Associated Equipment 9520 Battery Charger User Manual
Contents
1. Black clamp to the vehicle chassis a heavy gauge metal part of the frame or the engine block away from the battery Do not connect the clamp to the carburetor fuel lines or sheet metal part of the frame For a Positive ground vehicle double check the polarity of the battery terminals Attach the Negative Black clamp to the Negative NEG N ungrounded post of the battery Attach the Positive Red clamp to the vehicle chassis a heavy gauge metal part of the frame or the engine block away from the battery Do not connect the clamp to the carburetor fuel lines or sheet metal part of the frame When disconnecting the charger follow these precautions e Turn the AC Power Switch to the O OFF position e Disconnect the AC cord e Remove the clamp from the vehicle chassis e And then remove the clamp from the battery terminal See section 4 LENGTH OF CHARGE for information on length and rate of charge A marine boat battery must be removed and charged on shore To charge it on board requires equipment specially designed for marine use 4 LENGTH OF CHARGE a b c Use a temperature compensating hydrometer or a voltmeter to determine the State of Charge of the battery Do not charge a battery that is over 75 charged or if the battery is determined to be defective Refer to the STATE OF CHARGE TABLE Determine the Battery Size Small Medium or Large Refer to the BATTERY SIZE table Refer to the CHARGE RATE Vs MI2. Worn parts can lead to poor connections and present a safety hazard See parts list for order numbers of service parts Any maintenance or repair of this unit that involves disassembly of the cabinet should be done be a qualified serviceman Incorrect reassembly may result in a risk of electric shock when unit is subsequently used 9520 amp REPAIR LIST tem Description 1 Handle 2 Cabinet Top 9520 Cabinet Top 9520GS 3 Transformer 9520 Transformer 9520GS ak W1960 ILLUSTRATION LIST 27 550E Circuit Board Rate Switch EXPLODED VIEW ASSOCIATED EQUIPMENT CORPORATION 5043 FARLIN AVENUE ST LOUIS MO 63115 9520 amp 9520GS ENGLISH SECTION 16 3 Stand Off set of 2 0OONOD 30 9520GS PART Rev 06 98 027 0550 FIG Filename Description 1 ENG TABL PLT CHARGE RATE TABLE ENGLISH 2 37 511E PLT WIRING DIAGRAM YAH1220 3 A4385 PLT EXPLODED VIEW 9520 DOCUMENT LISTING 027 0550 9520 9520GS OWNERS MANUAL DOC No FILENAME DESCRIPTION 1 27 550G MAN GERMAN LANGUAGE SECTION PG 1 4 2 27 550D MAN DUTCH LANGUAGE SECTION PG 5 8 3 27 550F MAN FRENCH LANGUAGE SECTION PG 9 12 4 27 550E MAN ENGLISH LANGUAGE SECTION PG 13 16 DO NOT COMBINE INDIVIDUAL FILES INTO ONE DOCUMENT THE FILE SIZE BECOMES UNMANAGEABLE AND THE COMPUTER SLOWS TO A CRAWL Revision record 11 94 first printing 05 98 A4385 plt graphic change 6digit p n for base was 610754 is
3. 610884 DC cable 610886 was 610760 17
4. ES a b Ifthe charger is connected to a fully charged battery the charger will shut off and the GREEN light will blink c If the clamps are removed during the battery test sequence the charger will shut off and the GREEN light will blink d Switch OFF O then ON I again e Any time a malfunction is suspected reset the control by turning the AC Power Switch OFF O VEHICLE STARTING Charge the battery for a minimum of 10 minutes using the procedure above Put the selector switch in the ENGINE START position Attempt to start the vehicle If the engine does not start put the selector switch back to the CHARGE position for another 10 minutes 1 2 3 before trying again NOTE The output circuit breaker may open during the engine start It will reset in a few seconds and battery charging will continue WIRING DIAGRAM D C LEADS A C CORD o 4 POSITIVE NEGATIVE 2 lw CLAMP CLAMP el Nee RED BLACK a jo ja TT POWER SWITCH P C BOARD ii TRANSFORMER S gt ag pee aay oO 1 ETT E27 WHITE 19 RED i RED I H BS E6 E4 E3 katte 22 9 pai S lu U U U 5 Z W 4 D r CHARGE O O CRANK SWITCH METER 15 MAINTENANCE INSTRUCTIONS Worn clamps cords or cables should be replaced
5. MODEL 9520 amp 9520GS 6 12 VOLT 0 20 AMP BATTERY CHARGER OWNER S MANUAL IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important safety and operating instructions for the battery charger you have purchased You may need to refer to these instructions at a later date CAUTION To reduce the risk of injury charge only lead acid type rechargeable batteries Lead accumulator battery Other types of batteries may burst causing personal injury and property damage WARNING RISK OF EXPLOSIVE GASES WORKING IN THE VICINITY OF A LEAD ACID OR OTHER AUTOMOTIVE BATTERY IS DANGEROUS BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION FOR THIS REASON IT IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE USING YOUR CHARGER YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY An extension cord should not be used unless absolutely necessary Use of an improper extension cord could result in the risk of fire and electric shock If an extension cord must be used make sure a b That it has a protective conductor earthed and a minimum cross section of 1 5mm in accordance with local electrical safety codes For industrial and agricultural usage use only electrical extension cords approved for these operations 1 PREPARING TO CHARGE a b c d Be sure the area around the battery is well ventilated while the battery is being charged Clean the battery terminals Add distilled water in e
6. NUOUS GREEN LIGHT Indicates correct connection If when battery is connected the green light does not light check for proper polarity or poor connections If the battery voltage is below 2 volts the green light will not come on 5 CONTINUOUS YELLOW LIGHT Indicates charging x BLINKING GREEN LIGHT Indicates charging is complete NOTES THREE SECOND DELAY To avoid sparking the charger control tests for correct polarity before applying current to the battery When connected properly the green light will come on for 3 seconds before the yellow light comes on BATTERY TEST After the 3 second delay the charger control will begin a 6 second battery test The yellow light will be on and the meter will indicate low current BATTERY CHARGE After testing the battery the control will select a charging rate suitable for the voltage and state of charge of the battery A small battery or a nearly charged battery will cause the charger to rapidly step down in current to avoid heating and gassing FINISH CHARGE In order to reach a 100 state of charge on the battery a 3 hour finish cycle has been programmed into the charger control During this cycle if the battery voltage does not change over a fixed period of time the charger shuts off and the green light comes on TIME OUT An 11 hour timer will terminate the charging cycle if for some reason 100 state of charge has not been reached COOLING FAN When charging current exceeds 10 amps
7. NUTES CHARGE table to determine the recommended length of charge for the battery based on its size state of charge and the charging amperes 13 d Discontinue charging when the specific gravity of the electrolyte reaches 1 260 or above A temperature compensating hydrometer should be used for this reading Discontinue charging if the battery begins to gas excessively or when the temperature of the electrolyte reaches approximately 59 C Do not overcharge the battery BAT TERT Su 2G TABE CHARGE RATE Vs MINUTES CHARGE BATTERY SIZE SMALL MEDIUM LARGE BATTERY SIZE CHARGE MINUTES Ampere Hours 4G 68 BA S38 45 68 75 30 Reserve Capacity 68 g 10 25 45 38 36 25 25 26 Cold Cranking Amps 275 256 AGA SMALL 25 58 A 30 20 20 15 15 16 50 75 M isji li jiajsis5 STATE OF CHARGE TABLE G 25 P 70 58 45 48 3513 STATE OF CHARGE 75 507 25 DEAD MEDIUM 25 59 E 45 38 25 20 20 20 Specific Gravity 1 225 1 185 1 148 1 118 50 75 25 15 15 10 10 18 Open Circuit Voltage 6 V 6 2 6 5 5 9 5 9 25 s 90 5555 50 45 45 Open Circuit Voltage 12 V 12 4 12 1 11 9 11 8 LARGE 25 58 68 48 35 30 38 38 Open Circuit Voltage 24 V 24 8 24 2 23 8 23 6 50 75 38 28 20 15 t5 15 OPERA TING INSTRUCTIONS x CONTINUOUS RED LIGHT Indicates AC power is on CONTI
8. ach cell until the battery acid reaches the level specified by the battery manufacturer The normal level is usually 1 cm above the lead plates Determine the voltage of the battery by referring to the vehicle owner s manual and make sure that the output voltage selector switches are set at the correct voltage If the charger has an adjustable charge rate charge the battery initially at the charger s lowest rate for the battery 2 DC CONNECTION PRECAUTIONS a b Connect and disconnect the DC output clamps only after setting the AC Power switch to the O OFF position and removing the AC cord from the electric outlet Never allow the clamps to touch each other When attaching a clamp to a battery post twist or rock the clamp back and forth several times to make a good connection 3 FOLLOW THESE STEPS WHEN CONNECTING THE BATTERY a b c Check the polarity of the battery posts The Positive POS P battery post usually has a larger diameter then the Negative NEG N battery post Determine which post of the battery is grounded connected to the chassis If the negative post is grounded to the chassis as in most vehicles see paragraph 4c If the positive post is grounded to the chassis see paragraph 4d For a Negative ground vehicle double check the polarity of the battery terminals Connect the Positive Red clamp from the battery charger to the Positive POS P ungrounded post of the battery Connect the Negative
9. the cooling fan will come on to keep the electronics from overheating Below 10 amps the fan shuts off The fan will also come on briefly when the AC power first comes on BATTERY MAINTAINER If the charger is left connected to the battery it will begin recharging if the terminal voltage falls below 12 44 VDC Itis recommended that the electrolyte level be checked regularly when charging batteries for an extended period of time OPERATING PROCEDURE 1 Plug AC cord into outlet Turn AC Power Switch on back of cabinet to the ON I position The Red light should come on and the fan will run briefly 2 Put selector switch in the CHARGE position 3 Connect the BLACK clamp to the negative terminal of the battery Connect the RED clamp to the positive terminal of the battery The GREEN light should come on for 3 seconds 4 The YELLOW light will come on when the GREEN light goes off After a 6 second battery test charging will begin The amount of charging current can be observed on the meter 14 The battery is charged when the GREEN light is blinking If a 100 state of charge is not needed the battery can be used when the If the charger is connected to a battery which will not accept a charge the charging cycle will end and the GREEN light will blink It is best to reset the charger control before beginning to charge another battery This can be accomplished by pulling the AC Power 5 meter indicates low charging current NOT
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