Theory Of Operation; Battery Equalizer Circuit Breaker; Battery Equalizer Troubleshooting - Kohler Decision-Maker 1 Manual

Input voltage (24 volts
nominal)
Input current 24 volt, max.
Output voltage
Output current (12 volts)
Standby current
Operating temperature
Storage temperature
Figure 8-3 Battery Equalizer Specifications
8.5.1

Theory of Operation

The application requires a 12-volt battery source in a
24-volt engine electrical system. Connection to the
12-volt battery A for the 12-volt source causes a battery
charging imbalance where the 12-volt batteries B/C are
overcharged. The solution to this charging imbalance
requires using a battery equalizer.
The battery equalizer connects at the +24 volt, +12 volt,
and ground connections. The battery equalizer provides
a simulated series connection for battery charging and
other 24-volt engine electrical requirements and a
simulated parallel connection for the 12-volt engine
electrical requirements where all batteries maintain a
voltage balance to within 0.10 volts under light load and
0.50 volts under full rated load.
When the voltage of one battery is higher than or equal
to the other battery voltages, the battery equalizer
remains in the standby mode. When a 12-volt load is
present and the battery A voltage decreases to just
below the voltage of the batteries B/C, the battery
equalizer provides battery current to the lower voltage
battery from the higher voltage batteries to satisfy load
and maintain an equal voltage and charge in each
battery.
8.5.2

Battery Equalizer Circuit Breaker

The battery equalizer has a manual reset circuit breaker,
see Figure 8-1. The circuit breaker trips to protect the
battery equalizer in the follows ways:
Note: To prevent reverse polarity damage to the battery
equalizer, remove the ground (GND) connection
first and attach the ground (GND) connection last
when disconnecting the battery equalizer.
D
When the battery is connected to +12 volt and GND
battery equalizer terminals incorrectly.
D
When the battery equalizer's GND terminal is
connected to the chassis and the battery negative (--)
terminal is disconnected, a short between +24 volt
and chassis creates a reverse polarity on the +12 volt
and GND circuit.
126 Section 8 Component Testing and Adjustment
20--35 volts
12 amps
(input voltage/2) 2%
0--20 amps
17 mA nominal at 28.4 volts
--40_C to 71_C (--40_F to 160_F
--54_C to 85_C (--65_F to 185_F)
D
When the battery equalizer's GND terminal is
connected to the chassis and the battery negative (--)
cable is disconnected, a short between +24 volt and
chassis creates a reverse polarity on the +12 volt and
GND circuit.
8.5.3

Battery Equalizer Troubleshooting

The battery equalizer test requires all batteries to have a
full charge and pass a battery load test prior to
performing the battery equalizer test.
conditions are not known or are questionable, test the
batteries with a battery load tester. Use the instructions
provided with the battery load tester.
Battery equalizer test equipment required:
D
12-volt test light with alligator clips on both ends.
D
Voltmeter with 0.01 volt resolution
Note: To prevent reverse polarity damage to the battery
equalizer, remove the ground (GND) connection
first and attach the ground (GND) connection last
when disconnecting the battery equalizer.
1. Remove the ground (GND) connections from the
battery equalizer. Do not allow these connections
to contact any of the other battery equalizer
connections.
2. Verify that there is a differential of 12 volts between
the +12 volt and +24 volt battery equalizer
terminals by connecting a 12-volt light between the
terminals. The test light will illuminate when
connected to a functional battery equalizer.
Remove the test light.
3. Connect the test light between the +12 volt and
GND battery equalizer terminals. The test light will
illuminate when connect to a functional battery
equalizer.
4. With the test light connected, measure and record
the voltage between the +12 volt and +24 volt
battery equalizer terminals.
5. With the test light connected, measure and record
the voltage between the +12 volt and GND battery
equalizer terminals.
6. Remove the test light.
7. Compare the values recorded in steps 4 and 5. The
difference between the values should be --0.5 and
+0.13 volts with a functional battery equalizer.
If battery
TP-6356 4/12