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OLY Battery Charger Troubleshooting
OLY Battery Charger Troubleshooting
SUMMARY: This service document provides diagnostic information for the effective
determination of faulty battery chargers as utilized with the aforementioned genset package
population.
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INVESTIGATION:
Over-heating - 24Volt Open-Type Chargers
Open-type chargers that are contained within a small, enclosed control panel may overheat.
This is especially true for 24 volt chargers. Overheating can cause the potentiometer within the
charger to fail.
Open-type chargers that are Non-UL approved and are date stamped from 13 September 2007
and later have improved components that have fitted assemblies. Also, Non-UL approved
Open-type chargers having a serial number beginning from 0709-1531 and larger are fitted
assemblies with an improved printed circuit board, version 6.3. The new circuit boards allow
the temperature compensation to be disabled by moving the jumper that is on the printed
circuit board from internal (INT) to (NON). The new circuit boards can be placed in either
vertical orientation regardless of the direction that is shown on the label.
False Alarms
Battery chargers are equipped with temperature compensation circuitry. Battery chargers can
intermittently initiate an erroneous alarm for either a Low Battery Voltage or a High Battery
Voltage. The erroneous alarms are attributed to the threshold set points of the digital controller
being incorrect. Refer to previously published Olympian Technical Information Bulletin, OLY
TIBU0031 for correct set point values and process for changing the set points.
The battery charger will stop operating when the battery charger supply voltage has been
disconnected or interrupted. This will result in the battery charge being depleted. You will
need to fully re-charge the battery prior to placing the battery charger on-line. If the battery is
not properly recharged, the battery charger will not produce the correct rated output. This
could be incorrectly interpreted as a failure of the battery charger.
• If the terminal connections between the battery charger and battery terminal posts are
loose.
• Prior to connecting a battery to the battery charger, ensure that the battery has been
fully charged. If the battery has not been fully charged, the battery charger output
voltage will be lower than the voltage specified in Table 1. You should charge the
battery and re-test. The battery should then output the proper full float voltage as
specified in Table 1.
• The battery charger’s internal temperature compensation feature adjusts the output
voltage to provide a correct charging voltage relative to the subjected ambient
temperature. Using Table 2 as reference, compare the battery chargers output voltage
the associated ambient temperature, which the battery charger is exposed to.
Table 2
Temperature 12V 12V 24V 24V
(degrees C) Float Boost Float Boost
-20 14.3V 14.8V 28.6V 29.6V
-10 14.1V 14.6V 28.3V 29.3V
0 14.0V 14.5V 27.9V 28.9V
10 13.8V 14.3V 27.6V 28.6V
20 13.6V 14.1V 27.2V 28.2V
30 13.4V 13.9V 26.8V 27.8V
40 13.2V 13.7V 26.5V 27.5V
50 13.1V 13.6V 26.1V 27.1V
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