CONFIDENTIAL

TECHNICAL INFORMATION BULLETIN

Olympian Genset Packages

OLY-TIBU0038-00
July 16, 2008
D4P (1-UP), DLD (1-UP), F4P (1-UP),
GAL (1-UP), LEA (1-UP), N3P (1-UP),
N4P (1-UP), NAT (1-UP), NFC (1-UP),
NFE (1-UP), NFS (1-UP), NFT (1-UP),
NGE (1-UP), NGF (1-UP), NGT (1UP), NGZ (1-UP), NNS (1-UP), NPE
(1-UP), NPS (1-UP), NPT (1-UP), NPX
(1-UP), RFT (1-UP), RPS (1-UP), RRT
(1-UP), RTG (1-UP), X4P (1-UP), XPT
(1-UP), N6A (1-UP), N6N (1-UP),
NGA (1-UP), NGB (1-UP), NGC (1UP), NGD (1-UP), NGG (1-UP), NGH
(1-UP), NGJ (1-UP)
Component Code: 1406

SUBJECT: Battery charger troubleshooting.

SERVICE PARTS AFFECTED:
Table 1
Service Part Current Charging Supply
UL
Type
Float voltage1 Boost voltage1
number
Rating
Volts
Volts
approval
652-301
3.5
12
120
Boxed
Yes
13.6V
14.1V
10000-14090
10
12
120
Boxed
Yes
13.6V
14.1V
652-302
3.5
24
120
Boxed
Yes
27.2V
28.2V
10000-14090
10
24
120
Boxed
Yes
27.2V
28.2V
652-170
5
12
120
Open
Yes
13.6V
14.1V
652-179
3
24
120
Open
Yes
27.2V
28.2V
10000-05858
5
12
120
Open
No
13.6V
10000-05861
5
12
120
Open
No
13.6V
14.1V
10000-05857
5
12
230
Open
No
13.6V
10000-05860
5
12
230
Open
No
13.6V
14.1V
10000-05859
5
24
120
Open
No
27.2V
10000-05863
5
24
120
Open
No
27.2V
28.2V
10000-05856
5
24
230
Open
No
27.2V
10000-05862
3
24
230
Open
No
27.2V
28.2V
Note 1: Voltage listed is rated for ambient temperature of 20 degrees C and a fully charged
battery.
SUMMARY: This service document provides diagnostic information for the effective
determination of faulty battery chargers as utilized with the aforementioned genset package
population.
Page 1 of 3

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.
Incorrect Supply Voltage
Battery chargers will fail to operate correctly if an incorrect supply voltage is applied to the
battery charger. Prior to energizing the battery charger, confirm that the actual supply voltage
matches the supply voltage rating of the battery charger as specified on the battery charger
data plate.
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.
Loose Termination Points or Terminal Ends
Confirm that all conductor termination points and conductor terminal ends are properly
secured. Loose terminations or poorly installed terminal ends will result in the battery charger
not working properly. Typically loose terminations or poorly installed terminal ends show up
as intermittent faults. Use a pull and wiggle test to confirm loose termination points or
poorly installed terminal ends.
When working with cage clamp type terminal strips, ensure you utilize the proper size tool.
An improperly sized tool will damage the cage clamp and introduce a new fault point in the
circuit. It is recommended to use a flat blade screwdriver with a non-flared tip having a
maximum blade width of 3.5mm (0.1378 inch).
Incorrect Battery Type - Mismatch
The battery chargers listed in Table 1 are only to be used with vented and lead acid type
batteries. Do not use a VRLA (sealed) battery or a NiCad type battery with any of the battery
chargers listed in Table 1.
Page 2 of 3

Battery Charger Output Voltage - Incorrect

An incorrect battery charger output voltage can typically be attributed to one of the following
conditions.
If the battery is not in good condition (i.e. Low electrolyte, unable to maintain proper
charge, etc.) The actual output voltage will typically be half of the rated output voltage.
Install a new, fully charged battery.

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 chargers 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
(degrees C)
-20
-10
0
10
20
30
40
50

12V
Float
14.3V
14.1V
14.0V
13.8V
13.6V
13.4V
13.2V
13.1V

12V
Boost
14.8V
14.6V
14.5V
14.3V
14.1V
13.9V
13.7V
13.6V

24V
Float
28.6V
28.3V
27.9V
27.6V
27.2V
26.8V
26.5V
26.1V

24V
Boost
29.6V
29.3V
28.9V
28.6V
28.2V
27.8V
27.5V
27.1V

Short Circuit to Chassis Ground

If the battery chargers positive output (B+) becomes connected to ground potential, either the
internal re-settable DC fuse or the external (B+) output fuse will open. Investigate wiring to
determine short circuit connection point. Upon repair of wiring, confirm that the battery
charger operates as intended. If you are unable to confirm that the battery charger operates
properly, replace the battery charger.
Additional Service Publication References
OLY-TIBU0026
Improved Battery Chargers and Troubleshooting
OLY-TIBU0031
EMCP Battery Charger - Battery Voltage and Temperature Alarms
Page 3 of 3
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