Minuteman 957732 User Manual

®

LOOK FOR THIS SYMBOL TO POINT OUT SAFETY PRECAUTIONS. IT MEANS:

IF YOU DO NOT FOLLOW THESE

24 VOLT AUTOMATIC

BATTERY CHARGER

PART NO. 957732

Specifications

AC Input: 230 volts, 50 hertz, 3.5 amps, single-phase

DC Output: 24 volts, 20 amps initially tapering to 6 amps

Battery Type: 24 volt, 12 cell, 168 to 275 amp-hour, liquid electrolyte (wet) lead-acid batteries

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.

IMPORTANT SAFETY INSTRUCTIONS

1. SAVE THESE INSTRUCTIONS - This manual
contains important safety and operating
instructions for battery charger Model 957732.

2. Before using battery charger, read all
instructions and cautionary markings on battery
charger, battery, and product using battery.

CAUTION: TO REDUCE RISK OF INJURY,

CHARGE ONLY LIQUID ELECTROLYTE (WET)
LEAD ACID RECHARGEABLE BATTERIES.
OTHER TYPES OF BATTERIES MAY BURST
CAUSING PERSONAL INJURY AND DAMAGE.

3. Do not expose charger to rain or snow.

4. Use of an attachment not recommended or sold
by the battery charger manufacturer may result
in a risk of fire, electric shock, or injury to
persons.

5. To reduce risk of damage to electric plug and
cord, pull by plug rather than cord when
disconnecting charger.

6. Make sure cord is located so that it will not be
stepped on, tripped over, or otherwise subjected
to damage or stress.

7. An extension cord should not be used unless
absolutely necessary. Use of improper
extension cord could result in a risk of fire and
electric shock. If extension cord must be used,
make sure:

a. Pins on plug of extension cord are the same

number, size, and shape as those of plug on
charger;

b. Extension cord is properly wired and in good

electrical condition;

c. Wire size is large enough for AC ampere

rating of charger.

8. Do not operate charger with damaged cord or
plug; replace it immediately.

9. Do not operate charger if it has received a sharp
blow, been dropped, or otherwise damaged in
any way; take it to a qualified service center.

10. Do not disassemble charger; take it to a
qualified service center when service or repair is

Operating Instructions 1 01367F

required. Incorrect reassembly may result in a
risk of electric shock or fire.

11. To reduce risk of electric shock, unplug charger
from a live outlet or disconnect AC power to the
outlet before attempting any maintenance or
cleaning. Turning off controls will not reduce
this risk.

INTRODUCTION

This battery charger is a self-regulating charger with
a minimum of moving parts, designed for long,
trouble-free service. Built-in line voltage compen­sation produces a consistent output when the AC
supply voltage varies by as much as 10% from
nominal. Convection cooling maximizes the
reliability and minimizes any maintenance costs.
ONLY LIQUID ELECTROLYTE (WET) LEAD ACID
BATTERIES should be recharged with this charger
to ensure superior battery performance and life. A
patented electronic circuit turns the charger on and
off automatically. When the battery has reached its
maximum state of charge, the circuitry will turn the
charger off.

RECEIVING AND INSTALLING THE CHARGER

When the charger is received, check for possible
in-transit damage. If any damage is found, it should
be reported as a claim to the carrier.

Proper installation of the charger is important in
order to achieve good charger performance and to
prevent damage to the charger and batteries. The
charger should be located in a clean, cool, dry, and
well ventilated area. To permit free air flow for
convection cooling, allow three inches (3") minimum
between the charger and any wall and six inches
(6") between the charger and other equipment.
Position the charger on a foundation of stone, brick,
concrete or grounded metal.

DANGER: TO REDUCE THE RISK OF FIRE,

DO NOT USE THE CHARGER A NEAR
FLAMMABLE MATERIALS OR VAPORS.

AC INPUT

CAUTION: TO REDUCE RISK OF ELECTRIC

SHOCK OR FIRE, DISCONNECT POWER TO
RECEPTACLE BEFORE INSTALLING OR
REMOVING UNIT.

This battery charger must be connected to a 230
VAC, 50 Hertz, single-phase AC power source and
is factory equipped with a specific electric cord.
Have a proper plug installed on the AC cord to
permit connection to an acceptable electric circuit.
Make sure the charger is connected to an outlet

having the same configuration as the plug. No
adapter should be used with this charger.

DANGER: NEVER ALTER AC CORD OR
PLUG PROVIDED IF IT WILL NOT FIT OUTLET.
HAVE A PROPER OUTLET INSTALLED BY A
QUALIFIED ELECTRICIAN. IMPROPER
CONNECTION CAN RESULT IN A RISK OF AN
ELECTRIC SHOCK.

GROUNDING INSTRUCTIONS

Charger should be grounded to reduce the risk of
electric shock. Charger is equipped with an electric
cord having an equipment-grounding conductor and
a grounding plug. The installed plug must be
plugged into an outlet that is properly installed and
grounded in accordance with all local codes and
ordinances.

DANGER: TO REDUCE RISK OF FIRE OR
ELECTRIC SHOCK, CONNECT BATTERY
CHARGER DIRECTLY TO GROUNDING
RECEPTACLE (THREE-PRONG). AN ADAPTER
SHOULD NOT BE USED WITH BATTERY
CHARGER.

Always use a three-conductor, No. 14 AWG (1.5
mm) heavy duty cord with ground, properly wired, in
good electrical condition and keep it as short as
possible. Make sure the pins on the plug of the
extension cord are the same number, size and
shape as the AC plug of the battery charger. The
use of an improper extension cord could result in a
risk of fire or electric shock. Locate all cords so they
will not be stepped on, tripped over, or otherwise
subjected to damage or stress.

DC OUTPUT

This battery charger is designed to produce a 24 volt
DC output with an initial charge current of 20 amps.
ONLY 24 VOLT, 12 CELL, 168 TO 275 AMP-HOUR,
LIQUID ELECTROLYTE (WET) LEAD-ACID
BATTERIES SHOULD BE USED. The charge
current will decrease gradually to about 6 amps as
the battery reaches full charge and will remain there
until the charger turns off. As the battery ages, the
charge current may no longer decrease to the 6 amp
finish current. Liquid electrolyte batteries will
normally be charged to 2.5-2.6 volts per cell.

OPERATING INSTRUCTIONS

1. Connect AC supply cord to a properly grounded

230 volt, 50 Hertz, single-phase outlet.

2. Connect the DC output plug by grasping the

plug body and pushing it straight into the

receptacle until it is fully engaged. The BLACK

wire must be connected to battery negative (-),

Operating Instructions 2 01367F

and the RED or WHITE wire to battery positive
(+). Make sure all connections are clean and
tight.

3. The charger will start after a short delay as
indicated by the transformer hum and the
ammeter movement.

WARNING: LEAD ACID BATTERIES

GENERATE GASES WHICH CAN BE EXPLOSIVE.
CHARGE ONLY IN WELL VENTILATED AREAS.
DO NOT DISCONNECT CHARGER DC OUTPUT
TERMINALS FROM BATTERY WHEN CHARGER
IS ON. THE RESULTING ARCING AND BURNING
COULD CAUSE THE BATTERY TO EXPLODE.
KEEP SPARKS, FLAME AND SMOKING
MATERIALS AWAY FROM BATTERY.

If the charger must be stopped, always
disconnect the AC supply cord from its outlet
before disconnecting the DC output terminals
from the battery.

4. Monitor the ammeter for connect charge current.
The initial charge current should be
approximately 20 amps. If the battery has not
been discharged, or the AC supply voltage is
lower than 230 volts, the initial charge rate may
be less than 20 amps.

5. Charger turns off automatically when battery is
fully charged. Charge time varies with battery
size and depth of discharge. Allow 8 hours for
normal charging. Severely discharged batteries
may require up to 12 hours to be properly
charged and equalized. After the charger has
turned off, disconnect the DC output plug from
the battery and the AC supply cord from outlet.

MAINTENANCE INSTRUCTIONS

The battery charger requires minimal maintenance.
It should be kept clean and all connections are to be
tightly secured. In the event of intermittent
operation, examine and tighten, if necessary, all
connections. BE SURE THE CHASSIS IS
SECURELY GROUNDED. If any problems cannot
be resolved consult a qualified service center.

Observe the following battery maintenance
procedures to obtain good performance and
maximum cycle life.

1. Always observe the following personal safety
precautions when working with lead acid
batteries:

a. Someone should be within range of your

voice or close enough to come to your aid
when you work near a battery.

b. Have plenty of fresh water and soap nearby

in case battery acid contacts skin, clothing
or eyes.

c. Wear complete eye protection and clothing

protection. Avoid touching eyes while
working near battery.

d. If battery acid contacts skin or clothing,

wash immediately with soap and water. If
acid enters eye, immediately flood eye with
running cold water for at least ten minutes
and get medical attention.

e. NEVER smoke or allow a spark or flame in

the vicinity of batteries.

f. Be extra cautious to reduce risk of dropping

a metal tool onto battery. It might spark or
short-circuit battery or other electrical part
that may cause explosion.

g. Remove personal metal items such as rings,

bracelets, necklaces, and watches when
working with a lead acid battery. A lead acid
battery can produce a short-circuit current
high enough to weld a ring or the like to
metal, causing a severe burn.

h. NEVER charge a frozen battery.

DANGER: TO REDUCE RISK OF ELECTRIC
SHOCK, ALWAYS DISCONNECT THE AC
SUPPLY CORD FROM ITS OUTLET AND THE DC
OUTPUT CORD FROM THE BATTERY BEFORE
ATTEMPTING ANY MAINTENANCE (CHANGING
FUSES, ETC.) OR CLEANING OF THE BATTERY
OR BATTERY CHARGER.

2. New batteries should be given a full charge

before their first use because it is difficult to

know how long batteries have been stored.

3. Limit use of new batteries for first five cycles.

New batteries are not capable of their rated

output until they have been discharged a

number of times.

4. Do not excessively discharge batteries.

Excessive discharge can cause polarity reversal

of individual cells resulting in complete failure

shortly thereafter. Limited use of new batteries

will minimize the chance of cell reversal.

5. CHECK THE LEVEL OF THE ELECTROLYTE

IN CONVENTIONAL LIQUID ELECTROLYTE

LEAD ACID BATTERIES MONTHLY.

MAINTAIN THE PROPER ELECTROLYTE

LEVEL BY ADDING DISTILLED OR PURIFIED

WATER WHEN NECESSARY. Electrolyte

levels lower during discharge and rise during

charge. Therefore, it is mandatory that water be

added to cells ONLY when they are fully

charged; do not overfill. Old batteries require

more frequent additions of water than new

batteries.

6. Keep tops of batteries clean and dry to prevent

excessive self-discharge. Keep battery terminals

reasonably tight.

Operating Instructions 3 01367F

TROUBLESHOOTING GUIDE
For safe and efficient troubleshooting, read this

guide completely before beginning any tests.

CAUTION: DO NOT OPERATE THE
CHARGER IF IT IS DAMAGED OR APPEARS TO
BE MALFUNCTIONING. PERSONAL INJURY OR
DAMAGE TO THE CHARGER OR BATTERIES
MAY RESULT. DO NOT DISASSEMBLE THE
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.

To determine if a charger malfunction exists,
eliminate the problems not associated with the
charger in the sections below. If the problem can
not be resolved, contact a qualified service center.

1. CHARGER DOES NOT TURN ON

a. Battery is not connected to charger.

b. Charger is not plugged into a live AC outlet.

WARNING: IF THE AC OR DC PLUG OR
RECEPTACLE IS BROKEN, TWISTED, BENT OR
LOOSE AND DOES NOT MAKE GOOD
ELECTRICAL CONTACT, HAVE IT REPLACED
BY QUALIFIED SERVICE PERSONNEL
IMMEDIATELY. DO NOT USE THIS CHARGER IN
THIS CONDITION AS FIRE OR PERSONAL
INJURY CAN RESULT.

c. DC fuses blown.

2. CHARGER REMAINS AT HIGH RATE

a. The charger is connected to a battery pack

with a system voltage lower than specified.

b. Battery amp-hour capacity is greater than

specified for charger.

c. One or more of the batteries in the battery

pack has reversed polarity.

3. CHARGER TURNS OFF EARLY

a. The DC cord was accidentally disconnected

from the battery during charge.

b. The battery has been allowed to sulfate.

Charge the battery at least once every three
days when the equipment is lightly utilized.
Once sulfation is allowed to take place it
may be partially reduced by returning,
temporarily, to daily charging.

c. AC circuit is not live (power outage or circuit

breaker blown).

4. CHARGER DOES NOT TURN OFF
a. The charger is connected to a battery with

an amp-hour capacity greater than specified.

b. The charger is connected to a battery pack

with a system voltage higher or lower than
specified.

c. New batteries (5 cycles or less), cold

batteries, or over-discharged batteries may
require an extended charge time to achieve
full charge.

5. CHARGER FUSE BLOWS (OR CIRCUIT
BREAKER)

a. DC fuse blows from improper polarity from

charger to battery.

6. BUILDING AC LINE CIRCUIT BREAKER OR
FUSE BLOWS

a. A "weak" fuse or circuit breaker is protecting

the circuit. Connect the charger to another
outlet on a different circuit If the charger
operates properly, have a qualified
electrician inspect and test the original
circuit.

b. The circuit is overloaded. Connect the

charger to another outlet on a different
circuit.

7. EQUIPMENT RANGE DECREASING
a. The electrolyte level in conventional liquid

electrolyte lead-acid batteries was allowed
to drop below the top of the battery plates.
Add distilled water to JUST COVER THE
TOPS OF THE PLATES immediately upon
discovery and fill to the proper level with
distilled water at the completion of the very
next charge cycle. Battery capacity lost in
this manner is permanent and is not
recovered with additional charge cycles.

b. Use of the equipment before the batteries

have been fully charged and the charger
turns off. This shortens battery life and
hastens the onset of reduced daily range.
Battery capacity lost in this manner is
permanent and is not recovered with
additional charge cycles.

c. This is the normal wear-out process for all

types of deep-cycle motive power batteries.

Operating Instructions 4 01367F

WIRING DIAGRAM

PARTS LIST FOR 24 VOLT BATTERY CHARGER

PART NO. 957732 230 VAC / 50 HZ

When replacing a part, USE ONLY ORIGINAL FACTORY REPLACEMENT PARTS of the correct size and
rating.

QTY. DESCRIPTION

1 CASE ASSEMBLY
1 TRANSFORMER
2 FUSEHOLDER
2 DC FUSE, AB-30
1 ELECTRONIC TIMER
1 AMMETER
1 AC CORDSET
1 DC CORDSET
1 HEATSINK W/ DIODES
1 CONTROL CABLE
1 BUSHING, AC CORD
1 BUSHING, DC CORD
1 RELAY
1 CAPACITOR

Operating Instructions 5 01367F

L I M I T E D W A R R A N T Y

Minuteman warrants each new Battery Charger for defects In material and workmanship for a period of one year from the
date of original purchase of the complete unit. Repairs can be made at the Minuteman factory. To do so send the defective
unit with transportation charges prepaid to:

Minuteman, Inc.
111 South Rohlwing Road
Addison, Illinois 60101
Attention: Service Department

For repairs made at other than the Minuteman factory, Minuteman will provide only the replacement parts. Defective pans
should be sent with transportation charges prepaid to the Minuteman factory at the previously mentioned address.

If the unit or parts are found in the reasonable judgment of Minuteman to be detective in material or workmanship, repair,
or replacement will be made by Minuteman without charge for parts or labor. Repair or replacement will be at the discretion of
Minuteman, with replacements being made using current models or parts performing the equivalent function. Labor charges
other than those incurred at the Minuteman factory are not covered under this warranty. All expenses associated with
delivering defective Items to the Minuteman factory arid the expense of returning repaired or replaced items from the
Minuteman factory to the owner will be paid for by the owner. All warranty work accomplished at the Minuteman factory will be
completed within a reasonable time after receipt of defective items.

This warranty does not cover any semiconductor parts, such as diodes, which are vulnerable to electrical overloads
beyond the control of Minuteman.

This warranty does not cover any charger that has been subject to misuse, neglect, negligence, or accident, or operated
in any way contrary to instructions specified on the charger case and in the owner's manual. No claim of breach of warranty
shall be cause for cancellation of the contract of sale of any Minuteman charger. Minuteman assumes no responsibility for
loss of time, inconvenience, or other damage, consequential or otherwise, resulting from a defective charger. All implied
warranties (including merchantability) are limited in duration to the one year warranty period.

Some states do not allow the exclusion or limitation of incidental or consequential damages; or limitations on how long an
implied warranty lasts, so the above limitations may not apply to you. This warranty gives you specific legal rights, and you
may also have other rights which vary from state to state.

Minuteman's obligation under this warranty is strictly and exclusively limited to the repair or replacement of defective
items. Minuteman issues this warranty in good faith and with full confidence in the workmanship and quality of Minuteman
products.

Operating Instructions 6 01367F