Minuteman 957722, 957733 Operating Instructions Manual

24 VOLT AUTOMATIC

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

IF YOU DO NOT FOLLOW THESE

*01838*

DUAL MODE BATTERY CHARGER

PART NO. 957722 & 957733

AC Input: 120 Volts AC, 60 Hertz, 5 amps, single-phase

DC Output: 24 Volts DC, 12 amps tapering to 3 amps

Battery Size: 50 to 120 amp hours

Normal Recharge Time: 8 hours

Battery Capacity: Two series connected, 6 cell, 12 volt deep-cycle motive power batteries. Gel cell

and sealed "maintenance-free" or conventional replaceable electrolyte deep­cycle batteries

®

Specifications

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

Read and familiarize yourself with this entire manual
before installing or operating the charger. Follow all
instructions on the battery, battery-powered
equipment and battery charger. This manual
contains important safety and operating instructions
for your battery charger.

DANGER: USE OF AN ATTACHMENT NOT
RECOMMENDED OR SOLD BY BATTERY
CHARGER MANUFACTURER MAY RESULT IN A
RISK OF FIRE, ELECTRIC SHOCK, OR INJURY
TO PERSONS.

INTRODUCTION

The Dual-Mode battery charger is designed to
recharge deep-cycle batteries of conventional
replaceable electrolyte or gel-cell and sealed

"maintenance-free" design. The different charge
characteristics required by these different types of
battery design are selected by sliding the "BATTERY
TYPE" selector switch to the correct setting. A
patented electronic circuit turns the charger on and
off automatically.

Batteries used on industrial equipment are subjected
to severe deep-cycle duty on a daily basis. For this
reason, it is important that only Deep-cycle batteries
be used.

CAUTION: THIS CHARGER IS FOR USE
ONLY ON 12 CELL, 50-120 AMP-HR. (20 HR.
RATE), 2.38-2.50 VOLTS PER CELL MAXIMUM
VOLTAGE RECHARGEABLE, DEEP-CYCLE
BATTERY SYSTEMS. THIS CHARGER IS FOR
USE ON REPLACEABLE ELECTROLYTE OR GEL
CELL AND SEALED "MAINTENANCE-FREE"
DEEP-CYCLE BATTERIES. THE "BATTERY

www.minutemanintl.com 1 01838H

TYPE" SWITCH MUST BE SET TO THE PROPER
TYPE OF BATTERY. BATTERIES IMPROPERLY
MATCHED WITH CHARGER MAY BURST,
CAUSING PERSONAL INJURY AND DAMAGE TO
BATTERIES OR CHARGER.

DANGER: IMPROPER CONNECTION OF THE
EQUIPMENT-GROUNDING CONDUCTOR CAN
RESULT IN RISK OF ELECTRIC SHOCK. DO
NOT REMOVE GROUNDING PRONG FROM
PLUG.

INSTALLATION

Circuit breaker or fuse protection in the 120 volt AC
outlet to which the charger is to be plugged should
allow 7 amps per charger. Do not overload electrical
outlet. Use of an extension cord with the charger
should be avoided unless necessary. Use of an
improper extension cord could result in a risk of a
fire and electric shock. If an extension cord is
needed, use a three-conductor, No. 14 AWG (or
larger) cord with ground, properly wired, in good
electrical condition and keep 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 subjected to damage or stress. Do not
operate the battery charger with a damaged cord or
plug. Do not operate the battery charger, if the
battery charger has received a sharp blow, or was
dropped, or otherwise damaged in any manner.
Refer to a qualified service agent.

Provide adequate ventilation for both 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") (5.08cm) away from walls and other
objects. Do not allow clothing, blankets, or other
material to cover charger.

DANGER: BEFORE USING THE ADAPTER
AS ILLUSTRATED, BE CERTAIN THAT THE
CENTER SCREW OF THE OUTLET PLATE IS
GROUNDED.

GROUNDING INSTRUCTIONS

This battery charger is equipped with a grounding
plug as illustrated in Figure A, for use on a nominal
120 volt, 60 Hertz circuit. A temporary adapter, as
illustrated in Figures B and C, may be used to
connect this plug to a two-pole receptacle as shown
in Figure B if a properly grounded outlet is not
available. The temporary adapter should be used
only until a qualified electrician can install a properly
grounded outlet. The GREEN colored rigid ear
extending from the adapter must be connected to a
permanent ground such as a properly grounded
outlet box.

GROUNDING METHODS

WARNING: CHARGERS CAN IGNITE
FLAMMABLE MATERIALS AND VAPORS. DO
NOT USE NEAR FUELS, GRAIN DUST,

NOTE: Use of adapter shown in Figures B and C is

not permitted in Canada.

SOLVENTS, THINNERS, OR OTHER
FLAMMABLES.

BATTERY TYPE

WARNING: KEEP THIS CHARGER DRY; DO
NOT EXPOSE TO RAIN OR SPRAY. FOR
STORAGE, KEEP IN A BUILDING. REPLACE
WORN, CUT, OR DAMAGED ELECTRICAL
CORDS AND PLUGS IMMEDIATELY.

Battery manufacturers frequently use the same
battery cases for different battery types.
Replaceable liquid electrolyte deep-cycle batteries
have removable cell caps. Water electrolyzed by
discharging and charging the battery is replaced
through these openings.

AC INPUT

This battery charger must be grounded to reduce the
risk of electric shock. It is equipped with an electric
cord having an equipment-grounding conductor and
a grounding-type plug. The plug must be plugged
into an appropriate outlet that is properly installed
and grounded in accordance with the National
Electrical Code and local codes and ordinances.

Non-removable cell caps generally distinguish gel
cell and sealed "maintenance-free" deep-cycle
batteries. The physical appearance of the battery
case is frequently the same as that of a replacement
liquid electrolyte battery, although the cell caps are
generally not removable.

Refer to the battery manufacturer information panel
on the battery case to determine the type battery
you have. If the information panel is missing or not
legible, do not use the battery. Refer to your dealer

www.minutemanintl.com 2 01838H

if you do not understand what type battery you are
using and have them set the "BATTERY TYPE"
switch accordingly.

The "BATTERY TYPE" switch is a two-position slide
switch visible in the rectangular opening on the front
of the charger. Using a small screwdriver, slide the
switch from one setting to the other through the
opening. Take care not to damage the switch when
moving it to the desired setting.

NORMAL OPERATION
Instructions printed on cover of charger are for

daily reference.

1. Set "BATTERY TYPE" switch to the proper style

of battery to be charged.

CAUTION: MAKE SURE THE BATTERY
PACK IS A 24-VOLT, 12-CELL, SERIES
CONNECTED, 50-120 AMP-HOUR (20 HR. RATE),
RECHARGEABLE DEEP-CYCLE BATTERY
SYSTEM. THE "GEL CELL AND SEALED DEEP­CYCLE BATTERY" SETTING CHARGES TO A
MAXIMUM ON-CHARGE VOLTAGE OF 2.38
VOLTS PER CELL. THE "REPLACEABLE
ELECTROLYTE DEEP-CYCLE BATTERY"
SETTING HAS AN ON-CHARGE VOLTAGE OF AT
LEAST 2.50 VOLTS PER CELL. VISUALLY
CHECK THAT THE BATTERY TYPE SWITCH IS
SET CORRECTLY FOR THE TYPE OF BATTERY
YOU ARE USING.

DANGER: TO PREVENT ELECTRIC SHOCK,
DO NOT TOUCH UNINSULATED PARTS OF THE
CHARGER DC OUTPUT CONNECTOR, BATTERY
CONNECTOR, OR BATTERY TERMINALS. MAKE
SURE ALL ELECTRICAL CONNECTORS ARE IN
GOOD WORKING CONDITION. DO NOT USE
CONNECTORS THAT ARE CRACKED,
CORRODED OR DO NOT MAKE ADEQUATE
ELECTRICAL CONTACT. USE OF A DAMAGED
OR DEFECTIVE CONNECTOR MAY RESULT IN A
RISK OF OVERHEATING OR ELECTRIC SHOCK.

2. Move the power switch to "OFF" position.

3. Connect the power supply cord to a properly

grounded, 120-volt, 60 Hertz single-phase

outlet.

4. Connect the charger’s DC output plug to the

equipment-charging receptacle. Do not connect

the DC plug unless the power switch is in the

"OFF" position.

5. Move the power switch to "ON" and the RED

and GREEN lights will come on steady for a few

seconds to test the lights. If the lights do not

come on, either the AC cord is not plugged in or

the AC outlet is not live. Test for a live AC outlet

by connecting a suitable appliance into the
specific outlet.

WARNING: CHARGER IS NOT TO BE USED

WHILE THE EQUIPMENT IS OPERATING.

ATTENTION: Ne pas utiliser le charger

pendant que l’equipment est en marche.

WARNING: LEAD-ACID BATTERIES
GENERATE GASES THAT CAN BE EXPLOSIVE.
TO PREVENT ARCING OR BURNING NEAR
BATTERIES, DO NOT DISCONNECT DC
CHARGING CORD FROM BATTERIES WHEN
THE CHARGER IS OPERATING. IF THE CHARGE
CYCLE MUST BE INTERRUPTED, MOVE THE
POWER SWITCH TO "OFF" AND DISCONNECT
THE CHARGER POWER SUPPLY CORD BEFORE
DISCONNECTING THE DC OUTPUT CORD FROM
THE BATTERIES. KEEP SPARKS, FLAME, AND
SMOKING MATERIALS AWAY FROM
BATTERIES.

WARNING: ALWAYS SHIELD EYES WHEN
WORKING NEAR BATTERIES. DO NOT PUT
WRENCHES OR OTHER METAL OBJECTS
ACROSS BATTERY TERMINAL OR BATTERY
TOP. ARCING OR EXPLOSION OF THE
BATTERY CAN RESULT.

Charger will output power three to five (3-5)

seconds after turning switch "ON" as indicated

by the RED light turning off, the slow blinking

GREEN light (once per second), and a slight

transformer hum.

If both lights go off about five seconds after AC

is applied, check to see if the DC plug is

correctly connected to the battery. If the DC

plug is connected properly, either an open circuit

exists in the equipment’s internal circuitry, or the

battery voltage is below 7 volts (see

Troubleshooting).

The charger has an under-voltage protection

mode, which will terminate the charge if battery

voltage does not increase above 18 volts after

10 minutes of charging. This prevents

destroying 12-volt battery systems with this 24-

volt charger. When this occurs, the RED light

will come on steady.

6. Correct initial charge rate should be between 11

to 13 amps. As the batteries become more

charged the charge rate decreases. When the

batteries reach approximately 80% of full

charge, the GREEN light will fast blink (eight

times per second), the charge rate will have

decreased as determined by the "BATTERY

TYPE" switch setting and the condition of the

batteries.

www.minutemanintl.com 3 01838H