Exide Technologies GB4128 - Manual (Page 15)

Ferro Magnetics Corporation, St. Louis, MO
4. TROUBLESHOOTING & GENERAL MAINTENANCE
Caution: There are lethal voltages exposed when the charger is energized with the door open.
Always disconnect the AC service voltage to the charger before opening the door. The following
chart lists the most probable cause of a malfunction.
4.1. SYMPTOMS AND POSSIBLE CAUSES
SYMPTOM POSSIBLE CAUSE
No charging current, the control has no display, contactor
does not operate.
Blown AC fuse.
No AC service voltage.
Incorrect AC voltage.
Control transformer output fuse blown.
Defective control transformer.
Defective control board.
No charging current, control has a display. Blown DC fuse.
Open battery cell.
Open diodes.
Defective capacitor.
Shorted power transformer secondary.
AC fuse blows. Incorrect fuse rating.
Incorrect AC voltage.
Fuse Block holding clips loose.
Shorted transformer winding.
DC fuse blows. Reversed battery connector.
Incorrect fuse rating.
Shorted diode.
Excessive water loss in battery. Charging rate is too high.
Charger am p-hour rati ng exceeds th e batt ery amp-hour
rating (50 amps per hundred amp-hour size of battery.
Battery has defective cells.
Low specific gravity at the end of the charge cycle. Battery was over-discharged.
Charger amp- hour rati ng is less than the batter y A H
rating.
Defective open diode.
Charging rate is too low. Consult factory.
Battery has defective cells.
Battery has been over-watered.
Charger does not turn off when the control terminates the
charge cycle.
Defective control.
AC contactor has welded contacts.
4.2. GENERAL MAINTENANCE
The charger requires a mi nimum of ma intenance. C onnections and terminals should be kept clean a nd
tight. The charger should be periodically cleaned with an air hose to prevent any excessive dirt build up
on components. Care should be taken not to bump or move any adjustments during cleaning. Make sure
that both the AC lines a nd the battery are di sconnected before cleaning. Th e frequency of this type of
maintenance depends on the environment in which this unit is installed. If any cabinet sheet metal panels
are removed for cleaning, be certain they are properly reinstalled upon completion.
NOTE: Due to the high currents experienced with this type of charging, the battery and charger
connectors should be checked frequently to verify good operating condition. Disconnecting the
battery while under load will cause arcing at the contacts and premature wear
.