Minuteman 957718 User Manual
®
BATTERY CHARGER
LOOK FOR THIS SYMBOL TO POINT OUT SAFETY PRECAUTIONS. IT MEANS:
IF YOU DO NOT FOLLOW THESE
PART NO. 957718
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.
BECOME ALERT—YOUR SAFETY IS INVOLVED.
SAFETY INSTRUCTIONS, INJURY OR PROPERTY DAMAGE CAN OCCUR.
INTRODUCTION
This battery charger is designed to recharge deepcycle, lead-acid batteries. A ferroresonant
transformer is used to provide a highly reliable, line
compensating unit with a minimum of moving parts,
designed for long, trouble-free service. A patented
electronic timer turns the charger on and off
automatically. This electronic timer determines full
charge of the batteries by measuring the rate at
which the battery voltage increases during charge.
When the voltage stops rising, the battery is fully
charged and the charger turns off.
INITIAL INSTALLATION
The AC line to which the charger is to be connected
must be of the proper voltage as indicated on the
nameplate of the charger and in TABLE 1. The line
must also be capable of supplying 15 amperes to
this charger.
TABLE 1
Part No. Input Voltage
957718 120
CAUTION: TO REDUCE THE RISK OF FIRE
USE THIS CHARGER ONLY ON CIRCUITS
PROVIDED WITH A MAXIMUM OF 20 AMPERE
BRANCH CIRCUIT PROTECTION (CIRCUIT
BREAKER OR FUSE), IN ACCORDANCE WITH
THE NATIONAL ELECTRICAL CODE, ANSI/NFPA
70, AND ALL LOCAL CODES AND ORDINANCES.
The use of an extension cord with the charger
should be avoided.
The use of an improper extension cord could result
in a risk of fire or electric shock. If an extension cord
must be used, use a three-conductor, No. 12 AWG
cord with ground, properly wired, in good electrical
condition and keep it as short as possible. Make
sure that the pins on the plug of the extension 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 subject to damage or
stress.
Do not operate this charger with a damaged cord or
plug. Do not operate this charger if it has received a
sharp blow, was dropped or otherwise damaged in
any manner; refer to a qualified service agent.
Provide adequate ventilation for the batteries and
charger. The convection-cooled design requires an
unobstructed flow of cooling air for proper operation.
Keep all charger ventilation openings at least two
inches (2") (5cm) away from walls and other objects.
Do not allow clothing, blankets, or other material to
cover the charger.
WARNING: CHARGERS CAN IGNITE
FLAMMABLE MATERIALS AND VAPORS. DO
NOT USE NEAR FUELS, GRAIN DUST,
SOLVENTS, THINNERS, OR OTHER
FLAMMABLES.
Operating Instructions 1 01370E
WARNING: KEEP DRY. DO NOT EXPOSE
CHARGER TO RAIN. FOR STORAGE, KEEP IN A
BUILDING. REPLACE WORN, CUT, OR
DAMAGED POWER CORDS OR WIRES
IMMEDIATELY.
GROUNDING INSTRUCTIONS
This battery charger must be grounded to reduce the
risk of electric shock. This charger is equipped with
an electric cord having an equipment-grounding
conductor and a grounding-type plug. This plug
must be connected to an appropriate receptacle that
is properly installed and grounded in accordance
with the National Electrical Code and all local codes
and ordinances.
DANGER: IMPROPER CONNECTION OF THE
EQUIPMENT-GROUNDING CONDUCTOR CAN
RESULT IN A RISK OF AN ELECTRIC SHOCK.
The conductor with insulation having an outer
surface that is green, with or without yellow stripe(s),
is the equipment-grounding conductor. If repair or
replacement of the electric cord or plug is necessary,
do not connect the equipment-grounding connector
to live terminal.
NORMAL OPERATION
REFER TO, READ, and FOLLOW ALL the
instructions and safety precautions printed on the
charger before every use!
WARNING: DO NOT MAKE ANY
CONNECTIONS UNTIL YOU READ THE
CHARGER NAMEPLATE AND VERIFY THAT THE
CHARGER IS FOR USE ON THE INTENDED
INPUT POWER (BOTH VOLTAGE AND
FREQUENCY), BATTERY SYSTEM VOLTAGE,
BATTERY TYPE, AND BATTERY AMP-HOUR
CAPACITY SIZE!
1. With the charger DC output cord disconnected
from the batteries, connect the power supply
cord to the needed AC voltage and frequency as
specified on the charger nameplate.
WARNING: TO REDUCE THE RISK OF AN
ELECTRIC SHOCK, CONNECT THE AC POWER
SUPPLY PLUG ONLY TO A PROPERLY
GROUNDED, SINGLE PHASE (3-WIRE) OUTLET.
REFER TO GROUNDING INSTRUCTIONS.
CAUTION: MAKE SURE THE BATTERY
PACK IS THE CORRECT NUMBER OF SERIES
CONNECTED LEAD-ACID CELLS, SYSTEM
VOLTAGE, AND AMP-HOUR CAPACITY AS
SPECIFIED ON THE CHARGER. USE
OTHERWISE MAY DAMAGE THE CHARGER
AND/OR BATTERIES.
DANGER: TO PREVENT ELECTRIC SHOCK,
DO NOT TOUCH UNINSULATED PARTS OF THE
CHARGER OUTPUT CONNECTOR, BATTERY
CONNECTOR, OR BATTERY TERMINALS. MAKE
SURE THAT BOTH THE CHARGER AND
BATTERY CONNECTORS ARE IN GOOD
WORKING CONDITION.
DANGER: DO NOT USE THE CHARGER IF
EITHER THE CHARGER OR BATTERY
CONNECTORS ARE CORRODED, CRACKED,
SHOW ANY SIGNS OF MELTING, ARE
DAMAGED IN ANY WAY OR DO NOT MAKE A
TIGHT CLEAN ELECTRICAL CONTACT. USING
ANY CHARGER WITH ANY OF THE ABOVE
SYMPTOMS COULD RESULT IN A FIRE,
PROPERTY DAMAGE, OR PERSONAL INJURY.
REPLACE DEFECTIVE, CRACKED OR
DAMAGED CORDS OR WIRES IMMEDIATELY.
DO NOT DISASSEMBLE CHARGER; TAKE IT TO
A QUALIFIED SERVICE AGENT WHEN SERVICE
OR REPAIR IS REQUIRED. INCORRECT
REASSEMBLY MAY RESULT IN A RISK OF
ELECTRIC SHOCK OR FIRE.
2. Connect the charger to a battery system of the
voltage, type, and amp-hour capacity as
specified on the charger. Connect DC output
connector to the battery connector by grasping
the plug body or handle and firmly pushing the
plug straight into the receptacle until the
connectors are fully engaged.
WARNING: DO NOT DISCONNECT THE DC
OUTPUT CONNECTOR FROM THE BATTERY
RECEPTACLE WHEN THE CHARGER IS
OPERATING. THE RESULTING ARCING AND
BURNING OF THE PLUG AND RECEPTACLE
COULD CAUSE THE BATTERIES TO EXPLODE
AND WILL DAMAGE THE CONNECTORS. IF THE
CHARGER MUST BE STOPPED, DEPRESS THE
STOP BUTTON UNTIL THE AMMETER
DECREASES TO ZERO OR DISCONNECT THE
AC PLUG FROM ITS RECEPTACLE. ONLY
AFTER THE AMMETER HAS DROPPED TO
ZERO, THEN DISCONNECT THE CHARGER DC
OUTPUT PLUG FROM THE BATTERY
RECEPTACLE.
Distinct steps occur in the process of the
charger turning on and charging. Pay attention
to these steps and monitor the initial charge rate
on the ammeter at the instant the charger starts
charging.
Three to five (3-5) seconds after the charger and
battery connectors are engaged, the control
relay inside the charger will pull in with a "click",
Operating Instructions 2 01370E
indicating complete electrical circuits between
the electronic timer inside the charger to the
equipment battery pack as well as to live AC
power.
After the control relay pulls in with a click, the
transformer will hum, indicating that the
transformer has been energized by AC power.
After the transformer hums, the ammeter needle
will deflect, indicating initial charge rate.
3. Monitor the ammeter for the initial charge rate.
The correct initial charge rate will vary due to
numerous factors. Refer to the chart to
determine the minimum and maximum initial
charge rate for the specific current rating
charger.
CORRECT INITIAL CHARGE RATE
Charger Current
Rating
40 31 40 48
Minimum Start
Rating
Maximum
If the batteries are heavily discharged and the
AC input line voltage is higher than nominal, the
initial charge rate may exceed the maximum
initial charge rate for the specific current rating
charger. Under normal conditions, the charge
rate will decrease to or less than the specified
maximum charge rate in less than 120 minutes.
If the ammeter still reads in excess of the
specified maximum charge rate after 120
minutes, turn the charger off by depressing the
STOP button until the ammeter decreases to
zero or disconnecting the AC plug from its
receptacle.
CAUTION: TO PREVENT BATTERY
DAMAGE, CHARGER OVERHEATING AND
TRANSFORMER BURN OUT, DO NOT ALLOW
THE CHARGER TO OPERATE FOR MORE THAN
120 MINUTES WITH THE AMMETER READING IN
EXCESS OF THE SPECIFIED MAXIMUM CHARGE
RATE. THIS MISUSE WILL CAUSE OVERHEATING AND TRANSFORMER BURNOUT WILL
RESULT.
This high charge rate is caused if the charger is
connected to a battery pack with a system
voltage lower than, or Amp-Hour capacity
greater than, specified on the charger. If battery
maintenance has recently been performed, test
to see if an individual battery in the battery pack
has been connected reverse polarity. A
common error is to install one or more of the 6
volt batteries in a battery pack in reverse
polarity. Using a suitable DC voltmeter, test to
be sure all batteries in a battery pack are
correctly installed, and also test by measuring
the battery system voltage at the equipment
battery connector, and compare it to the system
voltage specified in the charger nameplate.
After charging for 120 minutes at this excessive
rate, the measured on-charge voltage should
rise to the voltage specified by the charger
nameplate. Voltage measurements, while
charging, lower than the charger system voltage
indicates an incorrect or failed battery pack that
must be corrected before using the charger.
If the batteries have been recently charged, the
battery is cold (temperature below 65°F), or the
AC input voltage is lower than nominal, the initial
charge rate may only reach the minimum initial
charge rate at turn-on for the specific current
rating charger.
If the initial charge rate is less than half of the
specified minimum initial charge rate at the
moment of turn-on, the charger may be
malfunctioning due to electrical overload
damage. Turn the charger off by depressing the
STOP button until the ammeter decreases to
zero or disconnecting the AC plug from its
receptacle.
CAUTION: DO NOT USE THE CHARGER IF
THE OUTPUT IS LOW. BATTERIES WILL NOT
REACH FULL CHARGE, THEREBY INCREASING
THE POSSIBILITY OF A HARMFUL DEEP
DISCHARGE DURING THEIR NEXT USE.
This too low a charge rate at the instant of turn-
on can be due to a battery pack system voltage
that is higher than specified on the charger, a
charger malfunction resulting from electrical
overload damage, or component failure. Test
for the correct battery pack system voltage with
a suitable voltmeter at the equipment battery
connector and compare with the system voltage
specified on the charger nameplate.
DANGER: TO REDUCE THE RISK OF
ELECTRIC SHOCK, ALWAYS DISCONNECT
BOTH THE POWER SUPPLY CORD AND THE
OUTPUT CORD BEFORE ATTEMPTING ANY
MAINTENANCE OR CLEANING.
The charger fuses are located behind the front
panel. DO NOT REMOVE THE FRONT PANEL
FOR INSPECTION WITHOUT FIRST DISCON-
NECTING BOTH THE POWER SUPPLY CORD
AND THE OUTPUT CHARGING CORD. RISK
OF ELECTRIC SHOCK.
Visually inspect and electrically test the fuses. A
blown (OPEN) DC fuse indicates an electrical
overload damage caused short circuit failure of a
rectifier diode or reverse polarity connection of
the charger to the batteries. Melted fuses or
fuse links can result from weak fuseholders or
fuseholder connections.
Operating Instructions 3 01370E
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