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Service Information
Form 4C, Form 5, Form 6, and FXB Controls
Portable Lead Acid Battery Charger KA43ME7001
Operating Instructions S280-79-14

Figure 1.
Portable Lead Acid Battery Charger KA43ME7001.

Safety Information . ................................................... 2
Product Information . ................................................ 3
Introduction ............................................................. 3
Acceptance and Initial Inspection ............................ 3
Handling and Storage ............................................. 3
Use of Battery Charger . ........................................... 3
Connecting Charger to Battery . .............................. 3
Monitoring Battery Voltage ...................................... 4

September 2009 • Supersedes 5/2004

Form 4C, Form 5, Form 6, and FXB Controls Portable Lead Acid Battery Charger KA43ME7001 Operating Instructions


Cooper Power Systems products meet or exceed all applicable industry standards relating to product safety. We actively pro-
mote safe practices in the use and maintenance of our products through our service literature, instructional training programs,
and the continuous efforts of all Cooper Power Systems employees involved in product design, manufacture, marketing, and
We strongly urge that you always follow all locally approved safety procedures and safety instructions when working around
high voltage lines and equipment and support our “Safety For Life” mission.

The instructions in this manual are not intended as a Safety Instructions
substitute for proper training or adequate experience in
the safe operation of the equipment described. Only com- Following are general caution and warning statements that
petent technicians who are familiar with this equipment apply to this equipment. Additional statements, related to
should install, operate, and service it. specific tasks and procedures, are located throughout the
A competent technician has these qualifications:
• Is thoroughly familiar with these instructions.
• Is trained in industry-accepted high- and low-voltage
safe operating practices and procedures.
Hazardous voltage. Contact with hazardous voltage will
• Is trained and authorized to energize, de-energize, cause death or severe personal injury. Follow all locally
clear, and ground power distribution equipment. approved safety procedures when working around high-
and low-voltage lines and equipment. G103.3
• Is trained in the care and use of protective equipment
such as flash clothing, safety glasses, face shield, hard
hat, rubber gloves, hotstick, etc. WARNING:
Before installing, operating, maintaining, or testing
Following is important safety information. For safe installa-
tion and operation of this equipment, be sure to read and this equipment, carefully read and understand the
under­stand all cautions and warnings. contents of this manual. Improper operation, handling,
or maintenance can result in death, severe personal
injury, and equipment damage. G101.0

Hazard Statement Definitions

This manual may contain four types of hazard state- WARNING:
This equipment is not intended to protect human life.
Follow all locally approved procedures and safety
DANGER: Indicates an imminently hazardous practices when installing or operating this equipment.
situation which, if not avoided, will result in Failure to comply may result in death, severe personal
death or serious injury. injury, and equipment damage. G102.1

WARNING: Indicates a potentially hazardous

situation which, if not avoided, could result in
death or serious injury.
Power distribution and transmission equipment must be
properly selected for the intended application. It must
CAUTION: Indicates a potentially hazardous be installed and serviced by competent personnel who
situation which, if not avoided, may result in have been trained and understand proper safety proce-
minor or moderate injury. dures. These instructions are written for such personnel
and are not a substitute for adequate training and expe-
CAUTION: Indicates a potentially hazardous situa- rience in safety procedures. Failure to properly select,
tion which, if not avoided, may result in equipment install, or maintain power distribution and transmission
damage only. equipment can result in death, severe personal injury,
and equipment damage. G122.3



The battery charger is designed to charge sealed lead-acid
Introduction batteries used with Kyle® Form 4C, Form 5, Form 6 (pole
Service Information S280-79-14 provides operating instruc- mount), and FXB controls. It is equipped with a built-in
tions for portable battery charger KA43ME7001. The char- feature to prevent overcharging.
ger operates at 117 V +/-15%, 50/60 Hz and is intended Note: Do not attempt to charge a battery with a measured
for indoor use only. It is used to charge the batteries for the voltage of below 2 VDC. The charger will not operate
following recloser controls: if it does not detect a battery above 2 VDC.
• Form 4C
IMPORTANT: The charger is not intended for use with
• Form 5 a dead battery (below 2 VDC). Use a voltmeter to check
• Form 6 (Pole Mount) battery voltage before attempting to charge it.
• FXB If the battery is below 19 VDC for more than two days,
replace the battery. The expired battery should be
Read This Manual First disposed of in an environmentally responsible manner.
Consult local regulations for proper battery disposal.
Read and understand the contents of this manual. Follow
all locally approved procedures and safety practices before
installing or operating this equipment. The charger is equipped with a power-input cord with a
standard 3-pin 120 VAC plug. The output cord is a two-
Additional Information conductor cord. The solid black conductor terminates at
a black connector. The black-with-white stripe conductor
These instructions cannot cover all details or vari­ations terminates at a red connector.
in the equipment, procedures, or process described nor
can they provide directions for meeting every possible These connectors are exact duplicates of the battery’s
contingency during installation, operation, or maintenance. mating connectors. Each connector is keyed to fit its mat-
For additional information, contact your Cooper Power ing connector in only one orientation. Each charger con-
Systems representative. nector must join the same color battery connector.

Quality Standards Connecting Charger to Battery

ISO 9001:2000 Certified Quality Management System • If the control uses a single 24 V battery, the charger con-
nects directly to the battery.
Acceptance and Initial Inspection • If the control uses two 12 V batteries, adapter KME5-
This product is tested, carefully packaged, and in good 325-1 is required to connect the two batteries to the
condition when accepted by the carrier for shipment. charger.
Upon receipt, inspect the carton for signs of damage.
Unpack the product and inspect it thoroughly for damage
incurred during shipment. If damage is discovered, file a
claim with the carrier immediately.

Handling and Storage

Use care during handling and storage of a battery charger
to minimize the possibility of damage. When charger is
not in use, store it in a clean, dry environment away from
excessive heat or cold.

Form 4C, Form 5, Form 6, and FXB Controls Portable Lead Acid Battery Charger KA43ME7001 Operating Instructions

Battery Charger / LED Operation

When the battery charger is plugged in, the red LED will
illuminate. This indicates the 117 VAC input voltage is
The yellow LED will then illuminate to indicate the charger
is charging. Once the charger senses an 80% charge
level (or more), the yellow LED will oscillate ON and OFF.
Once the battery has reached a fully charged state, the
charger will illuminate the green LED. The charger will
maintain the fully charged battery with a voltage of 27.3
@ 25°C until it is disconnected or the input power is dis-
A flashing green LED indicates a battery or charger
problem. Specifically, this indicates the overrun timer
has expired (approximately 19 hours) prior to the battery
reaching full charge. This could indicate a battery with a
shorted cell, a problem with the charger output current,
or a problem with the charger voltage sensing.
Note: A battery may require 24 hours to reach a full charge
when using this charger.

Figure 2.
Charging LED illuminates yellow while battery is

KA2048-524 Rev: 02

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