Tornado Battery Charger, 24 VoltAutomaticBattery Charger User Manual

24 Volt

Automatic

01515j

TORNADO© CORP.

7401 W. LAWRENCE AVENUE

CHICAGO, IL 60656-3489

[phone] FAX [phone]

Battery Charger

U.S. PAT. NO. 3,794,905

GR. BR. PAT. NO. 1,414,359

FR. PAT. NO. 2,203,199

W. GR. PAT. NO. 2,351,559

6

U.S. STANDARDS FOR

LABORATORIES, INC.

U

L

1

20

LISTED TO CANADIAN AND

SAFETY BY UNDERWRITERS

7

Mfd. Exclusively for Corp., Chicago, IL, USA

JAPAN PAT. NO. 33133/1978

U

C

L

L2616 FOR COMMERCIAL USE ONLY; CATALOG NO. 99510, 99567 & 99568
B/T 10/94

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This illustrated parts book covers:

CATALOG NO. 99510, 99567 & 99568
VOLTS 24V
UL *

* Tested to Canadian and US standards for safety by Underwriters Laboratories, Inc.

All specifications are subject to change without notice.

Table of Contents

Introduction and Installation 3
Operation Instructions and Maintenance 4
Troubleshooting Guide 6

Limited Warranty

Tornado Corp. warrants each new Battery Charger for defects in material and workmanship for a period of two
years from the date of original purchase of the complete unit. Repairs can be made at the factory. To do so,
send the defective unit with transportation charges prepaid to an authorized Tornado service centers.

For repairs made at other than the service centers, Tornado Corp. will provide only the replacement parts.
If the unit or parts are found in the reasonable judgment of Tornado Corp. to be defective in material or
workmanship, repair, or replacement will be made by Tornado Corp. without charge for parts or labor. Repair or
replacement will be at the discretion of the service center or factory with replacements being made using current
models or parts performing the equivalent function. Labor charges other than those incurred at the service center
or factory are not covered under this warranty. All expenses associated with delivering defective items to the
service center or factory and the expense of returning repaired or replaced items from the service center or
factory to the owner will be paid for by the owner. All warranty work accomplished at the service center or 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 Tornado Corp.

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 charger. Tornado Corp. 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 two years from
date of manufacture 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.

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

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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.

LOOK FOR THIS SYMBOL TO POINT OUT SAFETY PRECAUTIONS. IT MEANS:
BECOME ALERT—YOUR SAFETY IS INVOLVED. IF YOU DO NOT FOLLOW THESE
SAFETY INSTRUCTIONS, INJURY OR PROPERTY DAMAGE CAN OCCUR.

IMPORTANT SAFETY INSTRUCTIONS

1. This manual contains important safety and
operating instructions for battery charger Model
99510, 99567 & 99568.

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 that:

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
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

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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 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 120
VAC, 60 Hertz, single-phase AC power source.

GROUNDING INSTRUCTIONS

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

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

This battery charger is for use on a nominal 120 volt
circuit and has a grounding plug, which looks like the
adapter illustrated in Figure A. A temporary adapter,
which looks like the adapter illustrated in Figures B
and C, may be used to connect this plug to a two­pole receptacle as shown in Figure B if a properly
grounded outlet is not available. The temporary
adapter should be used only until a properly
grounded outlet can be installed by a qualified
electrician.

GROUNDING METHODS

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

is not permitted in Canada.

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

The green-colored rigid ear or lug extending from
adapter must be connected to a properly grounded
outlet. If necessary, replace original outlet cover
plate screw with a longer screw that will secure
adapter ear or lug to outlet cover plate and make
ground connection to grounded outlet.

EXTENSION CORD REQUIREMENTS

Always use a three-conductor, No. 14 AWG (1.5mm)
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, SERIES CONNECTED,
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

120 volt, 60 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 (-),

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.

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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 correct charge current.

The initial charge current should be

approximately 20 amps. If the batteries have

not been discharged, or the AC supply voltage is

lower than 120 volts, the initial charge rate may

be less. If the batteries have been excessively

discharged, or AC supply voltage is higher than

120 volts, the initial charge rate may be more

than 20 amps.

5. Charge current will gradually taper to

approximately 6 amps depending on the age

and condition of the batteries. Charger turns off

automatically when battery is fully charged.

Charge time varies with battery size and depth

of discharge. Allow 13-15 hours for normal

charging. Severely discharged batteries may

require more time to be properly charged and

equalized.

6. 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 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 10 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.

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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 overdischarged batteries may
require an extended charge time to achieve
full charge.

5. CHARGER FUSE BLOWS (OR CIRCUIT
BREAKER)

a. AC fuse blows when wrong AC power

supply is used.

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 at 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 wearout process for all

types of deep-cycle motive power batteries.

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NOTES

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