MAINI BATTERY CHARGER
USER MANUAL
Manufactured By
Maini Materials Movement Pvt Ltd
Survey No. 32, Chandapura, Hosur Road,
Bangalore – 560099
Tel: +91 80 4352 6555 Fax: +91 80 4352 6580
Email: customercare@maini.com
Website: www.mainimaterials.com
Table of Contents
Sl No. Content Page Number
1 General 2
2 Charger Mounting Instructions 3
3 Working Principles 4
4 Instructions for Servicing 5
5 Installation and Commissioning 6
6 Safety Instruction 7
7 Spare Part List for Load Wheels and 8
Support Wheels
General
General Description:
The Battery Charger is for charging lead acid traction batteries only. The Charger is
electronically protected against over current, short circuit and reverse battery connection.
The charging profile is constant current followed by a forced taper, while sensing voltage to
evaluate 100% charge condition.
General Instruction:
1. Operate the charger at 230V AC. The charger input should be connected through an
ELCB (Earth Leakage Circuit Breaker) of 30/ 100 mA fault current
2. Always cover the plug when not in use
3. Servicing should be done by authorized personnel only
Technical Specification:
1. Input voltage/ Frequency : 230V + 10%/ -15%, 50Hz
2. Output @ 56 Volts : 25A max
3. Charging Time : 8 Hours for a 80% discharged Lead Acid Battery
4. Battery Operating Temp. : 0˚ to 45˚ C
5. Relative Humidity : 95%
Display Details:
1. If Power LED (RED) : ON Charger Input is ON
: OFF Charger Input Cable
Check switch is in ON Position
2. If Charger status LED (GREEN) : ON Batteries are Charging
: OFF Check Point No. 1
3. If OVER TEMPERATURE LED (RED) : ON Temperature has exceeded 80˚ C. Check
Blockage of airways of fan on charger. The
Charger will restart automatically in 30-45 mins.
Else contact Customer Care
4. If END OF CHARGE LED (AMBER) : ON Bateries fully charged in equalising mode.
Normal charging duration is 8 hrs for an 80%
discharged battery.
: OFF Charging in process
SAFETY INSTRUCTION
Important:
1. All designated users of the Battery Charger must read and understand the contents of this manual
before operating the Battery Charger
2. Do not tamper or open the Charger. Warranty will be void if tampered or opened
Important:
1. Please don’t open the charger to repair by yourself
2. Please don’t change power supply cables by yourself
3. AC power supply is with three core cable which has earthing wire. Ensure proper earthing, before connecting
4. Please do not expose charger to wet conditions
5. Insert DC socket tightly. If damaged, replace it
6. Turn off the charger if any abnormal noise or burning smell is observed
7. Dial Customer Care No. _91 9972122884 for any assistance
8. Please do not alter the cable lengths
9. Please don’t obstruct airways of the charger
10. Disconnect power supply and connector before relocating the charger
11. This charger is suitable only for lead acid batteries of nominal 48V and 150-240 AH capacities
12. While disconnecting, pull the connector body but not with the cables
WORKING PRINCIPLES
Charging Process:
First Stage: Constant current mode, charge voltage increases to set voltage
Second Stage: Constant voltage modem current decreases at constant output voltage of 56.5V
Third Stage: Voltage increases up to 61V and Current decreases to 1Amp
Charging automatically stops after the Battery Voltage reaches 61V
Note: The charger is suitable only for lead-acid battery of 48V nominal voltage and 150-240 AH capacities
Operating Procedure:
1. Connect the 3 pin plug to power supply
2. Connect the charge plug to the charge socket
3. Switch on MCB/ ELCB. Power Light ‘ON’ shows that power is supplied. After three seconds charger checks the
condition of the battery. After ascertaining the state of charge of the battery, charging commences and passes
through the various steps of charging
4. After batteries are charged completely, the charger automatically cut off
INSTRUCTIONS
Instructions for Servicing the Chargers:
Should it become necessary to send back the instrument to the factory, please observe the following
procedure:
1. Before despatching the instrument, please write to us giving complete details of the fault noticed
2. After receipt of your letter, CCC department will advise you whether it is necessary to send the
instrument back to us for repairs or the servicing is possible at your place
3. Despatch the instrument only on receipt of our advice, securely packed to original packing duly
insured and a copy of details of the faults sent to us to our factory address
INSTALLATION & COMMISSIONING
Receiving the Charger:
When received, the charger should be unpacked and checked for any transit damage. If any, it should be
notified to us immediately
Location of Charger:
Install the charger in cool, dry, well ventilated location away from corrosive fumes and moist atmosphere.
Allow 200mm free space on all sides for proper ventilation. Refer pictures below.
Note:
Park the vehicle for charging in a position as shown. Ensure that the cable is not stretched while
connecting to the charge port. Cable length provided is 2.5m.
CHARGER MOUNTING INSTRUCTION
Procedure for Installation of Charger:
Step 1: Drill holes using the given template
Step 2: Insert plastic screw plugs to the drilled holes
Step 3: Fasten screw to the plug, such that the screw head is projected 1” from the
wall surface
Step 4: Mount the charger onto the screws installed in the wall as shown in the
illustration below
Dos and Don’ts:
1. Do not tamper with the seal, warranty will be void, if seal is broken
2. Do not operate in a damp or wet environment
3. Turn-off the power before connecting or disconnecting the charger
4. Ensure charger airways are not blocked
