IQ PLUS BATTERY CHARGER OWNER’S MANUAL

General InformationNOTE: At one hour and at two hours into the charge cycle, the charger will shut off in order to run a selfdiagnostic program (ammeter will drop to zero). Charging will resume in a few moments (ammeterreturns to previous rate of charge).The onboard computer, having recorded the amount of energy consumed as the vehicle was used, directs thecharger to replace exactly the amount of energy needed to fully replenish the batteries. The charger thenshuts off automatically, preventing the possibility of either undercharging or overcharging. The computeraccomplishes this by detecting when the exact amount of energy necessary has been returned to the batteries.TOAC CORDREELTEKECHOTSH.ECZCIRATAHWMT60CEOEETRNRTONHS0V 50TOETC24 HDEES0/ISITDRND22,W. NION A0/GTTLY UE SIF20CN OINH IEYET RO R0/ T! TLEATRNU .S G 10D EER .NLEN TTE SOLE LY O T T-O GA AT ATP KRTCUE INIC EO ARS BB !LH PIT O K TP NAIS SPE TE ON T- C ETM EL.HV RICU KE O SA HA R DT LETSP.U E NIS C E H48! 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G RO R ED IN O M PE G UR T CTA AR D U:CH TE UTPO O N ETHFigure 4 Export IQ Plus Onboard ChargerModel 25660-40Figure 3 Export IQ Plus External ChargerModels 25880-11, and 25880-18Figure 2 Domestic IQ Plus Onboard ChargerModel 25260-40Figure 1 Domestic IQ Plus External ChargerModel 25730-11TOAC CORDREELPage 7IQ Plus Battery Charger Owner’s Manual

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GR NN TETL BATARE YSO E DCDEIQ Plus Battery Charger Owner’s ManualPage 8220 VAC INPUT VOLTAGESELECTION SWITCH(REAR CHARGER PANEL)Figure 5 AC Input Voltage Selection SwitchIQ PLUS EXTERNAL CHARGER FEATURES Charge InterlockIQ Plus battery charger DC plugs have three pins rather than two blades common on most standardcharger plugs. Two of these pins are the positive and negative leads as on standard chargers; the thirdpin is a sensing lead that is the communication link between the charger and the onboard computer.When the charger plug is plugged into the vehicle receptacle, the onboard computer locks out the vehicle drive system. This prevents the possibility of driving the vehicle while the charger is plugged in andpotentially damaging the vehicle and charger. Long-Term Storage ChargeIQ Plus vehicles with IQ Plus chargers are designed to be left connected with AC power to the charger,during off-season or long-term storage. The onboard computer will automatically activate the chargerevery 15 days. To return the vehicle to service, unplug the charger DC cord, wait 15 seconds for thecomputer to reset, and plug the charger back in. See following WARNING. This will ensure the batteriesare at their optimum charge prior to returning the vehicle to service.ý WARNING The charger plug must be pulled slowly from the receptacle. Jerking or pulling the DC cordout quickly could cause arcing and burning that could damage the plug and receptacle andcould cause batteries to explode.IQ PLUS ONBOARD CHARGER FEATURES Charge InterlockWhen the AC power cord is inserted into a wall receptacle, the onboard computer locks out the vehicledrive system. This prevents the possibility of driving the vehicle while the charger is plugged in andpotentially damaging the vehicle and charger. Long-Term Storage ChargeIQ Plus chargers are designed to be left connected with AC power to the charger, during off-season orlong-term storage. The onboard computer will automatically activate the charger every 15 days. Toreturn the vehicle to service, disconnect the AC cord from the wall outlet, wait 15 seconds and thenplug the AC cord back in. The charger will activate. Allow the vehicle to complete one full charge cyclebefore putting it into service.

External Charger Installation and OperationBATTERY WARNING LIGHTIQ Plus vehicles feature a dash mounted battery warning light (above the steering column) that, when thevehicle is in operation, indicates low battery voltage or, when the vehicle is being charged, indicates a charging problem. The battery warning light is controlled by the onboard computer.When the batteries receive an incomplete charge because 1) the DC power cord is disconnected, 2) ACpower to charger is interrupted, 3) automatic charger shut-off occurs after 16 hours of operation, or 4) chargermalfunctions, the warning light will indicate as follows: The battery warning light will not illuminate if the charge is 90% or more complete. The onboard computer will retain in memory the amount of charge needed to replenish the batteries and will completethe charge during the next charge cycle. When the charger DC cord is unplugged during a charge cycle, the battery warning light will illuminateand remain illuminated for 10 seconds if the charge is less than 90% complete but the vehicle hasenough power for 60 minutes of operation. This will alert the operator that the vehicle may be used, butthat it must be charged to completion as soon as possible. The battery warning light will repeatedly illuminate for 10 seconds, at 4 second intervals, if the chargertimes out at 16 hours and the batteries are not sufficiently charged. This indicates an abnormal chargecycle. The charger and batteries should be checked by your Club Car distributor/dealer. External chargers only: The battery warning light will repeatedly illuminate for 10 seconds, at 4 second intervals , during a charge cycle (with the DC plug still connected) if AC power to the charger isinterrupted. The light will go out when AC power is restored.UL AND CSA LISTINGWhen operated on a 120-volt / 60 Hz electrical system, the following IQ Plus battery chargers have beenlisted by Underwriters Laboratories and by the Canadian Underwriters (thereby meeting the criteria of theCanadian Standards Association).IQ Plus external battery charger model: 25730-11.IQ Plus onboard battery charger models: 25260-11.EXTERNAL CHARGER INSTALLATION AND OPERATIONý DANGER The charging area must be ventilated. Hydrogen level in the air must never exceed 2%. Thetotal volume of air in the charging area must be changed five times per hour. Exhaust fansshould be located at the highest point of the roof. Contact a local HVAC engineer. Do not charge the vehicle batteries with the vehicle covered or enclosed. Any enclosure orcover should be removed or unzipped and pulled back when batteries are being charged. Anaccumulation of hydrogen gas could result in an explosion.ý WARNING Only trained technicians should repair or service the charger. Contact your nearest Club Cardistributor/dealer. Each charger should have its own dedicated 15 or 20 ampere separately protected (circuit breakeror fuse) single phase branch circuit, in accordance with all applicable electrical codes for thelocation.WARNING CONTINUED ON NEXT PAGE.IQ Plus Battery Charger Owner’s ManualPage 9

External Charger Installation and Operationý WARNING Connect the charger AC supply cord to a properly grounded, three-wire outlet of the propervoltage and frequency as shown on the charger. Do not use an adapter to plug the charger with a three-prong plug into a two-prong outlet.Improper connection of the equipment-grounding conductor can result in a fire or anelectrical shock. An extension cord or electrical outlet must accept a three-prong plug. Extension cord shouldbe a three-wire no. 12 AWG (American Wire Gauge), and be as short as possible. The use ofimproper extension cord could result in fire or an electrical shock. Do not use near fuels, grain dust, solvents, thinners, or other flammables. Chargers can igniteflammable materials and vapors. Do not expose to rain or any liquid. Keep the charger dry. Prior to servicing the charger, disconnect the AC power supply cord from the wall outlet andthe DC plug from the vehicle charger receptacle. When the charger is on, the charger DC cord may be disconnected from the vehicle receptacleslowly. Jerking or pulling the DC cord out quickly could cause arcing and burning that coulddamage the plug and receptacle and could cause batteries to explode. Never push objects of any kind into the charger through cabinet slots. They may touchdangerous voltage points or cause an electrical short circuit that could result in fire or electricalshock. Do not connect the charger to battery packs that are not compatible with the DC outputvoltage specified on the charger. Overheating and transformer burnout will result. Do not connect a stationary charger to the receptacle if the charger cord, plug, or the vehiclereceptacle is broken, damaged, or does not make a good electrical connection. Fire orpersonal injury can result. Have a qualified technician replace the parts. Do not use a battery charger if the cord, plug, or receptacle is damaged in any way. Replaceworn or damaged parts immediately. Failure to heed this warning could result in a fire,property damage, severe personal injury, or death. Do not operate the charger if it has received a sharp blow, was dropped, or otherwisedamaged in any way. Have worn, cut, or damaged power cords or wires replaced immediately. Do not block or cover the charger ventilation slots. The slots provide ventilation and preventthe charger from overheating. Do not allow clothing, blankets, or other material to cover the charger. Do not allow the charger to operate for more than 30 minutes at 19 or more amperes. Install surge arrestors on incoming AC power lines. Surge arrestors will help protect electricalcomponents in the charger and on the vehicle from all but direct or close lightening strikes.NOTE: Charger operation instructions in the language of the user should be printed on or permanentlyaffixed to the top of the charger. If these instructions are not found on the charger, contact yourClub Car representative.EXTERNAL CHARGER AC POWER CONNECTIONThe AC line to which the charger is to be connected must be of the proper AC input voltage for the chargerand must be capable of supplying sufficient current. See Battery Charger Specifications on page 17. If thebattery charger is equipped with a multi-position switch for variable AC input voltage, the switch must be setfor the correct voltage before the AC cord is connected (Figure 5). See following CAUTION.Page 10IQ Plus Battery Charger Owner’s Manual

External Charger Installation and Operationý CAUT ION Failure to set the AC input voltage selector switch to the correct voltage could result indamage to the battery charger or batteries.NOTE: Make sure that the AC cord provided with your charger has the proper AC plug for your location. Ifit does not, contact your Club Car representative to obtain the proper cord or plug.With charger DC output cord disconnected, connect the power supply cord to an AC supply. See BatteryCharger Specifications on page 17.To reduce the risk of electric shock, the battery charger must be grounded. The charger is equipped with anAC electric cord with an equipment-grounding conductor and a grounding type plug. The AC plug must beconnected to an appropriate receptacle that is properly installed and grounded in accordance with theNational Electric Code and all local codes and ordinances.The use of an extension cord with the charger should be avoided. If an extension cord must be used, use athree-conductor no. 12 AWG (American Wire Gauge) or no. 14 SWG (British Standard Wire Gauge), heavyduty cord with ground, properly wired and in good electrical condition. Keep it as short as possible (no morethan 12 feet (3.7 m)). Place all cords so they will not be stepped on, tripped over, or otherwise subject to damage or stress.Ensure that the charger ventilation slots are unobstructed and that there is adequate ventilation.CHARGING BATTERIESý WARNING Do not bypass the sense lead fuse.Be sure the fuse link is clean and tight.Be sure all wire connections at the receptacle are clean and tight.Do not rock or bend the plug. To connect the charger plug to the vehicle receptacle, grasp theplug handle and push the plug straight into the receptacle (Figure 6).Do not pull on the DC cord (Figure 7). Do not twist, rock or bend the plug. To disconnect thecharger plug from the vehicle receptacle, grasp the plug by the handle and pull the plugstraight out of the receptacle.Do not connect a charger to the receptacle if the charger cord, plug, or the vehicle receptacleis broken, damaged in any manner, or does not make a good electrical connection. Fire orpersonal injury can result. Have it replaced by a qualified service person immediately. Failureto follow these instructions could result in damage to the charger cord, the plug, and (or) thevehicle receptacle.Do not use a charger if:- The plug is too loose or does not make a good connection.- The plug and receptacle feel hotter than normal during charge.- The plug pin or receptacle contacts are bent or corroded.- The plug, receptacle, or cords are cut, worn, have any exposed wires or are damaged in anyway.Using the charger with any of the above symptoms could result in a fire, property damage,personal injury, or death.1. With the charger DC cord disconnected from the vehicle charger receptacle, connect the AC power supply cord to an AC outlet designed to provide the proper AC voltage for the charger.2. Connect the charger DC plug to the vehicle charger receptacle located on the seat support panel(Fig

Oct 01, 2005 · er for correct current. i r om 13 t o 20 amps and then less than 5 amps if ba. unit shuts off a ut ica ll tteries a re. te: during periods of extended st ck on t ain t tter y if the output cord is connected t tter y and input