PRO Charging System Industrial Series

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

This document provides installation and operating instructions for the PRO Charging Systems Industrial Series battery chargers. These chargers are designed for permanent installation and are fully automatic.

Function Description

The PRO Charging Systems Industrial Series battery chargers are designed to charge 12V lead-acid batteries (including sealed lead acid, gel cell, and AGM types) in various configurations. They are waterproof, on-board systems built to withstand intense vibration, extreme temperature variations, and submersion. Each charging bank operates independently, ensuring that multiple batteries are charged simultaneously and to 100% capacity. The chargers incorporate temperature compensation for optimal charging in hot or cold environments and are controlled by microprocessors for precise control. They feature true reverse polarity protection and enter a float maintenance mode upon completion of each charge cycle to maintain the battery indefinitely and reduce sulfation on lead plates.

Important Technical Specifications

The Industrial Series chargers come in three models, each with different output configurations:

IS1 (One 6 Amp Bank):
- Total Output: 6 Amps
- Independently charges 12V batteries.
IS2 (Two 6 Amp Banks):
- Total Output: 12 Amps
- Independently charges 12V or 24V batteries.
IS3 (Three 6 Amp Banks):
- Total Output: 18 Amps
- Independently charges 12V, 24V, or 36V batteries.

All units operate with a VAC input range of 90VAC-264VAC. The charge cable assemblies are equipped with a temperature sensor at the junction of each set of ring terminals.

Usage Features

Installation: The chargers are designed for permanent installation in a well-ventilated area. Before installation, ensure no electrical connections are made to the power supply (AC) or battery (DC). When mounting in a boat, choose a flat surface as high above the water level as possible, or a compartment wall strong enough to support the charger's weight. Use the provided stainless steel screws and silicon sealer for secure and waterproof installation. The mounting brackets may have keyholes for easier installation.

Battery Preparation: Before connecting, ensure battery caps are securely in place. Clean the battery case and posts with a baking soda and water solution, being careful not to get any solution inside the case. Periodically clean posts, terminals, and connectors to ensure maximum conductivity. For wet cell batteries, add distilled water to each cell until the acid reaches the level specified by the manufacturer, helping to purge excessive gas. Follow manufacturer's recharging instructions regarding cell caps.

Connection: Route charge cables from the charger to the batteries, avoiding sharp objects, and secure them with supplied wire ties. Connect the red (positive/+) lead ring terminal to the positive (+) battery post and the black (negative/-) lead ring terminal to the negative (-) battery post for each 12V battery.

Power Connection: Always make the extension cord connection on the charger side first. Use an industrial-grade/heavy-duty UL approved and grounded extension cord. Plug the extension cord into a 120VAC GFCI protected A/C outlet. The unit will operate with a VAC input range of 90VAC-264VAC. Always remove the extension cord from the A/C outlet first when charging is completed, then unplug the charger.

Charging Process: Once plugged in, the system will simultaneously and independently charge batteries to 100%. Each charging bank will enter a "float" stage once the battery is charged, monitoring and maintaining it indefinitely. It is recommended to leave the system plugged in to reduce sulfation and keep batteries fully maintained.

LED Indicators: Each charging bank provides charging information using two Light Emitting Diodes (LEDs):

Red (CHARGING) LED: Indicates that DC current is flowing to the battery.
Green (READY) LED: Indicates that the charger has finished its bulk and absorption stage and has entered the float maintenance mode. There is also a Green (POWER) LED that illuminates when power is supplied to the charger from a functioning A/C outlet.

Safety Precautions:

Always read all safety, operating, and installation instructions before use.
Do not operate the charger with a damaged cord, plug, or if it has received a sharp blow or been dropped.
Do not disassemble the charger; contact technical support for service.
Unplug the charger from the outlet before any maintenance or cleaning.
Working near lead-acid batteries is dangerous due to explosive gases. Ensure the area is well-ventilated.
Wear complete eye and clothing protection. Have fresh water and soap nearby in case of acid contact.
NEVER smoke or allow sparks/flames near a battery or engine.
Be cautious to avoid dropping metal tools onto batteries, which can cause sparks or short-circuits.
Remove personal metal items (rings, bracelets, etc.) when working with lead-acid batteries.
Use the charger ONLY for LEAD-ACID batteries. Do not use for dry-cell batteries.
NEVER charge a frozen battery.

Maintenance Features

General Maintenance: The system is designed for minimal maintenance once installed. The float maintenance mode helps reduce sulfation on lead plates, keeping batteries ready for optimal performance.

Troubleshooting:

No LED indicators: Check the AC power supply from its source to the charger using a meter or test light.
Green (POWER) LED on, Red (CHARGING) and Green (READY) LEDs off: This indicates the charger doesn't recognize a battery with at least 2V. Unplug the AC cord and check ring terminals for correct polarity (Red to positive, Black to negative). Check for corrosion-free secure connections and in-line fuses in the charge cable.
Red (CHARGING) LED on for >16 hours, Green (READY) LED off: This means the battery isn't reaching sufficient voltage to indicate full charge. Disconnect AC power. For multi-bank chargers, swap the affected charge cable assembly to another battery to confirm if the issue is with the battery or the charger bank. If the rapid LED sequence (red to green repeatedly) occurs on a different bank, it confirms a battery problem. For single-bank systems, try the charger on another battery. If the charger operates normally, the original battery may be problematic.
Green (READY) LED was on, but upon reconnection, Red (CHARGING) LED appears and stays on: This is normal operating procedure. The system re-analyzes battery status, and the green LED will illuminate after a series of steps.

For any product, installation, or service questions, contact technical support at 800.742.2740. The manufacturer offers a limited warranty of 18 months from the date of retail purchase against defective materials and/or workmanship. The warranty is void if the product is misused, improperly maintained, handled carelessly, incorrectly operated, disassembled, altered without authorization, or if the serial number is removed or repair is attempted by unauthorized personnel.