FORMCHARGE 36V 18AMP Battery Charger Owner’s Manual

FORMCHARGE 36V 18AMP Battery Charger Owner’s Manual

INTRODUCTION

If you have any questions, concerns, or missing parts

DO NOT RETURN UNIT TO ONLINE RETAILER

FREQUENTLY ASKED QUESTIONS

We have FAQs available on our website to help answer all of your questions. Visit https://www.formcharge.com/ and click on “Help/FAQ” 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 a product questions, please reach out at https://www.formcharge.com/help and click on the “Contact Us” button. 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 online 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 15 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

Step1: 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 RU N mode

QUICK START INSTRUCTIONS

Follow these quick start instructions for proper charging of your LiFePO4 golf cart batteries.

Step1: 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 1 minute.

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

Step 3 : Disconnect the wall outlet AC Plug

TROUBLESHOOTING

1. CHARGE STATUS Light is Green / Red flashing, and nothing is happening.
   • a. Verify the DC Terminals are correctly connected to the LiFePO4 battery
   • b. Unplug the charger for10 seconds from the wall outlet.
   • c. Plug the charger back into the wall outlet.
   • d. 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. 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 1OOAH battery /15 A Charger = 6.6 Hours of charge time.
3. The golf cart battery meter is not reading the correct battery meter status.
   • a. 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 consume

After these codes have registered 5 times, they will become: (Red, Green, Red, 4 seconds off)

LED FAULT DIAGNOSTICS

The LED will Flash a pattern of Green and Red to notify of a fault. The dashes represent a l-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

1. 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.

2. How warm do FORM chargers get?

The FORM battery chargers can reach 14O°F. They may get warm in an enclosed area. The maximum recommended air temperature for charging batteries is 105°F. When the charger is hot, the output current will drop to protect the charger and the battery.

Do I need to leave my charger plugged in if leaving for a month?

No. The charger does not need to remain plugged in over a several-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 disconnected before terminating the charge cycle.

5. What is the warranty?

he manufacturer's warranty is18 months. You may return the charger for up to 30 days after delivery date.

6. When to Charge your LiFePO4 Battery?

If LiFePO4 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 LiFePO4 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 recommend storing batteries at a minimum 50% state of charge (SOC) to minimize irreversible ca pacity loss.

Can I charge my LiFePO4 battery in the winter?

Avoid charging a LiFePO4 battery in temperatures below 32°.

PRODUCT FEATURES

• Microprocessor-controlled high-frequency power supply
• lP67 rated against dust and water intrusion
• The DC output is isolated from AC input
• Single input12OVac
• Protections in place to help prevent short-circuiting, overvoltage, 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 fu nction

IMPORTANT SAFE I Y INSTRUCTIONS Ab

Before using your battery charger, read all safety instructions.

1. 1. Always use the charger in well-ventilated environ ments.
   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 uninsulated portion of
   AC or DC connectors or the uninsulated battery terminal.
   6. To prevent electrical shock, ensu re all electrical con nectors a re
   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 alterthe 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.

2.  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.

3. CAUTION – Always use a GFCl-protected outlet when using a charger in wet/moist environments to prevent electrical shock.

References

• FORM: GOLF CART CHARGERS – Form Charge
• FORM Charge

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