DPI Accusense Battery Chager
DPI Accusense Battery Chager
DPI Accusense Battery Chager
SPECIFICATIONS:
Part Numbers: X-72C012xxx-xxxx 72V 12A Lead-Acid Charger
X-64C014xxx-xxxx 64V 14A Lead-Acid Charger
X-60C014xxx-xxxx 60V 14A Lead-Acid Charger
X-48C017xxx-xxxx 48V 17A Lead-Acid Charger
X-48C885xxx-xxxx 48V 8.5A Lead-Acid Charger
X-42C017xxx-xxxx 42V 17A Lead-Acid Charger
X-36C018xxx-xxxx 36V 18A Lead-Acid Charger
X-24C020xxx-xxxx 24V 20A Lead-Acid Charger
X-24C018xxx-xxxx 24V 18A Lead-Acid Charger
1. Features
Fully Automatic - starts and stops charging automatically
5 L.E.D. display to easily interpret charge and/or charge error
conditions
Many safety features, including Reverse Battery Protection and
Wrong Battery Connections
Charge algorithm controls BOTH voltage and current for precise
charging
Microprocessor-based control implements an intelligent charge
After completion of charge, charger will maintain battery at full charge
2. Introduction
The Diversified Power International (DPI) battery charger is designed to
recharge deep-cycle, lead-acid batteries. It is factory preset to operate in
one of 4 different charge modes; refer to Section 6 for further details. A
Mode Select Jumper field, on front of charger, allows user to change
Mode settings to select a different battery set.
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Be extra cautious not to drop a metal tool onto battery. It might spark
or short circuit battery or other electrical part that may cause an
explosion.
Remove personal metal items such as rings, necklaces, watches, etc.
Batteries can produce a short-circuit current high enough to weld such
items causing a severe burn.
NEVER charge a frozen battery. Thaw it out for safer and more
efficient charging.
4. Installation
The AC line, to which the charger is to be connected, must be capable of
supplying 10 amperes to this charger. If the Charger part number begins
with ‘1’ connect to a 120Vac-60Hz line; if part number begins with ‘2’
connect to a 230V-50Hz line.
The use of an extension cord with the charger should be avoided. The
use of an improper extension cord could result in a risk of a fire or electric
shock. If an extension cord must be used, it must be UL and/or CSA
approved. Locate all cords so that they will not be stepped on, tripped
over or otherwise subjected to damage or stress. Extension cord must be
properly wired and in good electrical condition, and large enough for the
AC rating of charger as specified in this TABLE:
RECOMMENDED MINIMUM AWG SIZE FOR
EXTENSION CORDS FOR BATTERY CHARGERS
Length of cord (feet): 25 50 100 150
AWG size of cord: 12 12 10 8
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WARNING: CHARGERS CAN IGNITE FLAMMABLE MATERIALS
AND VAPORS. DO NOT USE NEAR FUELS, GRAIN DUST,
SOLVENTS, OR OTHER FLAMMABLES.
5. Grounding Instructions
This battery charger must be grounded to reduce the risk of electric
shock. This charger is equipped with an AC cord set having an
equipment-grounding conductor. This AC cord set must be connected to
an appropriate receptacle that is properly installed and grounded in
accordance with the National Electrical Code and all local codes and
ordinances.
The conductor with insulation having an outer surface that is green, with
or without yellow stripe(s), is the equipment-grounding conductor. If repair
or replacement of the charger’s AC cord set is necessary, refer to a
qualified service agent, and do not connect the equipment-grounding
connector to a live terminal.
6. Preparing to Charge
The instructions printed on the charger are for daily reference. Chargers may be
factory preset to Mode-2, but the MODE can be changed to suit different battery
types by rearranging the Jumpers found under the Cover Plate located on the
front of the charger, per the diagram found on the inside of the Mode Select
Cover Plate, accessible by removing its 2 screws. Also, this diagram is reprinted
below. Each Mode (‘color key’) is set to charge a particular Battery Type:
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Upon connection to Battery Pack, ALL FIVE L.E.D.s flash on, then off, up to 4
times. The charger is communicating the Mode Setting to you. Simply count the
number of times you see ALL FIVE L.E.D.s turn on, and off. Batteries are a
‘designed component’ and the materials used in their construction determines its
charge characteristic and also its suitability to your application. NEVER assume
differing battery types are equal in performance or charge requirements.
6.1 Be sure area around battery is well ventilated while battery is being
charged. Gas can be forcefully blown away using a non-metallic
material like cardboard.
6.2
The DC charging receptacle does not grip the DC cord set plug tightly,
is loose or does not make a good electrical connection.
The DC cord set plug or charging receptacle feel hotter than normal.
The DC cord set plug blades or charging receptacle contacts are bent,
corroded or are dark or bluish in appearance.
The DC cord set plug, cords, receptacle or equipment charging wiring
are cut, worn, broken or have any exposed conductors.
The DC cord set plug, cords, charger or receptacles are damaged or
distressed in any way.
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Using the charger with any of the above symptoms could result in a fire,
property damage or personal injury.
6.3 Connect the DC cord set plug to the charging receptacle by grasping
the plug body or handle and pushing the plug straight into the
receptacle. Then connect charger’s AC cord set to AC power. The
charger will start automatically in approximately three (3) seconds.
6.4 Ensure that the Charger Mode is appropriate for your battery voltage.
For example, do not use a 48V rated charger to charge a 42v rated
battery pack.
7. 5-STAGE CHARGE
3seconds after connection to A.C. Power, (and assuming the use of
the 120Vac 60Hz model part number 1-48C017xxx-xxxx, set to MODE-
2, all 5 charger L.E.D.s will flash on and off, twice, and then the Power
L.E.D. and Detection L.E.D. will illuminate. The Detection L.E.D. will
turn off when the charger’s output DC Cable connects to a battery
pack (means that the charger has detected the battery pack).
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The Mode Select is annunciated by the number of times you see all
five L.E.D.s flash on and off, at the beginning of power-up. If you
count ‘4’ flashes, this indicates Mode-4 operation.
If the charger is left connected to AC Power, and then the DC cord set
plug is re-connected to another battery pack, the charger will restart a
new charge cycle from the beginning (Stage 1).
If, while charging, the charger finds an abnormal charge condition, it
will attempt to shut down and indicate the ‘Condition’ by flashing one
or all of its RED L.E.D.s. Refer to the ‘Troubleshooting’ section for a
description of the Charge Error Condition, if you encounter a flashing
RED L.E.D.
8. L.E.D. DISPLAY
Under normal charge circumstances, the L.E.D.s operate as follows:
9. TROUBLESHOOTING GUIDE
To be able to troubleshoot safely and effectively, it is important to read
this guide completely before beginning any tests.
If any of the three red L.E.D.s flash, the charge cycle has terminated
prematurely. An abnormal charging condition was detected and charging
stopped due to a Charge Error Condition. Refer to the following Charge
Error Table for a description of the possible failure or condition.
CHARGE ERROR TABLE
Flashing L.E.D.s
Condition Power Abnormal Detection
Battery Voltage High Off Off Flash
Battery Polarity Reversed Off Flash Off
Output Overload Off Flash Flash
Charge Level Unbalanced Flash Off Off
Excessive Charging Time Flash Off Flash
Excessive Overload Flash Flash Off
Excessive Discharged Flash Flash Flash
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Battery Voltage High. Charger’s DC cord set possibly connected to a
battery pack with voltage higher than the output rating of the charger.
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to become unbalanced and may cause permanent damage to charger
or cause excessive battery gassing and/or personal bodily or property
damage. Never use charger for any purpose contrary to its intended
purpose of charging lead acid batteries in accordance with ALL
instructions printed in this manual.
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10. Schematic Drawing
NOTE: Relay optional - only installed in ‘1R’ or ‘2R’ models. Lockout circuits are model dependent
Parts Kits For Models: 1-24020, 1-36018, 1-42017, 1-48017, 1-64014, 1-72012
KITS0002 Strain Relief Bushing for A.C. And D.C. Cord Set 2, 8
KITS0001 A.C. Input Cord for models equipped with Input A.C. Relay (1R/2R models) 1, 2
KITS0119 A.C. Input Cord for models not equipped with Input A.C. Relay (1- / 2- models) 1, 2
KITS0107 Bumper Feet, Set of 4 pieces 3
KITS0113 Meter – 20A Scale 13
KITS0055 Mode Select Cover and 2 Jumpers 17, 18
KITS0109 Enclosure without Meter Hole, Handle, Screws, Label 16, 22, 23, 24, 25, 6
KITS0115 Enclosure with Meter Hole, Handle, Screws, Label 16, 22, 23, 24, 25, 6
KITS0120 Enclosure without Meter Hole, Handle, Screws, Label (1-48015 Series only) 16, 22, 23, 24, 25, 6
KITS0129 Electronic Control Card for 72V Charger (1-72C012 Series) 20, 7
KITS0106 Electronic Control Card for 48V Charger (1-48C017 Series) 20, 7
KITS0125 Electronic Control Card for 42V Charger (1-42C017 Series) 20, 7
KITS0156 Electronic Control Card for 36V Charger (1-36C018 Series) 20, 7
KITS0157 Electronic Control Card for 24V Charger (1-24C020 Series) 20, 7
KITS0154 Electronic Control Card for 72V Charger (1R-72C012 Series) 20, 7
KITS0130 Electronic Control Card for 64V Charger (1R-64C014 Series) 20, 7
KITS0152 Electronic Control Card for 48V 8.5A Charger (1R-48C885 Series) 20, 7
KITS0103 Electronic Control Card for 48V Charger (1R-48C017 Series) 20, 7
KITS0155 Electronic Control Card for 36V Charger (1R-36C018 Series) 20, 7
KITS0066 D.C. Output Cord Set, Club Car Round 3-pin 8,9
KITS0067 D.C. Output Cord Set, Club Car Crowfoot 2-pin Blade 8,9
KITS0068 D.C. Output Cord Set, EZgo 36V D-Shape 2-Pin 8,9
KITS0069 D.C. Output Cord Set, EZgo 48V TXT 2-Pin 8,9
KITS0070 D.C. Output Cord Set, Yamaha, 2-Pin 8,9
KITS0027 D.C. Output Cord Set, Yamaha, 3-Pin Powerdrive 8,9
KITS0079 D.C. Output Cord Set, Star-Car 3-Pin Black Tip 8,9
KITS0080 D.C. Output Cord Set, Star-Car 3-Pin Yellow Tip 8,9
KITS0081 D.C. Output Cord Set, Star-Car 3-Pin Green Tip 8,9
KITS0126 D.C. Output Cord Set, Red SB-50 2-Pin 8,9
KITS0127 D.C. Output Cord Set, Gray SB-50 2-Pin 8,9
KITS0121 Transformer Kit, 24V Charger 1-24C020 Series 10, 11, 12, 26
KITS0122 Transformer Kit, 36V Charger 1-36C018 Series 10, 11, 12, 26
KITS0123 Transformer Kit, 48V Charger 1-48C017 Series 10, 11, 12, 26
KITS0124 Transformer Kit, 48V Power Supply 1-48015 Series 10, 11, 12, 26
KITS0128 Transformer Kit, 72V Charger (1-72C012 Series) 10, 11, 12, 26
KITS0008 Relay – A.C. Disconnect 14, 15, 27
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Parts Kits For Models: 2-24020, 2-36018, 2-42017, 2-48017, 2-60014, 2-64014, 2-72012,
1-24018, 2-24018, or additional parts kits info, not listed…
Please call our factory
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12. LIMITED WARRANTY
Diversified Power International LLC (DPI) warrants exclusively to the
original purchaser that this product will be replaced or repaired, at DPI’s
option, if it fails during the first 3 years after date of purchase due to a
defect in material or workmanship. In order for a claim to be processed
the product must be returned to DPI (i) with all transportation charges
prepaid, (ii) accompanied by a acceptable proof of purchase, and with a
Return Material Authorization (RMA) number, previously obtained from
DPI, printed and clearly visible on the outside of the shipping container.
This warranty does not apply if the product has been modified, abused, or
damaged or improperly or negligently used, connected, maintained, or
operated in any manner contrary to the instructions stated in this manual
or affixed to the product’s enclosure. Repair or replacement as provided
under this warranty is the exclusive remedy of the purchaser, and the
purchaser shall have no claim against DPI except for the breach of an
express warranty stated herein. DPI shall not be liable for any incidental,
consequential, or special damages for breach of any expressed or implied
warranty. Except to the extent required by applicable law any implied
warranty of merchantability or fitness for a particular purpose is limited in
duration to the first three (3) years after the date of purchase (and lifetime
Transformer warranty for original purchaser, only). Some states do not
allow the exclusion or limitation of incidental or consequential damages or
allow limitations on how long an implied warranty lasts, so the above
limitations or exclusion may not apply to you. This limited warranty gives
you specific legal rights, and you may also have other rights which vary
from state to state. APART FROM THE WARRANTIES SET FORTH
ABOVE, DPI MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED,
WITH RESPECT TO THE SUITABILITY OR MERCHANTABILITY OF
THIS PRODUCT, THE FITNESS OR THIS PRODUCT FOR ANY
SPECIFIC USE OR PURPOSE, OR ANY OTHER MATTER
PERTAINING TO THIS PRODUCT.
Return information:
DIVERSIFIED POWER INTERNATIONAL LLC
414 CENTURY COURT
PINEY FLATS, TN 37686, U.S.A.
423 538-9002
RMA # ________________
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