FORM CHARGE LIFEP04 36v 18AMP Battery Charger Owner’s Manual

June 12, 2024
FORM CHARGE

FORM CHARGE LIFEP04 36v 18AMP Battery Charger

FORM-CHARGE-LIFEP04-36v-18AMP-Battery-Charger-product

INTRODUCTION

If you have any questions, concerns, or missing parts DO NOT RETURN UNIT TO ONLINE RETAILER: PLEASE CALL OUR SUPPORT LINE AT 320-373-2099

EMAIL US
You can email our customer service department with questions regarding your FORM Golf Cart Battery Charger at: sales@formcharge.com

CALL US
Our customer service representatives are available Monday­Friday between 8:00 a.m. – 5:00 p.m. CST at 320-373-2099.

FREQUENTLY ASKED QUESTIONS
We have FAQs on our website to help answer all of your questions. Visit https://www.formcharge.com/ and click on “FAQs” to find an answer to your questions. FAQs are also listed on page 7 of this manual.

YOU MADE THE RIGHT DECISION!
Congratulations on receiving your FORM Battery Charger! If you find that it doesn’t meet your needs or if you have product questions, please reach out at sales@formcharge.com or call us at 320-373-2099. We want to ensure your satisfaction and that the product meets your needs. If you love your new charger, please consider leaving us a review at the on line retailer you purchased from, it truly means a lot to us.

FEDERAL COMMUNICATIONS COMMISSION (FCC) STATEMENT
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 75 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his own expense.

INSTALLING THE ONBOARD CHARGER

  • Step 1: Switch the golf cart to TOW mode
  • Step 2: Find a suitable location on the golf cart and mount using appropriate hardware. (Example Locations: baggage well, Battery compartment, Bottom of the Seat) Provide at least 3 inches of space around the charger for cooling.
  • Step 3: Find the ends of the electrical series on your cart batteries. Attach the red lead (marked with red heat shrink) to the battery Positive(+). Attach the black lead (marked with black heat shrink) to the battery Negative(-). Applying Dielectric grease around the connections will help prevent corrosion.
  • Step 4: Switch the golf cart to RUN mode

QUICK START INSTRUCTIONS

Follow these quick start instructions for proper charging of your LiFeP04 golf cart batteries.

  1. Step 1: Plug the charger into a wall outlet AC plug.
    Note: When power is applied, the charger will establish communication with the battery pack. The red and fan may cycle. This process can take up to 7 minute.FORM-CHARGE-LIFEP04-36v-18AMP-Battery-Charger-
fig-1

  2. Step 2: Keep your battery charging until the CHARGE STATUS light turns green.

  3. Step 3: Disconnect the wall outlet AC Plug

TROUBLESHOOTING

  1. CHARGE STATUS Light is Green/ Red flashing, and nothing is happening.
    • Verify the DC Terminals are correctly connected to the LiFePO4 battery
    • Unplug the charger for 70 seconds from the wall outlet.
    • Plug the charger back into the wall outlet.
    • If the charger status light is still flashing Green/ Red, verify the BMS (Battery Management System) is functioning correctly.
  2. Your cart has been charging for multiple hours, but the CHARGE STATUS LED has not turned green.
    • A 36V or 48V cart that has depleted LiFePO4 batteries can take several hours to charge. To figure out the average charge time, take the Amp-Hour of your battery pack and divide it by the Amperage of the charger. Example l00AH battery/ 15 A Charger = 6.6 Hours of charge time.
  3. The golf cart battery meter is not reading the correct battery meter status.
    • Standard voltage meters that work with lead-acid batteries will not work for LiFePO4 batteries. LiFePO4 battery meters measure battery life based on the actual power consumed.FORM-CHARGE-LIFEP04-36v-18AMP-Battery-Charger-fig-2

LED FAULT DIAGNOSTICS
The LED will Flash a pattern of Green and Red to notify of a fault. The dashes represent a 1-second pause with no LED. To Reset the charger or any LED faults, Unplug the AC wall Plug for 10 seconds, and plug it in again. Temperature faults will automatical­ly start charging operations once the temperature has returned to a normal operating temperature.

INTELLIGENT CHARGING

Designed to protect & preserve your batteries automatically. The intelligent CC/CV charging algorithm is designed around optimal conditions for LiFePO4 (LFP) golf cart batteries.

FAQ

How loud should the charger be?
The noticeable sound of rushing air from the fan is a normal part of the cooling process on your FORM rapid charger.

How warm do FORM chargers get?
The FORM battery chargers can reach 140°F. They may get warm in an enclosed area. The maximum recommended air tempera- ture for charging batteries is 105°F. When the charger is hot, the output current will drop to protect the charger and the battery.

Dol need to leave my charger plugged in if leaving for a month?
No. The charger does not need to remain plugged in over a sev- eral-month period as LiFePO4 (LFP) batteries have little loss of charge over time.

Why does the LED on my FORM charger stay illuminated for some time after unplugging from AC power?
This is normal and does not affect your batteries. It is simply a function of the precision charging, ensuring the charger is dis- connected before terminating the charge cycle.

What is the warranty?
The manufacturer’s warranty is 18 months. You may return the charger for up to 30 days after delivery date.

When to Charge your LiFePO4 Battery?
If LiFeP04 batteries are not fully discharged, they do not need to be charged after each use. LiFePO4 batteries are not damaged when left in a partial state of charge (PSOC). You can charge your LiFeP04 batteries after each use or when they have been discharged up to 80% DOD (Depth of Discharge). Remove the load and charge immediately if the Battery Management System (BMS) disconnects the battery due to low voltage. We recom- mend storing batteries at a minimum 50% state of charge (SOC) to minimize irreversible capacity loss.

Can charge my LiFeP04 battery in the winter?
Avoid charging a LiFeP04 battery in temperatures below 32°.

PRODUCT FEATURES

  • Microprocessor-controlled high-frequency power supply
  • IP67 rated against dust and water intrusion
  • The DC output is isolated from AC input
  • Single input 120Vac
  • Protections in place to help prevent short-circuiting, over-voltage, over-current, and over-heating.
  • Forced ventilation with fans to keep the unit cool while charging
  • 8 Ft A/C Power Cable and 4 Ft DC Battery Cables
  • Portable & lightweight for easy transportation
  • Low voltage BMS Reset function
Specifications 36 Volt Charger 48 Volt Charger
Power Output 900W 900W
Input Voltage 720 ± 75 % Vac 720 ± 75 % Vac
AC input Current BAmp BAmp
LiFePO4 Nominal Voltage 38.4Vdc 57.2Vdc
LiFePO4 Cell Configuratoin 72S 76S
Max Output Voltage 43.BVdc 58.4Vdc
DC Output Current 78Amp 75Amp
Power Efficiency ::o:85   % ::o:85   %
Working Temperature -37° F  to   770   ° F -37 ° F to 770 ° F

IMPORTANT SAFETY INSTRUCTIONS

Before using your battery charger, read all safety instructions.

  1. Always use the charger in well-ventilated environments.
  2. This charger is only designed to charge LiFePO4 (LFP) batteries with a Battery Management System (BMS).
  3. DO NOT cover the aluminum case, this can cause your charger to overheat while charging.
  4. DO NOT disassemble the charger.
  5. Risk of electrical shock. DO NOT touch the uninsulated portion of AC or DC connectors or the uninsulated battery terminal.
  6. To prevent electrical shock, ensure all electrical connectors are in good working condition. DO NOT use connectors that are cracked, corroded, or do not make adequate electrical contact. The use of a damaged or defective connector may result in a risk of overheating or electrical shock.
  7. DANGER -Never alter the AC cord or plug provided if it will not fit the outlet installed by a qualified electrician. Improper connection can result in risk of an electric shock.
  8. DANGER -Do no attempt to repair or service the charger yourself. Opening the charger may expose you to high voltages, the risk of electric shock, and other hazards.
  9. DANGER -Do not splice the AC power cord.
  10. DANGER -Damaged cords and plugs can cause electric shock or electrocution.
  11. CAUTION -Even though the FORM charger can operate in a high ambient temperature environment, a minimum of three inches of unobstructed area should be allowed on all sides of the unit for proper air circulation and cooling.
  12. CAUTION -Always wear protective eye shields and clothing when working with batteries containing acids that can cause bodily harm. Do not put wrenches or other metal objects across the battery terminal or battery top. Arcing or explosion of the battery can result.
  13. CAUTION -Always use a GFCl-protected outlet when using a charger in wet/moist environments to prevent electrical shock.

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