View Links Series user`s manual for models 28080
Contents
1. 14 43 1 Gheck Charger Area 14 13 2 AMT 14 19 3 Conditions PE 14 14 TROUBLESHOOTING AND 15 Links Series Models 28080 28090 28100 3 of 19 User s Manual 10 11 12 13 14 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important safety and operating instructions Before using battery charger read all instructions and cautionary markings on battery charger battery and product using battery IT MEANS ALERT YOUR SAFETY IS INVOLVED IF YOU DO NOT FOLLOW THESE SAFETY INSTRUCTIONS INJURY OR PROPERTY DAMAGE CAN OCCUR LOOK FOR THIS SYMBOL TO POINT OUT SAFETY PRECAUTIONS DANGER TO REDUCE THE RISK OF FIRE OR ELECTRIC SHOCK CAREFULLY READ AND FOLLOW THESE IMPORTANT SAFETY AND OPERATING INSTRUCTIONS BEFORE INSTALLING OR OPERATING THE CHARGER INSTRUCTIONS IMPORTANTES CONCERNANT LA SECURIT Awarnine TO REDUCE THE RISK OF FIRE INSTALL THIS BATTERY CHARGER ON A SURFACE OF NON COMBUSTIBLE MATERIAL SUCH AS BRICK CONCRETE OR ME2. SEF Figure 4 2 Setting the Battery Profile Jumper Determines the Battery Type Acaution THIS CHARGER IS FOR USE ONLY ON RECHARGEABLE DEEP CYCLE LEAD ACID BATTERY SYSTEMS OF THE SAME TYPE AS THE SELECTED BATTERY PROFILE BATTERIES IMPROPERLY MATCHED WITH THE CHARGER MAY BURST CAUSING PERSONAL INJURY AND DAMAGE TO BATTERIES OR CHARGER Battery manufacturers frequently use the same battery cases for different battery types Wet batteries have removable cell caps Water electrolyzed by discharging and charging the battery is replaced through these openings Sealed batteries are generally distinguished by non removable cell caps The physical appearance of the battery case is frequently the same as a wet battery though the cell caps are generally not removable Refer to the battery manufacturer s 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 5 OFF BOARD SHELF CHARGING This charger is configured for off board charging Off board chargers are designed to be used in shelf or portable applications They include rubber feet If the AC input plug is connected to AC power a new charge cycle automatically starts when the DC output is connected to a battery pack of the proper voltage Disconnecting and reconnecting AC power while the DC output remains connected to a battery pack WILL NOT automati
3. 22 y J4 At a 9 x lt m 4 SHUNT 3LU Pi VO lee E JS V 3LK F2 5 WHT L pe c 72 2 Y Model 28100 Links Series Models 28080 28090 28100 17 of 19 User s Manual 5 Links Series Models 28080 28090 28100 18 of 19 User s Manual Represented sie 0 40071C Links Series Models 28080 28090 28100 19 of 19 User s Manual
4. DO NOT REMOVE GROUNDING PRONG FROM PLUG The conductor with insulation having an outer surface that is green with or without a yellow stripe s is the equipment grounding conductor repair or replacement of the AC cable or connector is necessary do not connect the equipment grounding conductor to a live terminal Contact your dealer This charger is equipped with a grounding connector as illustrated in Figure 7 1 A for use on a nominal 120 Vac 60 Hz circuit temporary adapter as illustrated in Figures 7 1 B and C may be used to plug this connector into a two pole receptacle as shown in Figure 7 1 C if a properly grounded outlet is not available NOTE use of an adapter as shown in Figures 7 1 B and C is NOT permitted in Canada The temporary adapter should be used only until a properly grounded outlet can be installed by a qualified electrician The green colored rigid ear extending from the adapter must be connected to a permanent ground such as a properly grounded outlet box DANGER BEFORE USING THE ADAPTER AS ILLUSTRATED BE CERTAIN THAT THE CENTER SCREW OF THE OUTLET PLATE IS GROUNDED Links Series Models 28080 28090 28100 8 of 19 User s Manual GROUNDING METHODS A B COVEROF ADAPTER n GROUNDED I OUTLET BOX Q On A P va 2 SR adi A Sx d NS m UN N I CONNECTED cy 222 SP SS TOCOVER W GROUNDING OF GROUNDED BLADE GROUNDED OUTLET Figur
5. Links Series Models 28080 28090 28100 2 of 19 User s Manual TABLE OF CONTENTS CHARGER RATINGS LABEL ka o da ka no aon c Ga CER ak qa oa ano EV EE CEP annua 2 TABLE OF See ppi gb 3 IMPORTANT SAFETY INSTRUCTIONS 4 DE IRieniagjom 6 2 RECEIVING THE CHARGET died tind 6 3 STORAGE EL M 6 BATTERY duc DTI DI III TL TI IT 6 5 OFF BOARD SHELF cni ER pa cx C ius 7 6 LOCATION AND 8 Te eig m 8 8 DC QUT PUT mum aapka NE 9 8 1 ROUND MOLDED 3 PIN CLUB CAR PLUG 9 9 PROPER CARE OF DEEP CYCLE MOTIVE POWER BATTERIES 10 9 1 Personal Safety Precautions DE RR CERRAR RR Rau do eR 10 10 CHARGER OPERATION iui bant 11 TT LED ppernwiep iq 12 12 13 18
6. Models 28080 28090 28100 11 of 19 User s Manual 4 The charge cycle 80 point is indicated by the Charge Status yellow LED beginning to blink quickly 5 The Finish charge cycle phase is indicated by the solid illumination of the Charge Status yellow LED Not all charge profiles include a Finish phase 6 An extended Balance Equalize charge cycle phase is indicated by the Charge Complete green LED beginning to blink quickly Not all charge profiles include a Balance Equalize phase 7 The charger automatically terminates the charge cycle when a battery reaches full charge which is indicated by 1 the solid illumination of the Charge Complete green LED or 2 the Charge Complete green LED beginning to blink slowly indicating a post charge phase The required charge time is affected by numerous factors including battery amp hour capacity depth of discharge battery temperature and battery age usage 8 After a charge cycle has completed disconnect the charger DC output connector plug from the battery connector receptacle by firmly grasping both connectors and pulling them straight apart 11 LED INDICATORS The charger includes three 3 LEDs to indicate charger status and fault information The functionality of the LEDs is outlined below CHARGE STATUS yellow Indicates charge cycle status See Figure 11 1 for descriptions of the possible states CHARGE COMPLETE green Indicates when a charge cycle completes successful
7. Wiring Kit N A Control Cables 40063S 40063S 40064S Case Assembly Painted N A Shelf Links Series 40061 01S 40061 01S N A Case Assembly Aluminum N A Shelf Links Series N A N A 40062 01S WIRING DIAGRAM Links Series Models 28080 28090 28100 16 of 19 User s Manual NEUTRAL WHT ELECTRONIC CONTROLLER EAKER YEL BR 24 BLK 6 ong TWISTED PAIR lt 5 6 c S BLK lt amp WHT BRN RED 7 9 RED OR DC TRANSFORMER SURUN BLK gt BLU C 2 4 4 a BLK 2 N e b J1 3R j 4 ty i BRN 5 x lt 4 PED lt BLU p BLK SHU NT 5 4 D A 7 Tus VV 1 c BLK C 5 C t5 at 4 94 YEL Y IG 10 WHT Models 28080 and 28090 ELECTRONIC CONTROLLER VHT J3 AC m BREAKER y BK on Z A J9 T 5 PIN 4 PIN 5 CORD SET BLUE WHITE L N A GREEN DW OUTPUT TRANSFORMER BLK u E 7 BLK lt gt 1 2 2 NE SN L m RE 2
8. ag Tl vy 22 TE 2 SERIES gt ine USER S MANUAL Industrial Battery Charger Models 28080 28090 28100 Important Safety Installation Operation and Maintenance Instructions MADE IN www LesterElectrical com u s A CHARGER RATINGS LABEL The ratings label is located on the back of the charger The label provides the model MODEL serial number SERIAL AC input configuration AC VOLTS AC AMPS PHASE and HERTZ and DC output specifications CELLS DC VOLTS DC AMPS and AMP HRS of the charger TYPE indicates the factory configured battery type An example charger ratings label is provided below LESTER ELECTRICAL SERIAL 101400002 625 West A Street MODEL 28100A01A181W4A1 Lincoln NE 68522 USA 28100 Industrial Battery Charger s hoe Please fill in the blank label that is provided below with the information from the ratings label on your charger for future reference L4 LESTER ELECTRICAL B SERIAL 625 West A Street MODEL Lincoln NE 68522 USA Industrial Battery Charger AC VOLTS AC AMPS PHASE HERTZ DC VOLTS DC AMPS AMP HRS TYPE CELLS Document any configuration or settings changes that are made by marking the ratings label on your charger or on an additional label or tag attached to your charger SAVE THIS MANUAL Keep it in a location where it is available to anyone who may operate the charger
9. battery was allowed to drop below the top of the battery plates If so add distilled water to just cover the top of the plates immediately upon discovery and then fill to the proper level with distilled water at the completion of the very next charge cycle b Use of the vehicle equipment before the battery has been fully charged and the charger automatically terminates the charge cycle This shortens battery life and accelerates the onset of reduced daily range The normal wear out pattern for the battery 4 Acharge cycle running longer than anticipated before terminating indicates one of the following conditions a An overly discharged battery b The charger output may have been reduced due to low AC input voltage high ambient temperature or obstructions to cooling airflow c The amp hour capacity of the battery is greater than the charger can fully charge in the anticipated amount of time Links Series Models 28080 28090 28100 15 of 19 User s Manual Configuration D E lt A Configuration SERVICE PARTS LIST 28080 28090 28100 Service Part Description 36V 21A 36V 25A 48V 13A Config A Config A Config B 1 SCR Assembly amp Heatsink 400675 400675 400685 2 Control Board Assembly Contact Your Sales Representative 3 DC Cordset Kit Contact Your Sales Representative 4 AC Cordset Kit 39859 08S 40072 08S 39859 08S 5 AC Circuit Breaker 34882S 34882S 318475 Misc
10. will reduce the current capacity and possibly the service life of the charger If the charger will be operated outside of these ranges contact your dealer to verify if it will withstand these conditions and perform at the needed capacity Do not operate the charger with a damaged AC or DC cable or connector Do not operate the charger if it has received a sharp blow was dropped or was otherwise damaged in any manner Contact your dealer Awarnine REPLACE WORN DAMAGED OR CUT ELECTRICAL CORDS AND PLUGS IMMEDIATELY Awarnine KEEP DRY DO NOT EXPOSE TO RAIN OR SPRAY FOR STORAGE KEEP CHARGER INA BUILDING NE PAS EXPOSER A LA PLUIE 7 AC INPUT This charger must be connected to a single phase nominal 120 Vac 60 Hz AC power source with a voltage of 110 Vac to 132 Vac charge times increase at lower AC voltages The frequency must be 57 Hz to 63 Hz Circuit breaker or fuse protection for the AC outlet to which the charger is connected should allow 15A per charger Do not overload an electrical outlet This charger must be grounded to reduce the risk of electric shock It is equipped with an AC cable with an equipment grounding conductor and a grounding type connector The connector must be plugged into an appropriate outlet that is properly installed and grounded in accordance with the National Electrical Code and all local codes and ordinances DANGER IMPROPER CONNECTION OF THE GROUNDING CONDUCTOR CAN RESULT IN A RISK OF ELECTRIC SHOCK
11. 25 26 27 WARNING LEAD ACID BATTERIES GENERATE EXPLOSIVE GASES TO PREVENT ARCING OR BURNING NEAR BATTERIES DO NOT DISCONNECT DC CHARGING CORD FROM BATTERIES WHEN THE CHARGER IS OPERATING 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 WARNING BATTERIES PRODUCE HYDROGEN GAS WHICH CAN EXPLODE IF IGNITED NEVER SMOKE USE AN OPEN FLAME OR CREATE SPARKS NEAR THE BATTERY VENTILATE THE AREA WHEN THE BATTERY IS CHARGING IN AN ENCLOSED PLACE Awarnine LEAD ACID BATTERIES CONTAIN SULFURIC ACID WHICH MAY CAUSE BURNS DO NOT GET ACID IN EYES ON SKIN OR CLOTHING IF CONTACT WITH THE EYES OCCURS FLUSH IMMEDIATELY WITH CLEAN WATER FOR 15 MINUTES AND OBTAIN MEDICAL ATTENTION WARNING ONLY YOUR DEALER S QUALIFIED SERVICE TECHNICIANS SHOULD PROGRAM OR SERVICE THIS EQUIPMENT Acaution DO NOT OPERATE THE CHARGER IF IT HAS RECEIVED A SHARP BLOW BEEN DROPPED OR OTHERWISE DAMAGED HAVE YOUR DEALER S QUALIFIED SERVICE TECHNICIAN EXAMINE AND REPAIR AS NEEDED WARNING DO NOT DISASSEMBLE THE CHARGER HAVE THE CHARGER EXAMINED BY YOUR DEALER S QUALIFIED SERVICE TECHNICIAN INCORRECT RE ASSEMBLY OF THE CHARGER MAY RESULT IN AN EXPLOSION ELECTRIC SHOCK OR FIRE Acaution MAKE SURE THE BATTERY SYSTEM HAS THE PROPERLY RAT
12. ED VOLTAGE AMP HOURS AND TYPE WET AGM GEL ETC FOR THIS CHARGING SYSTEM Awarnine NEVER CHARGE A FROZEN BATTERY Awarnine CONNECT AND DISCONNECT DC OUTPUT CORD ONLY AFTER REMOVING AC CORD FROM THE ELECTRICAL OUTLET Acaution POSITION AC AND DC CORDS TO REDUCE RISK OF DAMAGE BY HOOD DOOR OR MOVING ENGINE PART DANGER STAY CLEAR OF FAN BLADES BELTS FULLEYS AND OTHER PARTS THAT CAN CASE INJURY TO PERSONS Acaution CHECK POLARITY OF BATTERY POSTS A POSITIVE POS P BATTERY POST USUALLY HAS A LARGER DIMETER THAN NEGATIVE NEG POST SAVE THESE INSTRUCTIONS Links Series Models 28080 28090 28100 5 of 19 User s Manual 1 INTRODUCTION This Links Series battery charger is an advanced microprocessor based silicon controlled rectifier SCR charger designed to optimize both daily battery capacity and overall battery life It plugs directly into standard 120V 15A 60 Hz AC outlets receptacles for use in off board shelf applications The charger is natural convection cooled with no moving parts It was factory configured to charge wet flooded AGM or gel deep cycle lead acid batteries and includes a jumper that can be used to select between two battery profiles in the field This charger features fully automatic operation and LEDs to monitor charge cycle status Figure 1 1 provides specifications for Links Series models 28080 28090 and 28100 Model DC Output Gul Amp Hour Rat
13. H AC AND DC POWER FROM THE CHARGER BEFORE PERFORMING ANY MAINTENANCE CONTACT WITH LIVE COMPONENTS WITHIN THE CHARGER COULD CAUSE ELECTRICAL SHOCK SERIOUS INJURY OR DEATH Acaution KEEP CHARGER CLEAN AND DRY INSIDE AND OUT FAILURE TO DO SO MAY CAUSE DAMAGE OR FAILURE OF CHARGER The charger requires minimal maintenance It should be kept clean Twice a year or as often as the cleanliness of the area may dictate the interior of the charger should be thoroughly blown clean with dry compressed air The components of the charger are cooled by natural convection If dust and debris are allowed to build up they will restrict airflow and could cause components to overheat Always be careful not to bump wiring or components This could cause loose connections and failures Moisture may cause electrical shorting and or corrosion It may also combine with dust and debris making them more difficult to remove Do not use liquids to clean the charger Liquids could cause damage Compressed air should be used to clean dust and debris from the charger and its components 13 1 Check Charger Area The area around the charger must remain clean cool dry and well ventilated Check for obstructions to airflow clearances or other violations of the requirements in Section 5 13 2 Visual Inspections Check the charger for any physical failures such as loose contacts or hardware excess wear or damage Darkened or hot terminals should be tightened or repla
14. IES Awaanine ALWAYS SHIELD EYES WHEN WORKING NEAR BATTERIES DO NOT PUT WRENCHES OR OTHER METAL OBJECTS ACROSS BATTERY TERMINALS OR THE BATTERY TOP ARCING OR EXPLOSION OF THE BATTERY CAN RESULT Awarnine DO NOT DISCONNECT THE CHARGER DC OUTPUT PLUG FROM THE BATTERY RECEPTACLE WHILE A CHARGE CYCLE IS IN PROGRESS THE RESULTING ARCING AND BURNING OF THE PLUG AND RECEPTACLE COULD CAUSE THE BATTERIES TO EXPLODE Acaution TO AVOID DAMAGE TO THE CHARGER DC CABLE AND CONNECTOR AND BATTERY CONNECTOR DISCONNECT BY GRASPING THE CHARGER CONNECTOR HANDLE OR BODY AND PULLING IT STRAIGHT OUT OF THE BATTERY CONNECTOR DO NOT PULL ON THE CHARGER CABLE DO NOT TWIST ROCK OR PULL THE CONNECTOR SIDEWAYS The instructions printed on the charger are for daily reference Off Board Charger Operation 1 With the charger DC output connector plug disconnected from the battery connector receptacle connect the charger AC power cord to an appropriate AC outlet if not already connected 2 Connect the charger DC output connector plug to the battery connector receptacle The charger will start automatically which is indicated by the Charge Status yellow LED beginning to blink slowly 3 If the charger must be disconnected from the battery while a charge cycle is in progress first disconnect the AC power cord from the AC outlet Do not disconnect the charger DC output connector plug from the battery while a charge cycle is in progress Links Series
15. INJURY OR PROPERTY DAMAGE COULD RESULT The charger was fully tested and calibrated before leaving the factory It was delivered ready to charge If properly installed the charger should require very little attention If improper charger operation occurs it will require repair by a qualified service technician See the FAULTS section for information regarding the Fault LED 1 If the charger does not turn on check for one of the following conditions a The charger AC power cord is not plugged into live and or appropriate AC outlet b The battery connections are incorrect battery not connected reverse polarity or short circuit c The battery voltage is too high d The battery voltage is too low below 10 volts 2 If the charger turns off before a battery is fully charged and a fault condition is not indicated by the Fault LED this indicates one of the following conditions a The AC power was interrupted during the charge cycle b The charger DC output connector was disconnected from the battery during the charge cycle c The battery has been allowed to sulfate Charge the battery at least once every three 3 days when the equipment is lightly used Once sulfation is allowed to take place it may be partially reduced by returning temporarily to daily charging 3 A decrease in vehicle equipment range where the battery loses power faster indicates one of the following conditions a The electrolyte level in a wet lead acid
16. TAL RISK OF ELECTRIC SHOCK DISCONNECT CHARGER FROM BATTERY AND AC POWER BEFORE SERVICING TURNING OFF THE CHARGER DOES NOT REDUCE THIS RISK DANGER RISK OF ELECTRIC SHOCK DO NOT TOUCH UNINSULATED PORTION OF AC OR DC CONNECTORS OR UNINSULATED BATTERY TERMINAL DANGER RISQUE DE CHOCKS LECTRIQUES NE PAS TOUCHER LES PARTIES NON ISOLEES DU CONNECTEUR DE SORTI OU LES BORNES NON ISOLEES DE L ACCUMULATEUR Acaution CHARGE ONLY LEAD ACID BATTERIES OTHER TYPES OF BATTERIES MAY BURST CAUSING PERSONAL INJURY AND DAMAGE BEFORE CHARGING ANY OTHER TYPE OF RECHARGEABLE BATTERY CHANGE THE CHARGER SETTINGS AS RECOMMENDED BY THAT BATTERY MANUFACTURER UTILISER POUR CHARGER UNIQUEMENT LES ACCUMULATEURS AU PLOMB A ELECTROLYTE LIQUIDE D AUTRES TYPES D ACCUMULATEURS POURRAIENT ECLATER ET CAUSER DES Acaution DO NOT EXPOSE TO RAIN INDOOR USE ONLY ATTENTION NE PAS EXPOSER LA PLUIE DANGER TO PREVENT ELECTRICAL SHOCK DO NOT TOUCH EITHER AC OR DC UNINSULATED PARTS 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 A WARNING HAZARD OF ELECTRIC SHOCK Links Series Models 28080 28090 28100 4 of 19 User s Manual 15 16 17 18 19 20 21 22 23 24
17. able via a jumper that is accessible behind the plug on the front panel The last four 4 characters in the charger part number available in the MODEL field on the charger ratings label provide the battery profile codes for both the primary and secondary battery profiles For example charger part number 28100A01A1S1W1A1 has a primary battery profile code of W1 and a secondary battery profile code of A1 Figure 4 1 lists standard battery profile codes and their corresponding battery profiles If a battery profile code for your charger is not listed in Figure 4 1 please contact your dealer regarding which battery profiles are available on your charger Links Series Models 28080 28090 28100 6 of 19 User s Manual Part Number Battery Profile Code Battery Profile W1 Wet standard A1 AGM standard G1 Gel standard Figure 4 1 Standard Battery Profile Codes and Their Corresponding Battery Profiles To change the active battery profile on your charger remove the front panel plug and position the jumper as shown in Figure 4 2 Profile 1 is the primary battery profile and the factory configured jumper position Profile 2 is the secondary battery profile If changed from the factory configured jumper position Profile 1 mark the charger ratings label or add an additional label or tag PROFILE 2 PRIMARY BATTERY PROFILE SECONDARY BATTERY PROFILE
18. able with supported DC plug receptacle systems to a DC disconnect occurs during charging OVER TEMP Maximum temperature Slow Blink 1 was met Charge cycle will restart when the temperature decreases AC power was lost during charging Charge cycle will restart when Slow Blink 4 Slow Blink HARDWARE FAULT Contact Lester Electrical HARDWARE FAULT Contact Lester Slow Blink Slow Blink Electrical HARDWARE FAULT Contact Lester isla MA Electrical Unit is still able to charge a particular charge cycle phase start bulk Slow Blink hours for the overall charge cycle was met Fault Description Red LED voltage is still present at the charger output Third pin DC disconnect sensing minimize charger output inhibit time when LOW DC DC battery voltage is too low Slow Blink to start charging 10V Slow Blink AC power returns HARDWARE FAULT Contact Lester Slow Blink Slow Blink 1 Electrical PHASE A fault condition most commonly maximum time was met during 4 Slow Blink Slow Blink MAX TIME Maximum time for the overall charge cycle was met Figure 12 1 Charger LED States Faults Disconnecting the charger from the battery clears a fault If a fault cannot be cleared after taking appropriate corrective action contact your dealer for troubleshooting and or service Links Series Models 28080 28090 28100 13 of 19 User s Manual 13 MAINTENANCE Awarnine DISCONNECT BOT
19. b Car amp vehicles it is important to understand that this charger is intended for use with vehicles without an onboard computer or with the OBC properly bypassed disabled which can be accomplished with OBC bypass kit part number 38836 f the charger is connected to a vehicle with a non bypassed OBC the charger will not start a charge cycle Club Car is a registered trademark of Club Car Inc Links Series Models 28080 28090 28100 9 of 19 User s Manual 9 PROPER CARE DEEP CYCLE MOTIVE POWER BATTERIES Motive power battery packs are subjected to severe deep cycle duty on a daily basis Although these batteries are designed to withstand such duty the following precautions must be observed to obtain good performance and maximum cycle life Acaution ALWAYS WEAR PROTECTIVE EYE SHIELDS AND CLOTHING WHEN WORKING WITH BATTERIES BATTERIES CONTAIN ACIDS WHICH CAN CAUSE BODILY HARM DO NOT PUT WRENCHES OR OTHER METAL OBJECTS ACROSS THE BATTERY TERMINAL OR BATTERY TOP ARCING OR EXPLOSION OF THE BATTERY CAN RESULT 1 2 10 When installing new batteries be sure the polarity of each battery and the overall battery pack is correct Otherwise battery and or charger damage can result New batteries should be given a full charge before their first use because it is difficult to know how long the batteries have been stored New batteries and older batteries that have been in storage are not capable of their rated outpu
20. cally start a new charge cycle unless a storage mode condition has been met Disconnecting the DC output from the battery pack IS REQUIRED to automatically start a new charge cycle Links Series Models 28080 28090 28100 7 of 19 User s Manual 6 LOCATION AND INSTALLATION Awarnine DO NOT INSTALL THE CHARGER ON OR NEAR FLAMMABLE MATERIALS POSITION THE CHARGER ON A FOUNDATION OF STONE BRICK CONCRETE OR GROUNDED METAL Awarnine CHARGERS CAN IGNITE FLAMMABLE MATERIALS AND VAPORS DO NOT USE NEAR FUELS GRAIN DUST SOLVENTS THINNERS OR OTHER FLAMMABLES The charger may have been attached to a plywood board in the factory to protect it during shipping If so remove the plywood shipping board before installation and operation of the charger Proper installation of the charger is important in order to achieve good 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 airflow for convection cooling allow 2 inches 5 08 cm minimum between the charger ventilation openings and any walls or other objects Do not obstruct the airflow space around and beneath the charger Do not allow clothing blankets or other materials to cover the charger Install the charger in an area where the temperatures will remain within the range of 13 F to 122 F 25 C to 50 and the relative humidity will remain below 95 percent Exceeding these ranges
21. ced 13 3 Battery Conditions Acaution CHECK THE DC CONNECTIONS FROM THE CHARGER TO THE BATTERY AND MAKE SURE THEY ARE TIGHT AND CLEAN TIGHTEN AND OR CLEAN IF NEEDED FAILURE TO DO SO COULD CAUSE MALFUNCTION FIRE OR EXPLOSION Batteries must be well maintained for the charging system to operate properly Follow battery manufacturer instructions for battery maintenance Check for loose connections or corrosion DC connections may become corroded over time If the connections become corroded they should be cleaned as recommended by the battery manufacturer After the connections have been cleaned a battery connection treatment should be applied to help prevent corrosion from reoccurring Contact the battery manufacturer for their recommendations Periodic cleaning and watering of non sealed batteries is very important Logging the water usage of non sealed batteries is useful As a battery ages it will use more water Links Series Models 28080 28090 28100 14 of 19 User s Manual 14 TROUBLESHOOTING AND SERVICE Acaution DO NOT DISASSEMBLE THE CHARGER TAKE IT TO A QUALIFIED SERVICE TECHNICIAN WHEN SERVICE OR REPAIR IS REQUIRED INCORRECT REASSEMBLY MAY RESULT IN A RISK OF ELECTRIC SHOCK OR FIRE DANGER TO REDUCE THE RISK OF ELECTRIC SHOCK ALWAYS DISCONNECT BOTH THE POWER SUPPLY CORD AND THE OUTPUT CORD BEFORE ATTEMPTING ANY MAINTENANCE OR SERVICE WARNING DO NOT OPERATE THE CHARGER IF IT IS MALFUNCTIONING PERSONAL
22. e 7 1 Grounding Methods NOTE Use of an adapter as shown in Figures B and C is NOT permitted in Canada Use of an extension cord with the charger should be avoided Use of an improper extension cord could result in a risk of a fire and electrical shock If an extension cord is needed use a three conductor No 14 AWG or larger cord that is grounded properly wired and in good electrical condition and keep the cord as short as possible Make sure that the pins on the connector of the extension cord are the same number size and shape as those on the AC connector on the charger Locate all extension cords so that they will not be stepped on tripped over or otherwise subjected to damage or stress The charger includes an AC input circuit breaker to protect the charger and the system 8 DC OUTPUT Only charge battery packs with cell counts CELLS and DC voltages DC VOLTS equal to those listed on the ratings label on the back of the charger The DC output cordset includes a commonly used connector plug The polarity of the charger connector plug must be the same as the battery connector receptacle The marked BLACK DC cable must be connected to the battery negative and the marked WHITE OR RED DC cable must be connected to the battery positive The charger will not operate if the polarity is reversed 8 1 ROUND MOLDED 3 PIN CLUB CAR PLUG If the DC cordset includes the round molded 3 pin plug for use with Clu
23. ing apt Shipping Weight Number Volts Amps C20 Rate 12 Hrs Amps Approx Lbs 28080 36 21 130 225 11 5 37 28090 36 25 150 305 13 5 39 28100 48 13 80 170 9 5 31 Figure 1 1 Specifications for Links Series Models 28080 28090 and 28100 2 RECEIVING THE CHARGER Unpack the charger and examine it for shipping damage In the event that shipping damage is found report it as a claim with the freight company 3 STORAGE When the charger is stored prior to being installed and powered up it must be stored indoors in a clean and dry environment where the temperatures will remain within the range of 40 f to 185 F 40 to 85 C The charger should be stored upright in the shipping carton that it was shipped in This will help protect the charger from dust and abrasion It should be stored in an area where it is not likely to be damaged Do not stack anything on top of the charger 4 BATTERY TYPE Awarnine DISCONNECT BOTH AC AND DC POWER FROM THE CHARGER BEFORE OPENING THE CASE CONTACT WITH LIVE COMPONENTS WITHIN THE CHARGER COULD CAUSE ELECTRICAL SHOCK SERIOUS INJURY OR DEATH This charger is designed to charge deep cycle lead acid batteries of wet flooded AGM absorbed glass mat or gel design The charger is factory configured to charge the type of battery indicated in the TYPE field on the charger ratings label for example Wet Additionally the charger includes a secondary battery profile avail
24. ly when an extended Balance Equalize charge cycle phase is active or when a post charge phase is active See Figure 11 1 for descriptions of the possible states FAULT red Indicates when a charger or battery fault has occurred See the FAULTS section Slow Blink Bulk Start charge cycle phase constant power or constant current Fast Blink Absorption Plateau charge cycle phase constant voltage Greater than 8096 charged Solid On B Finish charge cycle phase constant current Not all charge profiles include a Finish phase Balance Equalize phase An extended charge cycle Fast Blink is occurring because a trigger condition has been met cycle count etc Not all charge profiles include a Balance Equalize phase Solid On Charge cycle complete Charge cycle complete Post Charge phase Off Slow Blink constant voltage float etc Not all charge profiles a Post Charge phase Figure 11 1 Charger LED States Non Fault Links Series Models 28080 28090 28100 12 of 19 User s Manual 12 FAULTS 0 Off 1 plateau absorption finish etc MAX VOLTAGE Maximum voltage was met MIN VOLTAGE Minimum voltage was NOT met after a specified time from the start of the charge cycle MAX AMP HOURS Maximum amp Slow Blink 1 On Solid N A Not applicable LED state does not matter DC DISCONNECT DC disconnect detected via the third pin but DC battery SIN nn is an optional feature avail
25. ould cause an explosion 7 Remove personal metal items such as rings bracelets necklaces and watches when working with a battery A battery can produce a short circuit current that is high enough to cause a severe burn 8 NEVER charge a frozen battery Links Series Models 28080 28090 28100 10 of 19 User s Manual 10 CHARGER OPERATION Awarnine TO REDUCE THE RISK OF AN ELECTRIC SHOCK CONNECT ONLY TO A SINGLE PHASE PROPERLY GROUNDED 3 WIRE OUTLET REFER TO GROUNDING INSTRUCTIONS MAKE SURE THE BATTERY IS RECHARGEABLE DEEP CYCLE BATTERY WITH THE PROPER RATED VOLTAGE FOR THIS CHARGER DANGER TO PREVENT ELECTRICAL 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 MAKE ADEQUATE ELECTRICAL CONTACT USE OF A DAMAGED OR DEFECTIVE CONNECTOR MAY RESULT IN A RISK OF OVERHEATING OR ELECTRIC SHOCK Awarnine CHARGER IS TO BE USED WHILE THE BATTERY POWERED EQUIPMENT IS OPERATING TTENTION Ne pas utiliser le charger pendant que l equipment est en marche Awarnine LEAD ACID BATTERIES GENERATE GASES WHICH CAN BE EXPLOSIVE TO PREVENT ARCING OR BURNING NEAR BATTERIES DO NOT DISCONNECT THE CHARGER DC OUTPUT FROM THE BATTERIES WHEN THE CHARGER IS OPERATING KEEP SPARKS FLAME AND SMOKING MATERIALS AWAY FROM BATTER
26. ps of batteries and battery hold downs must be kept clean and dry at all times to prevent excessive self discharge and the flow of current between the battery posts and frame Electrolyte spilled on batteries never dries or evaporates All connections to batteries must be maintained clean and tight Due to heating and discharge rates bolted connections loosen over time Re tighten the connections twice yearly to the torques specified by the battery manufacturers Follow all operating instructions cautions and warnings as specified in this manual on the charger in the battery manuals and in the vehicle manuals 9 1 Personal Safety Precautions 1 Have someone within the range of your voice and close enough to quickly come to your aid when you work near a lead acid battery 2 Ensure that ample fresh water and soap are nearby in case battery acid contacts your skin clothing or eyes 3 Wear complete eye and clothing protection Avoid touching your eyes while working near a battery 4 f battery acid contacts your skin or clothing wash immediately with soap and water If acid enters your eye immediately flush your eye with running cold water for at least 10 minutes and get medical attention immediately 5 NEVER smoke or allow a spark or flame to be in the vicinity of a battery 6 Be extra cautious to reduce the risk of dropping a metal tool onto a battery It could spark or short circuit the battery or other electrical components that c
27. t until they have been discharged and charged a number of times Consult the manufacturer of your batteries for more information DO NOT EXCESSIVELY DISCHARGE THE BATTERIES Excessive discharge can cause polarity reversal of individual cells resulting in complete failure shortly thereafter Maintain the proper electrolyte level of wet flooded batteries by adding water when necessary Distilled or deionized water is best for battery life Never allow the electrolyte level to fall below the top of the battery plates Electrolyte levels lower during discharge and rise during charge Therefore to prevent the overflow of electrolyte when charging it is mandatory that water be added to cells AFTER they have been fully charged do not overfill Old batteries require more frequent additions of water than new batteries Hard crystalline sulfates form when batteries in storage are not maintained in a charged active state Internal self discharge can bring about the start of this condition in as little as three days in warm temperatures Batteries not maintained and allowed to sit in storage will self discharge sulfate and lose capacity Repeated charging without using the batteries between charges can recover some of the lost power range and life but some permanent loss should be expected Cold batteries require more time to fully charge When the temperature falls below 65f the batte ries should be placed on charge as soon after use as possible The to
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