Ezgo PowerWise QE - 36 Volt Charger Operating Manual

Important Safety Instructions

This manual contains important safety, operating, and installation instructions. Read before using charger.

Battery Safety Information

Use charger only on 36 volt battery systems. Other usage may cause personal injury and damage. Lead acid batteries may generate explosive hydrogen gas during normal operation. Keep sparks, flames, and smoking materials away from batteries. Provide adequate ventilation during charging. Never charge a frozen battery. Study all battery manufacturers' specific precautions such as recommended rates of charge and removing or not removing cell caps while charging.

Electrical Safety Information

Risk of electric shock. Connect charger power cord to an outlet that has been properly installed and grounded in accordance with all local codes and ordinances. A grounded outlet is required to reduce risk of electric shock – do not use ground adapters or modify plug. Do not touch uninsulated portion of output connector or uninsulated battery terminal. Disconnect the AC supply before making or breaking the connections to the battery while charging. Do not open or disassemble charger. Do not operate charger if the AC supply cord is damaged or if the charger has received a sharp blow, been dropped, or otherwise damaged in any way – refer all repair work to qualified personnel. Not for use by children.

OPERATING INSTRUCTIONS

1. With the enclosed case design, the charger may beplaced virtually anywhere, but the choice of placement and orientation is extremely important. For optimum performance and shortest charge times, place the charger in an area with adequate ventilation. The charger should also be placed in an area that will be relatively free of dirt, mud, or dust since accumulations within the fins of the charger will reduce their heat-dissipating qualities. Optimal cooling also occurs when the charger is placed on a horizontal surface with the fins vertical. More airflow from below the charger will help cool the fins, so placement above open areas or areas with cut-outs for airflow is desirable. As the charger may get hot in operation, the charger must be placed such that risk of contact by people is reduced. Wall mount or shelf mount using #10-M5 screws. The charger's status display must be visible to the user.
2. Always use a grounded outlet. When using an extension cord, avoid excessive voltage drops by using a grounded 3-wire 14 AWG cord.
3. When plugged into the vehicle's charger receptacle, the charger will automatically turn on and the charger's LED will start flashing GREEN to indicate the battery is charging.
4. Once a minimum battery voltage of 2 volts per cell(Vpc) is reached, the charger's output current will change from a trickle current to the full rated charging current. The length of charge time will vary by how depleted the battery pack is, the input AC voltage, and/or charger ambient temperatures. The charger's LED will flash a SHORT flash (off more than on) if charge is <80% and a LONG flash if >80%.
5. When the charger's LED is continuously GREEN,the batteries are completely charged. The charger may now be unplugged from the vehicle. If left plugged in and the battery pack voltage drops below a minimum voltage or 30 days has elapsed, the charger will automatically restart a complete charge cycle.
6. If a fault occurred anytime during charging, a faultindication is given by quickly flashing the RED LED on the charger. The specific fault is indicated on the charger by flashing RED a number of times, pausing, and then repeating. There are several possible conditions that generate errors. Some errors require human intervention to first resolve the problem and then to reset the charger by unplugging the DC cord from the vehicle. Others may be simply transient and will automatically recover when the fault condition is eliminated. If the AC voltage is interrupted and restored, the charger will turn back on automatically.

Visual LED Display Information
LED Operation Codes:
SHORT LED flash green = less than 80% charged
LONG LED flash green = more than 80% charged
SOLID LED green = 100% charged
RED LED flash = fault code

LED Fault Code Display Information
LED Fault Code:
0-FLASH RED Light turns on briefly but nothing after that - Check for valid AC voltage.
1-FLASH RED Charge Enable Fault: Poor contact in DC connector.
2-FLASH RED Battery Voltage Fault: Battery Pack is < 27.0V or > 50.4V. Battery is too discharged or overcharged to be charged.
3-FLASH RED Battery Charge Timeout: Charge time 24hrs. exceeded. This may indicate a problem with the battery pack (old battery pack) or that the charger output current was severely reduced due to high ambient temperatures.
4-FLASH RED Battery Fault: Charge time exceeded. This indicates a problem with the battery pack voltage not attaining the required nominal level within tmax.
6-FLASH RED Charger Fault: an internal fault has been detected. If Fault 6 is again displayed after unplugging and then plugging the DC power cord, the charger must be brought to a qualified service center.

1. For flooded lead-acid batteries, regularly checkwater levels of each battery cell after charging and add distilled water as required to level specified by battery manufacturer. Follow the safety instructions recommended by the battery manufacturer.
2. Make sure charger connections to battery terminalsare tight and clean. Check for deformation/cracks in plastic parts. Check the charger harness for chaffing and rubbing. Inspect all wiring for fraying, loose terminals, chaffing, corrosion or deterioration of insulation.
3. Keep cooling fins free of contamination and do notexpose charger to oil, dirt, mud or to direct heavy water spraying when cleaning equipment.
4. Inspect the plug of the battery charger and vehicle receptacle housing for dirt or debris. Monthly, or sooner if needed, clean the DC connector auxiliary contact. To clean the auxiliary contact, slide an emery board between main contact and auxiliary contact located in the hole of the charger plug nearest the rounded corners. (See Cleaning Contact Figure). Press emery board down to apply pressure to the auxiliary contact and slide board in and out of plug approximately 10 to 20 times, keeping pressure applied to the auxiliary contact surface. Repeat cleaning process if charger turns off while the handle is moved back and forth. If, after re-cleaning and retesting, the charger still turns off, check plug for a broken red wire in DC cord.
   

E-Z-GO Division of Textron, Inc.,
1451 Marvin Griffin Road, Augusta, Georgia
USA 30906-3852 Phone: 1-800-241-5855