Page 16
Testing the Charging Cycle
In typical installations, The charge cycle will be completed in 8 to 12 hours depending on the state of charge of the batteries
when the charge cycle was started.
NOTE: The charge cycle time is limited to 20-hours (max). A fault will occur if charging time exceeds the time limit. Refer to
the fault code table for more information.
A charger could remain on for longer than 12 hours if:
• The vehicle is equipped with batteries larger than 220 Amp hour capacity.
• The charging cycle is interrupted at any time during the charging cycle.
• Defective batteries causing a uctuating DC voltage that confuses the charger.
• One or more defective cells in the battery pack.
• A brownout (drop in AC line voltage) during the charging cycle.
• An electrically noisy charging environment.
NOTE: This charger has a maintenance mode that will restart the charger if the battery voltage drops below a threshold after
the charge cycle is complete. In some cases, it may appear that the charger is not turning off due to that the charger
has restarted. Fully test the battery pack before assuming that the charger is not turning off or running too long.
A charger could turn off in less than 12 hours, but still show symptoms of overcharging if:
• The electrolyte in the batteries is too high (boil over).
• The electrolyte in the batteries is too low (excessive gassing or sulfur smell).
To test the charger to see if it is turning off correctly, monitor the battery voltage and charging current during the charging cycle
as indicated below.
Using a digital voltmeter and clamp on DC ammeter, monitor the battery voltage and current during the charging cycle. The
charging current should remain within 10% of the DC output current (see previous page) until the battery voltage reaches V1.
When the voltage reaches V1, the charging current will drop signicantly and slowly taper off (voltage will remain constant). The
charger should turn off within 2 to 4 hours after entering the second stage when the charging current is down to A1.
While connected to an AC outlet, the charger cabinet
must remain electrically grounded. Disconnect both
of the battery leads and unplug the charger from
the AC source before disconnecting any electrical
component or wire. Failure to do so may result in
serious bodily injury.
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