AMETEK/PRESTOLITE POWER 180M1-6G Owner'S Manual Download Page 1

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OWNER’S MANUAL 193111-079

Issued March 7, 2008

IMPORTANT: Read these instructions before installing, operating, or
servicing this system.

BATTERY-MATE 100

CHARGERS

Silicon Diode Ferroresonant

Transformer Type

DO NOT DESTROY

AMETEK/PRESTOLITE POWER , TROY, OHIO 45373-1099, U.S.A.

Note: This manual also applies to ST-100 units that were shipped prior to
January 1, 2005.

Summary of Contents for 180M1-6G

Page 1: ...before installing operating or servicing this system BATTERY MATE 100 CHARGERS Silicon Diode Ferroresonant Transformer Type DO NOT DESTROY AMETEK PRESTOLITE POWER TROY OHIO 45373 1099 U S A Note This...

Page 2: ...odel number is the 8 hour ampere hour capacity case size input power phase and number of cells in battery for which charger is intended The following example explains the basic model numbering arrange...

Page 3: ...reliminary 5 1 Normal or Daily Charge 5 1 Equalize or Weekend Charge 5 1 Manual Stop 5 2 Battery Discrimination 5 2 Refresh Charge 5 2 Backup Timer Shutdown 5 2 Battery Disconnect Shutdown 5 3 Low Cur...

Page 4: ...ill be shown in italics Equipment Identification The unit s identification number specification model serial number usually appears on a nameplate attached to the front panel Receipt Of Equipment When...

Page 5: ...ode NFPA 70 and local codes A power disconnect switch must be located at the equipment Check nameplate for voltage and phase requirements If only 3 phase power is available connect single phase equipm...

Page 6: ...he battery If the charger is equipped with an ammeter the ammeter should not indicate current flow Always connect battery before turning charger ON F Medical and First Aid Treatment First aid faciliti...

Page 7: ...high and low battery voltage discrimination and AC power fail recovery The AC500 Control is matched to the output voltage of the charger by means of a printed circuit board mounted DIP switch It will...

Page 8: ...tic electrical charges which tend to build up on the surfaces of equipment These static charges can cause painful shock to personnel and can lead to the erroneous conclusion that an electrical fault e...

Page 9: ...e Changeover Instructions 1 Determine if the charger is connected for available line voltage A label located near AC input terminals is marked with the AC voltage for which the charger is factory conn...

Page 10: ...onnect to positive battery terminal If necessary trace cables into charger and use supplied connection diagram to determine polarity The use of a DC voltmeter may show polarity Improper connections wi...

Page 11: ...d from the charger NOTE To disconnect battery from charger before charge is complete first press the STOP key then disconnect the battery from the charger Equalize or Weekend Charge The AC500 features...

Page 12: ...control will start a normal charge sequence If the battery connected to the charger has a terminal voltage of less than 1 75 volts cell and the operator wishes to start the charge regardless of this l...

Page 13: ...er mined level a low current shutdown will occur All 4 LEDs will flash then the Equalize LED will flash AC POWER FAIL During an AC power failure the AC500 Control stores key information about the char...

Page 14: ...ously high voltage Be sure to replace all charger cabinet panels after any servicing to assure proper flow of cooling air through unit and to protect internal components WARNING ELECTRICAL SHOCK HAZAR...

Page 15: ...ameplate On fully discharged battery approx 1 140 specific gravity rate should not exceed 110 of MAX AMPS On three phase chargers both transformer terminal blocks must be identically connected Fuse Re...

Page 16: ...Testing 1 Heed WARNING in Silicon Diode Testing section 2 Disconnect capacitor and connect leads of ohmmeter set to highest scale to capacitor terminals 3 If capacitor is good pointer will deflect ind...

Page 17: ...ds zero Check line voltage Close fused disconnect switch or repair open circuit Check for proper line voltage Refer to Line Voltage Changeover instructions in Installation chapter Check for blown fuse...

Page 18: ...es not shut OFF automatically or start automatically Check Charge Control 1 If equipped with electromechanical timer A Check timer switch contacts If they are welded together and show continuity when...

Page 19: ...RD Before checking electrical components turn OFF and remove fuses of disconnect switch supply AC power to charger disconnect battery and check for voltage on capacitors Discharge through insulated sc...

Page 20: ...RD Before checking electrical components turn OFF and remove fuses of disconnect switch supply AC power to charger disconnect battery and check for voltage on capacitors Discharge through insulated sc...

Page 21: ...RD Before checking electrical components turn OFF and remove fuses of disconnect switch supply AC power to charger disconnect battery and check for voltage on capacitors Discharge through insulated sc...

Page 22: ...pere hour capacity of both batteries plus the voltage number of cells of only one of the batteries must be within the range of the charger Refer to charger nameplate for ratings For example two 12 vol...

Page 23: ...box must be connected to charger as instructed on label provided with remote charge control Closely observe wire color coding Operate this charger as instructed in Operation chapter of this manual an...

Page 24: ...193111 079 PARTS LIST 8 1 March 7 2008 Figure 8 1 3 Phase...

Page 25: ...25 See Table Transformer T3 26 W10080 5 Connector Strain Relief 27 378234 13 Cover Neoprene 28 See Table Cable Output Charging 29 See Table Label AC Input 30 194335 Label Danger Input Volt Fuse 31 191...

Page 26: ...94089 406243 1 402832 3 TRY154 4 TRY154 2 406461 406247 2 396143 61 880H3 18G 500410C 200 W10386 9 W10386 9 W10386 9 Y1890 6 193125 2 404605 5 194093 194094 406243 1 402832 3 TRY154 6 406461 406247 2...

Page 27: ...4 194137 194138 406243 1 402832 3 TRY154 4 TRY154 2 191252 406247 4 396143 61 880H3 18G 500410C 201 W10386 5 W10386 5 Y1890 6 193125 2 404605 4 194269 194270 406243 1 402832 3 TRY154 6 191252 406247 4...

Page 28: ...193111 079 PARTS LIST 8 5 March 7 2008 Figure 8 2 1 Phase...

Page 29: ...mer Power 18 Contact Factory Terminal Block 19 193114 Insulator Fuse Shunt 20 392458 Bus Bar 21 See Table Shunt Meter 22 See Table Fuse Output 23 See Table Block Input Fuse 24 See Table Fuse Input 25...

Page 30: ...W 10386 5 Y 1890 4 193125 2 406207 1 192412 406240 1 TRY 154 6 402832 3 406461 406247 2 396143 60 510M1 12G 500735A 200 W 10386 7 W 10386 7 W 10386 5 Y 1890 4 193125 2 406207 1 192552 406240 1 TRY 154...

Page 31: ...5 W 10386 5 Y 1890 4 193125 2 406207 1 192412 406240 1 TRY 154 6 402832 3 191655 406247 4 396143 60 510M1 12G 500735A 201 W 10386 5 W 10386 5 Y 1890 4 193125 2 406207 1 192552 406240 1 TRY 154 6 40283...

Page 32: ...125 1 405357 1 191395 406240 1 TRY 154 2 402832 3 406465 406247 1 396143 72 380M1 6G 500726A 204 W 10386 5 W 10386 5 W 10386 5 Y 1890 3 193125 1 405357 1 192439 406240 1 TRY 154 4 402832 3 406465 4062...

Page 33: ...ODEL NO INFORMATION DIAGRAM 208 240 480V DIAGRAM 480 575V DIAGRAM 120 208 240V OUTLINE DIMENSION 3 PHASE 2 TRANSFORMERS 192120 192954 N A 194449 1 PHASE 1 TRANSFORMER 197325 197326 197325 197203 See m...

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Page 40: ...third party beneficiary to this warranty 4 LIMITATION OF REMEDY The existence of claimed defects in any product covered by this warranty is subject to Prestolite s factory inspection and judgement Pre...

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