Confidential OLYTIBU0026-00 CDIM NUMBER: 46959

TECHNICAL INFORMATION BULLETIN August 1, 2006

Olympian Genset Packages
D4P, F4P, GAL, LEA, N4P, NAL, NAT, NGA,
NGB, NGC, NGF, NGG, NGH, NGJ, NGT,
NNS, NPE, NPF, NPS, NPT, NPX, RFT, RRT,
XPT

Component Code: 1406

SUBJECT: Improved battery chargers for new production and service part replacement use with, battery
charger troubleshooting procedures.

PROBLEM: Previous versions of the battery chargers could incur internal faults, which the field service
technician was not able to diagnosis and repair successfully. Additionally, these same battery chargers had
limited fault protection features.

SOLUTION: A series of new service replacement battery chargers for use with Gensets equipped with
ventilated, lead acid batteries has been established and made available thru the Service Parts. The new
service replacement battery chargers have improved protection features such as short circuit protection,
reverse polarity protection, current limiting, temperature compensation, auto resetting electronic fuse for
the DC output and a battery charger wiring diagram label has been added to assist in troubleshooting. An
additional feature, Auto Boost, is available for select battery chargers.

The Auto Boost operation provides an increased output voltage when the batteries are below a preset
voltage reference. When the charge level on the battery increases to the battery chargers threshold voltage
set point, the battery charger will automatically transition to the Float mode. The battery charger is also
equipped with terminal points for Manual Boost initiation. The Manual Boost mode has a default time out
period of 2.5 hours to prevent any damage to the battery.

Refer to Table 1 for service part number cross-reference.

Original Olympian New Olympian Auto Boost Feature

Part Number Part Number Available
652-005 10000-05856 No
652-001 10000-05857 No
652-038 10000-05858 No
652-132 10000-05859 No
652-002 10000-05860 Yes
652-131 10000-05861 Yes
652-030 10000-05862 Yes
652-133 10000-05863 Yes
Table 1

PROCEDURE: To assist the field service technician in troubleshooting battery chargers, the following
guideline is provided. This guideline will prevent an incorrect diagnosis of the battery charger and avoid
the replacement of a properly functioning battery charger.

1. De-energize the battery charger.

2. Disconnect the existing battery(s) from the DC output of the battery charger being evaluated.
 3. Connect a known “fully charged” battery(s) to the DC output of the battery charger being
evaluated.
4. Confirm that the proper input voltage is provided to the battery charger.
5. Energize the battery charger.
6. Observe the DC output voltage of the battery charger. Compare the observed DC output voltage
to the values specified in Table 2.

Original Olympian New Olympian DC Float Boost

Part Number Part Number Voltage Voltage Voltage
652-005 10000-05856 24V 27.2V N/A
652-001 10000-05857 12V 13.6V N/A
652-038 10000-05858 12V 13.6V N/A
652-132 10000-05859 24V 27.2V N/A
652-002 10000-05860 12V 13.6V 14.1V
652-131 10000-05861 12V 13.6V 14.1V
652-030 10000-05862 24V 13.6V 28.2V
652-133 10000-05863 24V 13.6V 28.2V
Table 2

Operational Notes
a. The battery charger will produce only half of it’s rated DC output voltage for a No Load
condition (i.e. No battery connected) or if a poor condition battery is connected.
b. A DC output voltage less than the rated value but greater than half the rated value
indicates that the test battery(s) have a low charge and need to be charged. Repeat the
evaluation with fully charged batteries.
c. The charging current for a fully charged battery in proper condition, will have a value
between 0.1% and 0.5% of the AH rating of the battery. (i.e. A 90AH rated battery will
have a charging current ranging from 0.09amps to 0.45amps.)
d. The charging current for a proper condition battery which is not fully charged will have a
value between 5.0% minimum and 25.0% maximum of the AH rating of the battery or
equal to the maximum rated output of the battery charger, whichever limit is achieved
first. (i.e. A 90AH rated battery will have a charging current between 4.5A to 23.5A. The
current will be limited to the rated output current of the battery charger.).
e. When measuring the output current of the battery charger, ensure that you consider the
current draw for all ancillary loads that are energized while the battery is being charged.
(i.e. Control panel).
f. If the battery voltage level increases rapidly during the charging cycle and the charging
current is at a minimum or nonexistent level, the battery may have become sulphated. In
this condition, the battery will not hold a charge and the battery should be replaced.
g. The “float” feature of the battery charger is to maintain a full charge on the battery. Do
not use the “float” feature to recharge a severely drained battery.
h. Be aware that a charging alternator may supply a higher charging current than the battery
charger.

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ALL RIGHTS RESERVED