Instruction 1905072740 Rev A - 3 -
Unpacking Battery Charger
Packed with each charger is a temperature sensor plug, two jumper wires and two MOV assemblies. The
charger is secured to a shipping board along with a styrofoam pad. The screws and packaging should be retained
for return shipment should it be necessary. Inspect the charger for any damage during transit and report it
immediately to the carrier.
DO NOT INSTALL THE CHARGER IF THERE IS EVIDENCE OF ANY SHIPMENT DAMAGE.
Battery Charger Installation
Location of the charger installation requires air flow for convection cooling of the equipment. There should be a
minimum space of 3” on the sides and 4” above the top of the charger for free air flow. Mounting keyhole brackets
are provided at the sides of the charger rear panel. Proper gage wiring must be used to avoid voltage drops across
the DC wiring to the batteries.
DO NOT PLACE ANYTHING ON TOP OF THE CHARGER WHEN OPERATING. DAMAGE TO THE
CHARGER OR BATTERIES MAY OCCUR.
The two MOV assemblies and jumper wires are installed at the time of AC input power line connection.
Connections are made to the terminal board mounted at the bottom of the front panel (see page 1 photo). The 320
volt MOV (longer lead wires) is attached to terminals 1 & 4 of the input terminals. The 150 volt MOV (shorter lead
wires) is attached to terminals 2 & 3. For 120 volts supply line, install jumper 16 across terminals 1 & 2 and jumper
17 across terminals 3 & 4. For 240 volts supply line install the jumper wire across terminals 2 & 3 only. In either
configuration the MOV installation remains the same and the AC supply line is connected to terminals 1 & 4 with a
ground wire to the terminal marked GND. The DC output portion of the charger should not be connected to
batteries until all control switches and adjustments have been made on the front panel. IF THE BATTERIES ARE
CONNECTED AT THIS TIME A SPARK WILL OCCUR DUE TO CHARGING OF THE FILTER CAPACITOR BANK
INSIDE THE CHARGER.
MAKE SURE ALL JUMPER, MOV AND INPUT POWER LINES ARE CONNECTED PROPERLY BEFORE
THE CHARGER IS ENERGIZED. CHARGER MUST BE SOLIDLY GROUNDED!
Battery Charger Control Set-up
1. Select the battery type Lead-Acid or Nickel-Cadmium.
2. Select the number of cells, Lead-Acid 5-8 cells or Ni-Cad 5-12 cells (ON to the left, OFF to the right).
The control board is designed so cells 9 through 12 will not operate in the Lead-Acid switch position.
3. Do not connect the temperature sensor plug or cable at this time.
4. Connect a digital DC Voltmeter to the charger DC output terminals.
5. Turn ON the AC main power supply to the charger.
6. After allowing the charger output voltage to stabilize, set the FLOAT VOLTAGE ADJUST potentiometer to the
desired float voltage. Recommended voltages at 77°F (25°C) are as follows;
Lead Acid Flooded = 2.20 volts/cell
Lead Acid Sealed = 2.25 volts/cell
Nickel Cadmium = 1.47 volts/cell all +/- .03 volts/cell
Always refer to the battery manufacturer’s recommendations for charging voltages.
7. Turn OFF the AC main power supply to the charger.
8. If desired, external wiring (22 GA minimum) may be connected from the battery terminals to the remote sense
terminal block. Simply remove the jumpers that are factory installed. This will monitor the voltage at the
batteries rather than the output terminals of the charger. Be sure the polarity is correct.
9. Connect the temperature sensor plug or cable to the front panel.
10. The batteries may now be connected to the DC output positive and negative terminals.
CAUTION: POLARITY OF THE DC CONNECTIONS MUST BE CORRECT.
11. The output current limit is preset at the factory. Although we do not recommend doing so, it is internally
adjustable. An additional adjustment pot is located on the setup controls indicated as OUTPUT CURRENT
ADJUST. It will adjust from full output current to approximately 50 - 60% of rated output current at the minimum
position. Selection should be made based on the application.
