadmium and Li. Each charging profile, or algorithm, uniquely controls the output current and voltage
to optimally charge a particular type of battery, based on battery manufacturer’s recommendations. The
control can be set to start charging at a certain time of day.
Keypad

The keypad has 4 directional buttons, UP(+), DOWN(-), LEFT(=), RIGHT(info), and a center On/Off (I/O)
button.
‐ To terminate a charge cycle, press the I/O button
‐ To select/unselect an equalize cycle for the current charge, press the LEFT(=) button
‐ To view additional charge data during a charge cycle, press the RIGHT(info) button. The data area of
the display will show the data and the units area will display the units for the parameter being displayed.
Press RIGHT(info) again for additional data. After 10 seconds, the display will return to the normal
display of amps.
‐ To view charge history, press the UP(+) or DOWN(-) buttons to display a previous charge cycle. The
charge cycle number will be displayed in the charge cycle message area and the data will be displayed
in the data area along with the units in the units area. Cycle 1 is the most recent and 100 is the oldest.
To view additional data for the charge cycle, press the RIGHT(info) button. The data area of the display
will show the data and the units area will display the units for the parameter being displayed. Press
RIGHT(info) again for additional data. After 10 seconds, the display will return to the normal display of
amps.
LED Indication
The keypad center I/O button has a multi-color LED backlight to indicate charger status.
LED COLOR STATUS
Flashin
g
GREEN Char
g
er read
y
for batter
y
Solid GREEN Char
g
e complete
Flashin
g
AMBER Char
g
in
g
Solid AMBER Batter
y
connected. Char
g
er OFF
Solid RED
A
bnormal char
g
e detected

8
46-304 Control Reference Guide
AMPS VOLTS V/C AHTIME
=!
USB
TOBi
°F °C % KW
~
1. BATTERY HIGH TEMPERATURE INDICATOR
2. BATTERY LOW WATER INDICATOR
3. CHARGE STATE / CHARGE CYCLE MESSAGE
4. WI-Z COMMUNICATION INDICATOR
5. USB COMMUNICATTION INDICATOR
6. TOBI COMMUNICATION INDICATOR
7. HF MODULE HIGH TEMPERATURE INDICATOR
8. HF MODULE DC FAULT INDICATOR
9. HF MODULE AC FAULT INDICATOR
10. CHARGER WAITING INDICATOR
11. CHARGE STATUS BAR GRAPH
12. DATA AREA
13. UNITS AREA
14. BATTERY CHARGING INDICATOR
15. EQUALIZE CHARGE SELECTED INDICATOR
16. ABNORMAL CHARGE INDICATOR
17. CHARGE COMPLETE INDICATOR
Display Icons
1. The battery high temperature indicator will be displayed when a battery connected to the charger having
a Tobi PI installed is above the OK to charge temperature stored in the Tobi.
2. The battery low water indicator will be displayed when a battery connected to the charger having a Tobi
PI installed detects low water and the charge cycle is complete.
3. The charge state/charge cycle message area is used to indicate the charger state during normal
operation. It will display the charge cycle number when reviewing charge history.
4. The Wi-Z communication indicator will be displayed when the charger is connected to a Wi-Z network
and communicating with the coordinator.
5. N/A.
6. The TOBi communication indicator will be displayed when a battery connected to the charger having a
Tobi PI installed is communicating with the charger.
7. The HF module high temperature indicator will be displayed when an HF module in the charger has
exceeded the safe operating temperature.
8. The HF module DC fault indicator will be displayed when an HF module in the charger has detected a
fault on the DC output.
9. The HF module AC fault indicator will be displayed when an HF module in the charger has detected a
fault on the AC input.
10. The charger waiting indicator will be displayed when the charger is in a wait state.
11. The charge status bar graph displays the status of the charge cycle.
12. The data area will display charging amps during a charge cycle. It will display additional charge data
when reviewing charge parameters and will display data for previous charge cycles when reviewing
history.
13. The units are will display the units for the value shown in the data area.
14. The battery charging indicator will be displayed when the charger is on and charging.
15. The equalize charge selected indicator will be displayed when an equalize cycle has been selected for
the current charge cycle.
16. The abnormal charge indicator will be displayed when the charger detects an abnormal charge
condition.
17. The charge complete indicator will be displayed when the charge cycle is complete.



9

OPERATION
With no battery connected, the control displays ‘CONNECT BATTERY’ and the keypad will be flashing
GREEN. When a battery is connected, a lamp test is performed. The charge then begins and the keypad
will be flashing AMBER. The display show ‘CP1’ along with the charging amps. If equalize is active, an ‘=’
icon appears on the display to indicate an equalizing charge.
When phase 1 is completed, the charger starts phase 2 of the charge cycle. The display shows ‘CP2’ along
with the charging amps. Depending on the charger and battery type, the charger may utilize up to 4 phases
to complete a charge.
During the equalize portion of the charge cycle the display shows ‘EQU’ along with the charging amps.
When a charge is finished, the charger automatically turns off. The display shows a full battery icon and the
keypad will be solid GREEN. The battery may then be disconnected at any time.
EQUALIZE CHARGE
Over time batteries can develop inequalities in cell charge. This can lower the effective capacity of the
battery and shorten life. An equalizing charge re-balances the charge in the battery cells. Perform an
equalize charge if any of the following conditions exist:
1. On flooded batteries, the specific gravity of any cell at the end of charge is 20 points less than the
average of all the cells.
2. The on-charge voltage of any cell at the end of charge is 20 millivolts less than the average of all the
cells.
3. The battery has been stored for 30 days.
The control can perform an equalize automatically based on the number of charge cycles or on a specific
day of the week. Normal equalize consists of an additional charge time at the end of a normal charge cycle.
The control can also perform an equalize charge when requested manually. Press the left arrow (=) button.
The equalize icon appears below the data display signifying an equalize cycle has been selected. If no
battery is connected, the equalize occurs on the next charge cycle to allow the cells to equalize their charge.
The auto-equalize or manual equalize charge can be cleared by pressing the left arrow (=) button again.
The next auto equalize charge occurs after the programmed number of charge cycles or day of the week.

10
TOBI® PI OPERATION
The control has the ability to communicate with a Tobi® PI battery module. For communication to occur, it
must be enabled in the control. This is accomplished by setting the ‘BC’ parameter.
Setting the BC parameter to 0 disables communication.
Setting the BC parameter to 1 enables normal communication. While the battery is connected to the
charger, information is transferred between the charger and the Tobi® PI on the battery including the battery
temperature. For the charger to utilize the temperature, the temperature sensor must also be enabled.
Temperature compensation is enabled by setting the OK to charge temperature (OT) to a non-zero value.
This value indicates the maximum temperature that allows the charge to start. If the battery is above this
temperature when it is connected, the control displays the temperature and waits for the battery to cool
down before starting the charge.
If the thermal sensor is enabled and is missing or damaged, the control displays an F11 indication when the
battery is connected.
The ‘Low charge temp’ (LT) parameter indicates the temperature at which the charge current is reduced to
limit the temperature rise of the battery. The current is reduced proportional to the amount the battery
temperature exceeds the limit.
The ‘No charge temp’ (NT) parameter indicates the temperature at which the charge is terminated. If this
temperature is reached during charge, the charger shuts down and displays an F2 indication.
Refer to the battery manufacturers recommendations before setting these parameters.
If the thermal sensor is enabled, the battery voltage milestones on charge (trip point, cutoff, etc.) are
compensated by 2.5mV/C per degree F (1.5mV/C per degree F for NiCad) above or below 77 degrees F. If
the temperature is below 77 degrees, the voltage is adjusted up and if the temperature is above 77 degrees,
the voltage is adjusted down.
Setting the BC parameter to 2 enables normal communication as well as algorithm upload. In addition to
the information transferred during normal mode, the charger also uploads and utilizes a charge algorithm
from the Tobi® PI on the battery. This can be useful if multiple battery types or AH sizes are used on the
same charger. Refer to the Tobi® PI manual for instructions on setting the charge algorithm. Note: If the
communication between the charger and Tobi® PI fails, the charger utilizes its own algorithm settings to
charge the battery.

11
CHARGE INDICATIONS
The following indications are not necessarily a result of a charger problem. They are typically caused by
external problems such as AC line, poor battery conditions, connections, etc. If abnormal charge conditions
are detected, the charge is terminated, the keypad will be solid RED and the display shows the code:
DISPLAY DESCRIPTION POSSIBLE CAUSE
F0 SHORTED CELL
##:##
Battery voltage did not reach 2.00 V/C within
30 minutes. ##:## is the charge time.
- Shorted Cell
- Open diode
- Low Charging amps
- Low AC line voltage
- Wrong size battery
- Battery ove
r
-discharged
F1 SHORTED CELL
##:##
Battery did not reach gassing voltage within
the allowable time. ##:## is the charge time.
- Shorted Cell
- Open diode
- Low Charging amps
- Low AC line voltage
- Wrong size battery
- Battery ove
r
-discharged
F2 HOT BATTERY
###°F
Hot battery. The battery exceeded the NT
temperature. ###°F is the battery temperature
- Battery is overheated
- Damaged thermal sensor
- Faulty control board
F3 LOW VOLTS
#.## V/C
Low battery voltage, less than 1.60 V/C at start
up. #.## V/C is the battery volts per cell.
- Wrong size battery
- Battery over-discharged
- Voltage jumper setting incorrect
F4 HIGH VOLTS
#.## V/C
High battery voltage, more than 2.40 V/C at
start up. #.##V/C is the battery volts per cell.
- Wrong size battery
- Battery fully charged
- Voltage jumper setting incorrect
F5 NO DC CURRENT
### AMPS
No charging current to the battery. ### AMPS
is the current at the end of charge.
- Faulty AC line contactor
- Open diode
- Faulty resonant capacitor
- Poor battery connections
- Open cell
- Faulty control board
F6 CHARGE ERROR
### AMPS
Charger current or voltage not what was
requested by control. ### AMPS is the current
at the end of charge.
- Incorrect control setup
- Poor battery connections or open Cell
- Faulty HF module (HF chargers)
- Faulty firing board or cable (CF chargers)
- Faulty control board
F7 LONG CHARGE
##:##
Long charge, the charger ran longer than the
allowed time. ##:## is the charge time.
- Open diode
- Low Charging amps
- Low AC line voltage
- Wrong size battery
- Battery ove
r
-discharged
F8 CHARGER ON
### AMPS
Charger stayed on when control requested it to
shut off. ### AMPS is the charger current.
- AC line contactor stuck on
- Open shunt sense lead or loose connection
- Incorrect control setup
- Faulty control board
F9 BAD KEYPAD
Faulty keypad detected. One or more buttons
are stuck on.
- Faulty keypad
- Faulty control board
F10 HIGH CURRENT
### AMPS
Charging current exceeds 110% of shunt
setting. ### A<PS is the current at the end of
charge.
- High charging amps or high AC line voltage
- Incorrect shunt size
- Open shunt sense lead or loose connection
- Faulty control board
F11
TEMP
ERROR
255°F
No thermal sensor. - Missing or damaged thermal sensor on Tobi
- Thermal sensor enabled when not installed
- Faulty Tobi
- Faulty control board

12
DISPLAY DESCRIPTION POSSIBLE CAUSE
M1 BIAS ERROR HF module bias error.
- Low AC Volts
- Bad power supply
- Bad HF Module
M2 HIGH DC
VOLTS HF module output DC volts high.
- Battery disconnected while charging
- Wrong size battery (too many cells)
- Bad HF module
M3 LOW DC
VOLTS HF module output DC volts low.
- Wrong size battery (too few cells)
- Shorted battery cell(s)
- Bad HF module
M4 HIGH AC
VOLTS HF module input AC volts high. - High AC line
- Bad power supply
M5 LOW AC
VOLTS HF module input AC volts low. - Low AC line
- Bad power supply
M6 OVERTEMP 1 HF module primary side over
temperature.
- Fans blocked
- Fans not running
- Too much dust on heat sink
M7 OVERTEMP 2 HF module secondary side over
temperature.
- Fans blocked
- Fans not running
- Too much dust on heat sink
Note: F3 and F4 clear automatically if the battery voltage falls within acceptable limits. All indications except
F8, F9 and F10 can be cleared by disconnecting the battery. For F8, F9, F10 and HF Module Faults, correct
the condition that caused the indication and disconnect the battery to clear the indication.
CAUTION: If F8 indication is showing, and the charger is providing current to the battery, remove AC
power from the charger before disconnecting the battery.
F3 (LOW BATTERY) OVERRIDE
If battery voltage is below 1.6 volts per cell the charger does not start automatically. If this is due to an overly
discharged battery of the correct voltage, the F3 indication can be manually overridden by pressing the I/O
button while the F3 message (Low Battery) displays.

13
HF Module Switch and LED Locations
Condition LED Possible Cause
Module OK. Not Charging SOLID GREEN No Battery Connected
Control Interface Cable Disconnected
Module Char
g
in
g
BLINKING GREEN Normal Condition
Output Over-Voltage BLINKING RED Battery Disconnected While Charging
Wron
g
Size Batter
y
(
too man
y
cells
)
Output Under-Voltage PULSING RED Wrong Size Battery (too few cells)
Shorted Batter
y
Cell
(
s
)
Input Over-Volta
g
e SOLID RED Hi
g
h AC Line
Input Under-Volta
g
e OFF Low AC Line
Temperature Fault SOLID AMBER Fans Blocked
Fans Not Running
Too Much Dust on Heat Sink

14
SECTION 3 – TROUBLESHOOTING & GENERAL MAINTENANCE
Caution: There are lethal voltages exposed when the charger is energized with the door open.
Always disconnect the AC service voltage to the charger before opening the door. The following
chart lists the most probable cause of a malfunction.
SYMPTOMS AND POSSIBLE CAUSES
3.1. No charging current, the control has no display.
POSSIBLE CAUSE
A. Blown AC fuse.
B. No AC service voltage.
C. Incorrect AC voltage.
D. Defective control board.
E. Defective power supply.
3.2. No charging current, control has a display.
POSSIBLE CAUSE
A. Blown DC fuse.
B. Open battery cell.
C. Defective power module.
3.3. AC fuse blows.
POSSIBLE CAUSE
A. Incorrect fuse rating.
B. Incorrect AC voltage.
C. Loose connection in AC circuit.
D. Shorted power module.
3.4. DC fuse blows.
POSSIBLE CAUSE
A. Reversed battery connector.
B. Incorrect fuse rating.
C. Shorted power module.
3.5. Excessive water loss in battery.
POSSIBLE CAUSE
A. Charger amp-hour rating exceeds the battery amp-hour rating.
B. Battery has defective cells.
3.6. Low specific gravity at the end of the charge cycle.
POSSIBLE CAUSE
A. Battery was over-discharged.
B. Charger amp-hour rating is less than the battery AH rating.
C. Battery has defective cells.
D. Battery has been over-watered.
3.7. Charger does not turn off when the control terminates the charge cycle.
POSSIBLE CAUSE
A. Defective control.
3.8 General Maintenance
The charger requires a minimum of maintenance. Connections and terminals should be kept clean and
tight. The charger should be periodically cleaned with clean dry compressed air to prevent any excessive
dirt build up on components. Care should be taken not to bump or move any adjustments during cleaning.
Make sure that both the AC lines and the battery are disconnected before cleaning. The frequency of this
type of maintenance depends on the environment in which this unit is installed. If any cabinet sheet metal
panels are removed for cleaning, be certain they are properly reinstalled upon completion.

15
SECTION 4 – REPLACEABLE PARTS
4.1 Ordering Information
The following information must be supplied when ordering a replacement part from your service agent to
ensure that the correct part is supplied:
A. Model or Spec. number of charger (Located on charger data plate)
B. Serial number of charger (Located on charger data plate)
C. Description of part
4.2 Recommended Spares
The quantity of spares stocked should be increased as the number of chargers increases. The following
chart is the minimum quantity recommended per model for multiple charger installations:
# OF CHARGERS # OF SPARE PARTS KITS
1-3 1
4-10 2
11-25 3
26-50 4
51-100 5
SCHEMATIC REF DESCRIPTION QUAN. USED QUAN. RECOMMENDED
6 DC FUSE 1 1
2 CONTROL BOARD 1 1
4 HF POWER MODULE 1 TO 4 0
1 POWER SUPPLY 1 0
4.3 Spare Parts List
Part Number Description
Controls
046-0304 Wireless LCD control
Power Supply
049-0539 Power supply, 480VAC
049-0561 Power supply, 120/240VAC (also used on 600V with step-down transformer)
003-2076 Step-down Transformer, 600V to 120V
DC Fuse
011-0243 80A 150VDC Fuse
011-0045 150A 150VDC Fuse
011-0046 200A 150VDC Fuse
011-0047 250A 150VDC Fuse
011-0048 300A 150VDC Fuse
011-0113 350A 150VDC Fuse
011-0049 400A 150VDC Fuse
011-0062 500A 150VDC Fuse

16

17